Allison Transmission 3000 & 4000 Product Families 5th Generation Controls Troubleshooting Manual – PDF DOWNLOAD

Description

Allison Transmission 3000 & 4000 Product Families 5th Generation Controls Troubleshooting Manual – PDF DOWNLOAD

DESCRIPTION:

Allison Transmission 3000 & 4000 Product Families 5th Generation Controls Troubleshooting Manual – PDF DOWNLOAD

3000 and 4000 Product Families
3000 EVS 3000 HS 3000 MH 3000 PTS 3000 RDS 3000 TRV 3200 SP
3200 TRV 3500 EVS 3500 RDS 3500 SP 3700 SP 4000 EVS 4000 HS
4000 MH 4000 RDS 4000 TRV 4500 EVS 4500 HS 4500 RDS 4500 SP
4500 TRV* 4700 EVS 4700 OFS 4700 RDS 4800 EVS B 300PR B 500
B 500P B 500PR B 500R

FOREWORD-How to Use This Manual :

Welcome to the TS7149EN Troubleshooting Manual. Allison Transmission lncorporated strives to make every
effort to keep our service information current and accurate. Because of the time lag involved with writing and
printing processes, the Transmission Contrai Module (TCM) may reporta Diagnostic Trouble Code (DTC) that
has not yet been added to this document. lf you encounter a DTC that is not yet in this publication, please
call Allison Transmission, lnc. at 1-800-252-5283.
This manual providas troubleshooting information for the 3000 and 4000 Product Families Transmissions.
Service Manuais SM4013EN and SM4014EN, plus Parts Catalogs PC2150EN and PC2456EN may be
used in conjunction with this manual.
This manual includes:
• Description of the 3000 and 4000 Product Families Allison 5th Generation Electranic Contrai system.
• Description of the electranic contrai system components.
• Description of DTCs, system responses to faults, and traubleshooting steps for active DTCs.
• Wire, terminal, and connector repair information.
• System schematics.
• System wiring diagrams.
• Traubleshooting complaints without DTCs.
• lnpuUOutput Wiring Diagrams.
lnstructions for using the service toais used to traubleshoot active DTCs and make connector repairs are
included in this manual. Refer to the appropriate service manuais for pracedures and instructions to service
toais used to overhaul the transmission.
Additional information may be published from time to time in Service lnformation Letters (SIL) and will be
included in future revisions of this and other manuais. Please review all Slls to obtain up-to-date information
concerning Allison Transmission praducts.

TABLE OF CONTENTS:

Allison Transmission 3000 & 4000 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® ………………………………………………. 1-2
SECTION 2 ALLISON 5TH GENERATION CONTROL SYSTEM OPERATION
2-1 GENERAL SYSTEMS OVERVIEW ……………………………………………. 2-1
2-2 TRANSMISSION CONTROL MODULE (TCM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2-3 SHIFT SELECTORS …………………………………………………… 2-4
A. Selector Classification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
B. Select and Monitor Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
C. Mode Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
D. Mode Button ……………………………………………………… 2-8
E. Trans Service lndicator (Wrench lcon) …………………………………………. 2-8
F. Backlighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
G. Keypad Pushbutton Shift Selector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
H. Bump Levar Shift Selector ………………………………………………. 2-9
1. Strip Pushbutton Shift Selector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
J. Dual Stations or Multiple Transmission Contrai ……………………………………. 2-10
K. Dual Allison Shift Selector Capability on CAN2 ……………………………………. 2-10
2-4 THROTTLE POSITION SENSOR (TPS) …………………………………………. 2-10
2-5 SPEED SENSORS ……………………………………………………. 2-10
2-6 CONTROL VALVE MODULE (ELECTROHYDRAULIC) …………………………………. 2-11
A. Assembly Overview …………………………………………………. 2-11
B. C6 Valva Body Assembly (7-speed) …………………………………………. 2-16
C. Filter Life Valve Body Assembly ……………………………………………. 2-16
D. Main Pressure Modulation (MM) Solenoid ………………………………………. 2-16
E. Temperatura Fluid Temperatura (TFT) Sensor …………………………………….. 2-17
F. Oil Levei Sensor (OLS) ……………………………………………….. 2-17
G. Diagnostic Pressure Switch (PS1) ………………………………………….. 2-19
H. Turbina Shaft Speed Sensor (3000 Family) ……………………………………… 2-19
2-7 WIRE HARNESSES …………………………………………………… 2-19
A. Extemal Hamess …………………………………………………… 2-19
B. Internai Wiring Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
2-8 OPTIONAL VEHICLE INTERFACE MODULE (VIM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23
2-9 AUTO-DETECT LOGIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24
A. Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24
B. Reset Auto-Detect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24
C. Override Auto-Detect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25
D. Retardar Auto-Detect Logic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25
E. Oil Levei Sensor (OLS) Auto-Detect Logic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25
2-10 Adaptive Contrais ……………………………………………………. 2-25
A. Adapt Shifts Report Patterns and Regions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26
2-11 Shift Schedules ……………………………………………………… 2-26
A. Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26
Copyright© 2016 Allison Transmission, lnc. AII Rights Reserved. xi
Allison 3000 and 4000 Product Families
B. Shift Calibrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27
2-12 PRIMARY ANO SECONDARY SHIFT SCHEDULES …………………………………… 2-27
A. Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27
B. Common Shift Schedule Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27
2-13 HOLD SCHEDULE FOR UPSHIFTS …………………………………………… 2-28
2-14 PRESELECT SCHEDULE FOR DOWNSHIFTS …………………………………….. 2-28
A. During Non-Engine Brake Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28
B. During Engine Brake Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28
2-15 CRUISE MODE SHIFT SCHEDULE …………………………………………… 2-29
2-16 OVER-TEMPERATURE SHIFT SCHEDULE ………………………………………. 2-29
2-17 UNDER-TEMPERATURE (COLO) SHIFT SCHEDULE ………………………………….. 2-29
2-18 KICKDOWN SHIFT SCHEDULE …………………………………………….. 2-30
2-19 OUTPUT RETARDER SHIFT SCHEDULE ……………………………………….. 2-30
A. High Retarder Fluid Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30
B. Retarder Cruise Contrai lnteractions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30
2-20 SHIFT ENERGY MANAGEMENT (SEM) ANO LOWER RANGE TORQUE PROTECTION (LRTP) . . . . . . . . . . . . . . . . 2-30
A. Shift Energy Management (SEM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30
B. Lower Range Torque Protection (LRTP) ……………………………………….. 2-31
2-21 DYNAMIC SHIFT SENSING ………………………………………………. 2-31
A. Overview ………………………………………………………. 2-31
B. Super Economy Shift Schedule (SESS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32
C. Acceleration Rate Management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32
2-22 VEHICLE ACCELERATION RATE LIMITING ………………………………………. 2-32
2-23 INPUT ANO OUTPUT (1/0) FUNCTIONS ………………………………………… 2-33
2-24 CUSTOMER MODIFIABLE CONSTANTS (CMCs) ……………………………………. 2-33
2-25 SHIFT INHIBIT LOGIC ………………………………………………….. 2-33
A. Engine Speed lnhibit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34
B. Direction Change lnhibit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34
C. Auxiliary Function Range lnhibit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34
D. Notification in Shift Selector Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34
E. Reset (Clearing) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35
F. Viewing lnhibits in Universal Allison DOC® . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35
G. Transfer Case lnhibit from Universal Allison DOc® Action Requests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35
SECTION 3 FLUID CHECK PROCEDURES
3-1 TRANSMISSION FLUI □ (OIL) ………………………………………………. 3-1
A. lmportance of Transmission Fluids …………………………………………… 3-1
B. Approved Fluid Types …………………………………………………. 3-1
C. Keeping Fluid Clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
D. Preheating Requirements ……………………………………………….. 3-2
3-2 TRANSMISSION FLUI □ LEVEL CHECKS ………………………………………… 3-2
A. Cold Check Procedure (Dipstick Method) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
B. Hot Check Procedure (Dipstick Method) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
C. Checking Dipstick Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
D. Electronic Fluid Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
E. Fluid Levei Check using Universal Allison DOc® ……………………………………. 3-7
3-3 TRANSMISSION FLUI □ CAPACITY ……………………………………………. 3-8
SECTION 4 PROGNOSTICS PACKAGE AND FEATURES
4-1 OVERVIEW ……………………………………………………….. 4-1
4-2 TRANS SERVICE INDICATOR (WRENCH ICON) …………………………………….. 4-1
4-3 PROGNOSTICS PREREQUISITES ……………………………………………. 4-1
xii Copyright © 2016 Allison Transmission, lnc. AII Rights Reserved.
TABLE OF CONTENTS
4-4 PROGNOSTICS FEATURES AVAILABILITY ……………………………………….. 4-2
4-5 TURNING PROGNOSTICS PACKAGE ON OR OFF ……………………………………. 4-2
4-6 PROGNOSTICS INDICATION AT ENGINE START ……………………………………. 4-3
4-7 SETTING FLUI □ TYPE ………………………………………………….. 4-4
4-8 OIL LIFE MONITOR (OM) ………………………………………………… 4-4
A. Percentage Fluid Life Remaining Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
B. Maintenance Required Notification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
C. OM Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
D. OM Maintenance History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
4-9 FILTER LIFE MONITOR (FM) ………………………………………………. 4-6
A. Filter Life Status Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
B. Maintenance Required Notification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
C. Filter Life Monitor (FM) Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
D. FM Maintenance History ……………………………………………….. 4-7
E. Filter Life lndicator (FLI) Switch (PS2) Operation ……………………………………. 4-7
4-10 TRANSMISSION HEALTH MONITOR (TM) ………………………………………… 4-7
A. Clutch System Status Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
B. Maintenance Required Notification …………………………………………… 4-7
C. TM Reset ……………………………………………………….. 4-7
D. TM Maintenance History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
4-11 PROGNOSTICS IN UNIVERSAL ALLISON DOC® …………………………………….. 4-8
A. Viewing History ……………………………………………………. 4-8
B. Enabling/Disabling Prognostics Package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
C. Reset Prognostics Monitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
SECTION 5 DIAGNOSTIC CODES
5-1 OVERVIEW ……………………………………………………….. 5-1
5-2 TYPES OF SYSTEM RESPONSE …………………………………………….. 5-1
5-3 HYDRAULIC OPERATION DURING ELECTRICAL INTERRUPTION …………………………… 5-2
5-4 CHECK TRANS LIGHT ………………………………………………….. 5-3
5-5 USING SELECTOR FOR DIAGNOSTIC TROUBLE CODE (DTC) DISPLAY ……………………….. 5-3
A. Display Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
B. Read/Clear DTC with Keypad Pushbutton Selector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
C. Reading DTCs with Prognostics Package On . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
5-6 DIAGNOSTICS IN UNIVERSAL ALLISON DOC® …………………………………….. 5-7
A. Viewing DTCs …………………………………………………….. 5-7
B. Clearing DTCs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
5-7 DTC LIST ANO DESCRIPTION INDEX ………………………………………….. 5-9
SECTION 6 CONTROL SYSTEM AND TRANSMISSION SPECIFICATIONS
6-1 MEASURING TRANSMISSION PRESSURES ………………………………………. 6-1
6-2 TRANSMISSION ANO VEHICLE PREPARATION …………………………………….. 6-1
6-3 COMPARING RECORDE □ DATA TO SPECIFICATIONS …………………………………. 6-2
6-4 UNIVERSAL ALLISON DOC® CLUTCH TEST ACTION REQUEST ……………………………. 6-2
6-5 MAIN MODULATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
6-6 LOCKUP ANO CLUTCH PRESSURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
6-7 TORQUE CONVERTER PRESSURE …………………………………………… 6-3
6-8 3000 PRESSURE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6-9 4000 PRESSURE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
6-10 RETARDER CHARGE PRESSURE SPECIFICATIONS …………………………………. 6-10
6-11 SOLENOID ANO CLUTCH CHART ……………………………………………. 6-11
6-12 DIAGNOSTIC FLOW CHARTS USING CLUTCH TEST …………………………………. 6-15
Copyright© 2016 Allison Transmission, lnc. AII Rights Reserved. xiii
Allison 3000 and 4000 Product Families
6-13 SPEED SENSOR DATA …………………………………………………. 6-18
6-14 SOLENOID DATA ……………………………………………………. 6-18
6-15 TRANSMISSION FLUI □ TEMPERATURE (TFT) SENSORS ………………………………. 6-20
6-16 PRESSURE SWITCH DATA, PS1 ANO PS2 ………………………………………. 6-20
6-17 RETARDER MODULATION REQUEST (RMR) RESISTANCE MODULE DATA ……………………… 6-20
6-18 THROTTLE POSITION SENSOR (TPS) ADJUSTMENT …………………………………. 6-21
SECTION 7 GENERAL TROUBLESHOOTING OF PERFORMANCE COMPLAINTS
7-1 GENERAL TROUBLESHOOTING OF PERFORMANCE COMPLAINTS ………………………….. 7-1
APPENDICES
A. TOWING, JUMP STARTING, WELDING ANO PAINTING …………………………………. A-1
B. TRAINING ANO REQUIRED SKILLS …………………………………………… B-1
C. FIRST STEPS ANO TIPS FOR TROUBLESHOOTING ………………………………….. C-1
D. TROUBLESHOOTING WITH A DIGITAL MULTIMETER (DMM) ……………………………… D-1
E. TROUBLESHOOTING TRANSMISSION ANO VEHICLE CIRCUITS ……………………………. E-1
F. WIRE/CONNECTORNIM CHARTS ……………………………………………. F-1
G. CONNECTOR PART NUMBERS …………………………………………….. G-1
H. TRANSMISSION STALL TEST ……………………………………………… H-1
1. ENGINE/TRANSMISSION ADAPTATION REQUIREMENTS ……………………………….. 1-1
J. TROUBLESHOOTING NOISE ANO VIBRATION ……………………………………… J-1
K. TROUBLESHOOTING DRIVELINES …………………………………………… K-1
L. 3000 ANO 4000 TCM DIAGRAM ……………………………………………… L-1
M. HYDRAULIC SCHEMATICS ……………………………………………….. M-1
N. REVISION HISTORY …………………………………………………… N-1

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ALLISON TRANSMISSION 3000 & 4000 PRODUCT FAMILIES 5TH GENERATION CONTROLS TROUBLESHOOTING MANUAL – PDF DOWNLOAD:

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• This is the SAME exact manual used by your dealers to fix your vehicle.
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