CONTROLS SPECIFICATIONS

ALLISON 4TH GENERATION CONTROLS

Items presented in the CONTROLS SPECIFICATIONS section are:

1.0 MAXIMUM POWER AND GROUND WIRE LENGTHS

2.0 TRANSMISSION CONTROL MODULE (TCM) SPECIFICATIONS

• Voltages
• Current
• Temperature Limits
• Component Weight

3.0 ALLISON SHIFT SELECTOR SPECIFICATIONS

• Voltage Requirements
• Current Requirements
• Temperature Limits
• Component Weight
• Digital Display

4.0 SPECIFICATIONS: OTHER CONTROLS COMPONENTS

• Wiring Harness and Connectors
• Throttle Position Sensor (TPS)
• Vehicle Interface Module (VIM)

5.0 SPEEDOMETER OUTPUT

6.0 INPUT AND OUTPUT REQUIREMENTS

6.1 "Switch To Ground" Inputs
6.2 "Switch To Ground" Outputs
6.3 "Switch To Battery" Inputs
6.4 "Switch To Battery" Outputs
6.5 "Neutral Start" Output

G4CS October 20, 2004

 ALLISON 4TH GENERATION CONTROLS SPECIFICATIONS

TABLE 1 - MAXIMUM POWER AND GROUND WIRE LENGTHS

— BASED ON TOTAL CIRCUIT RESISTANCE REQUIREMENTS —

Input and output voltages for this control system are specified at the TCM pins. Voltage potentials
develop along all cables and circuit traces depending on material, length, and thickness. The
input and output voltages specified do not account for parasitic voltage drops in the vehicle wiring
system. Vehicle design must accommodate parasitic voltages associated with vehicle wiring.
Proper choices in wire lengths and thicknesses can reduce the effects of parasitic voltages. The
following table provides a guide to the selection of conductors for the TCM power and ground
circuits.

Maximum A +B
Wire Length for:

mΩ per Single Wire Double Wire

meter (ft) System* System*
GA at 20° C meter (ft.) meter (ft.)
6 1.2966 77.1 154.2
(0.3952) (253) (506)
8 2.0607 48.5 96.9
(0.6281) (159) (318)
10 3.2769 30.5 61.0
(0.9988) (100) (200)
12 5.22 18.9 37.8
(1.59) (62) (124)
14 8.27 11.9 23.8
(2.52) (39) (78)
16 13.19 7.3 14.6
(4.02) (24) (48)
18 20.96 N/A 9.1
(6.39) (30)
G4-108

Total resistance for Lengths (A + B)

Maximum C Wire Length: 12.2 meters (40 feet)
must be 100 mΩ or less.
* Lengths based on standard annealed copper wire.

NOTE: All data is applicable to both

12-volt and 24-volt installations.

Conversions between Metric and U.S. units are not necessarily equivalent.

Allison 4th Generation Controls Specifications – October 20, 2004 Page 2

 TABLE 2 - TRANSMISSION CONTROL MODULE (TCM) SPECIFICATIONS

NOTE:
• All voltages and currents specified are as measured
at the TCM pin.
• Wire lengths, connection points, terminal corrosion,
and system current draw should be considered when
choosing wire sizes and lengths for TCM battery
power and battery return connections.
• Conversions between metric and U.S. units are not
G4-118 necessarily equivalent.

TCM Configuration 12-volt 24-volt

TCM Model Designations A41, A42, A43 A43 only
PARAMETER VALUE VALUE UNITS
Voltage Input at TCM *
VBAT Minimum Temporary TCM Operation 9.0 9.0 Volts
Minimum Temporary CAN Communication 7.0 7.6 Volts
Minimum Continuous Operation 10.5 10.5 Volts
Maximum Continuous Operation 16.0 32.0 Volts
Minimum While Engine Cranking 4.5 4.5 Volts
Jump Start 26.5 36.0 Volts
Reverse Voltage Protection from 0.1Ω source 16.0 ** 32.0 ** Volts
Ignition Sense (VIGN) Minimum 9.0 9.0 Volts
Current Input at TCM * Transmission 1000 3000 1000 3000
Product Families 2000 4000 2000 4000
IBAT Maximum During Normal Operation t.b.d. t.b.d. t.b.d. t.b.d. Amperes
Maximum During Shift 6.5 t.b.d. t.b.d. t.b.d. Amperes
Maximum After Ignition Shutdown 0.5 0.5 mA
IIGN Maximum Ignition Input Current 15.0 15.0 mA
VIM* Relay Contacts***
Maximum Continuous 10.0 10.0 Amperes
Maximum Intermittent 14.0 14.0 Amperes
Maximum Continuous All Relays 30.0 30.0 Amperes
Minimum 5.0 5.0 Amperes
Temperature Limits Transmission 1000 3000 1000 3000
Product Families 2000 4000 2000 4000
Operating: Maximum Continuous 105 (220) 85 (153) 105 (220) 85 (153) o
C (oF)
Operating: Minimum Exposure (Startup) - 40 (- 40) - 40 (- 40) - 40 (- 40) - 40 (- 40) o
C (oF)
Non-Operating: Maximum Continuous 140 (284) 140 (284) 140 (284) 140 (284) o
C (oF)
Non-Operating: Minimum Continuous - 54 (- 65) - 54 (- 65) - 54 (- 65) - 54 (- 65) o
C (oF)
Component Weight
TCM * assembly 0.56 (1.23) 0.56 (1.23) kg (lb)

* TCM = Transmission Control Module. VIM = Vehicle Interface Module

** Reverse voltage for time required to blow Little fuse #257015 or equivalent
*** Values are for inductive loads

Allison 4th Generation Controls Specifications – October 20, 2004 Page 3

 TABLE 3 - ALLISON SHIFT SELECTOR SPECIFICATIONS

NOTE:
• Applicable only to 3000 and 4000 Product Family transmission installations
• All voltages and currents specified are as measured at the shift selector pin.
• Wire lengths, connection points, terminal corrosion, and system current draw should be
considered when choosing wire sizes and lengths for power and ground requirements.
• Conversions between metric and U.S. units are not necessarily equivalent.

PARAMETER VALUE UNITS

Voltage Input
Minimum Temporary Operation 9.0 Volts
Minimum Continuous Operation 10.5 Volts
Maximum Continuous Operation 32.0 Volts
Minimum While Engine Cranking 4.5 Volts
Maximum Reverse Battery Continuous (with no damage) 32.0 Volts

Current Input
Typical at Nominal Input Voltage 160 mA
Maximum Current Draw (IDRAW ) at Any Continuous VDC: 300 mA
Maximum at standby 2.5 mA
Maximum. Dimmer 100 mA

Temperature Limits
Operating: Maximum Continuous 85 (153) o
C (oF)
Operating: Minimum Exposure (Startup) – 40 (– 40) o
C (oF)
Non-Operating: Maximum Continuous 105 (220) o
C (oF)
Non-Operating: Minimum Continuous – 54 (– 65) o
C (oF)

Component Weight
Lever Selector 1.50 (3.30) kg (lb)
Standard Pushbutton Selector 0.22 (0.48) kg (lb)
Common Pushbutton Selector 0.23 (0.51) kg (lb)
Compact Pushbutton Selector 0.24 (0.54) kg (lb)
Strip Pushbutton Selector (3-Button) 0.25 (0.55) ** kg (lb)
Strip Pushbutton Selector (6-Button) 0.37 (0.82) ** kg (lb)

Digital Display
Minimum brightness at maximum intensity 350 Foot-Lamberts at 150 cm
Color Blue-green (490-500 nanometers)

* Values are for still air surrounding the component.

** Estimated data

Allison 4th Generation Controls Specifications – October 20, 2004 Page 4

 TABLE 4 - SPECIFICATIONS: OTHER CONTROLS COMPONENTS*
PARAMETER VALUE UNITS
HARNESS CONNECTORS: For harness information, refer to Technical Document 173 (TD-173)
Temperatures: Maximum Exposure 120 (250) ** o
C (oF)
Intermittent Heat Soak 150 (300) *** o
C (oF)

THROTTLE POSITION SENSOR (TPS)

Temperatures: Maximum Continuous 120 (250) *** o
C (oF)
Intermittent Heat Soak 150 (300) *** o
C (oF)

VEHICLE INTERFACE MODULE (VIM):

Component Weight: 1.05 (2.32) kg (lb)
Operating Temperatures:
Maximim Continuous 85 (153) *** o
C (oF)
Minimum Exposure (Start-Up) – 40 (– 40) *** o
C (oF)
Non-Operating Temperatures:
Maximim Continuous 105 (220) *** o
C (oF)
Minimum Continuous – 54 (– 65) *** o
C (oF)

* For TCM specifications, refer to Table 2. For shift selector specifications, see Table 3.
** Values are for surface of the component.
*** Values are for still air surrounding the component.

Conversions between Metric and U.S. units are not necessarily equivalent.

Allison 4th Generation Controls Specifications – October 20, 2004 Page 5

 TABLE 5 - SPEEDOMETER OUTPUT

G4-116

5.1 - WAVEFORM CHARACTERISTICS

Parameter Min. Typ Max. Unit Notes
Duty Cycle 45 50 55 %
VSpeedo Low 0 — 0.5 Volts
VSpeedo High VBAT – 2.0 — VBAT Volts
Source Current* — — 8 mA @ VSpeedo = VBAT – 2.0
Sink Current** — — 8 mA @ VSpeedo = 0.5 V
Frequency
3700 models — 9 or 18 — Pulses per
All Others — 8, 16, — output rev.
or 40
Load Capacitance — — 0.1 µF Depends on speedometer
(CLoad) system on vehicle.

NOTE: All data is applicable to both

* When VSpeedo is High 12-volt and 24-volt installations.
** When VSpeedo is Low

• Under no load condition, rise and fall

time is 90% of steady state voltage
obtained in 10% of period.

• Waveform rise and fall times will vary

as a function of the load impedance.

G4-117-1

Allison 4th Generation Controls Specifications – October 20, 2004 Page 6

 TABLE 6 - INPUT AND OUTPUT REQUIREMENTS
6.1 "SWITCH-TO-GROUND" INPUTS

Resistance - Based Voltage / Current

Specification Based Specification

G4-115
G4-114

Parameter Min. Nom. Max. Units Notes

Input Activated:
• ISwitch 5 — — mA ISwitch is present with Ignition On and Off

• VGPI 0 — 2.0 Volts VGPI is specified for an open collector

transistor output.
Input Deactivated:
• ILeakage 0 — 500 µA ILeakage is the leakage current
of an open collector transistor.

• VGPI 3.44 — — Volts VGPI is specified for an open collector

transistor output.

• VPU — 5.0 — Volts

NOTE: All data is applicable to both 12-volt and 24-volt installations.

• SFI switch to ground inputs are designed to be used with two input types:
1. Switches from TCM SFI's to wire 103.
2. Open collector transistor outputs of other electronic control modules.
• Voltage differentials between the TCM battery return and the vehicle ground point for another module can
cause problems such as high current flow through the transmission TCM or ground loops.
• Switch to ground inputs should only be switched to Signal Return wire (wire 103) of the Plus 4 control
system.
• Wire 103 should ONLY be connected to Plus 4 General Purpose Input (input function activating) wires.

Allison 4th Generation Controls Specifications – October 20, 2004 Page 7

 TABLE 6 - INPUT AND OUTPUT REQUIREMENTS (CONTINUED)

6.2 "SWITCH-TO-BATTERY" INPUTS

Switch - Based Voltage / Current

Specification Based Specification

G4-112 G4-111

Parameter Min. Max. Units Notes

Input Activated:
• ISwitch 5.0 — mA
• VGPI 3.44 — Volts

Input Deactivated:
• VGPI — 2.0 Volts

NOTE: All data is applicable to both 12-volt and 24-volt installations.

• All voltages specified are as measured at the TCM pin.

• Problems can be averted by minimizing the differential between the

TCM ground and the ground of voltage source based SFI inputs.

Allison 4th Generation Controls Specifications – October 20, 2004 Page 8

 TABLE 6 - INPUT AND OUTPUT REQUIREMENTS (CONTINUED)

6.3 "SWITCH-TO-GROUND" OUTPUTS

G4-113

Parameter Min. Max. Units Notes

Signal Active:
• VGPO — 1.0 Volts at IGPO = 500 mA

• I GPO — 500 mA at VGPO = 1 volt

Signal Inactive:
• TCM On: IGPO — 150 µA

• TCM Off: IGPO — 20 µA

NOTE: All data is applicable to both 12-volt and 24-volt installations.

• All voltages specified are as measured at the TCM pin.

Allison 4th Generation Controls Specifications – October 20, 2004 Page 9

 TABLE 6 - INPUT AND OUTPUT REQUIREMENTS (CONTINUED)

6.4 "SWITCH-TO-BATTERY" OUTPUT

G4-110

GPO1 (General Purpose Output 1) Specification

Parameter Min. Max. Units Notes

Signal Active:
• VGPO1 (VBAT - 1.2 v) VBAT Volts Min. VGPO1 when IGPO1 = 500 mA

• IGPO1 — 500 mA Max. IGPO1 when,

(Max. Source VGPO1 = (VBAT - tbd) volts
Current)

Signal Inactive:
• IGPO1
– TCM On: — 100 mA (Leakage Current when inactive)
– TCM Off: — 20 mA (Leakage Current when inactive)

NOTE: All data is applicable to both 12-volt and 24-volt installations.

• All voltages specified are as measured at the TCM pin.

Allison 4th Generation Controls Specifications – October 20, 2004 Page 10

 TABLE 6 - INPUT AND OUTPUT REQUIREMENTS (CONTINUED)

6.5 "NEUTRAL START" OUTPUT

G4-109

NS (Neutral Start) Specification

Parameter Min. Max. Units Notes

Signal Active:
• VNS (VBattery Power - 1.2 v) VBattery Power
Volts Min. VNS when INS = 800 mA

• INS — 800 mA
(Max. Source
Current)

Signal Inactive:
• INS
– TCM On: — 100 mA (Leakage Current when inactive)
– TCM Off: — 20 mA (Leakage Current when inactive)

NOTE: All data is applicable to both 12-volt and 24-volt installations.

• All voltages specified are as measured at the TCM pin.

• Once activated, the neutral start output will remain ON down to VBAT of 4.5 volts.

Allison 4th Generation Controls Specifications – October 20, 2004 Page 11

 REVISION HISTORY

OCTOBER 20, 2004

• Updated shift selector current requirements and reformatted table 3. Added Revision History.

JUNE 23, 2004

• Original Issue of this document.

Allison 4th Generation Controls Specifications – October 20, 2004 Page 12