Allison Transmission 4000 Series Troubleshooting Service Manual – PDF DOWNLOAD

Description

Allison Transmission 4000 Series Troubleshooting Service Manual

FILE DETAILS:

Allison Transmission 4000 Series Troubleshooting Service Manual

Allison Transmission 4000 Series Troubleshooting Service Manual
Size: 145 MB
Fomat: PDF
Language: English
Brand: JCB
Type of machine: Allison Transmission 4000 Series Troubleshooting
Type of document: Service Manual
Model: 9806-4040
Page of number: 747

TABLE OF CONTENTS:

Allison Transmission 4000 Series Troubleshooting Service Manual

Foreword ii
SAFETY INFORMATION
Important Safety NoticeIII
Warnings, Cautions, and NotesIII
Trademarks Used in This Manual IV
Shift Selector Terms and Display Indications IV
SECTION 1 GENERAL DESCRIPTION
1–1 TRANSMISSION1–1
1–2 TRANSMISSION CONTROL MODULE (TCM) 1–3
1–3 SHIFT SELECTOR 1–4
A Pushbutton Shift Selector 1–4
B Lever Shift Selector 1–5
1–4 THROTTLE POSITION SENSOR 1–5
1–5 SPEED SENSORS 1–6
1–6 CONTROL MODULE 1–7
1–7 WIRING HARNESSES 1–9
A External Wiring Harness 1–9
B Internal Wiring Harness 1–11
1–8 VEHICLE INTERFACE MODULE1–12
1–9 AUTODETECT FEATURE1–12
A Retarder 1–13
B Oil Level Sensor (OLS) 1–13
C Throttle Source 1–13
D Engine Coolant Temperature1–14
1–10 TRANSID (TID)1–14
SECTION 2 DEFINITIONS AND ABBREVIATIONS
2–1 CHECK TRANS LIGHT 2–1
2–2 ALLISON TRANSMISSION DIAGNOSTIC TOOL2–1
2–3 ABBREVIATIONS 2–3
TABLE OF CONTENTS
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4
th
GENERATION CONTROLS
vi Copyright © 2007 Allison Transmission, Inc
Page
SECTION 3 BASIC KNOWLEDGE
3–1 BASIC KNOWLEDGE REQUIRED3–1
3–2 USING THE TROUBLESHOOTING MANUAL3–1
3–3 SYSTEM OVERVIEW 3–2
3–4 IMPORTANT INFORMATION IN THE TROUBLESHOOTING PROCESS 3–2
3–5 BEGINNING THE TROUBLESHOOTING PROCESS 3–4
3–6 TCM DIAGNOSTIC PROCEDURE 3–5
3–7 RESTTING OF TCM PARAMETERS TO SUPPORT ENGINE UPDATE …………3–6
3–8 RESETTING TCM AUTOSELECT ………………………………………………………3–6
3–9 HYDRAULIC OPERATION DURING ELECTRICAL INTERRUPTION3–6
SECTION 4 WIRE CHECK PROCEDURES
4–1 TESTING FOR OPENS, SHORTS BETWEEN WIRES, AND SHORTS-TO-GROUND 4–1
4–2 TESTING AT TRANSMISSION FEEDTHROUGH CONNECTOR FOR INTERNAL
HARNESS OPENS, SHORTS BETWEEN WIRES, AND SHORTS-TO-GROUND 4–3
SECTION 5 OIL LEVEL SENSOR
5–1 INTRODUCTION5–1
5–2 ELECTRONIC FLUID LEVEL READING (SHIFT SELECTOR) 5–3
A Fluid Level Reading Procedure 5–3
5–3 ELECTRONIC FLUID LEVEL CHECK (ALLISON DOC™ FOR PC–SERVICE TOOL)5–5
A Fluid Level Reading Procedure 5–5
SECTION 6 DIAGNOSTIC CODES
6–1 DIAGNOSTIC CODE MEMORY6–1
6–2 CODE READING AND CODE CLEARING6–2
6–3 DIAGNOSTIC CODE RESPONSE 6–3
6–4 SHIFT SELECTOR DISPLAYS RELATED TO ACTIVE CODES 6–4
6–5 DIAGNOSTIC CODE LIST AND DESCRIPTION 6–4
6–6 DIAGNOSTIC CODE TROUBLESHOOTING6–14
A Beginning the Troubleshooting Process 6–14
B Solenoid Locations 6–14
C Diagnostic Code Schematics6–14
SECTION 7 INPUT AND OUTPUT FUNCTIONS
7–1 INPUT FUNCTIONS7–1
7–2 OUTPUT FUNCTIONS 7–3
SECTION 8 GENERAL TROUBLESHOOTING OF PERFORMANCE COMPLAINTS
TABLE OF CONTENTS
(cont’d)
Copyright © 2007 Allison Transmission, Inc vii
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4
th
GENERATION CONTROLS
Page
APPENDICES
A IDENTIFICATION OF POTENTIAL CIRCUIT PROBLEMS A–1
B MEASURING CLUTCH AND RETARDER PRESSURESB–1
C SOLENOID AND CLUTCH CHART C–1
D WIRE/CONNECTOR CHART D–1
E CONNECTOR PART NUMBERS, TERMINAL PART NUMBERS, E–1
TOOL PART NUMBERS, AND REPAIR INSTRUCTIONS
F THROTTLE POSITION SENSOR ADJUSTMENTF–1
G WELDING ON VEHICLE/VEHICLE INTERFACE MODULEG–1
H HYDRAULIC SCHEMATICS H–1
J 3000 AND 4000 PRODUCT FAMILIES WIRING SCHEMATICJ–1
K SOLENOID RESISTANCE CHARTS K–1
L EXTERNALLY-GENERATED ELECTRONIC INTERFERENCEL–1
M DIAGNOSTIC TREE—3000 AND 4000 PRODUCT FAMILIES HYDRAULIC SYSTEM M–1
N ALLISON DOC™ FOR PC–SERVICE TOOL N–1
P INPUT/OUTPUT FUNCTIONS P–1
Q THERMISTOR TROUBLESHOOTING INFORMATION Q–1
R SAE J1939 COMMUNICATION LINK R–

DESCRIPTION:

Allison Transmission 4000 Series Troubleshooting Service Manual

FOREWORD:

This manual provides troubleshooting information for the 3000 and 4000 Product Families Transmissions. Service
Manuals 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 4 TH Generation 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 Information Letters (SIL) and will be
  included in future revisions of this and other manuals. 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 in the lower left corner of the rear cover.
• 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.

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ALLISON TRANSMISSION 4000 SERIES TROUBLESHOOTING SERVICE MANUAL – PDF DOWNLOAD:

PLEASE NOTE:

⦁ This is not a physical manual but a digital manual – meaning no physical copy will be couriered to you. The manual can be yours in the next 2 mins as once you make the payment, you will be directed to the download page IMMEDIATELY.
⦁ This is the same manual used by the dealers inorder to diagnose your vehicle of its faults.
⦁ Require some other service manual or have any queries: please WRITE to us at [email protected]