Operator’s Manual

750/754 SeriesAllison Off-Highway

OM1475EN

Allison TransmissionOFF-HIGHWAY TRANSMISSIONS

Operator’sManual

2006 MARCH

OM1475EN

CBT 750, 754CLBT 750, 754CLBT 750, 754DB REMOTE MOUNT

Printed in USA Copyright © 2007 Allison Transmission, Inc.

Allison Transmission, Inc.P.O. Box 894 Indianapolis, Indiana 46206-0894www.allisontransmission.com

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NOTES

TABLE OF CONTENTS

INTRODUCTIONKEEPING THAT ALLISON ADVANTAGE . . . . . . . . . . . . . . . . . . . . . . . . 7TYPICAL 750/754 SERIES OFF-HIGHWAYTRANSMISSION MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A BRIEF DESCRIPTION OF THE ALLISON AUTOMATIC . . . . . . . . . . . . . 9TORQUE CONVERTER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9LOCKUP CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10POWER TAKEOFF DRIVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10HYDRAULIC RETARDER (CBT, CLBT 750/754). . . . . . . . . . . . . . . . . . . 10TRANSFER GEAR HOUSING (DROPBOX). . . . . . . . . . . . . . . . . . . . . . 10MANUAL DISCONNECT CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . 11THROTTLE ACTUATED MODULATOR . . . . . . . . . . . . . . . . . . . . . . . . 11COOLER, FILTER CIRCUITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

SHIFT SELECTORSSHIFT SELECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13RANGE SELECTION POSITIONS (FIVE-SPEED). . . . . . . . . . . . . . . . . . 14

DRIVING TIPSOPERATING IN COLD WEATHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16DOWNSHIFT CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16DOWNSHIFT OR REVERSE INHIBITOR FEATURE. . . . . . . . . . . . . . . . . 17ACCELERATOR CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17USING THE ENGINE TO SLOW THE VEHICLE. . . . . . . . . . . . . . . . . . . 17USING HYDRAULIC RETARDER (CBT, CLBT) . . . . . . . . . . . . . . . . . . . 17DRIVING ON ICE AND SNOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18ROCKING OUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18TOWING OR PUSHING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18TEMPERATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

POWER TAKEOFF OPERATIONCONVERTER-DRIVEN POWER TAKEOFF (PTO). . . . . . . . . . . . . . . . . . 20ENGINE-DRIVEN POWER TAKEOFF (PTO) . . . . . . . . . . . . . . . . . . . . . 20

CARE AND MAINTENANCEPERIODIC INSPECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22IMPORTANCE OF PROPER FLUID LEVEL. . . . . . . . . . . . . . . . . . . . . . 22FLUID LEVEL TEST PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . 22FLUID SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

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KEEPING FLUID CLEAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26FLUID AND OIL FILTER CHANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . 26HOW TO KEEP LITTLE PROBLEMS FROMBECOMING BIG PROBLEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

CUSTOMER SERVICEOWNER ASSISTANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28SERVICE LITERATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30ALLISON TRANSMISSION DISTRIBUTORS . . . . . . . . . . . . . . . . . . . . . 31ALLISON TRANSMISSION REGIONAL OFFICES. . . . . . . . . . . . . . . . . . 33

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TRADEMARK USAGEThe 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 warningsand cautions described in this handbook. It is, however, important to understandthat these warnings and cautions are not exhaustive. Allison Transmission couldnot possibly know, evaluate, and advise the service trade of all conceivable waysin which 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 handbook 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.

The following three types of heading are used to attract your attention toimportant information:

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 transmissions provide many advantages for the driver whose vehicle mayencounter vigorous, tough use and sometimes abuse. Driving is easier, safer, andmore efficient.

These transmissions are rugged and designed to provide long, trouble-free service.This handbook will help you gain maximum benefits from your Allisontransmission-equipped vehicle.

INTRODUCTION

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TYPICAL 750/754 SERIES OFF-HIGHWAYTRANSMISSION MODELS

Figure 1. CLBT 750/754 Remote Mount

Figure 2. CLBT 750/754DB Remote Mount

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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 anhydraulic cushion between the engine and gearing. The clutches and gear setsprovide multiple forward ranges and one reverse range. The torque converterlockup clutch engages automatically after the vehicle is moving, for maximumfuel economy. The hydraulic control system automatically selects the mostefficient gear ratio for vehicle speed and throttle position.

TORQUE CONVERTERThe 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

FORWARDCLUTCH

FOURTHCLUTCH

THIRDCLUTCH

ENGINE-DRIVENPTO GEAR – TOP

ENGINE-DRIVENPTO GEAR – SIDE

CONVERTER-DRIVENPTO GEAR

HYDRAULICRETARDER

TORQUECONVERTER

LOWPLANETARY

FIFTH CLUTCHFRONT PLANETARY

REAR PLANETARY

GOVERNOR

CENTER PLANETARY

OIL SCREENCONTROLVALVE

SPEEDOMETERDRIVE

OUTPUTSHAFT

SECONDCLUTCHLOCKUP

CLUTCH

H01980

FIRSTCLUTCH

Figure 3. CLBT 750/754 Remote Mount–Cross Section

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pump speed, torque multiplication stops and the torque converter functions as afluid coupling. With a fixed-capacity stator, engine power is always directed to thevehicle power train.

LOCKUP CLUTCHThe lockup clutch (refer to Figure 3) is designed to hydraulically engage anddisengage at predetermined turbine speeds. When turbine speed approaches thepump speed, hydraulic pressure automatically engages the lockup clutch. Thefunction of the lockup clutch is to lock the input element (pump) and the outputelement (turbine) together. With the lockup clutch engaged, the engine output isdirected to the transmission gearing at 1:1 speed ratio. Reduction in the turbinespeed (output speed) automatically disengages the lockup clutch. When the lockupclutch 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 DRIVESThe CBT, CLBT 750/754 Series off-highway transmission (refer to Figure 1) hasprovisions for three power takeoff (PTO) drives—two engine-driven PTO drives,and one converter-driven PTO drive. Engine-driven PTOs may be mounted at topand/or lower-left side of the torque converter housing. A converter-driven PTOmay 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. Amanually-controlled valve fills the cavity around the rotor with fluid when thevehicle must be slowed on steep downgrades. When the cavity is emptied, therotor is free of drag. Added safety and longer service brake life are the benefitsgained from a retarder.

TRANSFER GEAR HOUSING (DROPBOX)The dropbox is a vertical transfer gear case mounted (refer to Figure 2) to the rearof 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 leftof vertical as viewed from the rear of the dropbox. These positions are bolt holespecific.

The dropbox provides a 1:1 gear ratio at three specific output locations. The toprear location is in line with the input. The bottom rear and bottom front areextensions of the drive, idler, and driven gears in the dropbox.

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MANUAL DISCONNECT CLUTCHA manually-applied disconnect housing is available at any one or all three of thedropbox output locations. Linkage controls the movement of the shift lever in thedisconnect housing, engaging or disengaging the clutch.

THROTTLE ACTUATED MODULATORMechanical linkage between the engine throttle and the transmission moves thecontrol system modulator valve. This feature makes the transmission automaticcontrol system responsive to throttle position. Opening the throttle will raise thespeed at which upshifts occur. Timing of shifts and clutch applications areregulated by the modulator system. Precise and smoother shifts are obtained.

Other modulator control systems may be used including air and electricallyactuated devices.

1 VERTICAL

REAR VIEWOF DROPBOX

3

4

5

30°

30°15°45°

V07146

2

Figure 4. Dropbox Mounting Positions

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COOLER, FILTER CIRCUITSA separate oil cooler or connection to the vehicle engine cooling system is used tocool the transmission fluid. An external oil filter is placed in theconverter-to-cooler line on all models equipped with an hydraulic brake. Anauxiliary filter may be installed in the converter-to-cooler line on non-retardermodels at customer option.

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SHIFT SELECTORS

The vehicle manufacturers may choose different types of shift selectors for theirequipment. Different transmission models may also require different designationson the shift selectors.

Some of the typical shift selectors found in Allison transmission-equipped vehiclesare shown in Figure 5. The lever shift selector in a particular vehicle may varyfrom these or may have1 (Low) at the top andR (Reverse) at the bottom.

The best performance will be obtained by using the correct range for each drivingcondition.

When a vehicle is equipped with an Allison automatic transmission, it is notnecessary to select the right moment to upshift or downshift because the Allisontransmission shifts automatically during changing road and traffic conditions. Aknowledge of the ranges available at the shift selector will make control of thevehicle and driving easier.

FIVE-SPEEDLEVER

SELECTOR

RN

2-52-321

FIVE-SPEEDLEVER

SELECTOR

RND4321

V07145

Figure 5. Five-Speed Lever Shift Selector Configurations

SHIFT SELECTORS

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RANGE SELECTION POSITIONS (FIVE-SPEED)

WARNING: Take the following precautions so that unexpected,possible sudden vehicle movement is avoided. Whenever itbecomes necessary to leave the vehicle, even momentarily, whilethe engine is running, place the transmission shift selector inN (Neutral), set the parking brake and/or emergency brakes, andchock the wheels.

NOTE: The shift information below is applicable to the majority ofinstallations. However, some transmissions have automatic shiftingin all ranges.

R Use this to back the vehicle. Completely stop vehicle beforeshifting from forward toR (Reverse) or fromR (Reverse) toforward. The reverse warning signal is activated when the shiftselector is in this position. Reverse has only one range.

WARNING: Do not allow your vehicle to coast in neutral. Thispractice can result in severe transmission damage. Enginebraking and hydraulic retarder action (CBT, CLBT) are notavailable during neutral coast.

N UseN (Neutral) when you start the engine. If the engine starts inany other position, the neutral start switch is malfunctioning.N (Neutral) is also used during stationary operation of the powertakeoff (if your vehicle is equipped with a PTO).

2–5 Use this for all normal driving conditions. The vehicle will begin tomove forward in second-range. As the accelerator is depressed, thetransmission will upshift to third, fourth, and fifth rangesautomatically. As the vehicle slows, the transmission will downshiftto the correct range automatically.

2–42–3

Occasionally, the road, load, or traffic conditions will make itdesirable to restrict the automatic shifting to a lower range. Whenconditions improve, return the shift selector to the normal drivingposition. These positions also provide progressively greater enginebraking and hydraulic retarder effect (the lower the range, thegreater the braking or retarding effect).

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2 This is second range. Use this when pulling through mud and snowor driving up steep grades. The vehicle will start out insecond-range if calibrated for second-range start. Otherwise it willstart in first-range and shift automatically to second-range as theaccelerator is depressed.

1 This is first-range hold (low). No upshift will occur when the shiftselector is in this position. This position provides the greatesttractive advantage. It also provides maximum engine braking andhydraulic retarder effect.

NOTE: All models except those for scraper applications havelockup capability in all forward ranges. Scraper transmissions havelockup available in all forward ranges except first-range.

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OPERATING IN COLD WEATHER

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

Table 1 lists the minimum fluid temperatures by fluid type at which thetransmission may be safely operated in a forward or reverse range. When ambienttemperature is below the minimum fluid temperature limit and the transmission iscold, preheat is required. If auxiliary heating equipment is not available, run theengine to preheat the fluid to the minimum temperature limit before operating in aforward or reverse range. Failure to observe the minimum fluid temperature limitcan result in transmission malfunction or reduced transmission life.

Transmission Fluid Operating Temperature Guide

SAE Vicosity Grade or Fluid TypeMinimum Operating Temperature

Fahrenheit CelsiusMIL-PRF-46167 –25 –32SAE 0W*-20 or TranSynd™ –22 –30DEXRON®-III –13 –25SAE 10W* –4 –20SAE 15W*-40 5 –15SAE 30W* 32 0SAE 40W* 50 10* SAE “W” designation indicates winter weight based on cold temperature properties.

DOWNSHIFT CONTROLDownshifting is a manual shift to a lower range to match driving conditionsencountered or expect to be encountered. Learning to take advantage of manualdownshifts will give better control on slick or icy roads, and on steep downgrades.Downshifting to lower ranges increases engine braking and hydraulic retardereffect. The selection of a lower range often prevents cycling between a range andthe next higher range on a series of short up-and-down grades.

DRIVING TIPS

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DOWNSHIFT OR REVERSE INHIBITOR FEATUREThe transmission hydraulic system will not permit a shift into any lower forwardrange at a speed that will cause excessive engine overspeed. A lower forwardrange may be selected at any time, but the actual shift into that range will notoccur until road speed is reduced; downshifting is progressive as road speeddecreases. The inhibitor effect will cause downshifts to occur at slightly higherspeeds than normal automatic downshifts.

Shifting into reverse cannot be accomplished accidentally while traveling forwarduntil vehicle speed is very low, even though the shift lever is moved into thereverse position. A full stop is required for any shift from forward to reverse orfrom reverse to forward to avoid shift shock.

ACCELERATOR CONTROLThe Allison automatic transmission can upshift or downshift under influence ofaccelerator movement. The operator can get a quicker downshift or can delay theupshift by managing the throttle to get the best performance from thetransmission.

USING THE ENGINE TO SLOW THE VEHICLETo use the engine as a braking force, the convertermust be in lockup mode. Iflockup disengages, the frictional horsepower (braking force) from the engine islost. Downshift the transmission to the next lower range. If excessive speedprohibits a downshift, apply the service brake, slowing the vehicle to anacceptable 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 aloss of control and an accident.

Each CBT and CLBT transmission model has an hydraulic retarder installedbetween the torque converter and the transmission gearing (refer to Figure 3).Apply the retarder to slow the vehicle on curves or downgrades. Maximumretarder effect occurs in the lowest range. The throttlemust be closed when theretarder 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-releasewill aid cooling. Do not exceed 330°F (165°C) during intermittent retarderoperation.

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DRIVING ON ICE AND SNOWThe Allison automatic transmission continuously provides proper balance betweenrequired power and good traction. The operator can have better control of thevehicle because of this smooth, constant flow of power through the drive train.When driving on ice or snow, any acceleration or deceleration should be madegradually.

ROCKING OUTIf 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,neverfull throttle . Then by moving the shift selector back and forth betweenD (Drive)or second to fifth andR (Reverse), rock the vehicle. Shifts from forward range toreverse-range and reverse-range to forward-range should be made with thethrottle backed off.

Time the shifts to take advantage of the forward and reverse momentum. If thewheels spin, back off the throttle. Discontinue the attempt to “rock out” if thewheels spin without moving the vehicle.Do not apply full power for more than30 seconds if the drive wheels are not turning.

TOWING OR PUSHING

WARNING: To help avoid injury or equipment damage, DO NOTattempt ro jump-start the equipment using an arc welder. Arc weldingequipment requires dangerously high currents and voltage which cannotbe sufficiently reduced to permit its use for jump-starting.

CAUTION: Failure to lift drive wheels off the road, disconnect thedriveline, or remove the axle shafts before pushing or towing can causeserious transmission damage.

The engine cannot be started by pushing or towing. Disconnect the driveline orlift the vehicle drive wheels completely off the ground before towing or pushingany distance at any speed.

PARKING BRAKE

WARNING: Take the following precautions so that unexpected,possible sudden vehicle movement is avoided. Whenever it becomesnecessary to leave the vehicle, even momentarily, while the engine isrunning, place the transmission shift selector inN (Neutral), set theparking brake and/or emergency brakes, and chock the wheels.

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There is noP (Park) position on the shift selector. Therefore,always selectN (Neutral) and apply the parking brake to hold the vehicle when it is parked.

TEMPERATURESLook at the temperature gauge occasionally to be sure that the converter-outtemperature is in the normal range of 180–220°F (82–104°C) . If it exceeds275°F (135°C) due to overload, shift toN (Neutral) and run the engine at1200–1500 rpm. This should reduce the temperature in two or three minutes to thenormal level. Transmission-to-cooler fluid temperature should never be permittedto exceed 330°F (166°C) during retarder operation.

CAUTION: The engine should NEVER be operated for more than30 seconds at full throttle with the transmission in gear and the outputstalled. Prolonged operation of this type will cause the transmission fluidtemperature to become excessively high and will result in severeoverheating damage to the transmission.

If the transmission overheats during normal operation, determine the fluid level inthe transmission. Refer to the fluid test procedure that is described in the CAREAND 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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CONVERTER-DRIVEN POWER TAKEOFF (PTO)A PTO may be mounted onto the pad on the top-left side of the transmission mainhousing. The PTO drive gear is converter driven and thus provides infinitelyvariable speeds. The PTO can be operated when the vehicle is either moving orstopped.

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 drivenequipment during operation of the PTO.

• If the PTO will be operated while the vehicle is stopped, set the parkingbrake, shift the transmission toN (Neutral), and depress the accelerator asrequired.

• If the PTO will be operated while the vehicle is moving, simply select thedesired range and depress the accelerator as required. However, the speedof the PTO during this type of operation will be affected by the ranges andspeed 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 converterhousing. 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 converterhousing, and a friction clutch is used to connect the PTO load, the PTO can beengaged or disengaged at any time (except at engine speeds that exceed drivespeed limits imposed on the driven equipment). If the PTO is engaged by either a

POWER TAKEOFFOPERATION

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sliding gear or dog clutch, the vehicle enginemust be shutoff to engage ordisengage the PTO.Do not exceed the drive speed restrictions of the drivenequipment.

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PERIODIC INSPECTIONSThe Allison automatic requires little maintenance. Careful attention to fluidcondition and level, selector linkage, and throttle (modulator) linkage is mostimportant.

For easier inspection, the transmission should be kept clean. Make periodicinspections for loose bolts and leaking fluid lines. Inspect the condition andadjustment of the control linkage regularly. Inspect the engine cooling systemoccasionally for evidence of transmission fluid, which would indicate a faulty oilcooler (if transmission is cooled by engine cooling system). Report any abnormalconditions to your maintenance personnel.

IMPORTANCE OF PROPER FLUID LEVELSince the transmission fluid cools, lubricates, and transmits power, it is importantthat the proper fluid level be maintained at all times. If it is too low, the converterand clutches will not receive an adequate supply of fluid. This can result in poorperformance or transmission failure. If the level is too high, the fluid will aerate,causing the transmission to overheat. Determine the fluid level at intervalsspecified in your vehicle service instructions, or more frequently if operatingconditions indicate.

FLUID LEVEL TEST PROCEDURE

WARNING: To help avoid injury and property damage caused bysudden and unexpected vehicle movement, DO NOT performmaintenance or service procedures until all of the following have beencompleted:

• Put the transmission inN (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.

CARE AND MAINTENANCE

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Before determining the fluid level, clean around the end of the fill tube beforeremoving the dipstick(s). Dirt or foreign mattermust not be permitted to enter thefluid 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 fordetermining the fluid level. The transmission and dropbox have separatefluid 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.

Cold Test.

NOTE: The cold test procedure is primarily used to establish if thequantity of fluid in the transmission sump is sufficient to perform a hotrun test.

V01961.01

REFFILL

COLDRUNBAND

OR

HOT RUNBAND

CHECK IN NEUTRAL AT

IDLE - USE DEXRON® FLUID

COLD RUNBAND

HOT OVERFILLCHECK IN NEUTRAL AT

IDLE - USE DEXRON® FLUID

RECOMMENDED DIPSTICK MARKINGS

ALTERNATE DIPSTICK MARKINGS

Figure 6. Typical Dipstick Markings

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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, pushingdown until it stops.

3. Remove the dipstick and determine the fluid level. Any level within theCOLD 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 andif readings are not consistent, inspect the transmission breather to be surethat it is clean and not clogged. If readings are still consistent, contact yournearest Allison dealer or distributor.

5. If the level is at or below the COLD RUN band, add fluid until the fluidlevel is within the COLD RUN band.

CAUTION: DO NOT operate the transmission for extended periods oftime until a hot test has verified proper fluid level. Transmission damagecan result from extended operation at improper fluid level conditions.

6. Perform a hot test at the first opportunity after the normal operatingtemperature of 160–200°F (71–93°C) is reached.

Hot Test.

NOTE: A hot test is made to determine if there is sufficient fluid forextended operation of the transmission.

WARNING: The normal operating temperature of transmission fluid is180–200°F (82–93°C) and it can be hotter. Hot fluid can cause severeburns and eye injuries. To help avoid personal injury when making hotfluid level tests:

• AVOID CONTACT WITH HOT FLUID BY WEARING HEAVYGLOVES 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 temperatureof 160–200°F; 71–93°C is reached.

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NOTE: The fluid level rises as temperature increases. The fluidmust beat 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 fillthe clutches and fluid passages with fluid.

2. Park the vehicle on a level spot, shift toN (Neutral), apply the parkingbrake and service brakes, and chock the wheels. Let the engine run at idlespeed.

3. Remove the dipstick and wipe clean. Re-insert the dipstick, pushing downuntil it stops.

4. Remove the dipstick and determine the fluid level. The safe operating levelis 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 tobring the fluid level within the HOT RUN band.

6. Be sure fluid level tests are consistant. Test fluid level more than once andif readings are not consistant, inspect the transmission breather to be surethat it is clean and not clogged. If readings are still inconsistant, contactyour 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 beat the top of the tube.

9. If the dropbox has a dipstick, remove it, wipe it clean, re-insert pushing itdown until it stops, and remove again.

10. Safe level for the dropbox is any fluid level between the ADD and FULLmarks on the dipstick.

FLUID SPECIFICATIONSAllison approved C-4 fluid is recommended for use in transmissions inoff-highway service. Use the C-4 fluid which conforms to the minimumtemperature (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 inthe transfer case (dropbox).

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KEEPING FLUID CLEAN

CAUTION: Containers or fillers that have been used for antifreezesolution or engine coolantMUST NEVER be used for transmissionfluid. Antifreeze and coolant solutions contain ethylene glycol which, ifput into the transmission, can cause the clutch plates and some seals tofail.

It is absolutely necessary that the fluid put into the transmission be clean. Fluidmust be handled in clean containers and fillers to prevent foreign materialentering the transmission.

FLUID AND OIL FILTER CHANGE

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

Fluid and oil filter change frequency is determined by transmission application andseverity of operating conditions. In general, the fluid should be changed after each1000 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 filtersdo not have a mileage limitation.Allison high efficiency external oil filters, which have a change filter indicator,donot have to be changed when the fluid is changed unless a restriction is indicated.

WARNING: The normal operating temperature of transmission fluid is180–200°F (82–93°C) and it can be hotter. Hot fluid can cause severeburns and eye injuries. To help avoid personal injury when making hotfluid level tests:

• AVOID CONTACT WITH HOT FLUID BY WEARING HEAVYGLOVES 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 the1/2 inch plug at the rear of the deep oilpan. To drain the dropbox, remove the plug from the bottom of the dropboxhousing.

Fluid will drain better if the fluid is at operating temperature. Replace the plugafter the fluid is drained.

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Remove the filter element(s) and sealrings from the external oil filters. Install newelement(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 FROMBECOMING BIG PROBLEMSBy observing the operation of the transmission and making periodic inspections,minor mechanical problems can be kept from becoming major problems. Notifymaintenance 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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OWNER ASSISTANCEThe satisfaction and goodwill of the owners of Allison transmissions are ofprimary concern to Allison Transmission, its distributors, and their dealers.

As an owner of an Allison transmission, you have service locations throughout theworld 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, orservice of your transmission will be handled by the distributor or dealer in yourarea. Consult the telephone directory for the Allison Transmission service outletnearest you or utilize Allison Transmission’s Sales and Service Locator tool on theAllison Transmission web site atwww.allisontransmission.com.You may alsorefer 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 havedeveloped the following three-step procedure to be followed in the event aproblem has not been handled satisfactorily.

Step One—Discuss your problem with a member of management from thedistributorship or dealership. Frequently, complaints are the result of abreakdown in communication and can quickly be resolved by a member ofmanagement. If you have already discussed the problem with the Sales or ServiceManager, contact the General Manager. All Allison Transmission dealers areassociated with an Allison Transmission distributor. If the problem originates witha dealer, explain the matter to a management member of the distributorship withwhom the dealer has his service agreement. The dealer will provide his AllisonTransmission distributor’s name, address, and telephone number on request.

CUSTOMER SERVICE

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Step Two—When it appears the problem cannot be readily resolved at thedistributor level without additional assistance,contact the Allison TechnicalAssistance Center at 800-252-5283.They will place you in contact with theRegional 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 (ifequipped with electronic controls, also provide the TCM assembly number).

• Transmission delivery date and accumulated miles and/or hours ofoperation.

• Nature of problem.

• Chronological summary of your transmission’s history.

Step Three—If you are still not satisfied after contacting the Regional CustomerSupport Manager,present the entire matter to the Home Office by writing tothe following address:

Allison TransmissionManager, Warranty AdministrationPO Box 894, Mail Code 462-470-PF9Indianapolis, IN 46206-0894

The inclusion of all pertinent information will assist the Home Office inexpediting the matter.

When contacting the Home Office, please keep in mind that ultimately theproblem will likely be resolved at the distributorship or dealership using theirfacilities, equipment, and personnel. Therefore, it is suggested thatStep Onebefollowed when experiencing a problem.

Your purchase of an Allison Transmission product is greatly appreciated, and it isour sincere desire to be sure of your complete satisfaction.

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SERVICE LITERATUREAdditional 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 surethat you get maximum performance and service life from your unit, you mayorder publications from:

SGI, Inc.Attn: Allison Literature Fulfillment Desk8350 Allison AvenueIndianapolis, IN 46268TOLL FREE: 888-666-5799INTERNATIONAL: 317-471-4995

Available Service Literature

Publication CBT/CLBT 750/754Mechanic’s Tips* MT1366ENParts Catalog* PC1315EN

CD1315ENService Manual SM1314ENTechnician’s Guide** GN2055ENWorldwide Sales and Service Directory* SA2229EN* Also available on the internet atwww.allisontransmission.com

** Automatic Transmission Fluid, Technician’s Guide

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ALLISON TRANSMISSION DISTRIBUTORS

EASTERN REGION

Atlantic Detroit Diesel-Allison, LLC180 Route 17 SouthLodi, NJ 07644201-489-5800

Penn Detroit Diesel-Allison, Inc.8330 State RoadPhiladelphia, PA 19136-2986215-335-0500

Covington Detroit Diesel-Allison8015 Piedmont Triad ParkwayGreensboro, NC 27409336-292-9240

Western Branch Diesel, Inc.3504 Shipwright StreetPortsmouth, VA 23703757-673-7000

Johnson & Towers, Inc.2021 Briggs RoadMount Laurel, NJ 08054856-234-6990

W.W. Williams S.E., Inc.2849 Moreland Avenue, S.EAtlanta, GA 30315-0037404-366-1070

New England Detroit Diesel-Allison, Inc.90 Bay State RoadWakefield , MA 01880-1095781-246-1810

CENTRAL REGION

Central Power Systems & Services9200 Liberty DriveLiberty, MO 64068816-781-8070

Inland Detroit Diesel-Allison, Inc.210 Alexandra WayCarol Stream, IL 60188630-871-1111

Clarke Power Services, Inc.3133 East Kemper RoadCincinnati, OH 45241513-771-2200

Inland Diesel, Inc.13015 West Custer AvenueButler, WI 53007-0916262-781-7100

Detroit Diesel-Allison Canada EastDiv. of Integrated Power Systems Corp.2997 Rue WattSte. Foy, Quebec G1X 3W1418-651-5371

Interstate Power Systems, Inc.2501 American Boulevard, EastMinneapolis, MN 55425952-854-5511

Harper Detroit Diesel Ltd.10 Diesel DriveToronto, Ontario M8W 2T8416-259-3281

W.W. Williams M.W., Inc.1176 Industrial ParkwayNorth Brunswick, OH 44212-2342330-225-7751

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SOUTHERN REGION

Caribe Detroit Diesel-AllisonDivision of GT CorporationCeramic Ind. ParkCampo Rico Ave., Block CCarolina, Puerto Rico 00982787-750-5000

Stewart & Stevenson Power, Inc.5840 Dahlia StreetCommerce City, CO 80022303-287-7441

Detroit Diesel-Allison de Mexico S.A.de C.V.Av. Santa Rosa No. 58Col. Ampliacion NorteTlalnepantla C.P. 54160, Mexico525-5-5333-1800

Stewart & Stevenson Power Products, LLC2707 North Loop WestHouston, TX 77008713-868-7700

Florida Detroit Diesel-Allison, Inc.2277 N.W. 14th StreetMiami, FL 33125-0068904-737-7330

United Engines, LLC5555 West Reno AvenueOklahoma City, OK 73127405-947-3321

WESTERN REGION

Detroit Diesel-Allison BritishColumbia Ltd.9300 - 192nd StreetSurrey, British Columbia V4N 3R8604-888-1211

Stewart & Stevenson1755 Adams AvenueSan Leandro, CA 94577-1001510-635-8991

Midwest Detroit Diesel-Allison Ltd.1460 Waverly StreetWinnipeg , Manitoba R3T OP6204-452-8244

Valley Power Systems, Inc.425 South Hacienda BoulevardCity of Industry, CA 91745-1123626-333-1243

Pacific Power Products Company7215 South 228th StreetKent, WA 98032253-854-0505

Waterous Power Systems10025 - 51st AvenueEdmonton, Alberta T6E OA8780-437-3550

Smith Power Products, Inc.3065 West California AvenueSalt Lake City, UT 84104801-415-5000

W.W. Williams S.W., Inc.2602 S. 19th AvenuePhoenix, AZ 85009602-257-0561

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ALLISON TRANSMISSION REGIONAL OFFICES

EASTERN REGION19 Oaklynn DrivePO Box 400Columbus, NJ 08022-0400609-298-2541

SOUTHERN REGIONAv. Ejercito Nacional No. 843Colonia GranadaMexico, D.F. C.P. 11520936-321-4248

CENTRAL REGIONPO Box 894, Mail Code 462-470-PF06Indianapolis, IN 46206-0894317-242-2327

WESTERN REGIONSuite 351039465 Paseo Padre ParkwayFremont, CA 94538510-226-8037

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OM1475EN 200603 Printed in USA 200605www.allisontransmission.com