Allison Transmission 1000 & 2000 Product Families 5th Generation Controls Troubleshooting Manual – PDF DOWNLOAD

Description

Allison Transmission 1000 & 2000 Product Families 5th Generation Controls Troubleshooting Manual – PDF DOWNLOAD

DESCRIPTION:

Allison Transmission 1000 & 2000 Product Families 5th Generation Controls Troubleshooting Manual – PDF DOWNLOAD

1000 and 2000 Product Families

1000 1350 PTS 2200 2350 HS 2500 SP 1000 EVS 1350 RDS 2200 EVS 2350 MH 2550 1000 HS 1350 SP 2200 HS 2350 PTS 2550 EVS 1000 MH 2000 MH 2200 MH 2350 RDS 2550 HS 1000 PTS 2100 2200 PTS 2350 SP 2550 MH 1000 RDS 2100 EVS 2200 RDS 2500 2550 PTS 1000 SP 2100 HS 2200 SP 2500 EVS 2550 RDS 1350 2100 MH 2300 HS 2500 HS 2550 SP 1350 EVS 2100 PTS 2300 PTS 2500 MH B 210 1350 HS 2100 RDS 2300 RDS 2500 PTS B 220 1350 MH 2100 SP 2350 EVS 2500 RDS

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 5th Generation Controls Troubleshooting Manual – PDF DOWNLOAD

FOREWORD-How to Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii
IMPORTANT SAFETY INFORMATION …………………………………………………. iii
ABBREVIATIONS ANO ACRONYMS ………………………………………………….. iv
TRADEMARK USAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii
LITERATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii
LIST OF WARNINGS …………………………………………………………. viii
SECTION 1 ESSENTIAL TOOLS FOR TROUBLESHOOTING AND CALIBRATION
1-1 GENERAL TOOLS INFORMATION ……………………………………………. 1-1
1-2 ESSENTIAL TOOLS LIST ………………………………………………… 1-1
1-3 UNIVERSAL ALLISON DOC® ………………………………………………. 1-3
SECTION 2 GENERAL INFORMATION
2-1 TRANSMISSION …………………………………………………….. 2-1
2-2 TRANSMISSION CONTROL MODULE (TCM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2-3 SHIFT SELECTOR ……………………………………………………. 2-3
A. Shift Selector Range Positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
B. Manual Selector Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
C. Internai Mode Switch (IMS) ………………………………………………. 2-4
2-4 THROTTLE POSITION SENSOR (TPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2-5 SPEED SENSORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
A. Input (Engine) Speed Sensor ……………………………………………… 2-6
B. Turbina Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
C. Output Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
2-6 CHECK TRANS LIGHT ………………………………………………….. 2-7
2-7 RANGE INHIBIT RESPONSES ……………………………………………… 2-8
2-8 UNIVERSAL ALLISON DOC® INHIBITS ………………………………………….. 2-8
2-9 CONTROL VALVE ASSEMBLY ……………………………………………… 2-10
A. Variable Modulated Main Pressure ………………………………………….. 2-10
2-10 WIRING HARNESS …………………………………………………… 2-11
A. External Wiring Harness ……………………………………………….. 2-11
B. Internai Wiring Harness ……………………………………………….. 2-13
2-11 TRANSMISSION PROGNOSTICS ……………………………………………. 2-14
2-12 VARIABLE MODULATED MAIN PRESSURE ………………………………………. 2-14
2-13 DYNAMIC SHIFT SENSING ………………………………………………. 2-15
A. Overview ………………………………………………………. 2-15
B. Load-Based Shift Scheduling (LBSS) Torque-Based …………………………………. 2-16
C. Super Econorny Shift Schedule (SESS) ……………………………………….. 2-16
D. Accel-Based Shift Scheduling (ABSS)/Accel-Based MODE Selection (ABMS) …………………….. 2-16
E. Load-Based Shift Scheduling (LBSS) lnhibits/Delays …………………………………. 2-16
2-14 NEUTRAL AT STOP STANDARD ANO PREMIUM ……………………………………. 2-17
2-15 CONVERTER OVERTEMP TORQUE PROTECTION (COTP) ………………………………. 2-17
2-16 CONVERTER TEMPERATURE MODELING (CTM) …………………………………… 2-17
2-17 ACCELERATION RATE MANAGEMENT (FORMALLY VEHICLE ACCELERATION CONTROL (VAC)) ………….. 2-18
SECTION 3 FLUID CHECK PROCEDURES
3-1 TRANSMISSION FLUID (OIL) ………………………………………………. 3-1
A. lrnportance of Transrnission Fluids …………………………………………… 3-1
B. Approved Fluid Types …………………………………………………. 3-1
C. Keeping Fluid Clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3-2 TRANSMISSION FLUID LEVEL CHECKS ………………………………………… 3-2
A. Manual Fluid Check Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Copyright© 2016 Allison Transmission, lnc. AII Rights Reserved. xi
Allison 1000 and 2000 Product Families
B. Cold Check Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
C. Hot Check Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
D. Consistency of Readings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
3-3 TRANSMISSION FLUI □ CAPACITY ……………………………………………. 3-5
SECTION 4 BASIC KNOWLEDGE
4-1 BASIC KNOWLEDGE REQUIRED …………………………………………….. 4-1
4-2 USING THE TROUBLESHOOTING MANUAL ………………………………………. 4-1
4-3 SYSTEM OVERVIEW …………………………………………………… 4-1
4-4 IMPORTANT INFORMATION IN THE TROUBLESHOOTING PROCESS …………………………. 4-2
4-5 BASIC TROUBLESHOOTING INFORMATION ………………………………………. 4-3
4-6 TCM DIAGNOSTIC PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
SECTION 5 WIRE CHECK PROCEDURES
5-1 CHECKING OPENS, SHORTS BETWEEN WIRES, ANO SHORTS-TO-GROUND (Use J-34520-A Digital VolUOhmmeter
and J-39197 Jumper Wire Set) ………………………………………………. 5-1
5-2 CHECKING AT TRANSMISSION CONNECTOR ANO THE INTERNAL HARNESS FOR OPENS, SHORTS BETWEEN
WIRES, ANO SHORTS-TO-GROUND …………………………………………… 5-3
SECTION 6 DIAGNOSTIC CODES
6-1 DTC MEMORY ……………………………………………………… 6-1
6-2 FAILURE RECORDS …………………………………………………… 6-1
6-3 DTC READING AND CLEARING …………………………………………….. 6-1
A. Clearing DTCs …………………………………………………….. 6-1
B. Clearing Active lndicators ……………………………………………….. 6-1
6-4 BEGINNING THE TROUBLESHOOTING PROCESS …………………………………… 6-2
A. Starting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
B. Solenoid Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
C. Wire/Terminal Numbering Scheme …………………………………………… 6-3
D. Available Diagnostic Adapters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6-5 DIAGNOSTIC TROUBLE CODE (DTC) REFERENCE TABLES ……………………………… 6-6
6-6 DTC LIST ANO DESCRIPTION INDEX …………………………………………. 6-14
SECTION 7 INPUT AND OUTPUT FUNCTIONS
7-1 SPECIAL INPUT ANO OUTPUT FUNCTIONS ………………………………………. 7-1
SECTION 8 GENERAL TROUBLESHOOTING OF PERFORMANCE COMPLAINTS
8-1 GENERAL TROUBLESHOOTING OF PERFORMANCE COMPLAINTS ………………………….. 8-1
APPENDICES
A. DIAGNOSING INTERMITTENT DTCs ………………………………………….. A-1
B. MAIN PRESSURE CHECK PROCEDURE ………………………………………… B-1
c. SOLENOID ANO CLUTCH TABLE ……………………………………………. C-1
D. WIRE/CONNECTOR TABLES ………………………………………………. D-1
E. CONNECTOR REPAIR INFORMATION ………………………………………….. E-1
F. THROTTLE POSITION SENSOR ADJUSTMENT …………………………………….. F-1
G. WELDING ON VEHICLENEHICLE INTERFACE MODULE ………………………………… G-1
H. RESISTANCE VS. TEMPERATURE ……………………………………………. H-1
1. ELECTRONIC INTERFERENCE ……………………………………………… 1-1
J. WIRING SCHEMATIC …………………………………………………… J-1
K. HYDRAULIC SCHEMATICS ……………………………………………….. K-1
L. REVISION HISTORY …………………………………………………… L-1

IMAGES PREVIEW OF THE MANUAL:

ALLISON TRANSMISSION 1000 & 2000 PRODUCT FAMILIES 5TH GENERATION CONTROLS TROUBLESHOOTING MANUAL – PDF DOWNLOAD:

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• This is the same manual used by the dealers to diagnose and troubleshoot your vehicle
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