Allison Transmission 1000 & 2000 Product Families 4th Generation Controls Troubleshooting Manual

Description

Allison Transmission 1000 & 2000 Product Families 4th Generation Controls Troubleshooting Manual – PDF DOWNLOAD

DESCRIPTION:

Allison Transmission 1000 & 2000 Product Families 4th Generation Controls Troubleshooting Manual – PDF DOWNLOAD

FOREWORD-How to Use This Manual:

This manual provides troubleshooting information for Allison Products.
This manual includes:
• Description of the electronic control system.
• Description of the electronic control system components.
• Description of diagnostic codes, system responses to faults, and troubleshooting.
• Wire, terminal, and connector repair information.
Specific instructions for using many of the available or required service tools and equipment are not included
in this manual. The service tool manufacturer will furnish instructions for using the tools or equipment.
Additional information may be published from time to time in Service lnformation Letters (SILs) and will be
included in futura revisions of this and other manuais. Please use these SILs to obtain up-to-date information
concerning Allison Transmission products.
This publication is revised periodically to include improvements, new models, special tools, and procedures.
A revision is indicated by a new date on the title page and rear cover. Check with your Allison Transmission
service outlet for the currently applicable publication. Additional copies of this publication may be purchased
from authorized Allison Transmission service outlets. Look in your telephone directory under the heading
of Transmissions-Truck, Tractor, etc.
Take time to review the Table of Contents and the manual. Reviewing the Table of Contents will aid you
in quickly locating information.

TABLE OF CONTENTS:

Allison Transmission 1000 & 2000 Product Families 4th Generation Controls Troubleshooting Manual – PDF DOWNLOAD

FOREWORD-How to Use This Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii
IMPORTANT SAFETY INFORMATION …………………………………………………. iii
TRADEMARK USAGE ………………………………………………………….. iv
LITERATURE ………………………………………………………………. iv
SECTION 1 GENERAL DESCRIPTION
1-1 VARIABLE MODULATED MAIN PRESSURE 2010 UPRATE ………………………………… 1-1
1-2 LOAD BASE □ SHIFT SCHEDULE (LBSS) …………………………………………. 1-1
1-3 CONVERTER OVERTEMP TORQUE PROTECTION (COTP) ……………………………….. 1-1
1-4 CONVERTER TEMPERATURE MODELING (CTM) …………………………………….. 1-1
1-5 VEHICLE ACCELERATION CONTROL (VAC) ……………………………………….. 1-2
1-6 TRANSMISSION ……………………………………………………… 1-2
1-7 TRANSMISSION CONTROL MODULE (TCM) ………………………………………. 1-5
1-8 1000 ANO 2000 PRODUCT FAMILIES SERVICE PROGNOSTICS …………………………….. 1-5
1-9 TRANSMISSION PROGNOSTICS …………………………………………….. 1-6
1-10 SHIFT SELECTOR …………………………………………………….. 1-7
A. Shift Selector Range Positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
B. Manual SelectorValve …………………………………………………. 1-8
C. Internai Mode Switch (IMS) ………………………………………………. 1-8
1-11 THROTTLE POSITION SENSOR (TPS) ………………………………………….. 1-8
1-12 SPEED SENSORS …………………………………………………….. 1-9
A. Input (Engine) Speed Sensor …………………………………………….. 1-10
B. Turtiine Speed Sensor ………………………………………………… 1-10
C. Output Speed Sensor ………………………………………………… 1-10
1-13 CONTROL VALVE ASSEMBLY ……………………………………………… 1-11
A. Main Modulation …………………………………………………… 1-11
1-14 WIRING HARNESS …………………………………………………… 1-13
A. Externa! Wiring Harness ……………………………………………….. 1-13
B. Internai Wiring Hamess ……………………………………………….. 1-15
1-15 SPECIAL ELECTRONIC/ELECTRICAL TOOLS ……………………………………… 1-16
SECTION 2 DEFINITIONS AND ABBREVIATIONS
2-1 CHECK TRANS LIGHT ………………………………………………….. 2-1
2-2 RANGE INHIBIT RESPONSES ………………………………………………. 2-1
2-3 ALLISON DOC® FOR PC-SERVICE TOOL INHIBITS …………………………………… 2-1
2-4 ALLISON DOC® FOR PC-SERVICE TOOL ………………………………………… 2-3
2-5 DEFINITIONS and ABBREVIATIONS …………………………………………… 2-4
SECTION 3 BASIC KNOWLEDGE
3-1 BASIC KNOWLEDGE REQUIRED …………………………………………….. 3-1
3-2 USING THE TROUBLESHOOTING MANUAL ……………………………………….. 3-1
3-3 SYSTEM OVERVIEW …………………………………………………… 3-1
3-4 IMPORTANT INFORMATION IN THE TROUBLESHOOTING PROCESS ………………………….. 3-2
3-5 BASIC TROUBLESHOOTING INFORMATION ………………………………………. 3-3
3-6 TCM DIAGNOSTIC PROCEDURE ……………………………………………. 3-10
3-7 RESETTING OF TCM PARAMETERS TO SUPPORT ENGINE UPDATE …………………………. 3-10
3-8 RESETTING TCM SEM AUTOSELECT …………………………………………. 3-11
Copyright© 2010 Allison Transmission, lnc. V
ALLISON 1000 and 2000 Product Families
TABLE OF CONTENTS
SECTION 4 WIRE CHECK PROCEDURES
4-1 CHECKING OPENS, SHORTS BETWEEN WIRES, AND SHORTS-TO-GROUND (Use J 34520-A Digital VolUOhmmeter
and J 39197 Jumper Wire Set) ………………………………………………. 4-1
4-2 CHECKING AT TRANSMISSION CONNECTOR AND THE INTERNAL HARNESS FOR OPENS, SHORTS BETWEEN
WIRES, AND SHORTS-TO-GROUND …………………………………………… 4-3
SECTION 5 DIAGNOSTIC TROUBLE CODES (DTC)
5-1 DTC MEMORY ………………………………………………………. 5-1
5-2 FAILURE RECORDS ……………………………………………………. 5-1
5-3 DTC READING AND DTC CLEARING …………………………………………… 5-3
A. Clearing DTCs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
B. Clearing Active lndicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5-4 BEGINNING THE TROUBLESHOOTING PROCESS ……………………………………. 5-3
A. Starting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
B. Solenoid Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
C. Wire/Terminal Numbering Scheme . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
D. Available Diagnostic Adapters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
5-5 DIAGNOSTIC TROUBLE CODE (DTC) REFERENCE TABLES ………………………………. 5-8
5-6 DTC LIST ANO DESCRIPTION INDEX ………………………………………….. 5-17
SECTION 6 INPUT AND OUTPUT FUNCTIONS
6-1 SPECIAL INPUT AND OUTPUT FUNCTIONS ……………………………………….. 6-1
SECTION 7 GENERAL TROUBLESHOOTING OF PERFORMANCE COMPLAINTS
7-1 GENERAL TROUBLESHOOTING OF PERFORMANCE COMPLAINTS ………………………….. 7-1
APPENDICES
A. DIAGNOSING INTERMITTENT DTCs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
B. MAIN PRESSURE CHECK PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
C. SOLENOID AND CLUTCH TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1
D. WIRE/CONNECTOR TABLES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-1
E. CONNECTOR REPAIR INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-1
F. THROTTLE POSITION SENSORADJUSTMENT ……………………………………… F-1
G. WELDING ON VEHICLENEHICLE INTERFACE MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-1
H. HYDRAULIC SCHEMATICS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H-1
1. WIRING SCHEMATIC ……………………………………………………. 1-1
J. RESISTANCE VS. TEMPERATURE …………………………………………….. J-1
K. ELECTRONIC INTERFERENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . K-1
L. ALLISON DOC FOR PC-SERVICE TOOL …………………………………………. L-1
M. INPUT/OUTPUT FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-1
N. J1939 AND J2284 HARDWARE AND TCM CONNECTIONS ……………………………….. N-1
O. FLUI □ CHECK PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-1

IMAGES PREVIEW OF THE MANUAL:

ALLISON TRANSMISSION 1000 & 2000 PRODUCT FAMILIES 4TH GENERATION CONTROLS TROUBLESHOOTING MANUAL:

PLEASE NOTE:

• This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
• Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.

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