USER GUIDE

TCM REFLASH
(PCCS) V3.5
ALLISON 4th & 5th GENERATION CONTROLS

GN4137EN
 GN4137EN

User
Guide

TCM Reflash (PCCS)

V3.5

2014 July

© 2014 Allison Transmission, Inc., All Rights Reserved

 Table of Contents
1 TCM Reflash Introduction............................................................................................................. 3
1.1 TCM Reflash ....................................................................................................................... 3
1.2 TCM Reflash Prerequisites ................................................................................................ 3
1.3 Applicable Transmission Models ....................................................................................... 4
2 Overview of TCM Reflash Screens and Menus ............................................................................ 5
2.1 TCM Reflash Login ............................................................................................................ 5
2.2 Accessing the Host Server .................................................................................................. 6
2.3 Dynamic Messages Viewer ................................................................................................. 8
2.4 TCM Database Selection .................................................................................................... 9
2.5 Main Calibration Screen .................................................................................................. 10
2.5.1 Calibrations to Download from Web Server.............................................................. 12
2.5.2 Calibrations to Load into ECU/TCM ......................................................................... 13
2.5.3 Calibrations Older than Ten Days.............................................................................. 14
2.6 Calibration Request (Allison Distributors/Dealers Only).............................................. 15
2.7 Main Calibration Screen Drop-down Menus.................................................................. 17
2.7.1 File Menu ................................................................................................................... 17
2.7.2 ECU/TCM Menu ....................................................................................................... 21
2.7.3 Software Menu .......................................................................................................... 21
2.7.4 Reports Menu ............................................................................................................ 22
2.7.5 Help Menu ................................................................................................................. 23
3 Using TCM Reflash ....................................................................................................................... 26
3.1 Launching TCM Reflash .................................................................................................. 26
3.2 Downloading Calibrations From Web Server (PCCSWeb/CDS) ................................. 28
3.2.1 Adding Calibrations to TCM Reflash ........................................................................ 28
3.2.2 Modifying Calibration Request Information to Download From Web Server .......... 32
3.2.3 Submitting Calibrations (Distributors/Dealers Only) ................................................ 32
3.3 Loading Calibrations into TCM/ECUs ........................................................................... 34
3.3.1 Loading Calibrations into an H 40/50 EP System...................................................... 39
3.3.2 Requesting Copies of a Calibration Already Downloaded ........................................ 42
3.4 Downloading TCM/ECU Application Software ............................................................. 42
3.5 Loading Application Software into a TCM/ECU ........................................................... 44
3.6 Deleting Calibrations from TCM Reflash ....................................................................... 44
3.7 Printing TCM/ECU Labels .............................................................................................. 45
4 Basic Troubleshooting................................................................................................................... 47
4.1 Invalid CIN Message after Submitting............................................................................ 47
4.2 Unable to Communicate With TCM/ECU ...................................................................... 47

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 4.3 Read/Write Program Disconnects While Loading the Calibration .............................. 48
4.4 Intermec Printer is Not Working on PC ......................................................................... 48
5 Appendix A—Calibration Request Form .................................................................................... 49
6 Appendix B—TCM Reflash Required Hardware ...................................................................... 50
6.1 Intermec Setup .................................................................................................................. 51
6.2 Installing the InterDriver™ Software ............................................................................. 52
6.2.1 For ECU Labels ......................................................................................................... 53
6.2.2 For Report Printing .................................................................................................... 53
6.3 Other Hardware Required ............................................................................................... 53
7 Appendix C—Hardware Configuration ...................................................................................... 55
7.1 Allison 4th and 5th Generation Controls TCM / Load Box Bench Setup .................... 55
7.2 Allison 4th and 5th Generation Controls TCM / Vehicle Harness Setup .................... 57
7.3 Earlier Hardware Configurations ................................................................................... 59
7.3.1 WTEC-II ECU Reflash Load Station (Bench) .......................................................... 59
7.3.2 WTEC-III or CEC2 ECU Reflash Load Station (Bench) .......................................... 60
7.3.3 1000 / 2000 TCM Reflash Load Station (Bench) ...................................................... 61
7.3.4 All Product Families TCM Reflash Load Station (Vehicle) ...................................... 62
7.4 Current Hardware Configuration ................................................................................... 63

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 TCM Reflash (PCCS)

1 TCM Reflash Introduction

1.1 TCM Reflash

TCM Reflash is a PC-based system allowing authorized users to download and install Allison
Transmission calibrations for the TC10 Product Family, 1000/2000 and 3000/4000 Product
Families (including the new Allison 5th Generation Controls system), as well as Off-Highway
(CEC2 and CEC3) and Hybrid (H 40/50 EP) control systems. The TCM Reflash application can
be launched from the Allison DOC® For PC—Service Tool or TCM Reflash can function as a
standalone application.

TCM Reflash consists of mainframe host systems (PCCSWeb) and 5th Generation Calibration
Delivery System (CDS) and a PC subsystem or client (PC Load Station). The host system stores
calibrations that were assembled using data supplied by Allison Transmission’s product
engineering department, based upon user requirements and specific selection criteria. The PC
subsystem client allows the user to download calibrations from the host, systematically store the
calibrations and relevant information, and then load the calibrations into a TCM or ECU. TCM
Reflash also performs a series of tests and validation steps to make sure the user downloads and
loads the correct calibration into the correct TCM/ECU. TCM Reflash also keeps track of all
calibrations downloaded and applied to a TCM/ECU.

Typical users of TCM Reflash are Allison distributors and dealers, vehicle OEMs, DOEMs, and
Allison personnel.

1.2 TCM Reflash Prerequisites

To use the TCM Reflash application, the user must have:
 Load Station User Name
 Load Station Password
 Minimum hardware configuration
 Internet access
 TCM Reflash program installed on PC (refer to Appendix B for installation requirements)

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1.3 Applicable Transmission Models

TCM Reflash can download and install transmission calibrations for the following Allison
Product Families:
 TC10 Product Family with Allison 5th Generation Controls.
 3000/4000 Product Families with Allison 5th Generation Controls system and earlier control systems.
th
 1000/2000 Product Families with Allison 5 Generation Controls system and earlier control systems.
 Off-Highway control systems using CEC2 and CEC3 controllers.
 Allison Hybrid product (H 40/50 EP) controllers.

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2 Overview of TCM Reflash Screens and Menus

The TCM Reflash application is not a component of the Allison DOC® For PC—Service Tool,
but can be launched from the Allison DOC® For PC—Service Tool File menu. It can also be
installed and used as a standalone application.

2.1 TCM Reflash Login

Fields:
 Enter User Name—a valid Load Station User Name, required to access the TCM
Reflash application.
Note:
Previous Load Station ID (PCCS User Name and Password) can be
used to operate the TCM Reflash application.
 Enter User Password—a valid Load Station Password, required to access the TCM
Reflash application.
Note:
Users are encouraged to login at least every 90 days to keep their
accounts active.
Periodically a user may be prompted to change their password.
Forgotten passwords can be recovered/reset by correctly answering
the challenge questions accessible through the ‘Forgot Password’
button. If an account (login) is locked due to inactivity or multiple
login failures, contact the Allison Transmission Technical
Assistance Center at 1-800-252-5283.
Users are required to change their initial, temporary password and
may not change their passwords to a recently used password.

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Buttons:
 Login—requests login using the User Name and User Password.
 Cancel—closes the TCM Reflash application.
 Help—displays the Help menu.
 About—displays program and version information.
 Forgot Password—launches a challenge question for the user to answer in order to
obtain a new password.
 Check Connections—determines if the PC can connect to the Internet.

2.2 Accessing the Host Server

If the network server does not allow direct access to the Internet, access can be obtained through
a proxy server. Proxy server access requires entering the correct information in the Proxy Server
dialog box.

If you cannot directly access the Internet, the following message displays:

Buttons:
 Yes—displays the Proxy Validation dialog box.
 No—causes TCM Reflash to verify the User Name and Password. If the User Name
and Password is verified, TCM Reflash can be used, provided the needed applications
software and/or calibration have been previously downloaded to the PC. A message
displays if the User Name and/or Password cannot be validated.

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Access the Internet by entering the required information in the fields of the Enter Proxy
Information dialog box.

Fields:
 Address—the Universal Resource Locator (URL) of your proxy server.
 Port—the designator of the port used by the proxy server (usually port 80).
 Domain – the domain name of proxy server.
 Username—the user name to access the Internet. This is not the Load Station User
Name.
 Password—the password to access the Internet. This is not the Load Station
Password.

Note:
Contact your local IT Manager for help entering proxy server
information. Allison Transmission does not know your local
proxy address, domain, user name, or password.

Buttons:
 OK—submits the access information.
 Cancel—displays the Login screen.
 Reset proxy—removes current proxy settings.

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2.3 Dynamic Messages Viewer

The Dynamic Messages Viewer displays messages from the host server. The Dynamic Messages
Viewer operates in a similar manner to an e-mail system. Messages can be displayed, deleted, or
moved into a folder. Dialog boxes are displayed to create, delete, or access the folders displayed
in the folder tree.

Buttons:
 Previous—displays the previous message in the message queue.
 Next—displays the next message in the message queue.
 Save to Folder—saves the displayed or highlighted message to a message folder.
Saved messages can be viewed at a later time. Messages may also be moved into a
folder by dragging and dropping.
 Remove—deletes the message.
 Done—closes The Dynamic Message Viewer and displays the TCM Database
Selection dialog box.

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2.4 TCM Database Selection

The TCM Database Selection dialog box displays all calibration databases available to the user.
Any database that is not available is grayed-out and the button deactivated. Click the button of an
available database to select that database. After selecting a database, the Main Calibration screen
displays.

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2.5 Main Calibration Screen

The Main Calibration screen serves as the feature control screen for TCM Reflash activities. This
screen is divided into two sections: the upper half is Calibrations to Download from Web Server,
and the lower half is Calibrations to Load into ECU/TCM. Each section contains different
buttons that are available only when the respective section is selected. The Main Calibration
screen contains five drop-down menus which provide access to various TCM Reflash (PCCS)
features.

4th Generation screen

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5th Generation screen

Main Calibration Screen Sections:

 Calibrations to Download from Web Server—lists all calibrations available to be
downloaded from the host server (PCCSWeb/CDS).
 Calibrations to Load into ECU/TCM—contains all calibrations already downloaded
from PCCSWeb/CDS to the PC, and ready to be loaded into TCM/ECUs.

Note:
The command buttons in each section are enabled only when a
row in the section is selected or active.

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2.5.1 Calibrations to Download from Web Server

Fields:
 CIN—Calibration Identification Number of the calibration to be downloaded. The
CIN only appears if specified by the user. This field is not present in the 5th
Generation screen.
 TCM Serial—S/N of the TCM to be programmed with the calibration (5th Generation
only).
 TCM Assembly Number—the assembly number or part number to be applied to the
TCM. The TCM Assembly Number only appears if specified by the user.
 VIN—Vehicle Identification Number (5th Generation only).
 Serial Number—Transmission S/N (5th Generation only).
 Exact—indicates whether the user required the exact CIN specified in the Calibration
to Download Information dialog box, or not. If the user requests the calibration with
the TCM Assembly Number, the system always requests the latest calibration
associated with that Assembly Number.
 Dyno—indicates if the calibration to download is for a Stock or Dyno TCM/ECU.
 Quantity—indicates the number of calibrations to be requested/downloaded from the
host server.
 Expires—displays the expiration date of current calibration request. A calibration
expires 10 days from the day on which the entry was made.

Buttons:
 Add—displays the Add Calibration to Download Information dialog box.
 Modify—displays the Update Calibration to Download Information dialog box for a
selected/highlighted calibration.
 Delete—deletes a selected calibration from the current display.
 Delete All—deletes all calibrations from the current display.
 Submit—requests only the selected or highlighted calibration to be downloaded and
for Allison distributor/dealers, displays the Calibration Verification/Request dialog
box.
 Submit All—requests all calibrations from the current display to be downloaded. For
each calibration to download, the user, if an Allison distributor/dealer, must input the
required data in the Calibration Verification/Request dialog box.
 View Dyno Calibrations—displays all the calibrations available for Dyno use.
 WTEC2 Dynax Conversions—displays an alphabetized cross-reference list allowing
users to look up WTEC II Dynax calibration conversions.

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2.5.2 Calibrations to Load into ECU/TCM

Fields:
 CIN—Calibration Identification Number of the calibration to be loaded into a TCM.
This field is not present in the 5th Generation screen.
 TCM Serial—S/N of the TCM to be programmed with the calibration. This field is
only present on the 5th Generation screen.
 TCM Assembly Number—the assembly number or part number to be applied to the
TCM.
 Model—Transmission model based on the calibration information.
 Customer Name—the name of the customer/company (previously specified).
 Expires—displays the expiration date of the current calibration. A calibration expires
10 days from the day on which the entry was made.
 Quantity—the number of copies of a calibration with the same CIN available to load
into ECU/TCMs. If more calibrations are required, click on the Modify command
button.
Allison distributors/dealers will also see the following columns:
 Transmission Serial Number—the 10-digit serial number of the transmission the
ECU/TCM is used with.
 VIN—the 17-character Vehicle Identification Number the ECU/TCM is used with.
 PO/RO—Purchase order or repair order number. This field is used as a reference
number only for use by the user.

Buttons:
 Modify—displays the Add Calibration To Download Information dialog box for the
selected/highlighted calibration. Use Modify when more calibrations (with the same
CIN) are required.
 Load—applies a selected calibration to the TCM.
 Delete—deletes a selected calibration from the current display.
 Delete All—deletes all calibrations from the current display.

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2.5.3 Calibrations Older than Ten Days

Calibrations expire after 10 days. The application displays messages indicating which
calibrations have expired with the option to re-download them. If the user chooses not to
download them, the application removes them from the load station.

To re-download expired calibrations:

1. Select the calibration by checking the box or use the Select All button to select all
displayed calibrations.
2. Click the Download Selected Calibrations button.
If no expired calibrations are to be re-downloaded, click the Do Not Download
Anything button.

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2.6 Calibration Request (Allison Distributors/Dealers Only)

The Calibration Verification/Request dialog box checks to make sure there is not a vocational
mismatch between the calibration and the transmission, based upon the Transmission Serial
Number. The Done button submits the calibration request.

The following fields are required information:

 Calibration request X of Y—indicates the current calibration request count (X), the
quantity entered by the user when the calibration was staged for downloading (Y).
 CIN—displays the Calibration Identification Number of the calibration to request,
when available.
 TCM—displays the TCM Assembly number, when available.
 Transmission S/N—the transmission serial number of the unit in which the current
calibration will be installed. Once submitted, the PCCSWeb system checks for (1)
calibration validity, (2) transmission serial number validity, and (3) vocational
mismatch (that is, the calibration is not compatible with the specified transmission).
The following fields are optional information:
 PO/RO—allows the user to enter the production order or the repair order.
 VIN—the Vehicle Identification Number.
 ReCal Type—select or enter the reason for recalibrating the ECU/TCM.
 Customer Name—identifies the customer.
 Comments—input any comments with respect to the present activity.
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Buttons:
 Done—sends the request to verify and download the displayed calibration. This
button is not enabled until a Transmission S/N is entered.
Note:
If more than one copy of a calibration is being requested, enter
the information for each copy in the Calibration
Verification/Request dialog box, using the Add Another button,
before clicking the Done button.
 Cancel—cancels the current calibration request and displays the Main Calibration
screen.
Note:
When the Cancel button is clicked, information entered in the
Calibration Verification/Request dialog box is lost. If a user
requires ten copies of calibration CIN “XYZ,” and they enter the
required information for five copies using the Add Another
button, and while entering the sixth request clicks Done, only the
five entered requests will be sent and they must start over to
request the remaining five calibration copies.
 Add Another—adds another calibration to the calibrations to download, increments
the X in the X of Y field by one, and displays the Calibration Verification/Request
dialog box.
Note:
To add another calibration with the same CIN, a value greater
than 1 must have been entered in the Quantity field of the
Calibrations to Download from Web Server section of the Main
Calibration screen.

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2.7 Main Calibration Screen Drop-down Menus

TCM Reflash Main Calibration screen contains five drop-down menus:

 File
 ECU/TCM
 Software
 Reports
 Help

2.7.1 File Menu

The File menu contains the following items:
 Application Setup—displays current configuration of the TCM Reflash application
for the following:
o Communications adapter
o Printer port to print barcodes
o Reading/writing speed
o Customer name
o Connector information – Reflash Harness vs. In Vehicle (for 5th Generation
only)
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The adapter chosen is specific to the database selected; therefore, a user could have the DPA
USB selected for the WT Database, or the Softing CanCard2 selected for the H 40/50 EP
Database. The user must select the correct adapter while in each database they are using in order
to load a calibration. Wireless or Bluetooth connections for TCM Reflash are not allowed.

Fast Write and Fast Read are not checked by default. The user has the option to check these
boxes to decrease the amount of time it takes to load calibrations. If the user experiences
problems with making it part way through a TCM load and receives an error, the check boxes
can be toggled off to slow calibration load speed down and possibly fix the load error.

Note:
H 40/50 EP users should turn Fast Write and Fast Read off
(unchecked).

A Communications Protocol drop-down box displays when the Allison 4th Generation is selected
to allow the user to select CAN (J1939), or High Speed CAN-GMLAN (HSC). The user should
select J1939 if using the 9 pin connector, and GMLAN if using the 16 pin J1962 connector with
the GMLAN cable. The adapters in the other databases rely on TCM Reflash to attempt a
CAN/J1939 connection first, or default to a J1708 connection if the CAN connection fails.

Pre-5th Generation dialog

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 TCM Reflash (PCCS)
th
5 Generation dialog

Note:
The Application Setup Dialog box can also be viewed by
clicking the link following Translator Device on the Main
Calibration screen.

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 Select Database—displays the TCM Database Selection screen. All calibration

databases available to a particular user are displayed. This window allows the user to
select the transmission control system database from which a calibration is desired.
Any database that is not available is grayed-out and its button is deactivated.

 Check Connection—determines if the PC is connected to the Internet.

 Upload Logs—initiates uploads of Load Transaction logs to the PCCSWeb/CDS
server to maintain records of the transactions related to a particular TCM. The
changing text in the title bar from the selected TCM database to Uploading Log Files
indicates the logs are being uploaded. Once the files have uploaded successfully, the
text changes to Log Files Uploaded Successfully. If the upload fails or is incomplete,
a message displays indicating the status of the upload effort.

 Proxy Settings—displays Enter Proxy Information dialog to show current settings

and allows user to modify/reset them if necessary.
 Logout User—logs the current user out of the system and displays a confirmation
message. Clicking the Yes button logs the user out and displays the TCM Reflash
Login screen.
 Close—exits the TCM Reflash system.

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2.7.2 ECU/TCM Menu

The ECU/TCM menu contains the following items:
 Load Service Calibration—loads a special service calibration into the TCM/ECU.
 Erase Power Off Data—forces the TCM to erase all learned data saved in memory
when the vehicle ignition is turned off. After the data is erased, the TCM uses factory
values.

2.7.3 Software Menu

The Software menu contains the following items:
 Download from Server—displays the Download Application Software dialog box to
initiate the application software download from the PCCSWeb server. This item is not
available for 5th Generation.

 Apply to TCM—loads the application software downloaded from the server into a
TCM; for 5th Generation, loads the application software and calibration.

Pre-5th Generation dialog 5th Generation dialog

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2.7.4 Reports Menu

Prior to using Report menu item, select a calibration from the Calibration to Load into
ECU/TCM screen section. The Reports menu contains the following items:
 Summary Report for Calibration to Load—displays the calibration’s summary report.
The report can be printed, saved (Print to File), or closed.

Note:
For 5th Generation Controls, use your Allison Extranet
account to access Summary Reports.

 Shift Points Report for Calibration to Load (pre-5th Generation) or Shift Points
Report for connected TCM (5th Generation)—displays the Shift Point Report dialog
box. If the Driveline Reduction Ratio and Tire Revolutions per Mile/Kilometer field
values are zero (the default), the Shift Point Report will include the transmission
turbine shaft speed before and after the shift, and the transmission output shaft speed
at the shift.
 Print Calibration List—prints all calibrations located in the active section of the Main
Screen (Calibrations to Download from Web Server, or Calibrations to Load into
ECU/TCM).
 Print TCM Labels for Calibration to Load—prints a TCM/ECU barcode label on the
Intermec label printer. The Intermec drivers and ActiveX controls must be installed
separately.

Regarding Shift Points Reports menu item: If the Driveline Reduction Ratio and the Tire
Revolutions per Mile/Kilometer values are other than zero, the Shift Point Report will also
include the vehicle speed in mph.

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Fields:
 CIN—the CIN of the calibration selected for the Shift Point Report.
 Driveline Reduction Ratio—the gear reduction of the driveline.
 Tire Revolution per Mile/Km— tire revolution per unit of measure. English
(Rev/Mile), and Metric (Rev/Km).
Buttons:
 View—displays the Calibrations’ Shift Point Report, which can be printed or saved.
 Close—cancels the Shift Point Report request.

2.7.5 Help Menu

The Help menu contains the following items:
 Help Topics—displays the Help Topics window, which contains information based
on the User Guide.
 Change Password—initiates the Change Password procedure on the PCCSWeb server
and displays the Change Password dialog box. Passwords must be eight characters or
more and contain at least one alpha and one numeric character. A password cannot be
the same as the username.

 Setup Challenge Questions—allows the user to set up challenge questions. Challenge

questions are used as a security measure. Select exactly three challenge questions to
be used as identity verification (in case the password needs to be reset). Click
Submit Challenge Information to save these questions.

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 Calibration Verification/Request—displays the Calibration Verification/Request

dialog box (for further details, refer to section 3.2.3).
 Calibration Change Request—displays a form to request a calibration number from
Allison Transmission. Once required and optional information is entered, do one
of the following:
o Click Send to submit the request, or
Note:
In order to successfully submit this request, the TCM Reflash
e-mail feature must be compatible with the local e-mail system.
Seek help from the IT department to correctly configure TCM
Reflash e-mail.

o Click Print to print a hard copy of the entered information and transmit
the information to Allison Transmission via fax. Fax is the traditional
means by which users have been submitting these requests.

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 Dynamic Messages—displays the Dynamic Message Viewer.

 Access to Allison Web Site— provides a link to the Allison Transmission website.
 About—displays TCM Reflash program and version information.

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3 Using TCM Reflash

TCM Reflash (PCCS) is launched from the Allison DOC® For PC—Service Tool File drop-
down menu, or as a stand-alone application. TCM Reflash is not part of the Allison DOC® For
PC—Service Tool but it can be invoked from within the Allison DOC® For PC—Service Tool
software. You can use TCM Reflash without having the Allison DOC® For PC—Service Tool
loaded and operating on your PC.

3.1 Launching TCM Reflash

1. From Allison DOC® For PC—Service Tool File menu, select TCM Reflash. Or, from
the desktop, double-click on the TCM Reflash icon—the TCM Reflash Login window
displays.

2. Enter a valid TCM Reflash user name into the Enter User Name field.
3. Enter a valid TCM Reflash password into the Enter User Password field.

Note:
After six unsuccessful attempts to log in using an invalid ID or
password, the account is automatically disabled. Challenge
Questions, accessed by clicking Forgot Password, allows the
user to unlock the account and retrieve a temporary password.
Contact the Allison Transmission Technical Assistance Center,
1-800-252-5283, if unsuccessful

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 TCM Reflash (PCCS)
4. Click the Login button—a message displays asking if the User wants to connect to the
PCCSWeb server. Select Yes to connect to the PCCSWeb server. If the User will be
connecting only to the vehicle to load a calibration which has been saved to the
PC, select No.

5. Click the Yes button

• If there are connection issues, the Proxy Server message box displays.

• Click the Yes button in the message box—the Enter Proxy Information dialog
box displays.

• Enter a valid Address, Port, Domain, Username, and Password (as described in
section 2.2).
• Click the OK button.

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6. The TCM Database Selection dialog box displays.

7. Select the TCM Database button for the control system of interest (at any time, the
user can switch between databases from the File drop-down menu).

3.2 Downloading Calibrations From Web Server (PCCSWeb/CDS)

Before a calibration can be applied to a TCM/ECU, add the calibration to the Calibrations to
Download from Web Server list and submit a request to PCCSWeb or 5th Generation
Calibration Delivery System for verification.

3.2.1 Adding Calibrations to TCM Reflash

1. Click or select the Calibrations to Download from Web Server section of the Main
Calibration screen.
2. Click the Add button—the Add Calibration to Download Information dialog box
displays.

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4th Generation and earlier dialog box

5th Generation Full (Road Ready) calibration dialog box

Note:
When downloading a 5th Generation calibration package, TCM
Reflash assumes a fully calibrated "road ready" configuration is
desired. The user may request a calibration package by TCM
serial number of the replaced TCM, Road Ready TCM assembly
number, VIN or transmission serial number.

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5th Generation Vocational Model Base Cal Only (not a fully functional Road Ready
calibration) dialog box
Note:
Select the 'Vocational Model Base Cal Only' checkbox when
only loading the vocation model TCM assembly number. The
TCM serial number, VIN, and transmission serial number fields
are grayed out and not available for use.

3. 5th Generation only: Do not check “Vocational Model Base Cal Only” if a fully
functional Road Ready calibration is required. Vocational Model Base Cal Only will
not provide full functionality for vehicle operation. Use the "Vocational Model Base
Cal Only" mode when loading only the vocational model calibration package for use
at an OEM assembly line with a Vehicle Electronic Programming Station (VEPS).
4. Enter either the CIN (4th Generation only) of the calibration to add or the TCM
Assembly Number. Once the CIN or the TCM assembly number is entered, the
Summary Report and the Shift Point Report are available for viewing before actually
requesting the calibration. If necessary, preview the Summary and Shift Point Reports
to confirm the correct calibration has been selected for downloading.

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 TCM Reflash (PCCS)
Note: For 5th Generation:
 Summary Reports are available via Allison Extranet.
 Shift Point Reports are available via ReportsShift Points
Report menu item only. The TCM must be connected to
run 5th Generation Shift Point Reports.

Note:
When adding a calibration in the H 40/50 EP Database, a SID
number is used instead of a CIN. In addition, the Hybrid
Summary Report is different from other calibrations. This report
simply displays the calibration and software level for each
device used for the corresponding SID number. Shift Point
Reports are not available for Hybrid calibrations.

5. Select the quantity or number of copies of the calibration to download; the default is
one.
6. 4th Gen and earlier systems only: Either an Exact Calibration (if available) or the
Newest Calibration can be downloaded. Newest Calibration is automatically checked
if no action is taken to check Exact Calibration.
7. Click the Calibration for Dyno Usage box if the CIN or TCM Assembly Number is
for a transmission dyno or a stock ECU/TCM.
8. 4th Generation systems only: Click the A59 box if the calibration is being loaded
into an A59 TCM.
9. Click the Add button—the application adds the specified calibration into the
Calibrations to Download from Web Server list.
Note:
The information specified in the Calibrations to Download from
Web Server list can be modified as necessary by using the
Modify button.

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 TCM Reflash (PCCS)

3.2.2 Modifying Calibration Request Information to Download From Web Server

Calibration request information, displayed in the Main Calibration screen’s Calibrations to
Download from Web Server list, can be changed at any time. The Modify button displays the
Update Calibration to Download Information dialog box. The modify feature allows any of the
entered information to be changed and makes the Summary Report and the Shift Point Report
available for previewing the calibration.

To modify a displayed calibration:

1. Select or highlight the calibration to modify in the Main Calibration screen’s
Calibrations to Download from Web Server list.
2. Click the Modify button—the Update Calibrations to Download Information dialog
box displays.

3. Modify the information as required.

4. Click the Update button—the application updates the calibration information in the
Calibrations to Download from Web Server list.

3.2.3 Submitting Calibrations (Distributors/Dealers Only)

When a calibration download request is submitted to the PCCS Web Server, that transmission
serial number is verified and validated. Based upon the calibration request information and the
transmission serial number, PCCS either approves or disapproves the calibration for download.

Error messages indicating what failed in the process display if:

 An invalid CIN, TCM/ECU Assembly Number, or Transmission S/N is entered.
 The system detects a calibration and transmission serial number mismatch.

1. Click on the row in the Main Calibration screen’s Calibrations to Download from
Web Server list containing the calibration to be downloaded—the calibration data is
highlighted.
2. Click the Submit button—the Calibration Request dialog box displays (vocational
model check only).
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 TCM Reflash (PCCS)

 The system loads the CIN or TCM fields.

 The Calibration Request field indicates which set of Transmission Serial
Numbers and other Optional fields the user is on. In this case, the user is on
set 1 of 5.
 If the total number of requested calibrations has not been reached, the Add
Another button is activated to allow the user to enter additional Transmission
Serial Numbers and Optional fields. Once the request number has been
reached, the user must click the Done or Cancel button.

3. Enter the Transmission S/N. This is the only required field.

CAUTION:
Be careful and precise when entering the transmission serial
number, as it will be verified and validated once the request is
submitted. With the transmission serial number and the
calibration information, PCCSWeb approves or disapproves the
download of the request calibration.
If the transmission serial number is not known, (for example, in
cases of a stock ECU/TCM), then the user needs to check the
dyno box when the CIN or ECU number is added to the
Calibrations to Download from Web Server screen.

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 TCM Reflash (PCCS)

4. If another calibration copy is to be downloaded, click Add Another. A transmission

serial number is required for each download.
5. If the information for all requested calibrations has been entered, click the Done
button—TCM Reflash submits the request(s) to PCCS.

The calibrations successfully downloaded from PCCSWeb to the PC are displayed in the
Calibrations to Load into ECU/TCM portion of the Main Calibration screen, indicating they are
ready to be applied to ECU/TCMs.

3.3 Loading Calibrations into TCM/ECUs

Download the calibration from PCCSWeb/CDS to the PC before applying it to a TCM/ECU.
Connect the TCM/ECU to the PC and power it up, with the ignition on (refer to Appendix C for
connection diagrams).

To load a calibration into a TCM/ECU:

1. In the main calibration screen’s Calibrations to Load into ECU/TCM section, select
the row containing the calibration to be loaded to the TCM—the calibration data is
highlighted.
2. Click the Load button—the Vehicle Calibration Verification screen displays.

3. Confirm the vocational model of the vehicle into which the TCM to reflash will be
installed. If compatible, click OK. Otherwise, click Cancel and verify vehicle and/or
calibration compatibility. The Load Report Form screen displays and the application
reads the Current TCM Configuration from the connected TCM/ECU.

34
 TCM Reflash (PCCS)

Note:
While the application is reading the information from the
TCM/ECU, the OK button is grayed out.

 If the application is unable to establish communication with the TCM/ECU, a

message box displays.

35
 TCM Reflash (PCCS)

If an incorrect level of calibration is identified to be loaded into a TCM, a dialog box with a
message similar to this one will be displayed to explain the error.

 The New Calibration Configuration and the Current TCM Configuration

fields of the Load Report Form are filled in by the system. Only the
Additional Tracking and Barcode Information fields are to be filled in by the
user.

Note:
The user (if a Distributor or Dealer) is required to enter in the
RO#, VIN, Transmission S/N, and Comments.

4. Click the OK button to apply the calibration to the TCM—the Read/Write TCM
window displays. A message displays if one or more of the required fields have not
been filled in, or if a field contains invalid data.

36
 TCM Reflash (PCCS)

 Depending upon the translator device, PC configuration, and data link load,
the Read/Write process may take up to 15 minutes.
 The following screens will appear upon completion of the Write process.

5th Generation only: The following screen will appear when loading fully calibrated road ready
packages and indicates the calibration settings are being applied to the TCM.

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 TCM Reflash (PCCS)

5th Generation only screen

 Once the TCM/ECU has been successfully flashed/reflashed, the application

displays “Calibration load successful. Would you like to print a TCM barcode
label?”

5. Click Yes to print the barcode label—the print label screen displays (refer to section
3.7). If not printing a barcode label, click No.

After printing the label, or if a barcode label is not printed, the application uploads any pending
calibration logs to the PCCSWeb/CDS server. The upload progress is displayed in the title bar at
the top of the main calibration window.

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 TCM Reflash (PCCS)

3.3.1 Loading Calibrations into an H 40/50 EP System

When loading calibrations into an Allison Hybrid System, certain steps and windows are
different than the previously discussed load process (section 3.3).
To load a calibration into a Hybrid System:

1. In the Main Calibration screen’s Calibrations to Load into ECU/TCM section, select
the row containing the calibration to be loaded to the TCM—the calibration data is
highlighted.
2. Click the Load button. The Load Report Form window will be displayed.

Note:
As with other Load Report Forms, the user (if a distributor or
dealer) is required to enter in the RO#, VIN, Transmission S/N,
and Comment. Also, for Hybrid System, the user is required to
enter Customer Vehicle #.

3. The user has the option to either load the entire vehicle by clicking the Entire
Vehicle button, or load a single device by clicking the Single Device button.

Note:
It is recommended to load the entire vehicle when possible.

39
 TCM Reflash (PCCS)

 If Entire Vehicle is selected:

o The Read/Write TCM window displays and begins reflashing.

o Once each component has been attempted to reflash, the application

displays the following dialog box, which describes the results of the
load in each controller:

o Click OK and the application will ask if you would like to print
barcode labels. Click Yes to print the barcode label—the print label
screen displays (refer to section 3.7). If not printing a barcode label,
click No.

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 TCM Reflash (PCCS)

 If Single Device is selected:

o The Load HEV Devices dialog box will appear. If the status of a device
is online, a good connection exists between the computer and the
device.

o Select the device to be loaded and click Load. The Read/Write TCM
window displays and begins reflashing.
o Once each component has been attempted to reflash, the application
displays the following dialog box:

o Click OK and the application will ask if you would like to print a
barcode label. Click Yes to print the barcode label—the print label
screen displays (refer to section 3.7). If not printing a barcode label,
click No.

 After printing the label, or if a barcode label is not printed, the application
uploads any pending calibration logs to the PCCSWeb/CDS server. The
upload progress is displayed in the title bar at the top of the main calibration
window.

41
 TCM Reflash (PCCS)

3.3.2 Requesting Copies of a Calibration Already Downloaded

TCM Reflash allows users to obtain or request additional copies of a calibration that has already
been downloaded to the PC and is ready to be applied to ECU/TCMs.
To request additional copies of a calibration from the PCCSWeb/CDS server:
1. Select the calibration to be requested from the Calibrations to Load into ECU/TCM
list.
2. Click Modify, the Add Calibration to Download Information dialog box displays.

The CIN and TCM Assembly Number are system populated.

3. Enter the new information such as Quantity, Calibration for Dyno Usage or, when
available, the Newest Calibration or Exact Calibration selection.
4. Click the Add button, the entry is added to the Calibrations to Download from Web
Server list.
5. Refer to section 3.2.3 for submitting calibration verification requests.

3.4 Downloading TCM/ECU Application Software

TCM application software is normally downloaded with the calibration request. However, if the
application software failed to download during that process, or it is simply required for a special
circumstance, it can be downloaded separately. This item is not available for 5th Generation.
To download the application software:
1. Select Download From Server from the Software drop-down menu, the Download
Application Software dialog box displays.

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 TCM Reflash (PCCS)

2. Enter the appropriate software level to download and click Begin, the Application
Software Download Progress window displays.

3. When the download is complete, the Main Calibration screen displays.

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 TCM Reflash (PCCS)

3.5 Loading Application Software into a TCM/ECU

Before attempting to load the application software into a TCM/ECU, the TCM/ECU must be
connected to the PC and powered up, with the vehicle ignition on. If the TCM/ECU is not
connected and/or powered up, the application displays an error message stating that condition.
To apply application software to a TCM:
1. Select Apply to TCM from the Software drop-down menu. The Load Application
Software dialog box displays.
Pre-5th Generation dialog 5th Generation dialog

2. Select the application software to be applied to the TCM from the drop-down menu. If
5th Generation, select the calibration to be applied to the TCM.
3. Click the Begin button.

3.6 Deleting Calibrations from TCM Reflash

Calibrations can be deleted individually, or all that are displayed.
Use the following procedure to delete an individual calibration from any of the TCM Reflash
sections:
1. Select the row containing the calibration to be deleted. The selected row is
highlighted.
2. Click the Delete button.

Use the following procedure to delete all calibrations from any of the TCM Reflash sections:
1. Click the Delete All button. All displayed calibrations are deleted.

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 TCM Reflash (PCCS)

3.7 Printing TCM/ECU Labels

Attach a label containing calibration-specific data to a TCM/ECU after a Reflash event. TCM
Reflash provides a means of printing the barcode labels on an Intermec EasyCoder PC41 printer,
EasyCoder 3400, or EasyCoder 3400e. The driver for the printer must already be installed on the
PC.

The user is presented with the option of printing a TCM/ECU label after successfully loading a
calibration into a TCM/ECU. If the user elects to print the label, the following window displays:

The printer must already be connected to the PC and powered up. Click the Print button to start
the print job.

Note:
The serial communication port (COM1, COM2) is designated
during Application Setup.

A user can also print a barcode label for any of the calibrations listed in the Calibrations to Load
into TCM/ECU list. To print a barcode label for a listed calibration:
1. Select a calibration from the Calibration to Load into TCM/ECU section of the Main
Calibration screen.
2. Display the Reports drop-down menu.
3. Select Print TCM Labels for Calibrations to Load. The Print TCM Labels dialog box
displays.
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 TCM Reflash (PCCS)

4. Select a printer from the Choose a Printer drop-down menu, or use the default printer.
5. Click the Print button. The print job is sent to the printer.

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 TCM Reflash (PCCS)

4 Basic Troubleshooting

When trying to download and load calibrations using TCM Reflash, the user may encounter
problems. The following are recommended steps for troubleshooting the issue. Once the problem
has been resolved, the remaining steps do not need to be performed.

4.1 Invalid CIN Message after Submitting

If an invalid CIN of TCM assembly message has been entered, the following message is displayed:

 Confirm correct CIN or TCM assembly message was added to Calibrations

to Download from Web Server list.
 Make sure no I’s or O’s are used; only ones and zeros are possible valid entries.

4.2 Unable to Communicate With TCM/ECU

The following dialog box appears if TCM Reflash is unable to connect to the TCM/ECU:

 Confirm the vehicle is disconnected from Allison DOC® For PC—Service Tool.
 Confirm all cables and devices are properly connected.
 Confirm the correct translator device is selected in Application Setup.
 Confirm the bolt on the T-Harness for Allison 4th / 5th Generation TCMs is tight.
 Check that the adapter drivers are installed. Contact your adapter manufacturer for
assistance.

47
 TCM Reflash (PCCS)

Note:
For Softing CAN devices (PCI-AC2. CANcard2, CANusb), the
legacy CAN Layer 2 wrapper DLLs are installed in the TCM
Reflash folder by default. If you are having trouble connecting,
then you should replace the following files with the versions from
the Softing “CAN_V4.0x_wrapper” folder:
Canapci.dll
Cancard.dll
CanUSB.dll

4.3 Read/Write Program Disconnects While Loading the Calibration

A disconnection is indicated by the following message after the Read/Write program unexpectedly
stops running:

 Confirm cables and devices are properly connected.

 Uncheck Fast Read and Fast Write in the Application Setup if they are currently
checked.

4.4 Intermec Printer is Not Working on PC

 Download Intermec Setup Guide from Allison Extranet:

www.allisontransmission.com | Service | Electronic Tools | Allison TCM Reflash

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 TCM Reflash (PCCS)

5 Appendix A—Calibration Request Form

49
 TCM Reflash (PCCS)

6 Appendix B—TCM Reflash Required Hardware

TCM Reflash V3.5 has only been tested and validated on PCs with the following configurations:
 Microsoft® Windows® XP Professional, Windows Vista® Home Basic (or better), or
Windows 7®.
Note: In order to install and run TCM Reflash on Windows Vista®, the user must have full
administrator privileges, and must have the User Account Control feature turned off.
 20 GB Hard Drive (40 GB or greater recommended).
 600 MB free hard drive space required to install the program (after software installation, the
operating system requires sufficient free hard disk space to run the program).
 CPU: 1.3 GHz (or greater) (2.0 GHz Recommended).
 RAM: Windows® XP – 2 GB; Windows Vista® – 4 GB; Windows 7® – 4 GB.
 Internet connection capability (Internet Explorer® 6 or greater) (NOTE: A broadband
internet connection is recommended for receiving updates and file downloads).
 One available USB port—USB 1.1 (USB 2.0 recommended).
 A serial port is required when using some older model Intermec printers.
 Full administrative privileges are required to install, use, and update Allison TCM Reflash
and Allison DOC® For PC–Service Tool.

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 TCM Reflash (PCCS)

6.1 Intermec Setup

For Allison TCM/ECU label printing, one of the following Intermec printers must be used:

EasyCoder 7421………………………………...Out of Production

EasyCoder PC41………………………………..Replacement for EasyCoder 7421

Intermec 3400/B0010000, PM4i, or 3400e Serial Printer with non-volatile RAM, thermal
transfer adapter, null modem cable, and image RAM expansion (for barcode labels).
Intermec 3400…………………………..…....….Out of Production
EasyCoder 3400 or EasyCoder 3400e………......Out of Production
PM4i…………………………………………….Replacement for Intermec 3400
and EasyCoder 3400/3400e

For the most recent product information on these printers, go to www.intermec.com | Products |
Printers

These printers and TCM/ECU labels are available through:

Intermec Media Products

9290 Le Saint Dr
Fairfield, OH 45014
513-874-5882

CDW www.cdw.com
NextDayPC www.nextdaypc.com

All printers require installation of InterDriver™.

If possible, install InterDriver™ before TCM Reflash. If TCM Reflash is already present on the
machine, the ActiveX© Controls need to be installed after Interdriver™ is installed. See section
below.

Download InterDriver™ software from www.intermec.com | Support | Downloads. Click to

search Product Downloads. Select your printer type, then go to the Windows Drivers section and
download the InterDriver™.

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6.2 Installing the InterDriver™ Software

1. Install the InterDriver.exe file.
2. Once the installation is finalized, proceed to add a printer to the PC.
a. Click Start | Settings | Printers.
b. Click Add Printer and the Add Printer Wizard appears.
c. Click Next.
d. Deselect the Automatically detect and install my Plug and Play printer option,
then click Next.
e. Select COM1 as the printer port if your printer has a serial connection;
otherwise, select the appropriate port and click Next.
f. When the Install Printer Software window displays, click the Have Disk
button.
g. Click Browse, locate the intermec.inf file. It should be under
C:\Intermec\InterDriver7\. Select it and click Open.
h. Select the printer to use1 and click Next.
i. Select the new printer as your default printer if its primary use will be for
TCM Reflashing / Label Printing, then select the Do not share this printer
option.
j. Finish the installation process.

ActiveX© Controls (only necessary if InterDriver.exe was installed after TCM Reflash).
ActiveX Controls can be found on the same Windows Driver section of the Intermec website.
Download the file and install the program. You may need to restart your computer and/or restart
TCM Reflash for the changes to take effect.

Testing TCM Reflash

Test to make sure everything was installed/set up correctly by opening up the TCM Reflash
program; selecting a calibration from the Calibrations to Load into ECU/TCM; going to Reports
from the top menu; and then to Print Labels for Calibrations to Load. If the setup was successful,
you should see a Print TCM Labels preview window that allows you to select your Intermec
printer.

1
Make sure to select the Intermec 3400A (located towards the end of the selection list) printer if you do not have an
EasyCoder model of the 3400.

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 TCM Reflash (PCCS)
Go to the Printing Preferences for your printer and select the correct Label Stock size and
orientation, as shown below.

6.2.1 For ECU Labels

 Thermal transfer label stock for the Intermec printer (Super Premium 2 mil gloss
polyester labels with perforations. Size: 1.85-inch by 3.85-inch. Intermec P/N
E05551).
 Protective Overlaminate for either label type. Size: 4.25-inch by 2.25-inch butt cut
overlaminate, Intermec P/N E05552.
 Thermal Transfer Ribbon for Intermec printer: 2-inch by 6000-inch Black Super
Premium TTR Ribbon Cassette. Intermec P/N 1322006.

6.2.2 For Report Printing

 IBM-compatible printer for printing calibration summary and shift point schedule
reports.
 Laser printer is recommended.

6.3 Other Hardware Required

 ECU and TCM Calibration Load Box for calibrating the modules. This box simulates
a transmission and may be obtained from SPX Kent-Moore; P/N J-42455-A.
 J1939 Serial Card (CAN card) or Dearborn DPA4 translator.

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 TCM Reflash (PCCS)

 J1939 Serial Card (CAN card) plugs into the PC. For a laptop PC use PCMCIA
Format. For a desktop PC use PCI Format. The CAN card allows the PC to
communicate with the TCM or ECU using a 9 pin to 15 pin adapter cable and a
typical 15 pin cable to the Load Box. CAN cards are available from Noregon Systems
(P/N: N-00001). The CAN card is not required if the Dearborn translator is used.
 Translator Device Kit (DPA4 USB). This module translates between the PC and the
TCM, and can be obtained from SPX/Kent-Moore (P/N J-47943 / J-47943-A). This
P/N includes the module, a USB Cable (PC to module), and a J1939 9-pin cable. This
module is not required if J1939 Serial Card (CAN card) is used.
 TCM Harness for Bench or Vehicle. Depending on control system type, different
service harnesses are available. For the control system-specific service harness part
numbers, refer to the diagrams of Appendix C.

SOURCES FOR HARDWARE

Noregon Systems SPX Service Solutions

28635 Mound Road
7009 Albert Pick Road
Warren, Michigan 48092
Greensboro, NC 27409 Phone: 1-866-621-2128
Phone: (336) 615-8555 (US/Canada) or
Fax: (336) 615-8564 1-507-455-7223 / 1-800-345-
E-mail: sales@noregon.com 2233 (International)
www.noregon.com Fax: 1-800-578-7375 / 1-586-
578-7375 (US/Canada) or
Intermec 1-507-455-7063 (International)
Phone: 1-800-755-5505
www.intermec.com

DB9 to DB15 CAN Card Adapter Cable—User Furnished

54
 TCM Reflash (PCCS)

7 Appendix C—Hardware Configuration

7.1 Allison 4th and 5th Generation Controls TCM / Load Box Bench Setup
For TCM / Load Box setup (no connection to vehicle), use the J-47276 harness for TCM
Reflash. This harness is required for bench-type reflash of Allison 4th and 5th Generation
Controls TCMs. Use one of the following methods for TCM Reflash:
 J1939-13 connector (for J1939 communication) in combination with J-42455-A Load
Box/Power Supply.
 J1962 connector (for GMLAN / J2284, high-speed CAN communication) in
combination with J-42455-A Load Box/Power Supply.
The DPA4 Translator (J-47943 / J-47943-A) or a CAN card is required to establish a connection
between the PC and the vehicle.

Note:
To use the J1962 connector, an additional cable (J-47949 /
J-47949-A) is required. J-47949 / J-47949-A is available for
purchase from SPX/Kent-Moore.

55
 TCM Reflash (PCCS)

J-47276 Allison 4th and 5th Generation Controls TCM / Load Box Bench
Setup

56
 TCM Reflash (PCCS)

7.2 Allison 4th and 5th Generation Controls TCM / Vehicle Harness Setup
 On the vehicle, use the J-47276 harness to connect the PC directly to the TCM to
bypass the Diagnostic Tool Connector.
 Use the DPA4 Translator (J-47943 / J-47943-A) or a CAN card to establish
connection between the PC and the vehicle.
 Use one of the following Diagnostic Tool Connectors on the harness to establish a
connection between the TCM and the PC running PCCS:
• J1939-13 connector (for J1939 communication)
• J11962 connector (for GMLAN / J2284, high-speed CAN communications)

Note:
To use the J1962 connector, an additional cable (J-47949-A) is
required. J-47949 is available for purchase from SPX/Kent-
Moore.

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 TCM Reflash (PCCS)

J-47267 Allison 4th and 5th Generation Controls TCM / Vehicle Harness
Setup

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 TCM Reflash (PCCS)

7.3 Earlier Hardware Configurations

7.3.1 WTEC-II ECU Reflash Load Station (Bench)

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 TCM Reflash (PCCS)

7.3.2 WTEC-III or CEC2 ECU Reflash Load Station (Bench)

Note: The J-47943-A-DPA4 Plus USB Translator Kit

is pictured above. However, the J-47943-DPA4 USB
Translator Kit can be used in its place.

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 TCM Reflash (PCCS)

7.3.3 1000 / 2000 TCM Reflash Load Station (Bench)

61
 TCM Reflash (PCCS)

7.3.4 All Product Families TCM Reflash Load Station (Vehicle)

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 TCM Reflash (PCCS)

7.4 Current Hardware Configuration

63
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