Description

Allison PS700, PS7000, SS600, SS400 1998 Technical Manual

I’ve seen guys chase electrical ghosts for two days because they didn’t have the right bulletin. This 29-page Allison PS700, PS7000, SS600, SS400 1998 Technical Manual is a stack of factory electrical service bulletins for those transmissions. Not aftermarket guesses. Not reprints. Original OEM data straight from the manufacturer. If you’re rebuilding a powershift or chasing a low-pressure oil light that won’t go out, this is what you need on the bench next to your multimeter.

This manual covers the Elektrics T.I. Bulletin Index – a collection of technical information bulletins issued by ITL’s Technical Service Department. Each bulletin addresses a specific electrical issue, from alternator connections on Perkins engines to ECU diagnostics for 36-way controllers. You get the exact part numbers, wiring changes, and repair procedures that Allison released to dealers. That matters when one wrong connection can fry a solenoid valve coil or blow a diode.

Bulletin Index: 7 Systems Covered

The index lists bulletins grouped by system. You’ll find Gn-series bulletins for general engine electrical (alternators, starters, the Magneti Marelli service support), GX-series for transmission electrical changes (solenoid valve coils, powershift wiring changes, speed sensor tester introduction), and EL-series for diagnostics and harness repair. For example, bulletin GX 006 covers diode protection for solenoid valve coils on SS600, PS700, and SS400 electrically operated transmissions. Bulletin EL001 walks you through ECU diagnostics with the 36-way ECU. Each bulletin is dated and issued with a revision number – so you know exactly what supersedes what.

ECU Diagnostics: When the Control Unit Locks You Out

Bulletin EL007 gives an overview of the Powershift Transmission E.C.U. for the PS700 4-speed, introduced in December 1998. The manual includes full software installation procedures for the diagnostic tool (setup.exe for CD-ROM or floppy). It tells you how to connect the ECU, what the startup screen should look like, and what happens if the ECU is not powered up. No guesswork – you follow the factory flow. This is the same process dealership techs used. If you’ve ever had an ECU that won’t communicate, the bulletin on computer diagnostic equipment (Gn 019) might save your day.

Solenoid Valve Coils – Diode Protection and Retaining Nuts

Bulletin GX 006 specifically addresses solenoid valve coils with diode protection for the SS600, PS700, and SS400. It explains why the diode is there and what happens if you install the wrong coil or omit the diode. Then GX 017 follows up with retaining nuts and ‘O’ rings for all solenoid valves. These two bulletins alone can prevent a $200+ solenoid failure from a loose retaining nut or a shorted coil. The manual gives you the exact part numbers and torque? No – but it directs you to the correct assembly procedure. For actual torque values on those nuts, you’d pair this with the Allison Transmission MD 3000/HD 4000 Mechanic’s Tips Manual.

Does the Manual Cover Alternator and Starter Hookup?

Yes, but only in the context of Perkins engines. Bulletin Gn 008 covers alternator connections on the mainframe harness for Perkins engines as applicable. Gn 017 covers starter motors for all Perkins engines. These are factory electrical schematics and connection points – not generic wiring diagrams. If you’re swapping a Perkins into a different chassis, this tells you where the alternator wires tie into the Allison harness. Combined with the Allison 4000 & B 500 Transmission Inspection & Analysis for driveline mechanical specs, you can get the whole powertrain sorted.

Get the Right Electrical Harness Repair Procedure

Bulletins EL002 and EL003 cover repair components and procedures for IP67 electrical harnesses. These are the sealed connectors you find on off-highway equipment. The manual lists the repair components and then steps you through the proper crimping, sealing, and testing. Use the wrong connector, and water ingress will kill the circuit. If you need deeper theory on how manual transmissions transfer power, check Manual Transmission on Wikipedia for fundamentals, then come back to this manual for the Allison-specific electrical details. Another primer: Manual Transmission gives the basics on gear ratios and shift mechanisms – helpful for understanding how the ECU controls the powershift.

Source Authenticity: OEM vs Aftermarket Documentation

I’ve been burned by aftermarket electrical manuals that reverse-engineered pinouts and got them wrong. This is an original Allison / ITL Technical Information bulletin index. It says on page 1 “ISSUED BY THE TECHNICAL SERVICE DEPARTMENT OF I.T.L., WREXHAM, CLWYD, LL13 9UF, UNITED KINGDOM.” That’s the factory. The safety notice reminds you that the instructions assume sound knowledge of safety procedures – this is a professional-level document, not a hand-waving guide. Every bulletin is numbered, dated, and tied to specific products. You cannot get this level of specificity from a third-party reprint. If you’re serious about diagnosing a PS700 or SS600 electrical fault, you need the OEM source.

Also consider the Allison Transmission 4th Generation Controls 2005 Training Manual – OEM Specs for newer control systems. But for this generation (1998 and earlier), this 29-page manual is the correct reference.

FAQ

How do I install the ECU diagnostic software from this manual?

The manual includes step-by-step setup instructions for both CD-ROM and floppy disk. Insert the disk, run setup.exe, and follow the Windows 95 InstallShield wizard. It’s a DOS-based diagnostic tool that works with the 36-way ECU. If you’re running a modern OS, you may need a virtual machine. The manual lists all installation steps on pages 2–4.

Does this manual include torque specs for solenoid valve retaining nuts?

No.

Bottom line: If you’re working on an Allison PS700, PS7000, SS600, or SS400 transmission and need the factory electrical bulletins for diagnostics, solenoid coils, harness repair, or ECU troubleshooting, this is your reference. Don’t trust a copied PDF with missing pages. Access the Factory Manual from AutoRepairManuals and put the real specs on your bench.