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750/754 Series
Allison Off-Highway
OM1475EN
Operators
Manual
2006 MARCH
OM1475EN
Allison Transmission
OFF-HIGHWAY TRANSMISSIONS
CBT 750, 754
CLBT 750, 754
CLBT 750, 754DB REMOTE MOUNT
Printed in USA
NOTES
TABLE OF CONTENTS
INTRODUCTION
KEEPING THAT ALLISON ADVANTAGE . . . . . . . . . . . . . . . . . . . . . . . . 7
TYPICAL 750/754 SERIES OFF-HIGHWAY
TRANSMISSION MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
A BRIEF DESCRIPTION OF THE ALLISON AUTOMATIC . . . . . . . . . . . . . 9
TORQUE CONVERTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
LOCKUP CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
POWER TAKEOFF DRIVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
HYDRAULIC RETARDER (CBT, CLBT 750/754) . . . . . . . . . . . . . . . . . . . 10
TRANSFER GEAR HOUSING (DROPBOX) . . . . . . . . . . . . . . . . . . . . . . 10
MANUAL DISCONNECT CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
THROTTLE ACTUATED MODULATOR . . . . . . . . . . . . . . . . . . . . . . . . 11
COOLER, FILTER CIRCUITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
SHIFT SELECTORS
SHIFT SELECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
RANGE SELECTION POSITIONS (FIVE-SPEED) . . . . . . . . . . . . . . . . . . 14
DRIVING TIPS
OPERATING IN COLD WEATHER . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DOWNSHIFT CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DOWNSHIFT OR REVERSE INHIBITOR FEATURE . . . . . . . . . . . . . . . . .
ACCELERATOR CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
USING THE ENGINE TO SLOW THE VEHICLE . . . . . . . . . . . . . . . . . . .
USING HYDRAULIC RETARDER (CBT, CLBT) . . . . . . . . . . . . . . . . . . .
DRIVING ON ICE AND SNOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ROCKING OUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TOWING OR PUSHING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TEMPERATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16
16
17
17
17
17
18
18
18
18
19
22
22
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CUSTOMER SERVICE
OWNER ASSISTANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SERVICE LITERATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ALLISON TRANSMISSION DISTRIBUTORS . . . . . . . . . . . . . . . . . . . . .
ALLISON TRANSMISSION REGIONAL OFFICES . . . . . . . . . . . . . . . . . .
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TRADEMARK USAGE
The 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.
INTRODUCTION
Allison transmissions provide many advantages for the driver whose vehicle may
encounter vigorous, tough use and sometimes abuse. Driving is easier, safer, and
more efficient.
These transmissions are rugged and designed to provide long, trouble-free service.
This handbook will help you gain maximum benefits from your Allison
transmission-equipped vehicle.
ENGINE-DRIVEN
PTO GEAR TOP
TORQUE
CONVERTER
LOCKUP
CLUTCH
LOW
PLANETARY
SPEEDOMETER
DRIVE
FIRST
THIRD
CLUTCH CLUTCH
SECOND
CLUTCH
FOURTH
CLUTCH
FORWARD
CLUTCH
OUTPUT
SHAFT
GOVERNOR
HYDRAULIC
RETARDER
ENGINE-DRIVEN
PTO GEAR SIDE
CONVERTER-DRIVEN
PTO GEAR
REAR PLANETARY
CENTER PLANETARY
CONTROL
VALVE
FIFTH CLUTCH
OIL SCREEN
FRONT PLANETARY
H01980
TORQUE CONVERTER
The 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
9
pump speed, torque multiplication stops and the torque converter functions as a
fluid coupling. With a fixed-capacity stator, engine power is always directed to the
vehicle power train.
LOCKUP CLUTCH
The lockup clutch (refer to Figure 3) is designed to hydraulically engage and
disengage at predetermined turbine speeds. When turbine speed approaches the
pump speed, hydraulic pressure automatically engages the lockup clutch. The
function of the lockup clutch is to lock the input element (pump) and the output
element (turbine) together. With the lockup clutch engaged, the engine output is
directed to the transmission gearing at 1:1 speed ratio. Reduction in the turbine
speed (output speed) automatically disengages the lockup clutch. When the lockup
clutch is disengaged, the converter acts as a torque multiplier or a fluid coupling.
The lockup clutch is momentarily disengaged during upshifting and downshifting
10
REAR VIEW
OF DROPBOX
30
4
45
30
15
1 VERTICAL
V07146
11
12
SHIFT SELECTORS
SHIFT SELECTORS
R
N
D
4
3
2
1
R
N
2-5
2-3
2
1
FIVE-SPEED
LEVER
SELECTOR
FIVE-SPEED
LEVER
SELECTOR
V07145
13
25
24
23
Use N (Neutral) when you start the engine. If the engine starts in
any other position, the neutral start switch is malfunctioning.
N (Neutral) is also used during stationary operation of the power
takeoff (if your vehicle is equipped with a PTO).
Use this for all normal driving conditions. The vehicle will begin to
move forward in second-range. As the accelerator is depressed, the
transmission will upshift to third, fourth, and fifth ranges
automatically. As the vehicle slows, the transmission will downshift
to the correct range automatically.
Occasionally, the road, load, or traffic conditions will make it
desirable to restrict the automatic shifting to a lower range. When
conditions improve, return the shift selector to the normal driving
position. These positions also provide progressively greater engine
braking and hydraulic retarder effect (the lower the range, the
greater the braking or retarding effect).
14
This is second range. Use this when pulling through mud and snow
or driving up steep grades. The vehicle will start out in
second-range if calibrated for second-range start. Otherwise it will
start in first-range and shift automatically to second-range as the
accelerator is depressed.
This is first-range hold (low). No upshift will occur when the shift
selector is in this position. This position provides the greatest
tractive advantage. It also provides maximum engine braking and
hydraulic retarder effect.
NOTE: All models except those for scraper applications have
lockup capability in all forward ranges. Scraper transmissions have
lockup available in all forward ranges except first-range.
15
DRIVING TIPS
DOWNSHIFT CONTROL
Downshifting is a manual shift to a lower range to match driving conditions
encountered or expect to be encountered. Learning to take advantage of manual
downshifts will give better control on slick or icy roads, and on steep downgrades.
Downshifting to lower ranges increases engine braking and hydraulic retarder
effect. The selection of a lower range often prevents cycling between a range and
the next higher range on a series of short up-and-down grades.
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ACCELERATOR CONTROL
The Allison automatic transmission can upshift or downshift under influence of
accelerator movement. The operator can get a quicker downshift or can delay the
upshift by managing the throttle to get the best performance from the
transmission.
ROCKING OUT
If the vehicle is stuck in sand, mud, or snow, it is often possible to rock out.
Shift to D (Drive) or second to fifth (25) and apply a steady, light throttle, never
full throttle. Then by moving the shift selector back and forth between D (Drive)
or second to fifth and R (Reverse), rock the vehicle. Shifts from forward range to
reverse-range and reverse-range to forward-range should be made with the
throttle backed off.
Time the shifts to take advantage of the forward and reverse momentum. If the
wheels spin, back off the throttle. Discontinue the attempt to rock out if the
wheels spin without moving the vehicle. Do not apply full power for more than
30 seconds if the drive wheels are not turning.
TOWING OR PUSHING
WARNING: To help avoid injury or equipment damage, DO NOT
attempt ro jump-start the equipment using an arc welder. Arc welding
equipment requires dangerously high currents and voltage which cannot
be sufficiently reduced to permit its use for jump-starting.
CAUTION: Failure to lift drive wheels off the road, disconnect the
driveline, or remove the axle shafts before pushing or towing can cause
serious transmission damage.
The engine cannot be started by pushing or towing. Disconnect the driveline or
lift the vehicle drive wheels completely off the ground before towing or pushing
any distance at any speed.
PARKING BRAKE
WARNING: Take the following precautions so that unexpected,
possible sudden vehicle movement is avoided. Whenever it becomes
necessary to leave the vehicle, even momentarily, while the engine is
running, place the transmission shift selector in N (Neutral), set the
parking brake and/or emergency brakes, and chock the wheels.
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TEMPERATURES
Look at the temperature gauge occasionally to be sure that the converter-out
temperature is in the normal range of 180220F (82104C) . If it exceeds
275F (135C) due to overload, shift to N (Neutral) and run the engine at
12001500 rpm. This should reduce the temperature in two or three minutes to the
normal level. Transmission-to-cooler fluid temperature should never be permitted
to exceed 330F (166C) during retarder operation.
CAUTION: The engine should NEVER be operated for more than
30 seconds at full throttle with the transmission in gear and the output
stalled. Prolonged operation of this type will cause the transmission fluid
temperature to become excessively high and will result in severe
overheating damage to the transmission.
If the transmission overheats during normal operation, determine the fluid level in
the transmission. Refer to the fluid test procedure that is described in the CARE
AND 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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POWER TAKEOFF
OPERATION
CONVERTER-DRIVEN POWER TAKEOFF (PTO)
A PTO may be mounted onto the pad on the top-left side of the transmission main
housing. The PTO drive gear is converter driven and thus provides infinitely
variable speeds. The PTO can be operated when the vehicle is either moving or
stopped.
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 driven
equipment during operation of the PTO.
If the PTO will be operated while the vehicle is stopped, set the parking
brake, shift the transmission to N (Neutral), and depress the accelerator as
required.
If the PTO will be operated while the vehicle is moving, simply select the
desired range and depress the accelerator as required. However, the speed
of the PTO during this type of operation will be affected by the ranges and
speed 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.
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sliding gear or dog clutch, the vehicle engine must be shutoff to engage or
disengage the PTO. Do not exceed the drive speed restrictions of the driven
equipment.
21
PERIODIC INSPECTIONS
The Allison automatic requires little maintenance. Careful attention to fluid
condition and level, selector linkage, and throttle (modulator) linkage is most
important.
For easier inspection, the transmission should be kept clean. Make periodic
inspections for loose bolts and leaking fluid lines. Inspect the condition and
adjustment of the control linkage regularly. Inspect the engine cooling system
occasionally for evidence of transmission fluid, which would indicate a faulty oil
cooler (if transmission is cooled by engine cooling system). Report any abnormal
conditions to your maintenance personnel.
22
Before determining the fluid level, clean around the end of the fill tube before
removing the dipstick(s). Dirt or foreign matter must not be permitted to enter the
fluid 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 for
determining the fluid level. The transmission and dropbox have separate
fluid 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 RUN
BAND
HOT OVERFILL
UTRAL AT
CHECK IN NE
XRON FLUID
IDLE - USE DE
REF OR COLD
RUN
FILL
BAND
UTRAL AT
CHECK IN NE
XRON FLUID
IDLE - USE DE
23
A cold fluid test may be made when the fluid temperature is 60120F (1549C).
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, pushing
down until it stops.
3. Remove the dipstick and determine the fluid level. Any level within the
COLD 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 and
if readings are not consistent, inspect the transmission breather to be sure
that it is clean and not clogged. If readings are still consistent, contact your
nearest Allison dealer or distributor.
5. If the level is at or below the COLD RUN band, add fluid until the fluid
level is within the COLD RUN band.
CAUTION: DO NOT operate the transmission for extended periods of
time until a hot test has verified proper fluid level. Transmission damage
can result from extended operation at improper fluid level conditions.
6. Perform a hot test at the first opportunity after the normal operating
temperature of 160200F (7193C) is reached.
Hot Test.
NOTE: A hot test is made to determine if there is sufficient fluid for
extended operation of the transmission.
24
NOTE: The fluid level rises as temperature increases. The fluid must be
at 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 fill
the clutches and fluid passages with fluid.
2. Park the vehicle on a level spot, shift to N (Neutral), apply the parking
brake and service brakes, and chock the wheels. Let the engine run at idle
speed.
3. Remove the dipstick and wipe clean. Re-insert the dipstick, pushing down
until it stops.
4. Remove the dipstick and determine the fluid level. The safe operating level
is 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 to
bring the fluid level within the HOT RUN band.
6. Be sure fluid level tests are consistant. Test fluid level more than once and
if readings are not consistant, inspect the transmission breather to be sure
that it is clean and not clogged. If readings are still inconsistant, contact
your 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 be
at the top of the tube.
9. If the dropbox has a dipstick, remove it, wipe it clean, re-insert pushing it
down until it stops, and remove again.
10. Safe level for the dropbox is any fluid level between the ADD and FULL
marks on the dipstick.
FLUID SPECIFICATIONS
Allison approved C-4 fluid is recommended for use in transmissions in
off-highway service. Use the C-4 fluid which conforms to the minimum
temperature (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 in
the transfer case (dropbox).
25
Remove the filter element(s) and sealrings from the external oil filters. Install new
element(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.
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CUSTOMER SERVICE
OWNER ASSISTANCE
The satisfaction and goodwill of the owners of Allison transmissions are of
primary concern to Allison Transmission, its distributors, and their dealers.
As an owner of an Allison transmission, you have service locations throughout the
world 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, or
service of your transmission will be handled by the distributor or dealer in your
area. Consult the telephone directory for the Allison Transmission service outlet
nearest you or utilize Allison Transmissions Sales and Service Locator tool on the
Allison Transmission web site at www.allisontransmission.com. You may also
refer to Allison Transmissions 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 have
developed the following three-step procedure to be followed in the event a
problem has not been handled satisfactorily.
Step OneDiscuss your problem with a member of management from the
distributorship or dealership. Frequently, complaints are the result of a
breakdown in communication and can quickly be resolved by a member of
management. If you have already discussed the problem with the Sales or Service
Manager, contact the General Manager. All Allison Transmission dealers are
associated with an Allison Transmission distributor. If the problem originates with
a dealer, explain the matter to a management member of the distributorship with
whom the dealer has his service agreement. The dealer will provide his Allison
Transmission distributors name, address, and telephone number on request.
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SERVICE LITERATURE
Additional 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 sure
that you get maximum performance and service life from your unit, you may
order publications from:
SGI, Inc.
Attn: Allison Literature Fulfillment Desk
8350 Allison Avenue
Indianapolis, IN 46268
TOLL FREE: 888-666-5799
INTERNATIONAL: 317-471-4995
Available Service Literature
Publication
Mechanics Tips *
Parts Catalog*
Service Manual
Technicians Guide **
Worldwide Sales and Service Directory*
* Also available on the internet at www.allisontransmission.com
** Automatic Transmission Fluid, Technicians Guide
30
CBT/CLBT 750/754
MT1366EN
PC1315EN
CD1315EN
SM1314EN
GN2055EN
SA2229EN
31
SOUTHERN REGION
Caribe Detroit Diesel-Allison
Division of GT Corporation
Ceramic Ind. Park
Campo Rico Ave., Block C
Carolina, Puerto Rico 00982
787-750-5000
WESTERN REGION
Detroit Diesel-Allison British
Columbia Ltd.
9300 - 192nd Street
Surrey, British Columbia V4N 3R8
604-888-1211
32
SOUTHERN REGION
Av. Ejercito Nacional No. 843
Colonia Granada
Mexico, D.F. C.P. 11520
936-321-4248
CENTRAL REGION
PO Box 894, Mail Code 462-470-PF06
Indianapolis, IN 46206-0894
317-242-2327
WESTERN REGION
Suite 3510
39465 Paseo Padre Parkway
Fremont, CA 94538
510-226-8037
33
OM1475EN 200603
www.allisontransmission.com