JCB Allison Transmission 3000 and 4000 Series Families Troubleshooting Manual PDF

This troubleshooting manual provides detailed troubleshooting and service information for the Allison 3000 and 4000 Product Families Transmissions (for JCB equipment). 

This manual includes descriptions of the electronic control system components, diagnostic codes, system responses to faults, and troubleshooting, wire, terminal, and connector repair information.

This publication is periodically reviewed to include improvements, new models, special tools and procedures. Revision of this manual is dated 2015 December.

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This troubleshooting service manual is an e-book, in PDF format. You have to install the application Adobe PDF Reader (or any other equivalent). This application allows you to copy, save and print some useful information.

Models covered:
3000 VOCATIONAL MODELS
3000 HS 3500 RDS B 300(P)(R)
3000 RDS 3500 EVS B 400(P)(R)
3000 EVS T 200
3000 MH T 300
3000 PTS
3000 TRV
3200 SP 3500 SP 3700 SP
3200 TRV

4000 VOCATIONAL MODELS
4000 EVS 4500 EVS 4700 EVS 4800 EVS B 500
4000 HS 4500 HS 4700 RDS B 500P
4000 MH 4500 RDS 4700 OFS B 500R
4000 RDS 4500 SP B 500PR
4000 TRV 4500 TRV T 425
T 450

CONTENTS:

• SAFETY INFORMATION
  • Important Safety Notice
  • Warnings, Cautions, and Notes
  • Trademarks Used in This Manual
  • Shift Selector Terms and Display Indications
• SECTION 1. GENERAL DESCRIPTION
  • 1–1. TRANSMISSION
  • 1–2. TRANSMISSION CONTROL MODULE (TCM)
  • 1–3. SHIFT SELECTOR
  • 1–4. THROTTLE POSITION SENSOR
  • 1–5. SPEED SENSORS
  • 1–6. CONTROL MODULE
  • 1–7. WIRING HARNESSES
  • 1–8. VEHICLE INTERFACE MODULE
  • 1–9. AUTODETECT FEATURE
  • 1–10. TRANSID (TID)
• SECTION 2. DEFINITIONS AND ABBREVIATIONS
  • 2–1. CHECK TRANS LIGHT 
  • 2–2. ALLISON TRANSMISSION DIAGNOSTIC TOOL
  • 2–3. ABBREVIATIONS
• SECTION 3. BASIC KNOWLEDGE
  • 3–1. BASIC KNOWLEDGE REQUIRED
  • 3–2. USING THE TROUBLESHOOTING MANUAL
  • 3–3. SYSTEM OVERVIEW
  • 3–4. IMPORTANT INFORMATION IN THE TROUBLESHOOTING PROCESS
  • 3–5. BEGINNING THE TROUBLESHOOTING PROCESS
  • 3–6. TCM DIAGNOSTIC PROCEDURE 
  • 3–7. RESTTING OF TCM PARAMETERS TO SUPPORT ENGINE UPDATE
  • 3–8. RESETTING TCM AUTOSELECT
  • 3–9. HYDRAULIC OPERATION DURING ELECTRICAL INTERRUPTION
• SECTION 4. WIRE CHECK PROCEDURES
  • 4–1. TESTING FOR OPENS, SHORTS BETWEEN WIRES, AND SHORTS-TO-GROUND
  • 4–2. TESTING AT TRANSMISSION FEEDTHROUGH CONNECTOR FOR INTERNAL HARNESS OPENS, SHORTS BETWEEN WIRES, AND SHORTS-TO-GROUND 
• SECTION 5. OIL LEVEL SENSOR
  • 5–1. INTRODUCTION
  • 5–2. ELECTRONIC FLUID LEVEL READING (SHIFT SELECTOR)
  • 5–3. ELECTRONIC FLUID LEVEL CHECK (ALLISON DOC™ FOR PC–SERVICE TOOL)
• SECTION 6. DIAGNOSTIC CODES
  • 6–1. DIAGNOSTIC CODE MEMORY
  • 6–2. CODE READING AND CODE CLEARING
  • 6–3. DIAGNOSTIC CODE RESPONSE
  • 6–4. SHIFT SELECTOR DISPLAYS RELATED TO ACTIVE CODES 
  • 6–5. DIAGNOSTIC CODE LIST AND DESCRIPTION 
  • 6–6. DIAGNOSTIC CODE TROUBLESHOOTING
• SECTION 7. INPUT AND OUTPUT FUNCTIONS
  • 7–1. INPUT FUNCTIONS
  • 7–2. OUTPUT FUNCTIONS
• SECTION 8. GENERAL TROUBLESHOOTING OF PERFORMANCE COMPLAINTS
• APPENDICES
  • A. IDENTIFICATION OF POTENTIAL CIRCUIT PROBLEMS
  • B. MEASURING CLUTCH AND RETARDER PRESSURES
  • C. SOLENOID AND CLUTCH CHART
  • D. WIRE/CONNECTOR CHART
  • E. CONNECTOR PART NUMBERS, TERMINAL PART NUMBERS, TOOL PART NUMBERS, AND REPAIR INSTRUCTIONS
  • F. THROTTLE POSITION SENSOR ADJUSTMENT
  • G. WELDING ON VEHICLE/VEHICLE INTERFACE MODULE
  • H. HYDRAULIC SCHEMATICS
  • J. 3000 AND 4000 PRODUCT FAMILIES WIRING SCHEMATIC
  • K. SOLENOID RESISTANCE CHARTS
  • L. EXTERNALLY-GENERATED ELECTRONIC INTERFERENCE
  • M. DIAGNOSTIC TREE—3000 AND 4000 PRODUCT FAMILIES HYDRAULIC SYSTEM
  • N. ALLISON DOC™ FOR PC–SERVICE TOOL
  • P. INPUT/OUTPUT FUNCTIONS
  • Q. THERMISTOR TROUBLESHOOTING INFORMATION
  • R. SAE J1939 COMMUNICATION LINK