Operator’s Manual 750 50/754 /754 Series Series Allison Off-Highway
OM1475EN
Operator’s Manual
2006 MARCH OM1475EN
Allison Transmission OFF-HIGHWA OFF-H IGHWAY Y TRANSMISSIONS TRANSMI SSIONS CBT 750, 754 CLBT 750, 754 CLBT 750, 754DB REMOTE MOUNT
Allison Transmission, Inc.
P.O. Box 894 Indianapoli s, Indiana
46206-0894
www.allisontransmission.com
Printed in USA
Copyright © 2007 Allison Transmission, Inc.
NOTES
2
TABLE OF CONTENTS INTRODUCTION KEEPING THAT ALLISON ADVANTAGE . . . . . . . . . . . . . . . . . . . . . . . . 7 TYPICAL 750/754 SERIES OFF-HIGHWAY TRANSMISSION MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 A BRIEF DESCRIPTION OF THE ALLISON AUTOMATIC . . . . . . . . . . . . . 9 TORQUE CONVERTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 LOCKUP CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 POWER TAKEOFF DRIVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 HYDRAULIC RETARDER (CBT, CLBT 750/754) . . . . . . . . . . . . . . . . . . . 10 TRANSFER GEAR HOUSING (DROPBOX) . . . . . . . . . . . . . . . . . . . . . . 10 MANUAL DISCONNECT CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 THROTTLE ACTUATED MODULATOR . . . . . . . . . . . . . . . . . . . . . . . . 11 COOLER, FILTER CIRCUITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
SHIFT SELECTORS SHIFT SELECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 RANGE SELECTION POSITIONS (FIVE-SPEED) . . . . . . . . . . . . . . . . . . 14
DRIVING TIPS OPERATING IN COLD WEATHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . DOWNSHIFT CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DOWNSHIFT OR REVERSE INHIBITOR FEATURE . . . . . . . . . . . . . . . . . ACCELERATOR CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . USING THE ENGINE TO SLOW THE VEHICLE . . . . . . . . . . . . . . . . . . . USING HYDRAULIC RETARDER (CBT, CLBT) . . . . . . . . . . . . . . . . . . . DRIVING ON ICE AND SNOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ROCKING OUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TOWING OR PUSHING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TEMPERATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16 16 17 17 17 17 18 18 18 18 19
POWER TAKEOFF OPERATION CONVERTER-DRIVEN POWER TAKEOFF (PTO) . . . . . . . . . . . . . . . . . . 20 ENGINE-DRIVEN POWER TAKEOFF (PTO) . . . . . . . . . . . . . . . . . . . . . 20
CARE AND MAINTENANCE PERIODIC INSPECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IMPORTANCE OF PROPER FLUID LEVEL . . . . . . . . . . . . . . . . . . . . . . FLUID LEVEL TEST PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . FLUID SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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22 22 22 25
KEEPING FLUID CLEAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 FLUID AND OIL FILTER CHANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 HOW TO KEEP LITTLE PROBLEMS FROM BECOMING BIG PROBLEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
CUSTOMER SERVICE OWNER ASSISTANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SERVICE LITERATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ALLISON TRANSMISSION DISTRIBUTORS . . . . . . . . . . . . . . . . . . . . . ALLISON TRANSMISSION REGIONAL OFFICES . . . . . . . . . . . . . . . . . .
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28 30 31 33
TRADEMARK USAGE The following trademarks are the property of the companies indicated: •
TranSynd™ is a trademark of Castrol Ltd.
•
DEXRON® is a registered trademark of the General Motors Corporation.
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WARNINGS, CAUTIONS, NOTES IT IS YOUR RESPONSIBILITY to be completely familiar with the warnings and cautions described in this handbook. 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 handbook 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. The following three types of heading are used to attract your attention to important information: 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.
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INTRODUCTION
KEEPING THAT ALLISON ADVANTAGE
Allison transmissions provide many advantages for the driver whose vehicle may encounter vigorous, tough use and sometimes abuse. Driving is easier, safer, and more efficient. These transmissions are rugged and designed to provide long, trouble-free service. This handbook will help you gain maximum benefits from your Allison transmission-equipped vehicle.
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TYPICAL 750/754 SERIES OFF-HIGHWAY TRANSMISSION MODELS
Figure 1. CLBT 750/754 Remote Mount
Figure 2. CLBT 750/754DB Remote Mount
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ENGINE-DRIVEN PTO GEAR – TOP TORQUE CONVERTER LOCKUP CLUTCH
THIRD CLUTCH
FOURTH CLUTCH
LOW PLANETARY
FIRST CLUTCH
SPEEDOMETER DRIVE
SECOND CLUTCH
FORWARD CLUTCH
OUTPUT SHAFT
GOVERNOR REAR PLANETARY
HYDRAULIC RETARDER ENGINE-DRIVEN PTO GEAR – SIDE CONVERTER-DRIVEN PTO GEAR
CENTER PLANETARY CONTROL VALVE
OIL SCREEN FRONT PLANETARY
FIFTH CLUTCH
H01980
Figure 3. CLBT 750/754 Remote Mount–Cross Section
A BRIEF DESCRIPTION OF THE ALLISON AUTOMATIC •
An hydraulic torque converter
•
A planetary gear train
•
An hydraulic control system
The torque converter multiplies engine torque during starts and acts as an hydraulic cushion between the engine and gearing. The clutches and gear sets provide multiple forward ranges and one reverse range. The torque converter lockup clutch engages automatically after the vehicle is moving, for maximum fuel economy. The hydraulic control system automatically selects the most efficient gear ratio for vehicle speed and throttle position.
TORQUE CONVERTER The torque converter (refer to Figure 3) consists of three elements: •
The pump is the input element and is driven by the engine.
•
The turbine is the output element and is hydraulically driven by the pump.
•
The stator is the reaction (torque multiplying) element.
When the pump (input) rotates at a higher speed than the turbine (output) speed, the torque converter multiplies the torque. When the turbine speed approaches the 9
pump speed, torque multiplication stops and the torque converter functions as a fluid coupling. With a fixed-capacity stator, engine power is always directed to the vehicle power train.
LOCKUP CLUTCH The lockup clutch (refer to Figure 3) is designed to hydraulically engage and disengage at predetermined turbine speeds. When turbine speed approaches the pump speed, hydraulic pressure automatically engages the lockup clutch. The function of the lockup clutch is to lock the input element (pump) and the output element (turbine) together. With the lockup clutch engaged, the engine output is directed to the transmission gearing at 1:1 speed ratio. Reduction in the turbine speed (output speed) automatically disengages the lockup clutch. When the lockup clutch is disengaged, the converter acts as a torque multiplier or a fluid coupling. The lockup clutch is momentarily disengaged during upshifting and downshifting
POWER TAKEOFF DRIVES The CBT, CLBT 750/754 Series off-highway transmission (refer to Figure 1) has provisions for three power takeoff (PTO) drives—two engine-driven PTO drives, and one converter-driven PTO drive. Engine-driven PTOs may be mounted at top and/or lower-left side of the torque converter housing. A converter-driven PTO may be mounted at the upper-left side of the transmission main housing.
HYDRAULIC RETARDER (CBT, CLBT 750/754) A vaned rotor and two vaned stators are the basic components of the retarder. A manually-controlled valve fills the cavity around the rotor with fluid when the vehicle must be slowed on steep downgrades. When the cavity is emptied, the rotor is free of drag. Added safety and longer service brake life are the benefits gained from a retarder.
TRANSFER GEAR HOUSING (DROPBOX) The dropbox is a vertical transfer gear case mounted (refer to Figure 2) to the rear of the transmission adapter housing. It can be mounted (refer to Figure 4) vertically (Position 1) or in any of four other positions (Positions 2–5) to the left of vertical as viewed from the rear of the dropbox. These positions are bolt hole specific. The dropbox provides a 1:1 gear ratio at three specific output locations. The top rear location is in line with the input. The bottom rear and bottom front are extensions of the drive, idler, and driven gears in the dropbox.
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REAR VIEW OF DROPBOX
30
°
5
4 45
°
3
2
30
°
15
°
1
VERTICAL V07146
Figure 4. Dropbox Mounting Positions
MANUAL DISCONNECT CLUTCH A manually-applied disconnect housing is available at any one or all three of the dropbox output locations. Linkage controls the movement of the shift lever in the disconnect housing, engaging or disengaging the clutch.
THROTTLE ACTUATED MODULATOR Mechanical linkage between the engine throttle and the transmission moves the control system modulator valve. This feature makes the transmission automatic control system responsive to throttle position. Opening the throttle will raise the speed at which upshifts occur. Timing of shifts and clutch applications are regulated by the modulator system. Precise and smoother shifts are obtained. Other modulator control systems may be used including air and electrically actuated devices.
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COOLER, FILTER CIRCUITS A separate oil cooler or connection to the vehicle engine cooling system is used to cool the transmission fluid. An external oil filter is placed in the converter-to-cooler line on all models equipped with an hydraulic brake. An auxiliary filter may be installed in the converter-to-cooler line on non-retarder models at customer option.
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SHIFT SELECTORS
SHIFT SELECTORS
R N D 4 3 2 1
R N 2-5 2-3 2 1
FIVE-SPEED LEVER SELECTOR
FIVE-SPEED LEVER SELECTOR
V07145
Figure 5. Five-Speed Lever Shift Selector Configurations The vehicle manufacturers may choose different types of shift selectors for their equipment. Different transmission models may also require different designations on the shift selectors. Some of the typical shift selectors found in Allison transmission-equipped vehicles are shown in Figure 5. The lever shift selector in a particular vehicle may vary from these or may have 1 (Low) at the top and R (Reverse) at the bottom. The best performance will be obtained by using the correct range for each driving condition. When a vehicle is equipped with an Allison automatic transmission, it is not necessary to select the right moment to upshift or downshift because the Allison transmission shifts automatically during changing road and traffic conditions. A knowledge of the ranges available at the shift selector will make control of the vehicle and driving easier.
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RANGE SELECTION POSITIONS (FIVE-SPEED) WARNING: Take the following precautions so that unexpected, possible sudden vehicle movement is avoided. Whenever it becomes necessary to leave the vehicle, even momentarily, while the engine is running, place the transmission shift selector in N (Neutral), set the parking brake and/or emergency brakes, and chock the wheels.
NOTE: The shift information below is applicable to the majority of installations. However, some transmissions have automatic shifting in all ranges. R
Use this to back the vehicle. Completely stop vehicle before shifting from forward to R (Reverse) or from R (Reverse) to forward. The reverse warning signal is activated when the shift selector is in this position. Reverse has only one range. WARNING: Do not allow your vehicle to coast in neutral. This practice can result in severe transmission damage. Engine braking and hydraulic retarder action (CBT, CLBT) are not available during neutral coast.
N
2–5
2–4 2–3
Use N (Neutral) when you start the engine. If the engine starts in any other position, the neutral start switch is malfunctioning. N (Neutral) is also used during stationary operation of the power takeoff (if your vehicle is equipped with a PTO). Use this for all normal driving conditions. The vehicle will begin to move forward in second-range. As the accelerator is depressed, the transmission will upshift to third, fourth, and fifth ranges automatically. As the vehicle slows, the transmission will downshift to the correct range automatically. Occasionally, the road, load, or traffic conditions will make it desirable to restrict the automatic shifting to a lower range. When conditions improve, return the shift selector to the normal driving position. These positions also provide progressively greater engine braking and hydraulic retarder effect (the lower the range, the greater the braking or retarding effect).
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2
1
This is second range. Use this when pulling through mud and snow or driving up steep grades. The vehicle will start out in second-range if calibrated for second-range start. Otherwise it will start in first-range and shift automatically to second-range as the accelerator is depressed. This is first-range hold (low). No upshift will occur when the shift selector is in this position. This position provides the greatest tractive advantage. It also provides maximum engine braking and hydraulic retarder effect. NOTE: All models except those for scraper applications have lockup capability in all forward ranges. Scraper transmissions have lockup available in all forward ranges except first-range.
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DRIVING TIPS
OPERATING IN COLD WEATHER CAUTION: Disregarding minimum fluid temperature limits can result in transmission malfunction or reduced transmission life. Table 1 lists the minimum fluid temperatures by fluid type at which the transmission may be safely operated in a forward or reverse range. When ambient temperature is below the minimum fluid temperature limit and the transmission is cold, preheat is required. If auxiliary heating equipment is not available, run the engine to preheat the fluid to the minimum temperature limit before operating in a forward or reverse range. Failure to observe the minimum fluid temperature limit can result in transmission malfunction or reduced transmission life.
Transmission Fluid Operating Temperature Guide Minimum Operating Temperature Fahrenheit Celsius –25 –32 –22 –30 –13 –25 –4 –20 5 –15 32 0 50 10
SAE Vicosity Grade or Fluid Type MIL-PRF-46167 SAE 0W*-20 or TranSynd™ DEXRON®-III SAE 10W* SAE 15W*-40 SAE 30W* SAE 40W*
* SAE “W” designation indicates winter weight based on cold temperature properties.
DOWNSHIFT CONTROL Downshifting is a manual shift to a lower range to match driving conditions encountered or expect to be encountered. Learning to take advantage of manual downshifts will give better control on slick or icy roads, and on steep downgrades. Downshifting to lower ranges increases engine braking and hydraulic retarder effect. The selection of a lower range often prevents cycling between a range and the next higher range on a series of short up-and-down grades.
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DOWNSHIFT OR REVERSE INHIBITOR FEATURE The transmission hydraulic system will not permit a shift into any lower forward range at a speed that will cause excessive engine overspeed. A lower forward range may be selected at any time, but the actual shift into that range will not occur until road speed is reduced; downshifting is progressive as road speed decreases. The inhibitor effect will cause downshifts to occur at slightly higher speeds than normal automatic downshifts. Shifting into reverse cannot be accomplished accidentally while traveling forward until vehicle speed is very low, even though the shift lever is moved into the reverse position. A full stop is required for any shift from forward to reverse or from reverse to forward to avoid shift shock.
ACCELERATOR CONTROL The Allison automatic transmission can upshift or downshift under influence of accelerator movement. The operator can get a quicker downshift or can delay the upshift by managing the throttle to get the best performance from the transmission.
USING THE ENGINE TO SLOW THE VEHICLE To use the engine as a braking force, the converter must be in lockup mode. If lockup disengages, the frictional horsepower (braking force) from the engine is lost. Downshift the transmission to the next lower range. If excessive speed prohibits a downshift, apply the service brake, slowing the vehicle to an acceptable downshifting speed.
USING HYDRAULIC RETARDER (CBT, CLBT) WARNING: Do not use the retarder on wet, icy, or slippery surfaces. Activating the retarder while driving on a slippery surface can cause a loss of control and an accident. Each CBT and CLBT transmission model has an hydraulic retarder installed between the torque converter and the transmission gearing (refer to Figure 3). Apply the retarder to slow the vehicle on curves or downgrades. Maximum retarder effect occurs in the lowest range. The throttle must be closed when the retarder is used to maximize the retarder performance and prevent overheating. Partial application is permitted when maximum retarder effect is not required. Continuous retarder operation raises fluid temperature. Short periods of full-release will aid cooling. Do not exceed 330°F (165°C) during intermittent retarder operation. 17
DRIVING ON ICE AND SNOW The Allison automatic transmission continuously provides proper balance between required power and good traction. The operator can have better control of the vehicle because of this smooth, constant flow of power through the drive train. When driving on ice or snow, any acceleration or deceleration should be made gradually.
ROCKING OUT If the vehicle is stuck in sand, mud, or snow, it is often possible to “rock out.” Shift to D (Drive) or second to fifth (2–5) and apply a steady, light throttle, never full throttle. Then by moving the shift selector back and forth between D (Drive) or second to fifth and R (Reverse), rock the vehicle. Shifts from forward range to reverse-range and reverse-range to forward-range should be made with the throttle backed off. Time the shifts to take advantage of the forward and reverse momentum. If the wheels spin, back off the throttle. Discontinue the attempt to “rock out” if the wheels spin without moving the vehicle. Do not apply full power for more than 30 seconds if the drive wheels are not turning.
TOWING OR PUSHING WARNING: To help avoid injury or equipment damage, DO NOT attempt ro jump-start the equipment using an arc welder. Arc welding equipment requires dangerously high currents and voltage which cannot be sufficiently reduced to permit its use for jump-starting.
CAUTION: Failure to lift drive wheels off the road, disconnect the driveline, or remove the axle shafts before pushing or towing can cause serious transmission damage. The engine cannot be started by pushing or towing. Disconnect the driveline or lift the vehicle drive wheels completely off the ground before towing or pushing any distance at any speed.
PARKING BRAKE WARNING: Take the following precautions so that unexpected, possible sudden vehicle movement is avoided. Whenever it becomes necessary to leave the vehicle, even momentarily, while the engine is running, place the transmission shift selector in N (Neutral), set the parking brake and/or emergency brakes, and chock the wheels. 18
There is no P (Park) position on the shift selector. Therefore, always select N (Neutral) and apply the parking brake to hold the vehicle when it is parked.
TEMPERATURES Look at the temperature gauge occasionally to be sure that the converter-out temperature is in the normal range of 180–220°F (82–104°C) . If it exceeds 275°F (135°C) due to overload, shift to N (Neutral) and run the engine at 1200–1500 rpm. This should reduce the temperature in two or three minutes to the normal level. Transmission-to-cooler fluid temperature should never be permitted to exceed 330°F (166°C) during retarder operation. CAUTION: The engine should NEVER be operated for more than 30 seconds at full throttle with the transmission in gear and the output stalled. Prolonged operation of this type will cause the transmission fluid temperature to become excessively high and will result in severe overheating damage to the transmission. If the transmission overheats during normal operation, determine the fluid level in the transmission. Refer to the fluid test procedure that is described in the CARE AND MAINTENANCE section of this handbook. If the high temperature persists, stop the engine and have the system inspected by maintenance personnel.
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POWER TAKEOFF OPERATION
CONVERTER-DRIVEN POWER TAKEOFF (PTO) A PTO may be mounted onto the pad on the top-left side of the transmission main housing. The PTO drive gear is converter driven and thus provides infinitely variable speeds. The PTO can be operated when the vehicle is either moving or stopped. To operate the power takeoff, follow these instructions: •
Stop the vehicle, set the brakes, and idle the engine.
•
Place the shift selector in a drive range.
•
Engage the PTO. CAUTION: Do not exceed the speed limits imposed on the driven equipment during operation of the PTO.
•
If the PTO will be operated while the vehicle is stopped, set the parking brake, shift the transmission to N (Neutral), and depress the accelerator as required.
•
If the PTO will be operated while the vehicle is moving, simply select the desired range and depress the accelerator as required. However, the speed of the PTO during this type of operation will be affected by the ranges and speed of the vehicle.
•
To disengage the PTO, stop the vehicle, idle the engine, and set the brakes. Place the shift selector in a drive range and disengage the PTO.
ENGINE-DRIVEN POWER TAKEOFF (PTO) Some models provide PTO mountings on the top and side of the torque converter housing. The type of PTO installed will determine the operating procedures. If the PTO driven gear is in constant mesh with the drive gear in the converter housing, and a friction clutch is used to connect the PTO load, the PTO can be engaged or disengaged at any time (except at engine speeds that exceed drive speed limits imposed on the driven equipment). If the PTO is engaged by either a
20
sliding gear or dog clutch, the vehicle engine must be shutoff to engage or disengage the PTO. Do not exceed the drive speed restrictions of the driven equipment.
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CARE AND MAINTENANCE
PERIODIC INSPECTIONS The Allison automatic requires little maintenance. Careful attention to fluid condition and level, selector linkage, and throttle (modulator) linkage is most important. For easier inspection, the transmission should be kept clean. Make periodic inspections for loose bolts and leaking fluid lines. Inspect the condition and adjustment of the control linkage regularly. Inspect the engine cooling system occasionally for evidence of transmission fluid, which would indicate a faulty oil cooler (if transmission is cooled by engine cooling system). Report any abnormal conditions to your maintenance personnel.
IMPORTANCE OF PROPER FLUID LEVEL Since the transmission fluid cools, lubricates, and transmits power, it is important that the proper fluid level be maintained at all times. If it is too low, the converter and clutches will not receive an adequate supply of fluid. This can result in poor performance or transmission failure. If the level is too high, the fluid will aerate, causing the transmission to overheat. Determine the fluid level at intervals specified in your vehicle service instructions, or more frequently if operating conditions indicate.
FLUID LEVEL TEST PROCEDURE WARNING: To help avoid injury and property damage caused by sudden and unexpected vehicle movement, DO NOT perform maintenance or service procedures until all of the following have been completed: • Put the transmission in N (Neutral). • Set the parking brake and service brakes, and make sure they are properly engaged. • Chock the wheels. • Take all other steps necessary to keep the vehicle from moving.
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Before determining the fluid level, clean around the end of the fill tube before removing the dipstick(s). Dirt or foreign matter must not be permitted to enter the fluid system because it can cause: •
Valves to stick
•
Undue wear of transmission parts
•
Passages to clog. NOTE: Dropbox models have a dipstick or an oil filler tube for determining the fluid level. The transmission and dropbox have separate fluid systems. Each system may use a different grade of fluid.
Report any of the following to maintenance personnel: •
Abnormal fluid level
•
Milky appearance of fluid
•
Any trace of coolant in the fluid
•
Persistently high operating temperature.
C O L D R U N BA N D F I L L H O T O V E R
A T N E U T RA L C H EC K I N ® F L U I D D E X R O N I D L E - U S E
RECOMMENDED DIPSTICK MARKINGS H O T R U N BA N D
L D R E F O R C O R U N F I L L BA N D
A T N E U T RA L C H EC K I N ® F L U I D D E X R O N I D L E - U S E
ALTERNATE DIPSTICK MARKINGS V01961.01
Figure 6. Typical Dipstick Markings Cold Test. NOTE: The cold test procedure is primarily used to establish if the quantity of fluid in the transmission sump is sufficient to perform a hot run test.
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A cold fluid test may be made when the fluid temperature is 60–120°F (15–49°C). To perform a cold test, do the following with the engine at idle: 1. Run the engine for at least one minute to clear the fluid system of air. 2. Remove the dipstick and wipe it clean. Re-insert the dipstick, pushing down until it stops. 3. Remove the dipstick and determine the fluid level. Any level within the COLD RUN band (refer to Figure 6) is safe for operating the vehicle. 4. Be sure fluid level tests are consistent. Test fluid level more than once and if readings are not consistent, inspect the transmission breather to be sure that it is clean and not clogged. If readings are still consistent, contact your nearest Allison dealer or distributor. 5. If the level is at or below the COLD RUN band, add fluid until the fluid level is within the COLD RUN band. CAUTION: DO NOT operate the transmission for extended periods of time until a hot test has verified proper fluid level. Transmission damage can result from extended operation at improper fluid level conditions. 6. Perform a hot test at the first opportunity after the normal operating temperature of 160–200°F (71–93°C) is reached. Hot Test. NOTE: A hot test is made to determine if there is sufficient fluid for extended operation of the transmission.
WARNING: The normal operating temperature of transmission fluid is 180–200°F (82–93°C) and it can be hotter. Hot fluid can cause severe burns and eye injuries. To help avoid personal injury when making hot fluid level tests: • AVOID CONTACT WITH HOT FLUID BY WEARING HEAVY GLOVES AND SAFETY GLASSES. • REMOVE TEST PLUGS VERY SLOWLY. • DO NOT STAND DIRECTLY IN FRONT OF TEST PLUGS BEING REMOVED. Operate the transmission in a drive range until the normal operating temperature of 160–200°F; 71–93°C is reached.
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NOTE: The fluid level rises as temperature increases. The fluid must be at operating temperature (hot) to sure of an accurate test.
To perform a hot test, do the following with the engine at idle: 1. Shift through all drive, neutral, and reverse ranges to purge the air and fill the clutches and fluid passages with fluid. 2. Park the vehicle on a level spot, shift to N (Neutral), apply the parking brake and service brakes, and chock the wheels. Let the engine run at idle speed. 3. Remove the dipstick and wipe clean. Re-insert the dipstick, pushing down until it stops. 4. Remove the dipstick and determine the fluid level. The safe operating level is any level within the HOT RUN band (refer to Figure 6) on the dipstick. 5. If the fluid level is not within this range, add or drain fluid as necessary to bring the fluid level within the HOT RUN band. 6. Be sure fluid level tests are consistant. Test fluid level more than once and if readings are not consistant, inspect the transmission breather to be sure that it is clean and not clogged. If readings are still inconsistant, contact your nearest Allison dealer or distributor. 7. To determine the fluid level in the dropbox, turn off the engine. 8. If the dropbox has a fill tube, remove the fill tube plug. The fluid should be at the top of the tube. 9. If the dropbox has a dipstick, remove it, wipe it clean, re-insert pushing it down until it stops, and remove again. 10. Safe level for the dropbox is any fluid level between the ADD and FULL marks on the dipstick.
FLUID SPECIFICATIONS Allison approved C-4 fluid is recommended for use in transmissions in off-highway service. Use the C-4 fluid which conforms to the minimum temperature (refer to Table 3 in the Driving Tips section), fluid viscosity grade, and the dealer recommended specifications for the area. Use only SAE 30 fluid in the transfer case (dropbox).
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KEEPING FLUID CLEAN CAUTION: Containers or fillers that have been used for antifreeze solution or engine coolant MUST NEVER be used for transmission fluid. Antifreeze and coolant solutions contain ethylene glycol which, if put into the transmission, can cause the clutch plates and some seals to fail. It is absolutely necessary that the fluid put into the transmission be clean. Fluid must be handled in clean containers and fillers to prevent foreign material entering the transmission.
FLUID AND OIL FILTER CHANGE CAUTION: Transmission fluid and filter change frequency is determined by the severity of transmission service. To help avoid transmission damage, more frequent changes may be necessary than recommended in the general guidelines when operating conditions create high levels of contamination or overheating. Fluid and oil filter change frequency is determined by transmission application and severity of operating conditions. In general, the fluid should be changed after each 1000 hours of operation and the main external filter after 500 hours of operation. Severe operating conditions may require more frequent changes. Allison high efficiency external oil filters do not have a mileage limitation. Allison high efficiency external oil filters, which have a change filter indicator, do not have to be changed when the fluid is changed unless a restriction is indicated. WARNING: The normal operating temperature of transmission fluid is 180–200°F (82–93°C) and it can be hotter. Hot fluid can cause severe burns and eye injuries. To help avoid personal injury when making hot fluid level tests: • AVOID CONTACT WITH HOT FLUID BY WEARING HEAVY GLOVES AND SAFETY GLASSES. • REMOVE TEST PLUGS VERY SLOWLY. • DO NOT STAND DIRECTLY IN FRONT OF TEST PLUGS BEING REMOVED. To drain the transmission fluid, remove the 1 / 2 inch plug at the rear of the deep oil pan. To drain the dropbox, remove the plug from the bottom of the dropbox housing. Fluid will drain better if the fluid is at operating temperature. Replace the plug after the fluid is drained. 26
Remove the filter element(s) and sealrings from the external oil filters. Install new element(s) and sealrings. Pour 34 U.S. quarts (31 liters) (6 or 7 inch pan) or 38 U.S. quarts (36 liters) (81 / 2 inch pan) of C-4 transmission fluid into the transmission. Pour 2.6 U.S. quarts (2.5 liters) of C-4 transmission fluid, grade 30, into the dropbox.
HOW TO KEEP LITTLE PROBLEMS FROM BECOMING BIG PROBLEMS By observing the operation of the transmission and making periodic inspections, minor mechanical problems can be kept from becoming major problems. Notify maintenance personnel when one of these conditions occur: •
Overheating
•
Shifting feels odd
•
Unusual sounds
•
Transmission automatically upshifts or downshifts at irregular intervals
•
Fluid leaks from the transmission
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CUSTOMER SERVICE
OWNER ASSISTANCE The satisfaction and goodwill of the owners of Allison transmissions are of primary concern to Allison Transmission, its distributors, and their dealers. As an owner of an Allison transmission, you have service locations throughout the world that are eager to meet your parts and service needs with: •
Expert service by trained personnel.
•
Emergency service 24 hours a day in many areas.
•
Complete parts support.
•
Sales teams to help determine your transmission requirements.
•
Product information and literature.
Normally, any situation that arises in connection with the sale, operation, or service of your transmission will be handled by the distributor or dealer in your area. Consult the telephone directory for the Allison Transmission service outlet nearest you or utilize Allison Transmission’s Sales and Service Locator tool on the Allison Transmission web site at www.allisontransmission.com. You may also refer to Allison Transmission’s Worldwide Sales and Service Directory (SA2229EN). We recognize, however, that despite the best intentions of everyone concerned, misunderstandings may occur. To be sure of your complete satisfaction, we have developed the following three-step procedure to be followed in the event a problem has not been handled satisfactorily. Step One—Discuss your problem with a member of management from the distributorship or dealership. Frequently, complaints are the result of a breakdown in communication and can quickly be resolved by a member of management. If you have already discussed the problem with the Sales or Service Manager, contact the General Manager. All Allison Transmission dealers are associated with an Allison Transmission distributor. If the problem originates with a dealer, explain the matter to a management member of the distributorship with whom the dealer has his service agreement. The dealer will provide his Allison Transmission distributor’s name, address, and telephone number on request.
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Step Two—When it appears the problem cannot be readily resolved at the distributor level without additional assistance, contact the Allison Technical Assistance Center at 800-252-5283. They will place you in contact with the Regional Customer Support Manager for your area. For prompt assistance, please have the following information available: •
Name and location of authorized distributor or dealer.
•
Type and make of vehicle/equipment.
•
Transmission model number, serial number, and assembly number (if equipped with electronic controls, also provide the TCM assembly number).
•
Transmission delivery date and accumulated miles and/or hours of operation.
•
Nature of problem.
•
Chronological summary of your transmission’s history.
Step Three—If you are still not satisfied after contacting the Regional Customer Support Manager, present the entire matter to the Home Office by writing to the following address: Allison Transmission Manager, Warranty Administration PO Box 894, Mail Code 462-470-PF9 Indianapolis, IN 46206-0894 The inclusion of all pertinent information will assist the Home Office in expediting the matter. When contacting the Home Office, please keep in mind that ultimately the problem will likely be resolved at the distributorship or dealership using their facilities, equipment, and personnel. Therefore, it is suggested that Step One be followed when experiencing a problem. Your purchase of an Allison Transmission product is greatly appreciated, and it is our sincere desire to be sure of your complete satisfaction.
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SERVICE LITERATURE Additional service literature is available as shown in the service literature table. This service literature provides fully illustrated instructions for the operation, maintenance, service, overhaul, and parts support of your transmission. To be sure that you get maximum performance and service life from your unit, you may order publications from: SGI, Inc. Attn: Allison Literature Fulfillment Desk 8350 Allison Avenue Indianapolis, IN 46268 TOLL FREE: 888-666-5799 INTERNATIONAL: 317-471-4995
Available Service Literature Publication Mechanic’s Tips * Parts Catalog*
Service Manual Technician’s Guide ** Worldwide Sales and Service Directory* * Also available on the internet at
www.allisontransmission.com
** Automatic Transmission Fluid, Technician’s Guide
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CBT/CLBT 750/754 MT1366EN PC1315EN CD1315EN SM1314EN GN2055EN SA2229EN
ALLISON TRANSMISSION DISTRIBUTORS EASTERN REGION Atlantic Detroit Diesel-Allison, LLC 180 Route 17 South Lodi, NJ 07644 201-489-5800
Penn Detroit Diesel-Allison, Inc. 8330 State Road Philadelphia, PA 19136-2986 215-335-0500
Covington Detroit Diesel-Allison 8015 Piedmont Triad Parkway Greensboro, NC 27409 336-292-9240
Western Branch Diesel, Inc. 3504 Shipwright Street Portsmouth, VA 23703 757-673-7000
Johnson & Towers, Inc. 2021 Briggs Road Mount Laurel, NJ 08054 856-234-6990
W.W. Williams S.E., Inc. 2849 Moreland Avenue, S.E Atlanta, GA 30315-0037 404-366-1070
New England Detroit Diesel-Allison, Inc. 90 Bay State Road Wakefield , MA 01880-1095 781-246-1810 CENTRAL REGION Central Power Systems & Services 9200 Liberty Drive Liberty, MO 64068 816-781-8070
Inland Detroit Diesel-Allison, Inc. 210 Alexandra Way Carol Stream, IL 60188 630-871-1111
Clarke Power Services, Inc. 3133 East Kemper Road Cincinnati, OH 45241 513-771-2200
Inland Diesel, Inc. 13015 West Custer Avenue Butler, WI 53007-0916 262-781-7100
Detroit Diesel-Allison Canada East Div. of Integrated Power Systems Corp. 2997 Rue Watt Ste. Foy, Quebec G1X 3W1 418-651-5371
Interstate Power Systems, Inc. 2501 American Boulevard, East Minneapolis, MN 55425 952-854-5511
Harper Detroit Diesel Ltd. 10 Diesel Drive Toronto, Ontario M8W 2T8 416-259-3281
W.W. Williams M.W., Inc. 1176 Industrial Parkway North Brunswick, OH 44212-2342 330-225-7751
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SOUTHERN REGION Caribe Detroit Diesel-Allison Division of GT Corporation Ceramic Ind. Park Campo Rico Ave., Block C Carolina, Puerto Rico 00982 787-750-5000
Stewart & Stevenson Power, Inc. 5840 Dahlia Street Commerce City, CO 80022 303-287-7441
Detroit Diesel-Allison de Mexico S.A. de C.V. Av. Santa Rosa No. 58 Col. Ampliacion Norte Tlalnepantla C.P. 54160, Mexico 525-5-5333-1800
Stewart & Stevenson Power Products, LLC 2707 North Loop West Houston, TX 77008 713-868-7700
Florida Detroit Diesel-Allison, Inc. 2277 N.W. 14th Street Miami, FL 33125-0068 904-737-7330
United Engines, LLC 5555 West Reno Avenue Oklahoma City, OK 73127 405-947-3321
WESTERN REGION Detroit Diesel-Allison British Columbia Ltd. 9300 - 192nd Street Surrey, British Columbia V4N 3R8 604-888-1211
Stewart & Stevenson 1755 Adams Avenue San Leandro, CA 94577-1001 510-635-8991
Midwest Detroit Diesel-Allison Ltd. 1460 Waverly Street Winnipeg , Manitoba R3T OP6 204-452-8244
Valley Power Systems, Inc. 425 South Hacienda Boulevard City of Industry, CA 91745-1123 626-333-1243
Pacific Power Products Company 7215 South 228th Street Kent, WA 98032 253-854-0505
Waterous Power Systems 10025 - 51st Avenue Edmonton, Alberta T6E OA8 780-437-3550
Smith Power Products, Inc. 3065 West California Avenue Salt Lake City, UT 84104 801-415-5000
W.W. Williams S.W., Inc. 2602 S. 19th Avenue Phoenix, AZ 85009 602-257-0561
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ALLISON TRANSMISSION REGIONAL OFFICES EASTERN REGION 19 Oaklynn Drive PO Box 400 Columbus, NJ 08022-0400 609-298-2541
SOUTHERN REGION Av. Ejercito Nacional No. 843 Colonia Granada Mexico, D.F. C.P. 11520 936-321-4248
CENTRAL REGION PO Box 894, Mail Code 462-470-PF06 Indianapolis, IN 46206-0894 317-242-2327
WESTERN REGION Suite 3510 39465 Paseo Padre Parkway Fremont, CA 94538 510-226-8037
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