OM4119EN

Operators Manual

3000 and 4000Product Families

InternationalModels

C

M

Y

CM

MY

CY

CMY

K

OM4119EN F.pdf 9/30/05 8:49:41 AMOM4119EN F.pdf 9/30/05 8:49:41 AM

Allison Transmission

INTERNATIONAL MODELS

OperatorsManual

2005 MAY

Rev. 1 2005 SEPTEMBER

OM4119EN

3000 and 4000 Product FamiliesIncludes Allison 4

th

Generation Controls

3000 3000 SP3200 3200 MH 3200 ORS 3200 SP3500 3500 ORS 3500 SP3700 3700 SP

4000 4000 MH 4000 ORS 4000 SP4200 ORS

4500 4500 ORS 4500 SP4600 ORS

4700 4700 OFS 4700 SP4800 4800 SP

Printed in USA Copyright 2005 General Motors Corporation

2NOTES

TABLE OF CONTENTS

INTRODUCTIONKEEPING THAT ALLISON ADVANTAGE . . . . . . . . . . . . . . . . . . . . . . . . 7A BRIEF DESCRIPTION OF THE ALLISON 3000 AND 4000 PRODUCTFAMILIES TRANSMISSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11ELECTRONIC CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . 11TORQUE CONVERTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12PLANETARY GEARS AND CLUTCHES . . . . . . . . . . . . . . . . . . . . . . . . 13COOLER CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13RETARDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

SHIFT SELECTORSDESCRIPTION OF AVAILABLE TYPES . . . . . . . . . . . . . . . . . . . . . . . . . 15INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16LEVER SHIFT SELECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16PUSHBUTTON SHIFT SELECTOR (FULL FUNCTION, NON STRIP-TYPE) . . 18PUSHBUTTON SHIFT SELECTOR (STRIP-TYPE) . . . . . . . . . . . . . . . . . . 19RANGE SELECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

DRIVING TIPSCHECK TRANS LIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24DIAGNOSTIC CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25DIAGNOSTIC CODE DISPLAY PROCEDURE . . . . . . . . . . . . . . . . . . . . . 26ACCELERATOR CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28DOWNSHIFT AND DIRECTION CHANGE INHIBITOR FEATURE . . . . . . . 28USING THE ENGINE TO SLOW THE VEHICLE . . . . . . . . . . . . . . . . . . . 29USING THE HYDRAULIC RETARDER . . . . . . . . . . . . . . . . . . . . . . . . . 30RANGE PRESELECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33COLD WEATHER STARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33DRIVING ON SNOW OR ICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34ROCKING OUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34OPERATING DOWN STEEP GRADES (REAR-DISCHARGE MIXER) . . . . . . 35HIGH FLUID TEMPERATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36TOWING OR PUSHING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37TURNING OFF THE VEHICLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37PRIMARY/SECONDARY SHIFT SCHEDULES . . . . . . . . . . . . . . . . . . . . 37CRUISE CONTROL OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

POWER TAKEOFF OPERATIONENGINE-DRIVEN POWER TAKEOFF (PTO) . . . . . . . . . . . . . . . . . . . . . 39

3

CARE AND MAINTENANCEPERIODIC INSPECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40PREVENT MAJOR PROBLEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40IMPORTANCE OF PROPER FLUID LEVEL . . . . . . . . . . . . . . . . . . . . . . 40FLUID LEVEL CHECK USING PUSHBUTTON OR LEVER SHIFTSELECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41FLUID LEVEL CHECK USING STRIP-TYPE PUSHBUTTON SHIFTSELECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44FLUID LEVEL CHECK USING DIAGNOSTIC TOOLS . . . . . . . . . . . . . . . 44MANUAL FLUID CHECK PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . 45COLD CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47HOT CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48RECOMMENDED AUTOMATIC TRANSMISSION FLUID AND VISCOSITYGRADE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48KEEPING FLUID CLEAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49FLUID AND INTERNAL FILTER CHANGE INTERVALRECOMMENDATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

DIAGNOSTICSDIAGNOSTIC CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

CUSTOMER SERVICEOWNER ASSISTANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56SERVICE LITERATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58ALLISON TRANSMISSION REGIONAL OFFICES . . . . . . . . . . . . . . . . . . 59

4

TRADEMARK USAGEThe following trademarks are the property of the companies indicated:

Allison DOC is a trademark of General Motors Corporation. DEXRON is a registered trademark of the General Motors Corporation. TranSynd is a trademark of Castrol Ltd.

5

WARNINGS, CAUTIONS, NOTES

IT IS YOUR RESPONSIBILITY to be completely familiar with the warningsand cautions described in this manual. It is, however, important to understand thatthese warnings and cautions are not exhaustive. Allison Transmission could notpossibly know, evaluate, and advise the service trade of all conceivable ways inwhich service might be done or of the possible hazardous consequences of eachway. The vehicle manufacturer is responsible for providing information related tothe operation of vehicle systems (including appropriate warnings, cautions, andnotes). Consequently, Allison Transmission has not undertaken any such broadevaluation. Accordingly, ANYONE WHO USES A SERVICE PROCEDUREOR TOOL WHICH IS NOT RECOMMENDED BY ALLISONTRANSMISSION OR THE VEHICLE MANUFACTURER MUST first bethoroughly satisfied that neither personal safety nor equipment safety will bejeopardized by the service methods selected.

Proper service and repair is important to the safe, reliable operation of theequipment. The service procedures recommended by Allison Transmission (or thevehicle manufacturer) and described in this manual are effective methods forperforming service operations. Some of these service operations require the use oftools specially designed for the purpose. The special tools should be used whenand as recommended.

Three types of headings are used in this manual to attract your attention. Thesewarnings and cautions advise of specific methods or actions that can result inpersonal injury, damage to the equipment, or cause the equipment to becomeunsafe.

WARNING: A warning is used when an operating procedure, practice,etc., if not correctly followed, could result in personal injury or loss oflife.

CAUTION: A caution is used when an operating procedure, practice,etc., if not strictly observed, could result in damage to or destruction ofequipment.

NOTE: A note is used when an operating procedure, practice, etc., isessential to highlight.

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KEEPING THAT ALLISON ADVANTAGE

Allison 3000 and 4000 Product Families transmissions are rugged and designedto provide long, trouble-free service.

This manual will help you gain maximum benefits from your ALLISON-equippedvehicle.

INTRODUCTION

7

Abbreviations

ABS Anti-lock Brake SystemDOC Diagnostic Optimized ConnectionDTC Diagnostic Trouble CodeECM Electronic Control ModuleEMI Electromagnetic InterferenceFCC Federal Communications CommissionKOH Potassium HydroxideMIL Military SpecificationsOEM Original Equipment ManufacturerOLS Oil Level SensorPTO Power TakeoffRFI Radio Frequency InterferenceTAN Total Acid NumberTCM Transmission Control ModuleTPS Throttle Position SensorWTEC World Transmission Electronic Control

8

3000PRODUCT

FAMILY

4000PRODUCT

FAMILY4000

PRODUCTFAMILY

(SEVEN-SPEEDTRANSMISSION)

3000PRODUCT

FAMILY(WITH RETARDER)

4000PRODUCT

FAMILY(WITH RETARDER)

V06299.00.02

Figure 1. 3000 and 4000 Product Families Transmissions(WTEC III Controls)

9

3000PRODUCT

FAMILY

4000PRODUCT

FAMILY4000

PRODUCTFAMILY

(SEVEN-SPEEDTRANSMISSION)

3000PRODUCT

FAMILY(WITH RETARDER)

4000PRODUCT

FAMILY(WITH RETARDER)

V06299.05.00

Figure 2. 3000 and 4000 Product Families Transmissions(Allison 4th Generation Controls)

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A BRIEF DESCRIPTION OF THE ALLISON 3000 AND 4000PRODUCT FAMILIES TRANSMISSIONSThe Allison 3000 and 4000 Product Families transmissions described in thismanual include:

Allison 4th Generation Controls A torque converter with lockup and torsion damper Three planetary gear sets (four in 7-speed transmissions)

These transmissions may also include an integral retarder and provision to mounta power takeoff (PTO).

ELECTRONIC CONTROL SYSTEMAll Allison 3000 and 4000 Product Families transmissions come standard withAllison 4th Generation Controls. These systems consist of five major componentsconnected by OEM-furnished wiring harnesses. The five major components are:

Transmission Control Module (TCM) Three speed sensors Remote shift selector Control module (which contains solenoid valves, a pressure switch, and, if

available, an oil level sensor)

Engine Electronic Control Module (ECM) or Engine Throttle PositionSensor (TPS), if installed

The TCM receives information from the following:

Throttle position sensor, if installed Speed sensors Pressure switch Shift selector

The TCM processes information and then sends signals to actuate specificsolenoids located in the control valve module. These solenoids control bothoncoming and off-going clutch pressures to provide closed-loop shift control bymatching input rpm during a shift to a desired profile programmed into the TCM.

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A feature of Allison 4th Generation Controls is autodetect. Autodetect is activewithin the first several engine starts, depending upon the component or sensorbeing detected. These engine start cycles begin when the transmission is installedduring vehicle manufacture. Autodetect searches for the presence of the followingtransmission components or data inputs:

Transmission Components

Retarder Present, Not PresentOil Level Sensor (OLS) Present, Not PresentThrottle Analog, J1587, J1939Engine Coolant Temperature Analog, J1939, J1587

Seek help from the nearest Allison Transmission service outlet when any of theabove components are present, but are not responding properly.

Another feature of the 3000 and 4000 Product Families transmission is its abilityto adapt or learn as it operates. Each shift is measured electronically, stored, andused by the TCM to adapt or learn the optimum control for future shifts.

NOTE: Allison 4th Generation Controls are designed and manufacturedto comply with all FCC and other guidelines regarding radio frequencyinterference/electromagnetic interference (RFI/EMI) for transportationelectronics. Manufacturers, assemblers, and installers of radio-telephoneor other two-way communication radios have the sole responsibility tocorrectly install and integrate those devices into Allison 3000 and 4000Product Families transmission-equipped vehicles to customersatisfaction.

The TCM is programmed to provide the most suitable operating characteristics fora specific application. This manual does not attempt to describe all of the possiblecombinations. The information contained herein describes only the operatingcharacteristics most frequently requested by the vehicle manufacturer.

TORQUE CONVERTERThe torque converter consists of the following four elements:

Pumpinput element driven directly by the engine

Turbineoutput element hydraulically driven by the pump

Statorreaction (torque multiplying) element

Lockup Clutchmechanically couples the pump and turbine when engaged;controlled by TCM

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When the pump turns faster than the turbine, the torque converter is multiplyingtorque. When the turbine approaches the speed of the pump, the stator starts torotate with the pump and turbine. When this occurs, torque multiplication stopsand the torque converter functions as a fluid coupling.

The lockup clutch is located inside the torque converter and consists of thefollowing elements:

Piston and backplatedriven by the engine

Clutch plate/damper (located between the piston and thebackplate)splined to the converter turbine

The lockup clutch/torsional damper is engaged and released in response toelectronic signals from the TCM. Lockup clutch engagement provides a directdrive from the engine to the transmission gearing. This eliminates converterslippage and maximizes fuel economy and vehicle speed. The lockup clutchreleases at lower speeds or when the TCM detects conditions requiring it to bereleased.

The torsional damper absorbs engine torsional vibration to prevent transmittingvibrations through the powertrain.

PLANETARY GEARS AND CLUTCHESA series of three helical planetary gear sets (four in 7-speed transmissions) andshafts provides the mechanical gear ratios and direction of travel for the vehicle.The planetary gear sets are controlled by five multiplate clutches (six in 7-speedtransmissions) that work in pairs to produce up to six forward speeds (seven in7-speed transmissions) and one reverse speed. The clutches are applied andreleased hydraulically in response to electronic signals from the TCM to theappropriate solenoids.

COOLER CIRCUITThe transmission fluid is cooled by an integral (transmission-mounted) orremote-mounted oil cooler. Connections to the cooling circuit are located at thefront or rear of the transmission to facilitate installation of remote cooler lines. Onretarder models, only the rear cooler ports may be used. The integral cooler ismounted on the lower rear portion of the transmission, replacing the remote coolermanifold. Integral cooler oil ports are internal requiring coolant to be routed toand from the cooler.

A new feature has been added on all retarder-equipped transmissions. The retarderhousing now allows addition of either a remote or integral cooler for transmissionsump fluid in addition to retarder out fluid. A by-pass cover is placed over thesump cooling ports when the provision is not used. The sump cooler ports arelocated on the lower right rear face of the retarder housing.

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RETARDERThe self-contained retarder is at the output of the transmission and consists of avaned rotor which rotates in a vaned cavity. The rotor is splined to and driven bythe output shaft. An external accumulator holds transmission fluid until theretarder is activated. When the retarder is activated, the fluid in the accumulator ispressurized by the vehicle air system and directed into the retarder cavity. Theinteraction of the fluid with the rotating and stationary vanes causes the retarderrotor and output shaft to reduce speed, slowing the vehicle or limiting speed on adownhill grade. Refer to USING THE HYDRAULIC RETARDER for additionalinformation.

When the retarder is deactivated, the retarder cavity is evacuated and theaccumulator is recharged with fluid.

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DESCRIPTION OF AVAILABLE TYPES

61

71

61

MODE

61

RND654321

12345DNR

7 1

V07343.04.00

SIX-SPEED,LEFT-HAND

LEVER SELECTORWITH REVERSE

IN REAR

SEVEN-SPEED,RIGHT-HAND

LEVER SELECTORWITH REVERSE

TO FRONT

HOLD OVERRIDEBUTTON

HOLD OVERRIDEBUTTON

MODE ID MODE ID

*

MODE INDICATOR(LED) MODE INDICATOR

(LED)

MODE IDMODE

INDICATOR (LED)Push simultaneouslyto enter diagnosticmode and fluidlevel check

NOTE: The first number displayed is highest forward range available and second number is rangeattained in selected position.Visually check to confirm range selected. If display is flashing, shift is inhibited.

*

DIGITAL DISPLAY*

PUSHBUTTON SELECTORS

*

CONTOUREDBEZEL

MODE BUTTONMODE BUTTON

DIGITAL DISPLAYDIGITAL DISPLAY

DISPLAY MODEDIAGNOSTIC BUTTON

DISPLAY MODEDIAGNOSTIC BUTTON

Figure 3. Allison 4th Generation Controls Shift Selectors

SHIFT SELECTORS

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INTRODUCTIONVehicle manufacturers may choose different types of shift selectors for theirvehicles. The shift selector in your Allison-equipped vehicle will be similar to oneof the pushbutton or lever styles shown above.

With an Allison-equipped vehicle, it is not necessary to select the right moment toupshift or downshift during changing road and traffic conditions. The Allison 3000Product Family and 4000 Product Family transmission does it for you. However,knowledge of the shift selector positions, available ranges, and when to selectthem, make vehicle control and your job even easier. Select lower ranges whendescending long grades (with or without retarder) to reduce wear on servicebrakes. Refer to the Range Selection table at the end of this section for relatedinformation.

LEVER SHIFT SELECTOR

General Description. The lever shift selector is an electro-mechanical control.Typical lever positions are:

R (Reverse) N (Neutral) D (Drive) Some number of lower forward range positions

Allison 3000 Product Family and 4000 Product Family transmissions can beprogrammed to have up to six forward ranges (seven in 7-speed transmissions).Shift selector positions should agree with the programming of the TCM unit.

The lever selector includes the following:

HOLD OVERRIDE button MODE button Digital display DISPLAY MODE/DIAGNOSTIC button

HOLD OVERRIDE Button. The lever shift selector has three locked positions toprevent accidentally selecting R (Reverse), N (Neutral), or D (Drive). SelectR (Reverse), N (Neutral), or D (Drive) by pressing the HOLD OVERRIDEbutton and moving the lever to the desired position. Once D (Drive) is selected,lower forward range positions may be selected without pressing theHOLD OVERRIDE button.

MODE Button. The MODE button can allow the driver to enable a secondaryshift schedule, PTO, or other special functions that have been programmed intothe TCM unit at the request of the OEM. For example, an emergency vehicleOEM may have provided a secondary shift schedule for improved fuel economy.The name of the special function (ECONOMY) appears on the MODE ID label

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adjacent to the MODE button. Pressing the MODE button activates theECONOMY shift schedule and illuminates the MODE INDICATOR (LED).

When the Diagnostic Display Mode has been entered, the MODE button is usedto view and toggle through diagnostic code information. After viewing the firstdiagnostic code which appears in the digital display, press the MODE button toview the 2nd diagnostic code logged. Repeat this procedure to view the 3rd, 4th,and 5th code positions. The code displayed is active if the MODE INDICATOR(LED) is illuminated.

NOTE: Visually check the digital display whenever the lever is movedto be sure the range selected is shown. (For example: If N (Neutral) isselected, N should appear in the digital display.)

Digital Display. During normal operation, if D (Drive) is selected, the digitaldisplay shows the highest forward range attainable for the shift schedule in use.

Abnormal operation is indicated by the Allison 4th Generation Controls digitaldisplay as follows:

When all segments of the digital display are illuminated, the shift selectordid not complete initialization.

When both digital displays remain blank for 10 seconds after initializationand then show a \/\ (cateye), the shift selector is unable to communicatewith the TCM or has experienced an internal fault.

When the display shows a \/\ (cateye), a selector-related fault code hasbeen logged.

Conditions which illuminate the CHECK TRANS light disable the shiftselector. The SELECT digit is blank and the MONITOR digit displays therange actually attained. For a detailed explanation, refer to the CHECKTRANS LIGHT paragraph in the Driving Tips section.

The transmission will not shift into range if a CHECK TRANS code is active.When the display shows R or D has been requested and the display is flashing,the requested range has not been achieved due to an inhibit function.

Some inhibit functions are vehicle-related and do not result in diagnostic codes.Some examples are mentioned in the Range Selection tables at the end of thisSection.

Check for active codes if no other inhibit function has been located. OnceD (Drive) is attained, the transmission will shift into the lowest range programmedfor the D (Drive) position, usually first range.

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Display Mode/Diagnostic Button. The DISPLAY MODE/DIAGNOSTIC buttonallows access to optional fluid level check information and diagnostic codeinformation. Press the DISPLAY MODE/DIAGNOSTIC button once to obtaintransmission fluid level information and a second time to obtain diagnostic codeinformation.

PUSHBUTTON SHIFT SELECTOR (FULL FUNCTION, NONSTRIP-TYPE)

General Description. The pushbutton shift selector has the following:

R (Reverse)Press this button to select Reverse. N (Neutral)Press this button to select Neutral. D (Drive)Press this button to select Drive. The highest forward range

available will appear in the digital display window. The transmission willstart out in the lowest available forward range and advance automatically tothe highest range.

(Up) ArrowPress the (Up) Arrow when in DRIVE to request thenext higher range. Continuously pressing the (Up) Arrow will request thehighest range available.

(Down) ArrowPress the (Down) Arrow when in DRIVE to requestthe next lower range. Continuously pressing the (Down) Arrow willrequest the lowest range available.

MODE Button and Display Mode/Diagnostic ButtonThis is the samefunction as described previously in the LEVER SHIFT SELECTORparagraph, MODE Button paragraph.

NOTE: When an oil level sensor is present, fluid level information isdisplayed after pressing both the (Up) and (Down) arrow buttonssimultaneously. Simultaneously press both buttons again to obtaindiagnostic data.

Refer to the Care And Maintenance section, FLUID LEVEL CHECK USINGPUSHBUTTON OR LEVER SHIFT SELECTOR for more information about fluidlevel data. Refer to the Driving Tips section, DIAGNOSTIC CODES andDIAGNOSTIC CODE DISPLAY PROCEDURE, for more information aboutdiagnostic codes and display procedure.

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PUSHBUTTON SHIFT SELECTOR (STRIP-TYPE)

General Description. The strip-type pushbutton selector cannot be used indual-control applications. The forward range buttons are blocked whenR (Reverse) is selected. The R (Reverse) button is blocked when any forwardrange button is selected. Selecting N (Neutral) will clear all blocks. Strip-typepushbutton selectors require a separate switch (installed by the vehiclemanufacturer) to provide the same special functions as the MODE button on themore common shift selectors. Diagnostic information must be obtained using anAllison DOC diagnostic tool or an OEM-provided remote display. Refer to theDriving Tips sections, DIAGNOSTIC CODES and DIAGNOSTIC CODEDISPLAY PROCEDURE, for more information. The pushbutton selected isilluminated by a lamp under the button.

The strip-type pushbutton shift selectors have the following pushbuttons:

R (Reverse)Press this button to select Reverse. N (Neutral)Press this button to select Neutral. D (Drive)Press this button to select Drive. The transmission will start out

in the lowest available forward range and advance automatically to thehighest range.

3 (third range)*Only used when the highest range available in D (Drive)is fourth range. The transmission will start out in first range and advancesequentially and automatically to third range.

2 (second range)*Only used when the highest range available inD (Drive) is fourth range or third range. The transmission will start out infirst range and advance sequentially and automatically to second range.

1 (first range)*The transmission will be held in first range.

*Actual range buttons available on strip-type pushbutton selectors depends onvehicle configuration.

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RANGE SELECTION

RANGE SELECTIONPUSHBUTTON AND LEVER SHIFT SELECTORSWITH DIGITAL DISPLAY

Description of Available Ranges (refer to Figure 3)

WARNING: If you leave the vehicle and the engine is running,the vehicle can move unexpectedly and you or others could beinjured. If you must leave the engine running, do not leave thevehicle until you have completed all of the followingprocedures:

1. Put the transmission in N (Neutral).2. Be sure the engine is at low idle (500800 rpm).3. Apply the parking brakes and emergency brake and make

sure they are properly engaged.4. Chock the wheels and take any other steps necessary to

keep the vehicle from moving.

WARNING: R (Reverse) may not be attained due to an activeinhibitor. Always apply the service brakes when selectingR (Reverse) to prevent unexpected vehicle movement andbecause a service brake inhibit may be present. When R isflashing, it indicates the shift to R (Reverse) is inhibited.Check for active diagnostic codes if R (Reverse) is notattained. See DOWNSHIFT AND DIRECTION CHANGEINHIBITOR FEATURE in the Driving Tips section.

CAUTION: Do not idle in R (Reverse) for more thanfive minutes. Extended idling in R (Reverse) can causetransmission overheating and damage. Always select N (Neutral)whenever time at idle exceeds five minutes.

NOTE: Visually check the digital display window whenever abutton is pushed or the lever is moved to be sure the range selectedis shown (i.e., if the N (Neutral) button is pressed, N shouldappear in the digital display). A flashing display indicates the rangeselected was not attained due to an active inhibit.

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RANGE SELECTIONPUSHBUTTON AND LEVER SHIFT SELECTORSWITH DIGITAL DISPLAY (contd)

Description of Available Ranges (refer to Figure 3)R Completely stop the vehicle and let the engine return to idle before

shifting from a forward range to R (Reverse) or from R (Reverse)to a forward range. The digital display will display R whenR (Reverse) is selected.

WARNING: When starting the engine, make sure the servicebrakes are applied. Failure to apply the service brakes canresult in unexpected vehicle movement.

WARNING: Vehicle service brakes, parking brake, oremergency brake must be applied whenever N (Neutral) isselected to prevent unexpected vehicle movement. SelectingN (Neutral) does not apply vehicle brakes, unless an auxiliarysystem to apply the parking brake is installed (see theOperators Manual for the vehicle).

WARNING: If you let the vehicle coast in N (Neutral), there isno engine braking and you could lose control. Coasting can alsocause severe transmission damage. To help avoid injury andproperty damage, do not allow the vehicle to coast inN (Neutral).

N Use N (Neutral) when starting the engine, to check vehicleaccessories, and for extended periods of engine idle operation(longer than five minutes). For vehicles equipped with thepushbutton selector, N (Neutral) is selected by the TCM duringstart-up. For vehicles equipped with the lever selector, the vehiclewill not start unless N (Neutral) has been selected. If the vehiclestarts in any range other than N (Neutral), seek serviceimmediately. N (Neutral) is also used during stationary operation ofthe power takeoff (if the vehicle is equipped with a PTO). Thedigital display will show N when N (Neutral) is selected. Alwaysselect N (Neutral) before turning off the vehicle engine.

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RANGE SELECTIONPUSHBUTTON AND LEVER SHIFT SELECTORSWITH DIGITAL DISPLAY (contd)

Description of Available Ranges (refer to Figure 3)

WARNING: D (Drive) may not be attained due to an activeinhibitor. Always apply the service brakes when selectingD (Drive) to prevent unexpected vehicle movement andbecause a service inhibit may be present. When D isflashing, it indicates the shift to D (Drive) is inhibited. Checkfor active diagnostic codes if D (Drive) is not attained. SeeDOWNSHIFT AND DIRECTION CHANGE INHIBITORFEATURE in the Driving Tips section.

CAUTION: Do not idle in D (Drive) or any forward range formore than five minutes. Extended idling in D (Drive) can causetransmission overheating and damage. Always select N (Neutral)whenever time at idle exceeds five minutes.

NOTE: Turn off the vehicle HIGH IDLE switch, if present, beforeshifting from N (Neutral) to D (Drive) or R (Reverse). D (Drive)or R (Reverse) will not be attained unless the shift is made withthe engine at idle. Also, be aware of other interlocks that wouldprevent attaining D (Drive) or R (Reverse). Examples arewheelchair lift not stored and service brakes not applied(service brake interlock present).

D The transmission will initially attain first range when D (Drive) isselected (except for those units programmed to start in secondrange). As vehicle speed increases, the transmission will upshiftautomatically through each range. As the vehicle slows, thetransmission will downshift automatically through each range. Thedigital display will show the highest range available in D (Drive).

WARNING: The transmission incorporates a hold feature toprohibit upshifting above the range selected during normaldriving. For downhill operation, select a lower transmissionrange. If the engine governed speed is exceeded in the heldrange, however, the transmission will upshift to the next higherrange to prevent engine damage. To avoid injury and/or propertydamage due to loss of vehicle control, use the vehicle brakes toprevent exceeding engine governed speed in the held range.

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RANGE SELECTIONPUSHBUTTON AND LEVER SHIFT SELECTORSWITH DIGITAL DISPLAY (contd)

Description of Available Ranges (refer to Figure 3)7+6*5*4*32

Lower ranges provide greater engine braking for going downgrades (the lower the range, the greater the braking effect).Occasionally, it may be desirable to restrict automatic shifting to alower range because of:

Road conditions. Load. Traffic conditions. Etc.

The pushbutton shift selector arrow buttons access individualforward ranges. Push the (Up) or (Down) arrow for the desiredrange. The digital display shows the range chosen. Even though alower range is selected, the transmission may not downshift untilvehicle speed is reduced (this prevents excessive engine speed inthe lower range).

1 First range provides the vehicle with its maximum driving torqueand engine braking effect. Use first range when:

Pulling through mud and deep snow. Maneuvering in tight spaces. Driving up or down steep grades.

For vehicles equipped with the pushbutton selector, push the (Down) arrow until first range appears in the select window.

+ Only available in 7-speed transmissions.

* Actual ranges available depend on programming by vehicle manufacturer.

23

CHECK TRANS LIGHTThe electronic control system is programmed to inform the operator of a problemwith the transmission system and automatically take action to protect the operator,vehicle, and transmission. When the Transmission Control Module (TCM) detectsa problem condition, the TCM:

Restricts shifting.

Illuminates the CHECK TRANS light on the instrument panel.

Registers a diagnostic code.

NOTE: For some problems, diagnostic codes may be registered withoutthe TCM activating the CHECK TRANS light. Your AllisonTransmission authorized service outlet should be consulted wheneverthere is a transmission-related concern. They have the equipment tocheck for diagnostic codes and to correct problems which arise.

Each time the engine is started, the CHECK TRANS light will illuminate, thenturn off after a few seconds. This momentary lighting is to show that the statuslight circuits are working properly. If the CHECK TRANS light does notilluminate during ignition, or if the light remains on after ignition, the systemshould be checked immediately.

Continued illumination of the CHECK TRANS light during vehicle operation(other than start-up) indicates that the TCM has signaled a diagnostic code.Illumination of the CHECK TRANS light is accompanied by a flashing displayfrom the shift selector. The shift selector display will show the actual rangeattained and the transmission will not respond to shift selector requests.

Indications from the shift selector are provided to inform the operator thetransmission is not performing as designed and is operating in the limp homemode with reduced capabilities. Before turning off the ignition, the transmissionmay be operated for a short time in the selected range in order to limp home forservice assistance. Service should be performed immediately in order to minimizethe potential for damage to the transmission.

DRIVING TIPS

24

When the CHECK TRANS light comes on and the ignition switch is turned off,the transmission will remain in N (Neutral) until the condition causing theCHECK TRANS light is corrected.

Generally, while the CHECK TRANS light is on, upshifts and downshifts will berestricted and direction changes will not occur. Lever and pushbutton shiftselectors do not respond to any operator shift requests while the CHECKTRANS light is illuminated. The lockup clutch is disengaged when transmissionshifting is restricted or during any critical transmission malfunction.

DIAGNOSTIC CODES

Diagnostic Codes Overview. Diagnostic codes are numerical indications relatingto a malfunction in transmission operation. These codes are logged in a list in theTCM memory with the most severe or most recent code listed first. A maximumof five codes (numbered d1d5) may be listed in memory at one time. As codesare added, the oldest non-active code is dropped from the list. If all codes areactive, the code with the lowest priority that is not included on the severity list isdropped from the list.

Diagnostic codes and code information may be accessed through the pushbuttonand lever shift selectors or using an Allison DOC diagnostic tool.

The TCM separately stores the active and historical (non-active) codes. An activecode is any code that is current in the TCM decision-making process.

Historical codes are codes that are retained in the TCMs memory and will notnecessarily affect the TCM decision-making process. Historical codes are useful indetermining if a problem:

Is isolated. Is intermittent. Results from a previous malfunction.

The TCM may automatically delete a code from memory if it has not recurred.

If the MODE INDICATOR (LED) is illuminated, the displayed code is active. Ifthe MODE INDICATOR (LED) (refer to Figure 3) is not illuminated, thedisplayed code is not active. An illuminated MODE INDICATOR (LED) duringnormal operation signifies Secondary Mode operation. For more information, referto PRIMARY/SECONDARY SHIFT SCHEDULES.

25

Diagnostic CodesAllison 4th Generation Controls. When the diagnostic modeis entered, the first code (position d1) is displayed as follows:

ExampleCode P0722:Displayed as: d1, P, 07, 22The code list position is the first item displayed, followed by the DTC. Each itemis displayed for about one second. The display cycles continuously until the nextcode list position is accessed by pressing the MODE button. The followingexample shows how DTC P0722 is displayed on the pushbutton and lever shiftselectors.

SELECT MONITORd 1

P0 72 2

d1 (code list position)The position which a code occupies in the code list.Positions are displayed as d1 through d5 (Code List Position 1 throughCode List Position 5).

P0722 (DTC)The diagnostic trouble code number referring to the generalcondition or area of fault detected by the TCM.

DIAGNOSTIC CODE DISPLAY PROCEDUREDiagnostic codes can be read and cleared by two methods:

Using an Allison DOC diagnostic tool. For specific instructions on howto use an Allison DOC diagnostic tool, refer to the User Guide.

Using the pushbutton or lever shift selector.

Pushbutton Shift Selector.To begin the Diagnostic Process:

1. Bring the vehicle to a stop at a safe location.

2. Apply the parking brake.

To Display Stored Codes:

1. Access the Diagnostic Display Mode. Press the DISPLAYMODE/DIAGNOSTIC button once to access the diagnostic displaymodepress the button twice if a transmission oil level sensor is installed.

2. Observe the digital display for codes. Diagnostic codes will appear twocharacters at a time on Allison 4th Generation Controls pushbutton or levershift selectors.

3. Press the MODE button to see the next coderepeat for subsequent codes.

26

NOTE: Be sure to record all codes displayed before they are cleared.This is essential for troubleshooting.

To Clear Active Indicators and Inactive Codes then Resume Vehicle Operation:

1. Press and hold the MODE button for 10 seconds to clear both activeindicators and inactive codes.

2. Begin operating as normalhave the transmission checked at the earliestopportunity by an Allison Transmission distributor or dealer.

Lever Shift Selector.To Begin the Diagnostic Process:

1. Bring the vehicle to a stop at a safe location.

2. Apply the parking brake.

To Display Stored Codes:

1. Press the DISPLAY MODE/DIAGNOSTIC button once to access thediagnostic display modepress the button twice if a transmission oil levelsensor is installed.

2. Observe the digital display for codes. Diagnostic codes will appear twocharacters at a time on Allison 4th Generation Controls pushbutton or levershift selectors.

3. Press the MODE button to see the next coderepeat for subsequent codes.

NOTE: Be sure to record all codes displayed before they are cleared.This is essential for troubleshooting.

To Clear Active Indicators and Inactive Codes then Resume Vehicle Operation:

1. Press and hold the MODE button for 10 seconds to clear both activeindicators and inactive codes.

2. Begin operating as normalhave the transmission checked at the earliestopportunity by an Allison Transmission distributor or dealer.

NOTE: If the condition that caused the code is still present, the codewill again become active.

27

ACCELERATOR CONTROL

WARNING: To help avoid injury or property damage caused by suddenmovement of the vehicle, do not make shifts from N (Neutral) toD (Drive) or R (Reverse) when the throttle pedal is depressed. If youshift while the throttle pedal is depressed too far, the transmission willonly engage if the throttle pedal is released in the next three seconds.This may cause a sudden movement of the vehicle. Leaving the throttlepedal depressed longer than three seconds causes the transmission toremain in N (Neutral). Avoid this condition by making shifts fromN (Neutral) to D (Drive) or R (Reverse) only when the throttle isclosed.

The position of the accelerator pedal influences when automatic shifting occurs.An electronic throttle position signal tells the TCM how much the operator hasdepressed the pedal. When the pedal is fully depressed, upshifts will occurautomatically at high engine speeds. A partially depressed position of the pedalwill cause upshifts to occur at lower engine speeds. Excessive throttle positionaffects directional changesshifts from N (Neutral) to D (Drive) or R (Reverse).

DOWNSHIFT AND DIRECTION CHANGE INHIBITORFEATURE

NOTE: Turn off the vehicle HIGH IDLE switch, if present, beforeshifting from N (Neutral) to D (Drive) or R (Reverse). The shift fromN (Neutral) to D (Drive) or R (Reverse) is inhibited when engine speedis above idle.

There is no speed limitation on upshifting, but there is a limitation ondownshifting and for shifts that cause a direction change such asD (Drive)-to-R (Reverse) or R (Reverse)-to-D (Drive).

Manual range downshifts will not occur until a calibration output speed (preset) isreached. When a range downshift is manually selected and the transmission outputspeed is above the calibration speed, the transmission will stay in the range it wasin even though a lower range was requested. Apply the vehicle service brakes or aretarding device to reduce the transmission output speed to the calibration speedand then the shift to the lower range will occur.

Directional shifts, D (Drive)-to-R (Reverse) or R (Reverse)-to-D (Drive), will notoccur if selected when throttle position, engine speed, or transmission outputspeed is above the calibration limit for a calibration time period. The currentcalibration time period for engine speed is 0.5 seconds and for throttle positionand output speed is three seconds.

28

Shifts from N (Neutral)-to-D (Drive) or N (Neutral)-to-R (Reverse) are alsoinhibited when the TCM has been programmed (by input/output function) todetect that auxiliary equipment is in operation and the shift should not be allowed.

When directional change shifts are inhibited, the TCM will put the transmission inN (Neutral) and the digital display, if present, will flash the letter of the rangeselected (D or R). To reselect D (Drive) or R (Reverse) when engine throttle,engine speed, and/or transmission output speed are below the calibration value:

Pushbutton selectorPress the desired pushbutton again.

Lever selectorMove the lever to N (Neutral) and then to the desiredrange.

When a direction change shift is requested and engine throttle, engine speed, andtransmission output speed drop below the calibration value during the calibrationtime interval, the shift to D (Drive) or R (Reverse) will occur.

For example, if the transmission output speed was just above the calibrationlimit when R (Reverse) was selected, but dropped below the limit duringthe next three seconds, the shift to R (Reverse) would occur (assuming theengine was at idle and the throttle was closed).

USING THE ENGINE TO SLOW THE VEHICLE

WARNING: To avoid loss of control, use a combination ofdownshifting, braking, and other retarding devices. Downshifting to alower transmission range increases engine braking and can help youmaintain control. The transmission has a feature to prevent automaticupshifting above the lower range selected. However, during downhilloperation, if engine governed speed is exceeded in the lower range, thetransmission will upshift to the next higher range to prevent enginedamage. This will reduce engine braking and could cause a loss ofcontrol. Apply the vehicle brakes or other retarding device to preventexceeding engine governed speed in the lower range selected.

Engine braking provides good speed control for going down grades. When thevehicle is heavily loaded, or the grade is steep, it may be desirable to preselect alower range before reaching the grade. If engine-governed speed is exceeded, thetransmission will upshift automatically to the next range.

To use the engine as a braking force, select the next lower range. If the vehicle isexceeding the maximum speed for this range, use the service brakes and/orretarder to slow the vehicle. When a lower speed is reached, the TCM willautomatically downshift the transmission.

29

USING THE HYDRAULIC RETARDER

WARNING: DO NOT USE THE RETARDER DURING INCLEMENTWEATHER OR WHEN ROAD SURFACES ARE SLIPPERY.De-energize the retarder at the master control switch.To help avoid injury or property damage caused by loss of vehiclecontrol, be ready to apply vehicle brakes or other retarding device if thetransmission retarder does not apply. If a retarder is present but is notdetected by autodetect, the retarder will not function. Be sure to checkfor proper retarder function periodically. Whenever the retarder does notapply, seek service help immediately.

On vehicles which have the primary retarder control based upon closedthrottle position, brake pedal position, or brake apply pressure, alwaysmanually disable the retarder controls during inclement weather orslippery road conditions.

Regardless of the type of Allison retarder controls on your vehicle, the followingsafety features are common to each configuration:

The retarder can be disabled when inclement weather or slippery roadconditions are present.

Vehicle brake lights should always be on when the retarder is applied(periodically verify that they are working).

Anti-lock brake systems send a signal to the transmission TCM to indicatethat the brake system is activated.

NOTE: The retarder is automatically disabled and the lockup clutch isdisengaged whenever the vehicle anti-lock brake system (ABS) is active.However, in case the ABS system malfunctions, it is recommended thatthe retarder enable switch, if present, be disabled.

A hydraulic retarder is available on all of the models covered in this manual. Theretarder is activated and controlled in various ways. The control depends upon thevehicle type and particular duty cycle. Both manual and automatic controls areavailable. Automatic controls are applied by the TCM. In Allison 4th GenerationControl Systems, the TCM may also activate or limit retarder operation inresponse to torque speed control or electronic retarder control messages receivedon the vehicles J1939 Data Link. Some types of controls and the amount ofretarder application are shown in the Types of Retarder Control table that follows.

The presence of a retarder must be autodetected as part of the Allison 4th

Generation Controls system.

30

NOTE: If your transmission has a retarder but it is not functioning, itmay not have been autodetected during vehicle manufacture. Goimmediately to your nearest Allison Transmission service outlet to haveautodetect reset or the retarder enabled using the Allison DOC ForPCService Tool.

NOTE: When reduced retarder performance is observed, be sure thetransmission fluid level is within the operating band on the dipstick(refer to Figure 5). Low fluid level is a common cause for retarderperformance complaints.

NOTE: The retarder requires about one second to reach full capacityrequested. Be sure to anticipate this delay when using the retarder.Anticipation will prevent unnecessary service brake applications duringnon-emergency stops.

Types of Retarder Control

Type Description Amount of ApplicationManual Separate apply

pedalZero to Full apply

Hand lever * Six levels based on lever positionAutomatic Auto Full On * Full On when closed throttle sensedBrake PressureApply**

Single pressureswitch

Off or Full On (based on brakepressure)

Three pressureswitches

1/3,2/3, or Full On (based on brake

pressure)Pedal Position ** Special brake

pedal

1/3,2/3, or Full On (based on pedal

position)J1939 Data Link Digital message

from enginecontroller

Zero to Full Apply

31

Types of Retarder Control (contd)

Type Description Amount of ApplicationCombinations ofthe abovesystems **

Auto half-onplus pressureswitch *

Half capacity at closed throttle orFull On with brake pressure

Auto 1/3 on plustwo pressureswitches *

1/3, capacity at closed throttle or2/3

and Full On with brake pressure

Hand lever pluspressure switch *

6 levels of modulation with lever, orFull On with brake pressure

Foot pedal pluspressure switch

Full modulation with separate pedal,or Full On with brake pressure

Hand lever plusinterface forspecial pedal *

6 levels of modulation with lever, or 3levels of modulation based on pedalposition

* These control systems may apply the retarder at high speed on grades when the vehicle has roadspeed limiting and the retarder is enabled.

** For retarder apply systems integrated with the service brake system, the retarder is most effectivewhen applied with light brake pedal pressure for 12 seconds to allow the retarder to fullycharge. Added pedal pressure can be applied when more aggressive braking is desired.

NOTE: When the transmission fluid or engine water temperature(engine water is an OEM option) exceeds programmed limits, retardercapacity is automatically gradually reduced to minimize or avoidpossible system overheating.

Contact your vehicle manufacturer to understand how the retarder controls havebeen integrated into your vehicle.

CAUTION: Observe the following cautions when driving a vehicleequipped with a retarder:

THE RETARDER WORKS ONLY WHEN THE ENGINE IS ATCLOSED THROTTLE.

OBSERVE TRANSMISSION AND ENGINE TEMPERATURELIMITS AT ALL TIMES. Select the lowest possible transmissionrange to increase the cooling system capacity and total retardationavailable.

In the event of OVERHEATING, DECREASE THE USE OF THERETARDER; USE THE SERVICE BRAKES TO SLOW THEVEHICLE.

OBSERVE THE RETARDER/SUMP OVERTEMP LIGHT to besure it responds properly to retarder temperature.

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NOTE: Transmission fluid level must be set correctly for highestretarder effectiveness. As much as 2 liters (2 quarts) too high or too lowcan reduce retarder effectiveness and increase transmission temperature.

RANGE PRESELECTION

NOTE: Preselecting during normal operation may result in reduced fueleconomy.

Range preselection means selecting a lower range to match driving conditionsencountered or expect to be encountered. Learning to take advantage ofpreselected shifts will give you better control on slick or icy roads and ondowngrades.

Downshifting to a lower range increases engine braking. The selection of a lowerrange often prevents cycling between that range and the next higher range on aseries of short up-and-down hills.

COLD WEATHER STARTSAll 3000 and 4000 Product Families transmissions are programmed to restrict fulloperation until specific fluid temperatures are reached. Refer to the following tablefor temperature restrictions.

Minimum Fluid Operating Temperatures

Sump Fluid TemperatureCHECK

TRANS Light Operation32C (25F) to 7C (19F) OFF Neutral, Reverse, Second7C (19F) OFF Full operation in all ranges

NOTE: When sump temperature is below 10C (50F) and transmissionfluid is C4 (not DEXRON or TranSynd), follow these procedureswhen making directional shift changes:

To shift from forward to reverse, select N (Neutral) and thenR (Reverse).

To shift from reverse to forward, select N (Neutral) and thenD (Drive) or other forward range.

Failure to follow these procedures may cause illumination of theCHECK TRANS light and the transmission will be restricted toN (Neutral).

33

Transmission operation at cold ambient temperatures may require preheating orthe use of a lower viscosity transmission fluid. Refer to the Care And Maintenancesection, RECOMMENDED AUTOMATIC TRANSMISSION FLUID ANDVISCOSITY GRADE.

DRIVING ON SNOW OR ICE

WARNING: Using the retarder on wet or slippery roads may cause lossof traction on the drive wheelsyour vehicle may slide out of control.To help avoid injury or property damage, turn the retarder enable toOFF when driving on wet or slippery roads.

NOTE: The retarder is automatically disabled whenever the vehicleanti-lock brake system (ABS) is active. However, in case the ABSmalfunctions, it is recommended that the retarder enable switch, ifpresent, be disabled.

If possible, reduce vehicle speed and select a lower range before losing traction.Select the range that will not exceed the speed expected to be maintained.

Accelerate or decelerate very gradually to prevent the loss of traction. It is veryimportant to decelerate gradually when a lower range is selected. It is importantthat you reach the selected lower range before attempting to accelerate. This willavoid an unexpected downshift during acceleration.

ROCKING OUT

WARNING: To help avoid injury or property damage caused by suddenmovement of the vehicle, do not make shifts from N (Neutral) toD (Drive) or R (Reverse) when the throttle is open. The vehicle willlurch forward or rearward and the transmission can be damaged. Avoidthis condition by making shifts from N (Neutral) to a forward range orR (Reverse) only when the throttle is closed and the service brakes areapplied.

CAUTION: DO NOT make N (Neutral) to D (Drive) or directionalshift changes when the engine rpm is above idle. Also, if the wheels arestuck and not turning, do not apply full power for more than 10 secondsin either D (Drive) or R (Reverse). Full power for more than 10 secondsunder these conditions will cause the transmission to overheat. If thetransmission overheats, shift to N (Neutral) and operate the engine at12001500 rpm until it cools (23 minutes).

34

If the vehicle is stuck in deep sand, snow, or mud, it may be possible to rock itout using the following procedure:

1. Shift to D (Drive) and apply steady, light throttle (never full throttle).

2. When the vehicle has rocked forward as far as it will go, apply and holdthe vehicle service brakes.

3. When engine has returned to idle, select R (Reverse).

4. Release the brakes and apply a steady, light throttle allowing the vehicle torock in R (Reverse) as far as it will go.

5. Again, apply and hold the service brakes and allow the engine to return toidle.

This procedure may be repeated in D (Drive) and R (Reverse) if each directionalshift continues to move the vehicle a greater distance. Never makeN (Neutral)-to-D (Drive) or directional shift changes when the engine rpm isabove idle.

OPERATING DOWN STEEP GRADES (REAR-DISCHARGEMIXER)

CAUTION: With this transmission, the service brakes must be usedwhen backing a loaded rear-discharge mixer down a grade. But toomuch brake application, particularly on an unpaved surface, can lock thefront brakes and reduce steering control. A crash could then occur. Tohelp prevent injury or property damage:

1. Drive forward down the grade and then exit by backing up thegrade when you can do so.

2. If equipped, use the trailer brake when backing the mixer down agrade. Do not use the trailer brake as a parking brake once thevehicle is at the bottom of the grade.

3. If a trailer brake is not available, back the mixer down the gradeby modulating the service brakes to control and maintain a safe,steady vehicle speed. Avoid abrupt stops and starts.

HIGH FLUID TEMPERATUREThe transmission is considered to be overheated when any of the followingtemperatures are exceeded:

Sump fluid 121C (250F)Fluid to cooler 149C (300F)Retarder out fluid 165C (330F)

35

CAUTION: The engine should never be operated for more than10 seconds at full throttle with the transmission in range and the outputstalled. Prolonged operation of this type will cause the transmission fluidtemperature to become excessively high and will cause severe overheatdamage to the transmission.

If the transmission overheats during normal operations, do the following:

Check the fluid level in the transmission. See the CARE ANDMAINTENANCE section of this manual.

Safely stop the vehicle and check the cooling system. If it appears to befunctioning properly, run the engine at 12001500 rpm with thetransmission in N (Neutral). This should reduce the transmission and enginetemperatures to normal operating levels in 2 or 3 minutes. If temperaturesdo not decrease, reduce the engine rpm.

If high temperature in either the engine or transmission persists, stop theengine and have the overheating condition investigated by servicemanagement.

PARKING BRAKE

WARNING: If you leave the vehicle and the engine is running, thevehicle can move unexpectedly and you or others could be injured. Ifyou must leave the engine running, DO NOT LEAVE the vehicle untilyou have completed all of the following procedures:

Put the transmission in N (Neutral). Be sure the engine is at low idle (500800 rpm). Apply the parking brake and emergency brake and make sure they

are properly engaged. Chock the wheels and take other steps necessary to keep the

vehicle from moving.

The parking brake is only intended to secure an unattended vehicle with theengine ignition OFF. Always maintain the vehicle parking brake system accordingto the manufacturers specifications. The parking brake may not have sufficientcapacity to restrain a vehicle with the engine running and the transmission in aforward or reverse-range. When the vehicle is unattended and the engine is inoperation, the transmission must be in N (Neutral) with the brakes fully appliedand the wheels chocked.

36

TOWING OR PUSHING

CAUTION: Failure to lift the driving wheels off the road, disconnectthe driveline, or remove the axle shafts before pushing or towing cancause serious transmission damage.

The engine cannot be started by pushing or towing. Before pushing or towing avehicle do one of the following:

Disconnect the driveline.

Lift the drive wheels off the road.

Remove the axle shafts from the drive wheels.

An auxiliary air supply will usually be required to actuate the vehicle brakesystem.

When the axle shafts are removed, be sure to cover the wheel openings to preventloss of lubricant and entry of dust and dirt.

TURNING OFF THE VEHICLEAlways select N (Neutral) prior to turning off the vehicle engine.

PRIMARY/SECONDARY SHIFT SCHEDULESThe points at which shifts occur depend upon predetermined speeds and otheroperating conditions. A transmission shift calibration includes several sets ofshift points which may be used according to current or anticipated operatingconditions. Some shift schedules may be inhibited as a result of operatingconditions, such as engine or transmission fluid temperature. Shift schedules maybe changed using the MODE button (some applications may use a dash-mountedswitch)which is typically associated with a change in anticipated vehicleoperation.

The TCM includes the capacity for two separate and distinct shift calibrations(customer-selectable), one for use in Primary Mode operation and one for use inSecondary Mode operation.

Primary ModeThis shift schedule is typically used for all normal vehicleoperations.

Secondary ModeThis is an alternate shift schedule that the TCM usesupon request. Not all vehicles will be equipped with a secondary shiftschedule. The request can be interlocked with a vehicle component, or beoperator-controlled using the MODE button.

Your vehicle may have a dash-mounted light that illuminates when the secondarymode is active.

37

CRUISE CONTROL OPERATIONOperating an Allison 4th Generation Controls-equipped vehicle on cruise controlmay cause the transmission to shift cycle if the cruise control speed setting is settoo close to a scheduled shift point. One of the following actions may eliminateshift cycling:

Select the secondary shift schedule by pushing the MODE button (refer toFigure 3) on the shift selector.

Select a lower range by pushing the (Down) arrow or moving the leveron the shift selector.

Change the cruise control setting away from the shift point.

Some vehicles equipped with an engine brake and an Allison 4th GenerationControls-equipped transmission will have the engine brake controlled by the TCM.This is done so the transmission will automatically select a lower range when theengine brake is turned on and the throttle is near idle position.

Operating a vehicle on cruise control with the engine brake turned on andcontrolled by the transmission TCM may cause an unwanted application of theengine brake when the cruise control decelerates for downhill grades. Eliminatethis condition by turning off the engine brake while operating the vehicle oncruise control.

38

ENGINE-DRIVEN POWER TAKEOFF (PTO)

CAUTION: Do not exceed the engagement and operational speed limitsimposed on the driven equipment during the operation of the PTO.Exceeding the speed limits produces high hydraulic pressure in the PTOthat can damage the PTO components. Consult the vehiclemanufacturers literature for these speed limits.

On the 3000 Product Family transmission, if a PTO is present, it will normally bemounted on either the left or right side. An option to mount the PTO on the top of3000 Product Family transmissions (except in 7-speed models) is available. On the4000 Product Family transmission, the PTO will be located on the left side or onthe top of the transmission.

The PTO drive gear is engine-driven and therefore provides direct engine power.The PTO can be operated when the vehicle is either moving or stopped. The PTOgear is in constant mesh with the drive gear in the converter housing. However,the PTO may either be constant-drive (output always powered) or clutch-driven.When the PTO is clutch-driven, the clutch is part of the PTO, not thetransmission. A clutch-driven PTO is powered only when the PTO clutch isengaged.

All 3000 and 4000 Product Families equipped vehicles with PTO enable haveengagement and operational speed limits programmed into the TCM/ECU to helpprotect PTO equipment. Be sure the limits for PTO engagement speed andoperational speed are not exceeded. Consult the vehicle manufacturers literaturefor these speed limits. Some speed limits have default values which areprogrammed out of the operating range and will need to be set for your particularPTO duty cycle. Consult your vehicle manufacturer to see if your transmission hasbeen programmed and what operational limits have been established.

When the programmed engagement speed is exceeded, the PTO will not engage.The PTO engagement must be retried after the speed has been reduced. Whenoperational speeds (either engine or transmission output) are exceeded, the PTOwill deactivate and the PTO engagement process must be repeated.

POWER TAKEOFF OPERATION

39

PERIODIC INSPECTIONSCareful attention to the fluid level and connections for the electronic and hydrauliccircuits is very important.

For easier inspection, the transmission should be kept clean. Make regular periodicinspections and check:

For loose bolts.

For leaking fluid around fittings, lines, and transmission openings.

The condition of the electrical harnesses.

The engine cooling system for presence of transmission fluid and check thetransmission fluid for presence of coolant, which would indicate a faulty oilcooler.

The breather to make sure it is clean and free from dirt or debris.

Report any abnormal condition to service management.

PREVENT MAJOR PROBLEMSHelp Allison 4th Generation Controls oversee the operation of the transmission.Minor problems can be kept from becoming major problems if an AllisonTransmission distributor or dealer is notified when one of these conditions occur:

Shifting feels odd. Transmission leaks fluid. Unusual transmission-related sounds (changes in sound caused by normal

engine thermostatic fan cycling, while climbing a long grade with a heavyload, have been mistaken for transmission-related sounds).

CHECK TRANS light comes on frequently.

IMPORTANCE OF PROPER FLUID LEVELIt is important that the proper fluid level be maintained at all times because thetransmission fluid cools, lubricates, and transmits hydraulic power. If the fluidlevel is too low, the converter and clutches do not receive an adequate supply offluid. If fluid level is too high, the fluid can aerate. Aerated fluid can cause thetransmission to shift erratically or overheat.

CARE AND MAINTENANCE

40

3000 and 4000 Product Families transmissions (except for 3700 models) mayinclude an oil level sensor (OLS) that allows the operator to obtain an indicationof fluid level from the shift selector. No oil level sensor diagnostics take placeunless the OLS is autodetected by Allison 4th Generation Controls.

Frequently check for the presence of oil level diagnostics if the transmission isknown to contain an OLS. If an OLS is not detected during a fixed number ofengine starts, the Allison 4th Generation Controls system concludes that no OLS ispresent. If an OLS is known to be present, but has not been detected, thentroubleshooting of the OLS circuit is required. After the OLS circuit is repaired,reset autodetect or manually select the OLS function using Allison DOC ForPCService Tool. For detailed troubleshooting procedures refer to theTroubleshooting Manual. Refer to the SERVICE LITERATURE section forspecific publication numbers.

NOTE: To correctly check the transmission fluid level using thedipstick, the transmission fluid must be at operating temperature.The oil level sensor method of checking the fluid level compensates fortransmission fluid temperature between 60C104C (140F220F).Any temperature below 60C (140F) or above 104C (220F) willresult in an Invalid for Display condition.

FLUID LEVEL CHECK USING PUSHBUTTON OR LEVERSHIFT SELECTORThe transmission must be equipped with the oil level sensor to be able to readfluid level information.

NOTE: Allison 4th Generation Controls pushbutton and lever selectorsdisplay fluid level diagnostic information two characters at a time.

1. Park the vehicle on a level surface, shift to N (Neutral), and apply theparking brake.

2. Pushbutton shift selectorIf equipped with an oil level sensor,simultaneously press the (Up) and (Down) arrow buttons.

3. Lever shift selectorIf equipped with an oil level sensor, press thedisplay mode button one time.

41

NOTE: The fluid level check may be delayed until the followingconditions are met:

The fluid temperature is above 60C (140F) and below104C (220F).

The transmission is in N (Neutral). The engine is at idle. The transmission output shaft is stopped. The vehicle has been stationary for approximately two minutes to

allow the fluid to settle.

A delayed fluid level check for Allison 4th Generation Controls is indicated by aflashing display under SELECT and a digit countdown from 8 to 1 underMONITOR.

61

71

61

MODE

61

RND654321

12345DNR

7 1

V07343.04.00

SIX-SPEED,LEFT-HAND

LEVER SELECTORWITH REVERSE

IN REAR

SEVEN-SPEED,RIGHT-HAND

LEVER SELECTORWITH REVERSE

TO FRONT

HOLD OVERRIDEBUTTON

HOLD OVERRIDEBUTTON

MODE ID MODE ID

*

MODE INDICATOR(LED) MODE INDICATOR

(LED)

MODE IDMODE

INDICATOR (LED)Push simultaneouslyto enter diagnosticmode and fluidlevel check

NOTE: The first number displayed is highest forward range available and second number is rangeattained in selected position.Visually check to confirm range selected. If display is flashing, shift is inhibited.

*

DIGITAL DISPLAY*

PUSHBUTTON SELECTORS

*

CONTOUREDBEZEL

MODE BUTTONMODE BUTTON

DIGITAL DISPLAYDIGITAL DISPLAY

DISPLAY MODEDIAGNOSTIC BUTTON

DISPLAY MODEDIAGNOSTIC BUTTON

Figure 4. Allison 4th Generation Controls Shift Selectors andPushbutton Selectors

42

NOTE: To view Fluid Level Fault Codes in metric units, use an AllisonDOC diagnostic tool.

NOTE: Allison 4th Generation Controls displays fluid level diagnosticinformation two characters at a time. Use care when interpreting thedisplay sequence. Specifically that oL and Lo are not misread. Forexample:o L - - 5 9is an Invalid For Display fault code that indicates that theengine speed is too high to receive the proper fluid level information. Itdoes not indicate that the transmission is 5.9 quarts low on fluid.o L L o 0 5is a Low Fluid Level fault code that does indicate that thetransmission is 5 quarts low on fluid.

Fluid level fault codes for Low Fluid Level and High Fluid Level arenever displayed in fractional amounts.

Correct Fluid Levelo L is displayed (o L represents Fluid (Oil)Level Check Mode), followed by o K. The o K display indicates thefluid is within the correct fluid level zone. The sensor display and thetransmission dipstick may not agree exactly because the oil level sensorcompensates for fluid temperature.

Low Fluid Levelo L is displayed (o L represents Fluid (Oil) LevelCheck Mode), followed by L o (L o represents Low Oil Level) andthe number of quarts the transmission fluid is low.Example: o L L o 0 2Where 2 indicates that 2 additional quarts of fluid will bring the fluidlevel within the middle of the o K zone.

High Fluid Levelo L is displayed (o L represents Fluid (Oil) LevelCheck Mode), followed by H I (H I represents High Oil Level) andthe number of quarts the transmission is overfilled.Example: o L H I 0 1Where 1 indicates 1 quart of fluid above the full transmission level.

Invalid for Display o L is displayed (o L represents Fluid (Oil)Level Check Mode), followed by and a numerical display. Thenumerical display is a fault code and indicates conditions are not proper toreceive the fluid level information, or that there is a system malfunction.The fault codes that may be encountered are shown in the Invalid ForDisplay Fault Codes table:

43

Invalid For Display Fault Codes (for Allison 4th Generation Controls)

Display Cause of Codeo L, - -, 0 X Settling time too shorto L, - -, 5 0 Engine speed (rpm) too lowo L, - -, 5 9 Engine speed (rpm) too higho L, - -, 6 5 Neutral must be selectedo L, - -, 7 0 Sump fluid temperature too lowo L, - -, 7 9 Sump fluid temperature too higho L, - -, 8 9 Output shaft rotationo L, - -, 9 5 Sensor failure*

* Report sensor failure display to a distributor or dealer in your area (check the telephone directoryfor an Allison Transmission distributor or dealer).

CAUTION: A low or high fluid level can cause overheating andirregular shift patterns. Incorrect fluid level can damage thetransmission.

NOTE: To exit the fluid level display mode, press any range button onthe pushbutton shift selector, or press the display mode (diagnostic)button once on the lever shift selector.

FLUID LEVEL CHECK USING STRIP-TYPE PUSHBUTTONSHIFT SELECTOR

NOTE: The strip type pushbutton shift selector has no displaycapability. Fluid level information can only be obtained by using anAllison DOC diagnostic tool or by using an OEM-supplied auxiliarydisplay.

FLUID LEVEL CHECK USING DIAGNOSTIC TOOLSThe transmission must be equipped with an oil level sensor to be able to readfluid level information.

1. Park the vehicle on a level surface and shift to N (Neutral). Apply theparking brake and/or emergency brakes.

2. Obtain fluid level information by following the procedure in the AllisonDOC For PCService Tool User Guide, or by using the OEM-suppliedauxiliary display.

44

3. Fluid level information may be delayed when certain conditions are notmet. The Allison DOC For PCService Tool will display a messageshowing which conditions have not been met. The following conditionsmay delay a fluid level check:

Settling time too short

Engine speed (rpm) too low

Engine speed (rpm) too high

N (Neutral) must be selected

Sump fluid temperature too low (below 60C or 140F)

Sump fluid temperature too high (above 104C or 220F)

Output shaft rotation

MANUAL FLUID CHECK PROCEDURE

WARNING: If you leave the vehicle and the engine is running, thevehicle can move unexpectedly and you or others could be injured. Ifyou must leave the engine running, do not leave the vehicle until youhave completed all of the following procedures:

1. Put the transmission in N (Neutral).2. Be sure the engine is at low idle (500800 rpm).3. Apply the parking brakes and emergency brake and make sure

they are properly engaged.4. Chock the wheels and take any other steps necessary to keep the

vehicle from moving.

Clean around the end of the fill tube before removing the dipstick. This will aid inpreventing dirt or foreign matter from entering the hydraulic system, which cancause:

Valves to stick. Undue wear of transmission parts. Clogged passages.

Check the fluid level using the procedures in COLD CHECK and HOT CHECK.Report an abnormal fluid level to service management.

45

Figure 5. Standard 3000 and 4000 Product Families TransmissionDipstick Markings

46

COLD CHECKThe Cold Check determines if the transmission has enough fluid to be operatedsafely until a Hot Check can be made.

NOTE: The correct fluid level can not be determined unless thetransmission is in a level position.

CAUTION: DO NOT start the engine until the presence of sufficienttransmission fluid has been confirmed. Remove the transmission fluiddipstick and be sure the static fluid level is near the HOT FULL mark.

CAUTION: The fluid level rises as fluid temperature rises. DO NOT fillthe transmission above the COLD CHECK band if the transmissionfluid is below normal operating temperatures. During operation, anoverfull transmission can become overheated, leading to transmissiondamage.

A cold check may be made after initial start-up and the presence of transmissionfluid has been confirmed (the sump fluid temperature is then typically 1649C(60120F). To perform a Cold Check, do the following:

1. Start the engine and run it at idle (500800 rpm) in N (Neutral) for aboutone minute.

2. Shift to D (Drive) and then to R (Reverse) to clear the hydraulic circuits ofair.

3. Shift to N (Neutral) and leave engine at idle.

4. Move the vehicle to a level surface, put transmission in N (Neutral), andset the parking brake.

5. With the engine idling (500800 rpm), shift to D (Drive) and then toR (Reverse) to clear air from the hydraulic circuits.

6. Shift to N (Neutral) and leave engine at idle.

7. Remove the dipstick and wipe it clean. Insert the dipstick into the fill tube,pushing down until it stops.

8. Remove the dipstick and observe the fluid level. If the fluid on the dipstickis within the COLD CHECK band, the level is satisfactory. If the fluidlevel is not within this band, add or drain fluid as necessary to bring thelevel within the COLD CHECK band.

9. Perform a Hot Check at the first opportunity after normal operatingtemperature (7193C; 160200F) is reached.

47

CAUTION: DO NOT operate the transmission for extended periods oftime until a Hot Check has verified proper fluid level. Transmissiondamage can result from extended operation at improper fluid levelconditions.

CAUTION: Obtain an accurate fluid level by imposing the followingconditions:

Engine is idling (500800 rpm) in N (Neutral) Transmission fluid is at the normal operating temperature The vehicle is on a level surface

HOT CHECKThe transmission fluid must be hot to obtain an accurate check, because the fluidlevel rises as temperature increases.

To perform a Hot Check, do the following:

1. Be sure fluid has reached normal operating temperature (7193C;160200F). If a transmission temperature gauge is not present, checkfluid level when the engine water temperature gauge has stabilized and thetransmission has been operated under load for at least one hour.

2. Park the vehicle on a level surface and shift to N (Neutral). Apply theparking brake and allow the engine to idle (500800 rpm).

3. Remove the dipstick and wipe it clean. Insert the dipstick into the fill tube,pushing down until it stops.

4. Remove the dipstick and observe the fluid level. The safe operating level isanywhere within the HOT RUN band on the dipstick.

5. If the level is not within this band, add or drain fluid as necessary to bringthe level within the HOT RUN band.

6. Be sure fluid level checks are consistent. Check level more than once andif readings are not consistent, check to be sure the transmission breather isclean and not clogged. If readings are still not consistent, contact yournearest Allison distributor or dealer.

RECOMMENDED AUTOMATIC TRANSMISSION FLUID ANDVISCOSITY GRADE

Hydraulic fluids used in the transmission are important influences ontransmission performance, reliability, and durability. TranSynd andDEXRON-III fluids are recommended for on-highway applications.TranSynd and DEXRON-III fluids are recommended for all 3000 and4000 Product Families applications.

48

TranSynd is a full synthetic transmission fluid developed by AllisonTransmission and Castrol Ltd. This fluid meets Allison specifications forSevere Duty and Extended Drain Intervals. TranSynd is fully qualified tothe Allison TES 295 specifications and is available through Allisondistributors and dealerships.

To be sure a fluid is qualified for use in Allison transmissions check for theDEXRON-III license numbers on the container or consult the lubricantmanufacturer. Consult your Allison Transmission dealer or distributor beforeusing other fluid types.

CAUTION: Disregarding minimum fluid temperature limits can resultin transmission malfunction or reduced transmission life.

When choosing the optimum viscosity grade of fluid, duty cycle, preheatcapabilities, and/or geographical location must be taken into consideration.The Transmission Fluid Operating Temperature Requirements table lists theminimum fluid temperatures at which the transmission may be safelyoperated without preheating. Preheat with auxiliary heating equipment or byrunning the equipment or vehicle with the transmission in neutral for aminimum of 20 minutes before attempting range operation.

Transmission Fluid Operating Temperature Requirements

SAE Viscosity Grade* orFluid Type

Minimum Operating TemperatureCelsius Fahrenheit

MIL-PRF-46167 32 25SAE 0W20 or TranSynd 30 22DEXRON-III 25 13SAE 10W 20 4SAE 15W40 15 5SAE 30W 0 32SAE 40W 10 50* SAE W designation indicates winter weight based on cold temperature properties.

KEEPING FLUID CLEAN

CAUTION: Containers or fillers that have been used for antifreezesolution or engine coolant must NEVER be used for transmission fluid.Antifreeze and coolant solutions contain ethylene glycol which, if putinto the transmission, can cause the clutch plates and some seals to fail.

It is absolutely necessary that transmission fluid be clean. The fluid must behandled in clean containers to prevent foreign material from entering thetransmission.

49

FLUID AND INTERNAL FILTER CHANGE INTERVALRECOMMENDATIONS

CAUTION: Transmission fluid and filter change frequency isdetermined by the severity of transmission service. To help avoidtransmission damage, more frequent changes can be necessary thanrecommended in the general guidelines when operating conditions createhigh levels of contamination or overheating.

Allison requires all 3000 and 4000 Product Families transmissions to have themain filter (not the lube filter or fluid) changed after the first8000 km (5000 miles) or 200 hours of operation, whichever comes first. Refer tothe latest revision of Service Tips #1099 for convenient kit and fluid information.Refer to Mechanics Tips, latest version, for location of the main filter and thefilter change procedure. Service Tips #1099 and Mechanics Tips are availableonline at www.allisontransmission.com.

Refer to the following Recommended Fluid/Filter Change tables for guidelines forfluid and filter change intervals.

NOTE: Change fluid/filters at or before recommended mileage, months,or hours have elapsed, whichever comes first. In some cases, operatinghours may represent a more reliable measure of oil life; therefore, fluidchange intervals should not be based on mileage alone.

CAUTION: Transmission fluid and filters must be changed wheneverthere is evidence of dirt or a high temperature condition. A hightemperature condition is indicated when the transmission fluid isdiscolored, has a strong odor, or has exceeded oil analysis limits.

50

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