Application Manual: Allison 8000 Series Models
Application Manual: Allison 8000 Series Models
Application Manual: Allison 8000 Series Models
2.0 GENERAL
6.0 CONTROLS
6.1 Shift Calibrations
6.2 Control Functions
REVISION HISTORY
OHAM8
April 03, 2012
APPLICATION MANUAL – 8000 SERIES TRANSMISSIONS
1.0 PURPOSE
The purpose of the 8000 Series Application Manual is to provide a general description of the H8610,
M8610, and S8610 transmission models, their standard features, and options. Transmission operation,
technical specifications, and vehicle applications are also discussed.
In addition to the several transmission features and options which are available with these models, a vari-
ety of control system configurations permits the overall transmission systems to be tailored to anticipated
vehicle function and use. Properly identifying the vehicle use and desired transmission configuration are
therefore important factors in evaluating the proper application of an Allison transmission.
2.0 GENERAL
Unless otherwise noted, all documents referenced in this document may be found in the Extranet channel
of the Allison Transmission website, www.allisontransmission.com. To locate the referenced documents,
which are identified by italic font, look for Tech Data under the Engineering heading on the Extranet home
page. Contact your Allison Transmission representative if you do not have access to the Allison Trans-
mission Extranet.
A choice of torque converters is available to permit matching the transmissions to a wide variety of pre-
mium heavy-duty diesel engines. Refer to Technical Document 148 (TD-148), Engine/Converter Match-
ing for additional details on this subject.
The prefix of each model number is used to distinguish the vocational use of the model
H8610: for hauling applications
M8610: for other mobile vehicle applications
S8610: for stationary applications
Model suffixes are used to identify the type of shift controls of the transmission assembly:
M = Manual Electric
A = Automatic Electronic
CAUTION: Transmissions with manual electric controls are to be used only with stationary
applications such as oil field pumping. Transmissions with these controls are not to be
used for vehicle propulsion.
Each of these transmissions has up to six forward speeds and one reverse gear ratio. In their standard
configurations, all electronically-controlled models are fully-automatic in all forward gears (auto 1-6).
Through alternative programming of the control system, other starting and maximum gear selections may
be permitted — contact Allison Sales for more details.
For more information relating to manual electric controls, refer to Manual Electric Control Installations
section. For more information on electronic shift controls, refer to the appropriate topical section of the
CEC2 Controls Installation Manual or CEC3 Controls Installation Manual.
When the retarder identifier is combined with the basic transmission models and shift control identifier,
individual transmission model numbers are created:
In many types of duty, the effectiveness and productivity of the transmission may be enhanced by the
added flexibility provided by the CEC2 or CEC3 electronic shift control system. A complete description of
the available features can be found in the CEC2 Controls Installation Manual or CEC3 Controls Installa-
tion Manual.
Transmission capabilities, design requirements, and vocational expectations which may affect vehicle
design and transmission selection are discussed in this section.
Heat is generated at a greater rate as the severity of the duty cycle increases (i.e. steeper grades or
heavier vehicle weight). Consequently, the design point for transmission cooling must accommodate
higher heat loads generated by transmissions when used in more severe duty. The requirement to
maintain acceptable transmission temperatures is particularly demanding for vehicles which may rely on
the transmission retarder to maintain reasonable vehicle speeds on long downgrades. Refer to Section
E: Transmission Cooling Guidelines of the Off-Highway Transmission Installation Manual for additional
details.
The temperature of the transmission sump must also be maintained above a minimum level to ensure
proper operation of the transmission controls. Minimum temperatures are specified both for start-up and
during transmission operation.
Both minimum and maximum fluid temperature requirements should thus be considered when evaluating
the transmission application. Cooling requirements are discussed in detail in Section E: Transmission
Cooling Guidelines of the Off-Highway Transmission Installation Manual. Temperature requirements for
the following conditions are defined in the Off-Highway Transmission Specifications section:
• Sump temperature for start-up
• Sump temperature during operation
• To Cooler temperature
• Retarder Out temperature, if applicable
4.2 ATTITUDE
The transmission must be installed and used in a reasonably level (horizontal) manner. Specifications
for installed orientation of pitch (fore/aft) and roll (side-to-side) are included in the Off-Highway Transmis-
sion Specifications section. Maximum operating angles, which include the installed orientation, are also
discussed in the same document.
The calculated performance of a vehicle, and comparison of the results to identifiable standards, com-
prise a portion of the output of iSCAAN (See section 4.5). Illustrations of typical uses of the data include:
This analysis requires the conversion of engine performance to net power at the operating conditions
encountered by the vehicle, plus a matched performance calculation with a selected torque converter.
The vehicle performance calculation considers the appropriate axle ratio, tire size, rolling resistance, wind
resistance, and various loading or load distribution options.
Allison has created iSCAAN, an easily accessible computer program for calculating vehicle performance,
which is readily tailored to the various input parameters. iSCAAN is extremely useful in simultaneously
evaluating the several factors which affect engine/torque converter matches. Guidance is subsequently
provided toward the proper selection of a torque converter for a given engine, while considering all ap-
plicable product ratings.
Another useful feature of iSCAAN is to automatically compare a transmission application against Al-
lison minimum performance guidelines. The combination of these two checks assures the customer of
a proper transmission selection and a vehicle which should perform favorably as compared to long-term
experience in similar applications. The following are representative guidelines which might be applied
during these analyses (actual requirements for any review are based on specific criteria for the intended
vehicle vocation):
• Reserve gradeability (typically 0.25 percent) at top geared speed
• Gradeability at a specific converter efficiency point, which varies by the type of expected duty cycle
• Minimum vehicle top geared speed
• Minimum tractive effort available to slip the wheels at a specified converter efficiency point
The general use of iSCAAN for vehicle performance analysis, detailed vocation description, and perfor-
mance guidelines are discussed in detail in separate Allison documents. For further information regard-
ing access to iSCAAN, consult with your Allison Transmission representative. As a further extension of
iSCAAN, Allison provides a process for the customer to forward specific details regarding a vehicle and
its intended use — facilitating a formal Allison review of the intended transmission application. Details re-
garding this process are summarized in Technical Document 110 (TD110), Application Reviews for Allison
Transmissions.
8000 Series Application Manual – April 03, 2012 Page 5
5.0 DESIGN TOPICS
A selection of torque converters is available to facilitate matching the transmission to a wide variety of
diesel engines based on their respective power, torque, and governed speed characteristics. Refer to the
Off-Highway Transmission Specifications for a list of the available torque converters and their stall torque
ratios.
The torque characteristics of the converter, in conjunction with the torque/speed characteristics of the en-
gine to which it will be matched, have a significant effect on low-speed vehicle performance. Converter
selection is therefore a critical element of transmission definition / vehicle performance decisions. For a
summary of torque converter performance data, refer to Technical Document 166 (TD166), Allison Con-
verter Absorption Chart Summary – Off-Highway Transmission Models
iSCAAN (see paragraph 4.5) performs a variety of calculations which greatly simplify the process of se-
lecting the correct torque converter for a vehicle application. For more details on converter performance
and selection, refer to Technical Document 148 (TD148), Engine / Converter Matching.
These transmission models may require damping devices, or be otherwise prohibited from operating at
certain critical torsionally-resonant speeds, when used with certain types of diesel engines. Refer to
Section B: Transmission / Engine Packaging of the Off-Highway Transmission Installation Manual for ad-
ditional details.
The effectiveness of an engine-braking device, such as an exhaust brake or compression brake, is heav-
ily dependent upon the feedback characteristics of the torque converter since, in braking mode, power
flows through the torque converter toward the engine. Braking can be maximized by keeping the torque
converter lockup clutch applied during this mode. By properly integrating the engine brake controls with
the transmission control system, brake operation can be restricted to occur only when the transmission is
in lockup.
Operation of an engine brake with the torque converter lockup clutch engaged at lower engine speeds,
however, may introduce torsional vibration concerns. Refer to paragraph 5.4.1 above and Section H:
Transmission Retarder and Engine Braking of the Off-Highway Transmission Installation Manual.
Additional information on the subject of smoke controls, and their effects on torque converter matching,
are discussed in Allison Technical Document 115 (TD-115), Torque Converter Compatibility with Smoke-
Controlled Diesel Engines. If you have uncertainties about a specific engine/converter combination,
consult your Allison Transmission representative.
The iSCAAN program (see Section 4.5) may provide an effective means to evaluate design changes "on
paper" before a vehicle is assembled.
Allison transmissions are generally programmed to shift slightly into the engine droop. The goal is to
make each upshift at an engine speed beyond maximum power — assuring that, after the shift, the en-
gine will be at an equal or higher power level than it was prior to the shift.
If the engine is at a lower power level after the shift, it may not be possible to maintain operation there —
resulting in a downshift back to the previous range. Once the transmission attains the lower range, the
engine again accelerates to the upshift point, another upshift is initiated and the cycle repeats, creating
an undesirable condition called "shift cycling".
For engines with little or no droop, shifts must occur at or before reaching governed speed. Failure to do
so can result in inability to reach the shift point, thereby preventing the shift from even occurring.
For these reasons, low or zero-droop engines are not recommended with these transmission models. In
many cases, an engine rating with "zero droop" is also available (at the same power and torque rating)
with a 150 rpm (or greater) programmed droop. When the choice is available, an engine calibration with
droop is generally preferable with Allison products in lieu of the "zero droop" configuration.
5.5 FLUIDS
Allison Off-Highway (5000-9000 Series) transmissions are designed to operate with fluids as described
in “TES-439” available on the Allison Transmission website, and as listed in the TES-439 approved fluids
list also available on the Allison Transmission website. Acceptable oils may include some synthetic types
and some engine oils as described in SAE standard J300 “Engine Oil Viscosity Classification” as follows:
• SAE 0W-30
• SAE 0W-40
• SAE 30
As TES-439 is a new specification, and as it will take some time to populate the approved TES-439 oils
list, oils of the above viscosities found listed on the previous C-4 approved oils list found on the Allison
Transmission website are also acceptable at this time. Once the TES-439 approved list is populated, the
C-4 list will be cancelled.
Recommended sources of fluids are discussed in Allison Service Information Letter (S.I.L.) 10-TR-98,
Transmission Fluid and Filter Service Recommendations, found on the Allison Extranet, and the Approved
TES-439 Fluids List found in the fluids section of www.allisontransmission.com. For fluid fill volumes,
refer to Off-Highway Transmission Specifications.
6.0 CONTROLS
The transmission shifting function is performed through the use of hydraulically-operated clutches. Con-
trol of the clutches is accomplished electrically or electronically, depending upon the transmission model.
Each transmission is equipped with a variety of controls features which, when properly interfaced with
other vehicle components, perform vehicle or accessory control functions, assist the operator in vehicle
operation, protect the vehicle or transmission from abuse, or otherwise tailor operation to specific voca-
tional applications.
For an overview of the control system and control functionality, refer to Section I: Shift Controls of the
Off-Highway Transmission Installation Manual. For specific details regarding control system features,
relative vehicle design issues, and control system installation requirements, refer to
:
Examples of these features and functions, while not a complete list, are:
• Neutral start signal
The speed at which upshifts and downshifts occur is modulated in proportion to engine power demand.
A throttle position input signal, which is necessary for this function, can be provided by one of three
sources:
• If the engine is electronically controlled, throttle position data may be communicated directly to the
transmission controller via either (1) a serial communication link or with (2) a pulse width modulated
(PWM) signal from the engine controls. Consultation with Allison Application Engineering may be re-
quired to define the particular communication details.
• If the engine is not electronically controlled, its throttle position signal is not compatible with the trans-
mission controller, or it is preferable not to use the electronic signal, throttle position data may be com-
municated from the engine controls to the transmission controls through use of (3) an Allison-furnished
throttle position sensor (TPS).
Each transmission also includes provisions to interface the controls of other vehicle systems with trans-
mission operation indicators. For instance, proper use of the transmission neutral start provision permits
the engine starter circuit to operate only if the transmission is in neutral.
For further details regarding these items, refer to Off-Highway Controls tech data.
September 1, 2011
• Added reference to TES-439 in paragraph 5.5.