SECTION E: USING INPUT/OUTPUT (I/O) FUNCTIONS,

PACKAGES, AND GROUPS

ALLISON 4TH GENERATION CONTROLS

Items discussed in the "USING INPUT/OUTPUT (I/O) FUNCTIONS, PACKAGES, AND

GROUPS" section are:

1.0 GENERAL

2.0 VOCATION CONSIDERATIONS AND REQUIREMENTS

G4CME June 8, 2004

 SECTION E: USING INPUT/OUTPUT (I/O) FUNCTIONS,
PACKAGES, AND GROUPS

The purpose of this section is to provide an overview regarding use of the programmable controls
functions which are provided with the Allison 4th Generation Controls. An understanding of these
capabilities of the control system permit the vehicle manufacturer and/or body fabricator to optimize
the benefits of the transmission controls in the performance of related vehicle control functions.

1.0 GENERAL
The transmission shift control system performs several types of control functions:
• It provides the necessary shift control functions which permit the transmission to perform it's
primary function — the transmission of engine power to the driveline for vehicle propulsion.
• It includes features which protect the transmission against certain types of user abuse and, in the
event of a problem, the system to diagnose the controls hardware, software, and some transmis-
sion systems.
• As a standard feature, it performs operations which assist in the functional control of several
vehicle-related systems and functions. Included in this classification are electrical signals denot-
ing operation in reverse (for control of reverse warning and/or light systems), neutral-start (for
control of the system which prevents starting the engine unless the transmission is in neutral),
and other functions of this type. These features, which are included in the standard controls
system for all transmissions are discussed in further detail in Section D: Vehicle Electrical Sys-
tem Interface of this manual.
• In addition to the standard functional features discussed above, each transmission control system
provides additional functional control of transmission and/or vehicle operations which are tailored
to the expected duty of the vehicle. Some of the controls signals, called "Input Functions", send
vehicle data to the Transmission Control Module (TCM) to designate the operating state of other
vehicle systems. Other electrical signals, called "Output Functions", send data out of the TCM for
use in controlling the operation of other non-transmission components. The output functions may
be turned on and off based on the state of related input function signals and/or the operating state
of the transmission. An example of the combined use of input and output functions (I/O's) is a
combination of control signals which automatically commands the transmission to NEUTRAL
when the PTO is operated. This feature is commonly used in public utility trucks and wreckers/
recovery vehicles.

NOTE: Input and output functions are operational only when the engine is running.

This document provides additional detailed information relating to selection and use of these func-
tions for a specific vehicle installation.

2.0 VOCATIONAL CONSIDERATIONS AND REQUIREMENTS

The combination of input functions and output functions for a specific vehicle normally relate very
closely with the expected use of the vehicle, or the vehicle vocation. For that reason, Allison has
created "vocational control packages" which consolidate the typically-used controls I/O functions into
easily identifiable group. The number of groups and packages which are available for any transmis-
sion installation is thus reduced to only a small number which contain the functions normally used in
that vocation. This process of selecting an "I/O group and package" for each TCM calibration there-
fore simplifies the ordering and controls installation processes significantly, while providing the avail-
ability of commonly-used functions for each vocation on a consistent basis.

Allison 4th Generation Controls Installation Manual: June 8, 2004 Page E-2
Refer to the Extranet portal of the Allison website (www.allisontransmission.com/extranet) for access
to the materials discussed in the remainder of this section. Contact your Allison Transmission
representative if you do not have access to the Allison Transmission Extranet.

The Allison Technical Data channel on the Extranet is constructed with drill-down access to appli-
cable documentation for all Allison 4th Generation Controls "I/O Function Packages" for both the
1000/2000 and 3000/4000 Product Families. Because the available functions differ between the
product families, as well as by vocation, the appearance of the drill-down screens may differ. Con-
ceptually, the drill-down requires that the user follow these steps:

1. Select the 4th Generation Controls channel for the appropriate (1000/2000 or 3000/4000)
transmission Product Family

2. Use the I & O Selection Guide as

necessary.
The selection guide includes the limited list
!
of I/O Packages which are available for the
transmission model or model family which
you have chosen. Each individual column
depicts a separate I/O "package". Column
headings identify vocational "groups" which
are comprised of one or more packages.
Refer to Figure E-1.

Groups are significant from this standpoint: Figure E-1: Using I/O Selection Guide To
Through use of the Allison DOC® for PC Identify Groups and Packages
program, each TCM may be reprogrammed
from one I/O Package to another — but only
if the packages reside within the same
group. Example: For 3000/4000 EVS
transmission models, four different I/O
packages are released, each with a differ-
ent combination of available input and
output functions. A TCM programmed at
the factory with group/package 107/119 may
be field-reprogrammed to use either
group/package 107/118 or 107/120, but not
108/174.

3. Once I/O Package number is known,

either having been determined by the
I/O Selection Guide or from prior use...
select the file for the desired I/O package.
The front page of each of documents
contains a summary of only those input and
output functions which are included in the
package, including the wire numbers which
are used to enable each of the functions.
Refer to Figure E-2.

Figure E-2: Cover Page of I/O Package File

Listing Functions in Package

Allison 4th Generation Controls Installation Manual: June 8, 2004 Page E-3
 WARNING:
Some input functions involve the use of complex algorithms in the control logic. If the
function is enabled in the calibration but the control circuit for the function is not
installed, there is a potential risk for one or more system failure modes which could
result in undesirable transmission operation. Therefore, the activation circuit for these
functions MUST BE properly integrated in the vehicle in which they are installed, OR, if
the function will not be used in the vehicle, it MUST BE disabled in the calibration.

This warning is included on the schematic for each applicable input function which is subject to this
requirement. These input functions are:
D. Shift Selector Transition
E. Auxiliary Function Range Inhibit - Standard
J. Fire Truck Pump Mode
L. Automatic Neutral
V. Reverse Enable
W. Direction Change Enable
AJ. 4th Lockup Pump Mode
AL. Shift Selector Transition and Secondary Shift Schedule
BQ. 3rd Lockup Pump Mode

4. Follow recommended wiring instructions.

Each of the I/O Package files (previous paragraph) contains schematics which illustrate the
recommended interface for the control of each I/O function with other vehicle systems or compo-
nents. A recommended interface are provided for each function which is enabled in the selected
I/O Package. Some schematics document the necessary interrelationship of both input and
output functions to adequately perform the intended purpose. A typical schematic is illustrated in
Figure E-3.

In addition to the recommended

electrical interface of the I/O control Function
Description

"
circuit to other vehicle systems, each
wiring schematic (Figure E-3) con-
tains additional significant information:
Typical Uses
• Complete description of the
function, how it is enabled, and, if
"
applicable, required operating
conditions for enabling the func- "
Customer
tion. Modifiable
Constants
• Typical uses and/or potential
effects on vehicle operation.
• Customer modifiable constants. Recommended
Some functions become operable Electrical
Interface
only when certain transmission
and/or vehicle-related conditions
exist and, in some cases, the "
conditions which govern the logic
decisions may be customer-
specified. For instance, it may
be desired to permit activation of Figure E-3: Typical I/O Wiring Schematic

Allison 4th Generation Controls Installation Manual: June 8, 2004 Page E-4
 a function only if the engine speed is within a specific (customer-specified) rpm range. The
functions which may be specified, the acceptable range of values for each, and standard
(default) values are detailed on each schematic.

Allison 4th Generation Controls Installation Manual: June 8, 2004 Page E-5