RA40 TIVF/Stage 4 G10 Transmission

1st Sept 2021

 Allison 4000 Series Transmission

• Allison 4000 Series

• Electronically controlled

planetary gear transmission

• Fully automatic through 6

forward ranges & 1 reverse

• Integral retarder fitted as

standard

• Power and Economy mode

• Adaptive Shift Pattern

Customer Support
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 Right Hand Side View
Fill/Dip
Stick

Wiring
Harness
Engine Speed
Sensor

Output
Speed
Sensor Turbine Speed
Sensor

Retarder
Cooler
Ports Control
Module
Serial
Plate
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 Left Hand Side View

PTO
Drive

Pressure Tapping's

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 Inputs Outputs

SHIFT SELECTOR

SPEED SENSORS OIL LEVEL SENSOR

RETARDER MODULATION SOLENOIDS

TCM PRESSURE SWITCH
VEHICLE COMMUNICATION LINK
TEMPERATURE SENSOR

INPUTS OUTPUTS

Customer Support
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 Transmission Control Module (TCM)

• 24Volt

• Internal Temperature Sensor

to protect from overheating

damage

• Controls 6 Forward & 1

Reverse Gear
Remove • Located Rear RHS of Cab
Panel to
access behind Fuse box cover
TCM

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 TCM Fuses

• PCB Mounted Fuses & Relays

• Jumper links for manual

activation of circuits during

troubleshooting – Use S25

• x65a Trans oil cooler fan

• X66a TCU Fan Speed

• Emergency Key Switch on

Diagnostic Plate

• Transmission Fuses F8 & F72

Customer Support
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 TCM Power & Ground
+6
-K19
/70.F2
29 7
CAN 1
65 + 28
CAN 2.0B
5 - 8
J1939
24 DATA CAN 1 49
64 LINK SHIELD 48
50 68
• TCM Requires Battery Power
13 26
L CAN 2
4 + 6
CAN 2.0B
45 - 27
32 +
J1939
DATA CAN 2 67
& Battery Ground
SAE / ATA
72 - DRIVER (J1708) LINK SHIELD 66

•
46 47
78
ISO9141 DATA LINK
SENSOR SUPPLY
12 Battery Power from F8 is
41
VBAT PWM INPUT
+6 30 44
-K19.X 69
GND POWER SUPPLY
56 connected to TCM (K19)
69/80 9 24VDC 58

ANALOG INTERFACE
9/80 70
+UB 30 +UB 15 A
70/80 10 35 Pins 10 & 70
10/80 63 75
63/80 43 16
2
23
54
76
• Battery Ground is connected
+6 62 77
-K19.X
+6 42 18
42/80 1 11
to TCM (K19) Pins 9 & 69
1/80 61 HSD 1 55
DIGITAL INTERFACE

61/80 21 L 74
22
VBAT
HSD 2 71 • Power from F72 is connected
57 HIGH SIDE 36
PWM INPUT
79 DRIVERS 52
+6 17
L
33 to TCM (K19) Pin 63
-K19.X 3 51
3/80 73 D HSD 3 31
53
14 15
+6 38 37
-K19.X 34 SPEED 19
PWM INPUT INTERFACE
34/80 25
NZC
- + - + - + L
39 59 40 60 20 80 Customer Support
9 Transmission
Allison Transmission Controller
29545538
15354211
 TCM CAN Connections
PCB Connector • TCM Communicates on CAN2
-S21.X Shift Lever -A1.X30
1 1 CAN2_L -X3:E -W277 BU 1.0 mm²
2 2
3 Light position 1 parking lights ON -Xs1.SB:2 -W52 WH 1.0 mm² 3
4 4 CAN2_L -Xs3.SB:3 -W67 BU 1.0 mm²
5 GND -X30.c:3 -W49 BN 1.0 mm² 5
6 6 CR0232 RxD -Xs28.SB:3 -W293 WH 0.75 mm²
7 7 CAN2_L -K18.XL:28 -W241 BU 1.0 mm²
8 CAN2_H -Xs2.SB:4 -W68 YE 1.0 mm² 8
9 9 CR0232 TxD -Xs29.SB:3 -W294 WH 0.75 mm²
10 10 CAN2_L -K19.X:8 -W242 BU 1.0 mm²
11 TCU K19.X.34 Direction signal -K19.X:34 -W50 WH 1.0 mm² 11 CAN2_H -K19.X:28 -W242 YE 1.0 mm²
12 F72 10A to K19 X63 -Xs27.SB:2 -W70 BK 1.0 mm² 12 CR0232 Test -Xs32.SB:3 -W295 WH 0.75 mm²
13 F8 15 A to K19.X.10/70 TCU -X6.6b:1 -W69 RD 1.0 mm² 13 CAN2_H -K18.XL:46 -W241 YE 1.0 mm²
14 14
15 CAN2_L -Xs3.SB:4 -W68 BU 1.0 mm² 15
16 16 CAN2_H -X3:D -W277 YE 1.0 mm²
17
18
19 CAN2_H -Xs2.SB:3 -W67 YE 1.0 mm²
20
21

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 80 Pin TCU Connector
-K19. X#2
1 Auxilar yFunktionR ange - K1 8 .X2 :1 5 -W407
2
3 TCU K1 9 .X.3 Sig n a l r e tu r n - X6 .1 2 b :1 -W274
4
5
6
7
8
9 GND - XGN D 5 .c:3 -W270
10 F8 1 5 A to K1 9 .X.1 0 /7 0 TCU - Xs3 1 .SB:5 -W273
11 TCU K1 9 .X.1 1 T r a n s HSD1 - X11:j -W254
12 TCU K1 9 .X.1 2 Se n so r su p p ly - X6 .1 0 b :1 -W246
13
14
15 TCU K1 9 .X.1 5 Tr a n s Y1 4 - X11:u -W264
16 TCU K1 9 .X.1 6 O il le ve l se n d e r - X11:d -W249
17
18 TCU K1 9 .X.1 8 Tr a n s Filte r - X11:h -W253
19 TC U K1 9 .X.1 9 R e sisto r 2 2 OH M 75W - X6 .2 0 a :1 -W266
20 TCU K1 9 .X.2 0 Tu r b in sp e e d B -X11:x -W243
21 T CU K1 9 .X.2 1 to B1 .X.1
22
23
24
25
26
27
28
29
30
31 TCU K1 9 .X.3 1 T r a n s HSD3 - X6 .1 6 a :1 -W262
32
33 TCU K1 9 .X.3 3 Tr a n s PCS3 - X11:r -W260
34 TCU K1 9 .X.3 4 Dir e ctio n sig n a l - S2 1 .X:1 1 -W50
35
36 TCU K1 9 .X.3 6 T r a n s PCS1 - X11:n -W258
37 TCU K1 9 .X.3 7 Tr a n s TCC - X1 1 :v -W265
38
39 TCU K1 9 .X.3 9 En g in e sp e e d B - X11:D -W245
40 TCU K1 9 .X.4 0 O u tp u t sp e e d B - X1 1 :B -W244

Customer Support
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 80 Pin TCU Connector Cont’d
41
42 TCU K1 9 .X.4 2 In p u t 5 - K1 8 .X2 :1 7 -W282
43
44
45
46
47
48 CAN2 _ H - A1 .X3 0 :1 1 -W242
49
50
51 TCU K1 9 .X.5 1 Tr a n s SS1 - X1 1 :s -W261
52 TCU K1 9 .X.5 2 Tr a n s PCS2 - X11:p -W259
53
54 TCU K1 9 .X.5 4 o il su mp te mp se n d e r - X11:e -W250
55 TCU K1 9 .X.5 5 Tr a n s PCS4 - X1 1 :k -W255
56 TCU K1 9 .X.5 6 r e ta r d e r sig n a l - S2 2 .X:B -W74
57
58 TCU K1 9 .X.5 8 An a lo g r e tu r n - X6 .1 1 b :1 -W247
59 TCU K1 9 .X.5 9 En g in e sp e e d A - X11:C -W245
60 TCU K1 9 .X.6 0 O u tp u t sp e e d A - X1 1 :A -W244
61 TCU K1 9 .X.5 8 Re ta r d e r Re q u e st - K1 8 .X2 :3 -W411
62
63 F7 2 1 0 A to K1 9 X6 3 - Xs2 7 .SB:4 -W281
64
65
66
67
68 CAN2 _ L - A1 .X3 0 :1 0 -W242
69 GND - XGN D 5 .c:2 -W269
70 F8 1 5 A to K1 9 .X.1 0 /7 0 TCU - Xs3 1 .SB:2 -W272
71 TCU K1 9 .X.7 1 T r a n s HSD2 -X11:m -W257
72
73
74 TCU K1 9 .X.7 4 Tr a n s Ma in Mo d - X1 1 :l -W256
75 TC U K1 9 .X.7 5 o il r e ta r d e r te mp se n d e r - X1 1 :c -W248
76 TCU K1 9 .X.7 6 Tr a n s ID - X1 1 :f -W251
77 TCU K1 9 .X.7 6 T r a n s PSI - X11:g -W252
78
79
80 TCU K1 9 .X.8 0 Tu r b in sp e e d A -X11:w -W243

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Control Module

Main filter

Lube filter

Valve Block

20 Way Connector
Oil Level Sensor

Customer Support
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 Control Module Valve Block Designations

PS1
Pressure Prognostics
Switch

Torque
TCC Convertor
Clutch
Main Mod (Lock Up)
Pressure
Control PCS4 PCS1 Pressure
Solenoid 4 Control
Solenoid 1
Pressure PCS3
Control
Solenoid 3 Pressure
PCS2 Control
Solenoid 2
SS1
(Under Shift
PCS2)
Solenoid
(Latch
Valve C2)
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 Control Module – Pressure Taps

Customer Support
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 Recommended Service Intervals

• Replace Filters @ 3000

Hours

• Drain Oil & Refill @ 6000

Hours

• Items 1-4 are supplied within

filter kit part no. 29545779

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 Filter Life Monitor Reset

• After Replacing Filter the

Filter Life Monitor should be

reset:

• While in Filter Life Monitor

Mode Press & Hold Mode

button for 10 seconds

OR

• With Ignition on and Engine

shut off use the gear shift

lever to shift N-R-N-R-N-D-N

Customer Support
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 Oil Life Monitor Reset
• After Replacing Oil the Oil

Life Monitor should be reset:

• While in Oil Life Monitor

Mode Press & Hold Mode

button for 10 seconds

OR

• With Ignition on and Engine

shut off use the gear shift

lever to shift N-D-N-D-N-R-N

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 Recommended Oils
When seeking a fluid for your Allison transmission that is TES 295 OR TES 389 approved do
not fall to the claims of some companies that claim that their product is TES 295 OR TES 389
approved. The statements infer that these products "are designed to meet", "are equivalent
to", "meet or exceed", etc. When determining whether or not a fluid is TES 295 OR TES 389
approved, look and/or ask for one of two things:
⚫The Allison Approved logo
⚫The Allison TES-295 OR TES 389 approval number

TES 295 (OR TES 389)

Approval
Number Approved Marketer Product Brand name

AN-011001 Castrol Heavy Duty Lubricants TranSynd

AN-031002 BP Autran Syn 295
AN-031003 Cognis Corporation Emgard 2805
AN-031004 International Truck & Engine Company Fleetrite Synthetic ATF
AN-051005 Exxon Mobil Lubricants Mobil Delvac Synthetic ATF
and Petroleum Specialities Company
Customer Support
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 Allison Gen 5 Controls
• Shift Lever With Hold Button

• L – Lock In Range

• D – Drive automatic full

range forward gears (6)

• N – Neutral

• R – Reverse

• Press Hold button and move

lever to D or R

• From D – L can be selected

(Transmission will auto
select 1st gear & use
preselected downshift)

Customer Support
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 Allison Gen 5 Controls
• M – Manual Range (Forward
Only)

• When in Drive Push Lever to

RHS to M

• Push forward or pull

backward to change up or
down one gear

• Preselection in certain
applications can stop gear
hunting to enhance haul
cycle time and extend
transmission component life

Customer Support
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 Allison Gen 5 Controls
• Mode Button

• Top Gear – Selected

• Bottom Gear – Attained

• Display Mode Button – Oil

level / Prognostics /
Diagnostic Fault Codes

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 Allison Gen 5 Prognostics

• Press Display Mode Button:

• Once = Oil Level Check –

OK / LO / HI (Number of
Quarts)

• Twice = Oil Life Monitoring %

• Three Times = Filter Life

Monitoring OK / LO

1 2 3

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 Allison Gen 5 Prognostics
• Press Display Mode Button:

• Four Times = Transmission

Health Monitoring OK / LO

• Five Times = Diagnostic

Fault Code Retrieval Active
of Inactive

• Total of 5 Codes can be

displayed

• Press Mode button to move

to next code.

• Press and Hold Mode button

4 5 to clear codes

o 3-5 seconds for active

o 8-10 seconds for inactive

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 Gear Shift Control – Displaying Oil Level
Failure to meet conditions will stop • Press Display Mode Button
2 minute countdown and display
one of the following codes: Once

• o L, 0 X Setting time too short • A 2 minute countdown will

• o L, EL Engine RPM too low begin once the following
• o L, EH Engine RPM too high conditions are met:
• o L, SN Neutral not selected
• o L, TL Sump fluid 1. Engine at idle
temperature too low
2. Oil at Operating temperature
• o L, TH Sump fluid
82-104oC (140-220oF)
temperature too high
• o L, SH Output shaft rotation 3. Transmission in Neutral
detected
4. Transmission output shaft
• o L, FL Sensor failure
stationary

• Oil level will display at the

end of the 2 minutes

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 Retarder
K19 • Retarder Request Switch
TCM S14 grounds K19 Pin 61

• Retarder Level Lever S22

positive supply K19 pin 12 &
61 pin 58 ground
12
58
56 • Position of Lever determines
S14 15
31 signal voltage sent to pin 56
S22 on K19

• Retarder Solenoid Y14 is

switched on by the return
from K19 pin 15.

• Y14 power is supplied from

K19 pin 31

Control Module Customer Support

26 (A2)
 Retarder
• Retarder Request Switch
sends signal to the TCM.

• The Position of the retarder

lever determines the % of
retardation.

• 7 position lever (0-6)

• Pos 0 is OFF

• Pos 7 is Maximum
Retardation

• Operating Parameters
Position Volt
Retarder 1. Foot off the gas
Retarder Lever Application
Off 1.1v 0% 2. Lock Up clutch Engaged
Checks: Signal Voltages Position 1 1.5v 16%
Resistance Between A & C: Position 2 1.9v 28%
Between A & C = 32 kΩ Position 3 2.3v 48% 3. No Active Transmission
Position 4 2.8v 65%
Position 5 3.2v 84% Fault Codes
Position 6 3.6v 100%
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 Retarder

Retarder Temp
Sensor

Retarder
Actuator

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 Temperature Sensors

Control Module • Transmission fitted with 2

(A2) temperature sensors

• B21 – Sump Temperature

Sensor – K19 Pins 54 & 58

• B32 – Retarder Temperature

Sensor – K19 Pins 75 & 58

K19 TCM

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 Temperature Sensors

B21

• Sump Temperature Sensor

located inside the control
module at the bottom of the
main connector support

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 Speed Sensors

Output Speed
Sensor Engine Speed Sensor

Turbine Speed Sensor

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 Speed Sensor connections
K19 Trans Control Module A2 X Transmission harness plug
• The Transmission is fitted with 3
speed sensors

• Turbine Speed K19 Pins 20 & 80

• Output Speed K19 Pins 40 & 60

• Engine Speed K19 Pins 39 & 59

• The Engine and Turbine Speed

Sensors are interchangeable

• At an ambient temperature of
20degrees Celsius the
resistance of speed sensors will
be ~300Ω

K19 TCM
Customer Support
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 Gear Range Activation

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 Thank you for Listening

ANY QUESTIONS?
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