Allison Transmission HD4060 Operator Manual

Operator’s Manual

3000 and 4000 Product Families

International Models

OM4119ENOM4119EN 200805 Printed in USA 200806www.allisontransmission.com

Operator’s

2008 MAY

Manual

OM4119EN

Allison Transmission

INTERNATIONAL MODELS

3000 and 4000 Product Families Allison 4th Generation Controls and Model Year 2009 Prognostics

3000 3000 SP 3200 3200 MH 3200 ORS 3200 SP 3500 3500 ORS 3500 SP 3700 3700 SP

4000 4000 MH 4000 ORS 4000 SP

4200 ORS 4430 ORS 4440 ORS

4500 4500 ORS 4500 SP

4600 ORS 4700 4700 OFS 4700 SP 4800 4800 SP

Printed in USA

NOTES

INTRODUCTION

KEEPING THAT ALLISON ADVANTAGE . . . . . . . . . . . . . . . . . . . . . . . . 7

A BRIEF DESCRIPTION OF THE ALLISON TRANSMISSION . . . . . . . . . . 10

ALLISON 4

GENERATION ELECTRONIC CONTROL SYSTEM . . . . . . . 15

ALLISON 4

GENERATION MODEL YEAR 2009 PROGNOSTICS

FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

TORQUE CONVERTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

PLANETARY GEARS AND CLUTCHES . . . . . . . . . . . . . . . . . . . . . . . . 19

COOLER CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

RETARDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

TRANSFER CASE (DROPBOX) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

SHIFT SELECTORS

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

DESCRIPTION OF AVAILABLE ALLISON 4

GENERATION

SHIFT SELECTOR TYPES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

DESCRIPTION OF AVAILABLE ALLISON 4

GENERATION MY09

PROGNOSTICS SHIFT SELECTOR TYPES . . . . . . . . . . . . . . . . . . . . . . 27

RANGE SELECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

DRIVING TIPS

CHECK TRANS LIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

DIAGNOSTIC CODES OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

ALLISON 4

GENERATION CONTROLS DIAGNOSTIC CODE DISPLAY

PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

ALLISON 4

GENERATION MY09 PROGNOSTICS DIAGNOSTIC CODE

DISPLAY PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

ACCELERATOR CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

RANGE SHIFTS AND INHIBITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

USING THE ENGINE TO SLOW THE VEHICLE . . . . . . . . . . . . . . . . . . . 47

USING THE HYDRAULIC RETARDER . . . . . . . . . . . . . . . . . . . . . . . . . 48

RANGE PRESELECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

COLD WEATHER STARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

DRIVING ON SNOW OR ICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

ROCKING OUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

HIGH FLUID TEMPERATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

TOWING OR PUSHING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

TURNING OFF THE VEHICLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

PRIMARY/SECONDARY SHIFT SCHEDULES . . . . . . . . . . . . . . . . . . . . 56

CRUISE CONTROL OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

OPERATING DOWN STEEP GRADES

(REAR-DISCHARGE MIXER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

POWER TAKEOFF OPERATION

ENGINE-DRIVEN POWER TAKEOFF (PTO) . . . . . . . . . . . . . . . . . . . . . 58

CARE AND MAINTENANCE

PERIODIC INSPECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

PREVENT MAJOR PROBLEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

IMPORTANCE OF PROPER FLUID LEVEL . . . . . . . . . . . . . . . . . . . . . . 60

ALLISON 4

GENERATION MY09 PROGNOSTICS DISABLED AND SEVEN SPEED TRANSMISSION FLUID LEVEL CHECK USING ALLISON SHIFT

SELECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

PROGNOSTICS FUNCTIONALITY FOR MODEL YEAR 2009 . . . . . . . . . . 64

ALLISON 4

GENERATION MY09 PROGNOSTICS ENABLED FLUID LEVEL

CHECK USING ALLISON SHIFT SELECTORS . . . . . . . . . . . . . . . . . . . . 67

FLUID LEVEL CHECK USING DIAGNOSTIC TOOLS . . . . . . . . . . . . . . . 72

MANUAL FLUID CHECK PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . 73

COLD CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

HOT CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

RECOMMENDED AUTOMATIC TRANSMISSION FLUID AND VISCOSITY

GRADE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

KEEPING FLUID CLEAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

ALLISON 4

GENERATION AND MY09 PROGNOSTICS DISABLED FLUID

AND INTERNAL FILTER CHANGE INTERVAL RECOMMENDATIONS . . . . 78

ALLISON 4THGENERATION MY09 PROGNOSTICS ENABLED FLUID AND

FILTER CHANGE INTERVAL RECOMMENDATIONS . . . . . . . . . . . . . . . 85

FLUID ANALYSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

REFILL TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

DIAGNOSTICS

DIAGNOSTIC CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

CUSTOMER SERVICE

OWNER ASSISTANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

SERVICE LITERATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

ALLISON TRANSMISSION REGIONAL OFFICES . . . . . . . . . . . . . . . . . . 93

TRADEMARK USAGE

The 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.

WARNINGS, CAUTIONS, NOTES

IT IS YOUR RESPONSIBILITY to be completely familiar with the warnings and cautions described in this manual. It is, however, important to understand that these warnings and cautions are not exhaustive. Allison Transmission could not possibly know, evaluate, and advise the service trade of all conceivable ways in which service might be done or of the possible hazardous consequences of each way. The vehicle manufacturer is responsible for providing information related to the operation of vehicle systems (including appropriate warnings, cautions, and notes). Consequently, Allison Transmission has not undertaken any such broad evaluation. Accordingly, ANYONE WHO USES A SERVICE PROCEDURE

OR TOOL WHICH IS NOT RECOMMENDED BY ALLISON TRANSMISSION OR THE VEHICLE MANUFACTURER MUST ﬁrst be

thoroughly satisﬁed that neither personal safety nor equipment safety will be jeopardized by the service methods selected.

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

Three types of headings are used in this manual to attract your attention. These warnings and cautions advise of speciﬁc methods or actions that can result in personal injury, damage to the equipment, or cause the equipment to become unsafe.

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

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

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

INTRODUCTION

KEEPING THAT ALLISON ADVANTAGE

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

This handbook will help the operator gain the maximum beneﬁts from an Allison transmission-equipped vehicle.

Abbreviations

ABS Anti-lock Brake System DMD Display Mode/Diagnostic DOC Diagnostic Optimized Connection DTC Diagnostic Trouble Code ECU Electronic Control Unit EMI Electromagnetic Interference FCC Federal Communications Commission FM Filter Life Monitor I/O Input/Output KOH Potassium Hydroxide MY09 Model Year 2009 OEM Original Equipment Manufacturer OLS Oil Level Sensor OM Oil Life Monitor PTO Power Takeoff PWM Pulse Width Modulated RFI Radio Frequency Interference RMR Retarder Modulation Request SP Specialty Series TAN Total Acid Number TM Transmission Health Monitor TPS Throttle Position Sensor VIM Vehicle Interface Module

Your Allison transmission has one of two electronic control systems: Allison 4 Generation Controls, or Allison 4thGeneration MY09 Prognostics Controls. The current electronic control system being offered is Allison 4

Generation MY09

Prognostics Controls. The MY09 Prognostics functions of this control system are explained in Section 3, DRIVING TIPS and Section 5, CARE AND MAINTENANCE. The operation of the shift selectors is explained in Section 2, SHIFT SELECTORS.

Refer to the shift selectors shown in Figure 1 and Figure 2 to identify which system is installed in your transmission. The Allison 4 selectors have two LED digital displays (refer to Figure 1). The Allison 4

Generation Controls shift

Generation MY09 Prognostics Controls shift selectors have two LED digital displays and a service icon in the form of an open-end wrench between the digital displays (refer to Figure 2).

DOUBLE DIGIT LED DISPLAY

MODE

6 1

ALLISON 4TH GENERATION CONTROLS

6 1

V07344.01.01

Figure 1. Typical Allison 4thGeneration Controls Shift Selectors With

SELECT And MONITOR Digital Displays

DOUBLE DIGIT LED DISPLAY

WITH SERVICE ICON

MODE

ALLISON 4TH GENERATION MY09 PROGNOSTICS CONTROLS

V11059.00.01

Figure 2. Typical Allison 4thGeneration MY 09 Prognostics Controls

Shift Selectors With SELECT And MONITOR Digital Displays and

Service Icon (open-end wrench)

A BRIEF DESCRIPTION OF THE ALLISON TRANSMISSION

The Allison transmissions (refer to Figure 3 through Figure 6) described in this manual include:

• Allison 4

years)

• A torque converter with lockup clutch and torsion damper

• Three planetary gear sets (four for 4700 OFS/SP and 4800 SP)

• Five clutches (six for 4700 OFS/SP and 4800 SP)

Generation Controls

Generation MY09 Prognostics (not available on earlier model

An integral retarder is available as an option on all transmissions. A provision to mount a power takeoff (PTO) is available as an option on all transmissions.

NOTE: Allison electronic controls are designed and manufactured to comply with all FCC and other guidelines regarding radio frequency interference/electromagnetic interference (RFI/EMI) for transportation electronics. Manufacturers, assemblers, and installers of radio-telephone or two-way communication radios have the sole responsibility to correctly install and integrate those devices into Allison transmission-equipped vehicles to customer satisfaction.

BREATHER

MAIN-PRESSURE TAP

NOTE: Inch Series Threads

ASSEMBLY PADS

OUTPUT SPEED SENSOR

RETARDER VALVE BODY CONNECTOR

TACHOGRAPH PROVISION

NOTE: Metric Series Threads

TORQUE CONVERTER

WITH LOCKUP CLUTCH

AND TORSIONAL DAMPER

BREATHER

MAIN-PRESSURE TAP

NOTE: Inch series threads

COOLER PORTS

NOTE: Inch Series Threads

ASSEMBLY PADS (BOTH SIDES)

OUTPUT RETARDER

TO RETARDER ACCUMULATOR

OIL FILL TUBE AND DIPSTICK (AVAILABLE ON BOTH SIDES

)

V07307.02.00

Figure 3. 3200/3500 Model With Retarder

(Allison 4

Generation Controls)

TRANSFER CASE

FEEDTHROUGH

HARNESS

CONNECTOR

BREATHER

COOLER

PORTS

OIL FILL TUBE

AND DIPSTICK

(AVAILABLE BOTH SIDES)

NAMEPLATE

SCAVENGE PUMP

PTO PROVISION

OIL FILL TUBE

AND DIPSTICK

World Transmission

Manufactured By

n u f a

Division of General Motors CorporationDivision of General Motors Corporation

t u r e

R I

L N

Indianapolis, IndianaIndianapolis, Indiana

X X

A N D

UAW

933

D E

N O .

X X

RIGHT-FRONT VIEW

ASSEMBLY PADS (BOTH SIDES)

TRANSFER CASE

LEFT-REAR VIEW

V08626.01.01

Figure 4. 3700 SP With PTO (Allison 4thGeneration Controls)

FILL TUBE

RETARDER

TEMPERATURE

CONNECTOR

SOLENOID

CONNECTOR

NAMEPLATE

TURBINE-SPEED SENSOR

MOUNTING PAD

ENGINE-SPEED SENSOR

RIGHT-FRONT VIEW

PTO PROVISION (TOP RIGHT POSITION)

TORQUE CONVERTER MODULE

BREATHER

MOUNTING PADS

(BOTH SIDES)

PTO PROVISION

MAIN-PRESSURE TAP

Figure 5. 4000/4500 Model With PTO

LEFT-REAR VIEW

(Allison 4

MOUNTING PADS (BOTH SIDES)

PTO PROVISION

Generation Controls)

STANDARD REAR COVER

COOLER PORTS

V10695.00.01

BREATHER

PTO PROVISION

C6 ADAPTER HOUSING

RETARDER

MOUNTING

PAD

PTO PROVISION

MOUNTING PAD

C6 ADAPTER

HOUSING

OUTPUT

SPEED SENSOR

FEEDTHROUGH

HARNESS CONNECTOR

LEFT-REAR VIEW

NAMEPLATE

RIGHT-REAR VIEW

PTO PROVISION (TOP RIGHT POSITION)

FILL TUBE

OUTPUT FLANGE

COOLER PORTS

MOUNTING PAD

INPUT SPEED SENSOR

TURBINE SPEED SENSOR

V08619.01.01

Figure 6. 4700/4800 SP and OFS With PTO And Retarder

(Allison 4

Generation Controls)

The TCM/ECU is programmed to provide the most suitable operating characteristics for a speciﬁc application. This manual does not attempt to describe all of the possible combinations. The information contained herein describes only the operating characteristics most frequently requested by vehicle manufacturers.

ALLISON 4THGENERATION ELECTRONIC CONTROL SYSTEM

Allison 4thGeneration Controls consist of the following major components connected by an OEM-furnished wiring harness:

• Transmission Control Module (TCM)

• Three speed sensors (refer to Figure 3 through Figure 6):

— Input

— Turbine

— Output

• Remote shift selector

• Control module which includes:

— Solenoids

— Diagnostic pressure switch

— Oil level sensor (standard on the 3000 and 4000 Product Family

transmissions through six-speed, optional on the 4700 OFS/SP and 4800 SP, and not available on 3700 SP)

— Sump temperature sensor

— Valves

— Internal wire harnesses

• Optional Allison Throttle Position Sensor (TPS)

The TCM processes information and then sends signals to actuate speciﬁc solenoids located in the control module. These solenoids control clutch pressures to provide closed-loop control. The closed-loop control makes “during shift” adjustments. These adjustments in shift characteristics are based on vehicle conditions such as grade, load, and engine power. After a shift is completed, the TCM compares the shift to an “ideal” shift proﬁle in the TCM calibration and makes adjustments before the next shift of the same kind is made. This is “adaptive logic” which establishes initial conditions for shifts.

The Allison 4 active within the ﬁrst 30 seconds of the ﬁrst 24 engine starts or 49 engine starts, depending upon the component or sensor being detected. Autodetect searches for the presence of the following transmission components or data inputs.

Generation Control has an “autodetect” feature. Autodetect is

Retarder Present, Not Present Oil Level Sensor (OLS) Present, Not Present Throttle

* Analog, J1587, J1939

Engine Coolant Temperature Analog, J1587, J1939

* A pulse width modulated (PWM) throttle source is not “autodetected.” This source requires a

unique calibration or can be manually selected using Allison DOC™ For PC–Service Tool.

Even though autodetect has been completed, it can be reset to monitor an additional group of engine starts. Reset may be necessary if a device known to be present is not detected or if an autodetectable component or sensor was added after the initial vehicle build.

Reset is accomplished by using the Allison DOC™ For PC–Service Tool. The Allison DOC™ For PC–Service Tool may also be used to override autodetect and manually enter the component or sensor to be recognized by the TCM by changing appropriate “customer modiﬁed constants.”

ALLISON 4THGENERATION MODEL YEAR 2009 PROGNOSTICS FUNCTIONS

Allison Transmission, Inc. has introduced three new diagnostic parameters that are available only on 3-, 4-, 5-, and 6-speed transmissions for Model Year 2009 (MY09). These new diagnostic parameters will provide indicators of required maintenance actions and are named “Prognostics” because they predict required transmission maintenance. These new Prognostics include the following:

• Oil Life Monitor (OM)

• Filter Life Monitor (FM)

• Transmission Health Monitor (TM)

Prognostics are designed to maximize ﬂuid (the terms oil and ﬂuid are used interchangeably) and ﬁlter utilization and provide an early indication of clutch system concerns so that an inspection may be scheduled before a clutch fails and causes other transmission damage.

The following items are required to allow MY09 Prognostics:

• Allison approved TES 295 transmission ﬂuid and Allison High Capacity

Filters.

• Transmission with ﬁlter life valve body and pressure switch.

• MY09 TCM.

• Filter pressure switch wiring in the OEM wiring harness from the

transmission to the TCM.

• MY09 Allison pushbutton or lever shift selector or an OEM installed shifter

plus a service indicator light or J1939 text message display. The OEM service indicator light may also be used with a J1939 text messaging display.

Allison MY09 shift selectors contain an integrated service icon in the shape of an open-end wrench located between the SELECT and MONITOR displays (refer to DESCRIPTION OF AVAILABLE TYPES in the SHIFT SELECTOR section).

The vehicle manufacturer speciﬁes whether the Allison Prognostics Feature is made available in the calibration and, if so, whether the Prognostic function is defaulted ON or OFF for customer use. The transmission calibration can be made for the vehicle manufacturer (or the customer) so that the prognostics feature is in one of the following states:

• Available and the function is defaulted ON

• Available but the function is defaulted OFF

NOTE: An Allison service outlet can assist with programming Prognostics ON at customer expense if Allison requirements are met prior to Prognostics features being turned ON.

• Not available in the transmission calibration.

NOTE: An Allison service outlet can assist with a transmission calibration change so that MY09 Prognostics are available at customer expense if Allison requirements are met prior to TCM recalibration.

The three Prognostics functions are enabled or disabled as a group and cannot be enabled or disabled individually. The OEM may also specify whether Prognostics may be reset by the Allison shift selector, J1939 message, or only with the use of the Allison DOC™ For PC–Service Tool.

CAUTION: Prognostics requires the use of Allison approved TES 295 ﬂuids and Allison High Capacity Filters if turned ON. If

any other ﬂuids or ﬁlters are used, the Prognostics feature MUST BE turned OFF. Prognostics information will not be accurate with any other transmission ﬂuids and could result in missed maintenance activities resulting in transmission damage. If Prognostics functions are not programmed or are turned OFF, refer to the miles/hours/months ﬂuid and ﬁlter change interval charts in the CARE AND MAINTENANCE section or visit www.allisontransmission.com, click Service, Fluid/Filter Change Interval, then Fluids, and read the current revision of Service Tips 1099 for details.

The Allison 4

Generation Controls has an “autodetect” feature. Autodetect is active within the ﬁrst 30 seconds of the ﬁrst 24 engine starts or 49 engine starts, depending upon the component or sensor being detected. Autodetect searches for the presence of the following transmission components or data inputs.

Retarder Present, Not Present Oil Level Sensor (OLS) Present, Not Present Throttle

* Analog, J1587, J1939

Engine Coolant Temperature Analog, J1587, J1939

* A pulse width modulated (PWM) throttle source is not “autodetected.” This source requires a

unique calibration or can be manually selected using Allison DOC™ For PC–Service Tool.

TORQUE CONVERTER

The torque converter consists of the following four elements:

• Pump—input element driven directly by the engine

• Turbine—output element hydraulically driven by the pump

• Stator—reaction (torque multiplying) element

• Lockup Clutch—mechanically couples the pump and turbine when engaged;

controlled by TCM/ECU

When the pump turns faster than the turbine and the stator is stationary, the torque converter is multiplying torque. When the turbine approaches the speed of the pump, the stator starts to rotate with the pump and turbine. When this occurs, torque multiplication stops and the torque converter functions as a ﬂuid coupling.

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

• Piston and backplate—driven by the engine

• Clutch plate/damper (located between the piston and the

backplate)—splined to the converter turbine

The lockup clutch/torsional damper is engaged and released in response to electronic signals from the TCM/ECU. Lockup clutch engagement provides a direct drive from the engine to the transmission input. This eliminates converter slippage and maximizes fuel economy and vehicle speed. The lockup clutch releases at lower speeds or when the TCM/ECU detects conditions requiring it to be released.

The torsional damper tries to absorb engine torsional vibration to attempt to prevent transmitting engine torsional vibration on through to transmission components (clutches, etc), or items bolted to the transmission (PTO, etc.).

PLANETARY GEARS AND CLUTCHES

A series of three helical, constant mesh planetary gear sets (four for 4700 OFS/SP and 4800 SP) and shafts provides the mechanical gear ratios and direction of travel for the vehicle. The planetary gear sets are controlled by ﬁve multi-plate clutches (six for 4700 OFS/SP and 4800 SP) that work in pairs to produce up to six forward speeds (seven for 4700 OFS/SP and 4800 SP) and one reverse speed. The clutches are applied and released hydraulically in response to electronic signals from the TCM/ECU to the appropriate solenoids.

COOLER CIRCUIT

The transmission ﬂuid is cooled by an integral (transmission-mounted) or remote-mounted oil cooler. Connections to the cooling circuit are located at the front or rear of the transmission to facilitate installation of remote cooler lines. On retarder models, only the rear cooler ports may be used. The integral cooler is mounted on the lower rear portion of the transmission, replacing the remote cooler manifold. Integral cooler oil ports are internal requiring coolant to be routed to and from the cooler.

The retarder housing allows the addition of either a remote or integral cooler for transmission sump ﬂuid in addition to retarder out ﬂuid. A bypass cover is placed over the sump cooling ports when the provision is not used. The sump cooler ports are located on the lower right rear face of the retarder housing (refer to Figure 3 through Figure 6).

RETARDER

The self-contained retarder is at the output of the transmission and consists of a vaned rotor which rotates in a vaned cavity. The rotor is splined to and driven by the output shaft. When the retarder is activated, the ﬂuid in the accumulator is displaced into the retarder cavity. The pressurized ﬂuid in the cavity acting against the rotating and stationary vanes causes the retarder rotor and output shaft to reduce speed, slowing the vehicle or limiting speed on a downhill grade. Refer to USING THE HYDRAULIC RETARDER for additional information.

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

TRANSFER CASE (DROPBOX)

A transfer case (dropbox) module is provided for 3700 SP-equipped vehicles where front and rear wheel drive is desired. The transfer case (refer to Figure 4) is

merged with a six-speed close ratio gear train to produce a 7-speed conﬁguration. One of the two PTO drive provisions actuates a scavenge pump for the transfer case. A remote-mounted cooler is required for a dropbox unit.

Transfer case design features include helical transfer gears and a self-contained lubrication oil pump. The transfer gears provide a ratio of 1.2:1. The lubrication oil pump is driven directly by the output to the drive axles. Since lubrication is present whenever the drive axle is turning, it is not necessary to disconnect the drivelines or axles shafts when the vehicle is towed or pushed. A torque proportioning differential gives a front/rear torque split of 30/70 when the differential clutch (C7) is not engaged. When the multiplate differential clutch is engaged, the torque split becomes 50/50. The differential clutch is engaged in difficult traction situations.

The seventh forward speed in this transmission is the lowest numerical gear ratio provided and is intended for use in off-road conditions. This range is obtained when a multi-plate clutch (C6) in the transfer case is applied.

SHIFT SELECTORS

INTRODUCTION

Vehicle manufacturers may choose different types of shift selectors for their vehicles. The shift selector in your Allison-equipped vehicle will be similar to one of the pushbutton or lever styles (refer to Figure 7 and Figure 8) shown in the following sections that explain each Allison shift selector.

Allison transmissions can be programmed to have up to six (seven for 4700 OFS/SP and 4800 SP) forward ranges. Shift selector positions should agree with the programming of the TCM/ECU.

With an Allison-equipped vehicle, it is not necessary to select the right moment to upshift or downshift during changing road and traffic conditions. The Allison transmission does it for you. However, knowledge of the shift selector positions, available ranges, and when to select them make vehicle control and your job even easier. To reduce wear on service brakes, select lower ranges when descending long grades (with or without retarder). Refer to the Range Selection table at the end of this section for related information.

DESCRIPTION OF AVAILABLE ALLISON 4THGENERATION SHIFT SELECTOR TYPES

NOTE: This section is for Allison 4thGeneration Controls, Model Year 2009 Prognostics DISABLED, and seven-speed transmissions which don’t have Prognostics.

HOLD OVERRIDE

1 2 3

4 5

D N R

DIAGNOSTIC BUTTON

SIX-SPEED, LEFT-HAND

LEVER SELECTOR

WITH REVERSE

TO REAR

7 1

MODE

BUTTON

MODE ID

MODE INDICATOR

(LED)

MODE BUTTON

DIGITAL DISPLAY

DISPLAY MODE

DIGITAL DISPLAY*

MODE ID

MODE INDICATOR (LED)

MODE BUTTON Push simultaneously

to enter diagnostic mode and fluid level check

R N D 6

5 4

2 1

SEVEN-SPEED,

RIGHT-HAND

LEVER SELECTOR

WITH REVERSE

TO FRONT

HOLD OVERRIDE

BUTTON

MODE INDICATOR

DIGITAL DISPLAY*

DIAGNOSTIC BUTTON

(LED)

MODE BUTTON

DISPLAY MODE

CONTOURED

6 1

PUSHBUTTON SELECTORS

NOTE:

The first number displayed in the digital display is the highest forward range available and

second number is range attained in selected position.

Visually confirm that the range selected was attained. If display is flashing, shift is inhibited.

6 1

BEZEL

V10694.00.01

Figure 7. Typical Allison 4thGeneration Controls Shift Selectors

LEVER SHIFT SELECTOR.

General Description. The Allison 4

Generation lever shift selector (refer to

Figure 7) is an electromechanical control. Typical lever positions are:

• R (Reverse)

• N (Neutral)

• D (Drive)

• Some number of lower forward range positions

Allison transmissions can be programmed to have up to six (seven for 4700 OFS/SP and 4800 SP) forward ranges. Shift selector positions should agree with the programming of the TCM.

The lever shift 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 to prevent accidentally selecting R (Reverse), N (Neutral), or D (Drive). Select R (Reverse), N (Neutral), or D (Drive) by pressing the HOLD OVERRIDE button and moving the lever to the desired position. Once D (Drive) is selected, lower forward range positions may be selected without pressing the

HOLD OVERRIDE button.

MODE Button. The MODE button can allow the driver to enable a secondary

shift schedule, PTO enable, or other special functions that have been programmed into the TCM unit at the request of the OEM. For example, a vehicle OEM may have provided a secondary shift schedule for improved fuel economy. The name of the special function (ECONOMY) appears on the MODE ID label adjacent to the MODE button. Pressing the MODE button activates the ECONOMY shift schedule and illuminates the MODE INDICATOR LED.

When the Diagnostic Display Mode has been entered, the MODE button is used to view and toggle through diagnostic code information. The code displayed is active if the MODE INDICATOR LED is illuminated.

NOTE: Visually observe the digital display whenever the lever is moved. N should appear in the digital display if N is selected.

Digital Display. Allison 4thGeneration Controls contain two digital displays, SELECT and MONITOR. During normal operation, if D (Drive) is selected, the SELECT digital display shows the highest forward range attainable for the shift schedule in use. The MONITOR digital display shows the lowest available forward range.

Limited operation is indicated by the digital display as follows:

• All digital display segments are illuminated during initialization. If after

10 seconds communication is not established with the TCM, both digital displays show

• When both digital displays show

/\(cateyes).

/\(cateyes), a selector-related fault code

has been logged.

• When the SELECT display shows R or D has been requested and the

display is ﬂashing the selected range, then the selected range has not been attained due to an inhibit function. Refer to RANGE SHIFTS AND INHIBITS in the DRIVING TIPS section.

• Inhibited range, shown by a ﬂashing SELECT digital display, is not an

indication that there is a transmission condition or problem, nor does it indicate that a DTC has set. An inhibit means there is a vehicle or engine condition that won’t allow range selection or direction change such as:

— Too high idle speed in N to allow R or D

— Too high a throttle signal in N to allow R or D

— Too high of an output speed in N to allow R or D

— An active vehicle function or I/O function is operating which inhibits

range.

CAUTION: The transmission will not shift into range from N if a CHECK TRANS code is active. If a CHECK TRANS code is active,

move vehicle to a safe location before turning off the engine.

Conditions which illuminate the CHECK TRANS light disable the shift selector. The SELECT display is blank and the MONITOR display shows the range actually attained. For a detailed explanation, refer to the CHECK TRANS LIGHT paragraph in the DRIVING TIPS section.

Once D (Drive) is attained, the transmission will shift into the lowest forward range programmed for the D (Drive) position, usually ﬁrst-range.

Display Mode/Diagnostic Button. The DISPLAY MODE/DIAGNOSTIC button allows access to ﬂuid level information and diagnostic code information.

• Move the shift lever to N and apply the parking brakes.

• Press the DISPLAY MODE/DIAGNOSTIC (DMD) button once to access

oil level information (if an OLS is installed).

• Press the DMD again to access the diagnostic code information.

• Press the MODE button to view subsequent code positions d2 through d5.

• To exit the diagnostic code mode, move the shift lever to another position.

PUSHBUTTON SHIFT SELECTOR. General Description. The pushbutton shift selector (refer to Figure 7) has the

following components:

• 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 will start out in the lowest available forward range and advance automatically to the highest range.

• ↑ (Up) Arrow—Press the ↑ (Up) Arrow when in D (Drive) to request the next higher range. Continually pressing the ↑ (Up) Arrow will request the highest range available.

• ↓ (Down) Arrow—Press the ↓ (Down) Arrow when in D (Drive) to request the next lower range. Continually pressing the ↓ (Down) Arrow will request the lowest range available.

• MODE Button—The MODE button can allow the driver to enable a

secondary shift schedule, PTO enable, or other special functions that have been programmed into the TCM at the request of the OEM. For example, a vehicle OEM may have provided a secondary shift schedule for improved fuel economy. The name of the special function (ECONOMY) appears on the MODE ID label adjacent to the MODE button. Pressing the MODE button activates the ECONOMY shift schedule and illuminates the MODE INDICATOR LED. When the Diagnostic Display Mode has been entered, the MODE button is used to view and toggle through diagnostic code information. The code displayed is active if the MODE INDICATOR LED is illuminated.

Digital Display. Allison 4

Generation Controls contain two digital displays,

SELECT and MONITOR. During normal operation, if D (Drive) is selected, the SELECT display shows the highest forward range attainable for the shift schedule in use. The MONITOR display shows the lowest available forward range.

Limited operation is indicated by the digital display as follows:

• All digital display segments are illuminated during initialization. If after

10 seconds communication is not established with the TCM, both digital displays show

• When both digital displays show

/\(cateyes).

/\(cateyes), a selector-related fault code

has been logged.

• When the SELECT display shows R or D has been requested and the

display is ﬂashing the selected range, then the selected range has not been attained due to an inhibit function. Refer to RANGE SHIFTS AND INHIBITS in the DRIVING TIPS section.

• Inhibited range, shown by a ﬂashing SELECT digital display, is not an

— Too high idle speed in N to allow R or D

— Too high a throttle signal in N to allow R or D

— Too high of an output speed in N to allow R or D

— An active vehicle function or I/O function is operating which inhibits

range.

CAUTION: The transmission will not shift into range from N if a CHECK TRANS code is active. If a CHECK TRANS code is active,

move vehicle to a safe location before turning off the engine.

Once D (Drive) is attained, the transmission will shift into the lowest forward range programmed for the D (Drive) position, usually ﬁrst-range.

NOTE: The oil level sensor (OLS) is standard on 3000 and 4000 Product Families transmissions (optional on the 4700 OFS/SP, 4800 SP, not available on 3700 SP). Fluid level information is displayed by simultaneously pressing the ↑ (Up) Arrow and ↓ (Down) Arrow buttons. Simultaneously press both buttons again to obtain diagnostic code information.

To display stored codes, do the following:

• Select N and apply the parking brakes.

• Simultaneously press the ↑ (Up) Arrow and ↓ (Down) Arrow buttons once

to access oil level information (if an OLS is installed).

• Simultaneously press the ↑ (Up) Arrow and ↓ (Down) Arrow buttons again to access diagnostic codes.

• Press the MODE button to display the next code. Repeat for code positions d3 through d5.

• Press N (Neutral) to exit the diagnostic code mode.

Refer to the CARE AND MAINTENANCE section, FLUID LEVEL CHECK USING PUSHBUTTON OR LEVER SHIFT SELECTOR, for more information about ﬂuid level data. Refer to the DRIVING TIPS section, DIAGNOSTIC CODES DISPLAY PROCEDURE, for more information about diagnostic codes and display procedure.

DESCRIPTION OF AVAILABLE ALLISON 4THGENERATION MY09 PROGNOSTICS SHIFT SELECTOR TYPES

NOTE: This section is for Allison 4thGeneration Model Year 2009 (MY09) Prognostics ENABLED. Refer to the previous section for MY09 Prognostics DISABLED and seven-speed transmissions which don’t have Prognostics.

LEVER SHIFT SELECTOR. General Description. The Allison lever shift selector (refer to Figure 8) is an

electromechanical control. Typical lever positions are:

• R (Reverse)

• N (Neutral)

• D (Drive)

• Some number of lower forward range positions

Allison transmissions can be programmed to have up to six (seven for 4700 OFS/SP and 4800 SP) forward ranges. Shift selector positions should agree with the programming of the TCM.

The lever shift selector includes the following:

• HOLD OVERRIDE button

• MODE button

• DISPLAY MODE/DIAGNOSTIC button

• SELECT and MONITOR digital displays and service icon

HOLD OVERRIDE button.

MODE Button. The MODE button can allow the driver to enable a secondary

HOLD OVERRIDE

BUTTON

HOLD OVERRIDE

BUTTON

1 2 3 4 5 D N R

SIX-SPEED,

LEFT-HAND

LEVER SELECTOR

MODE ID

MODE

INDICATOR

(LED)

MODE BUTTON

DIGITAL DISPLAY

DISPLAY MODE

DIAGNOSTIC

BUTTON

SEVEN-SPEED,

RIGHT-HAND

LEVER SELECTOR

MODE

PUSHBUTTON SELECTORS

MODE

INDICATOR

(LED)

R N D 6 5 4 3 2 1

MODE BUTTON

MODE ID

DIGITAL

DISPLAY

DISPLAY MODE

DIAGNOSTIC

BUTTON

CONTOURED

BEZEL

DIGITAL DISPLAY MODE ID

MODE

INDICATOR (LED) MODE BUTTON Push simultaneously

to enter diagnostic mode and fluid level check

*NOTE:

The first number displayed in the digital display is the highest forward range available and second number is range attained in selected position.

Visually confirm that the range selected was attained. If display is flashing, shift is inhibited.

SERVICE ICON

Location of service icon on vertical and horizontal digital display

SERVICE ICON

V11058.00.00

Figure 8. Typical Allison 4thGeneration MY09 Prognostics Shift

Selectors

+ 66 hidden pages

Allison Transmission HD4060 Operator Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

TABLE OF CONTENTS

TRADEMARK USAGE

WARNINGS, CAUTIONS, NOTES

INTRODUCTION

KEEPING THAT ALLISON ADVANTAGE

Abbreviations

A BRIEF DESCRIPTION OF THE ALLISON TRANSMISSION

Figure 4. 3700 SP With PTO (Allison 4thGeneration Controls)

ALLISON 4THGENERATION ELECTRONIC CONTROL SYSTEM

ALLISON 4THGENERATION MODEL YEAR 2009 PROGNOSTICS FUNCTIONS

TORQUE CONVERTER

PLANETARY GEARS AND CLUTCHES

COOLER CIRCUIT

RETARDER

TRANSFER CASE (DROPBOX)

SHIFT SELECTORS

INTRODUCTION

DESCRIPTION OF AVAILABLE ALLISON 4THGENERATION SHIFT SELECTOR TYPES

Figure 7. Typical Allison 4thGeneration Controls Shift Selectors

DESCRIPTION OF AVAILABLE ALLISON 4THGENERATION MY09 PROGNOSTICS SHIFT SELECTOR TYPES