Allison Transmission 5000 6000 8000 & 9000 Product Families (CEC5) Troubleshooting Manual – PDF DOWNLOAD

Description

Allison Transmission 5000 6000 8000 & 9000 Product Families (CEC5) Troubleshooting Manual – PDF DOWNLOAD

DESCRIPTION:

Allison Transmission 5000 6000 8000 & 9000 Product Families (CEC5) Troubleshooting Manual – PDF DOWNLOAD

FOREWORD-How to Use This Manual:

Allison Transmission, lnc. 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 report a Diagnostic Trauble 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 provides troubleshooting information for Allison Transmission, 5000, 6000, 8000, and 9000
Series Off-Highway Transmissions which have CEC5. Service Manuais SM1866EN (5000, 6000), SM1228EN
(8000) and SM7336EN (9000), plus Parts Catalogs PC1860EN (5000, 6000), PC1249EN (8000), and
PC1830EN (9000) may be used in conjunction with this manual.

This manual includes:
• Description of the CEC5 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.
• Troubleshooting complaints without DTCs.

Instructions for using the service tools used to troubleshoot active DTCs and make connector repairs are
included in this manual. Refer to the apprapriate service manuals for pracedures and instructions for service
tools used to overhaul the transmission.
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 review all Service Information Letters to obtain
up-to-date information concerning Allison Transmission products.

TABLE OF CONTENTS:

Allison Transmission 5000 6000 8000 & 9000 Product Families (CEC5) Troubleshooting Manual – PDF DOWNLOAD

FOREWORD-How to Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii
IMPORTANT SAFETY INFORMATION …………………………………………………. iv
ABBREVIATIONS ANO ACRONYMS …. . ……………. . . . . . . . ………….. . . . . . . . ………. v
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 GENERAL INFORMATION
2-1 TRANSMISSION ………………. . . . . …. . . . …. . . . . . …. . . . . . …. . . . . . … .. 2-1
2-2 TRANSMISSION CONTROL MODULE (TCM) .. . . . . . ……………. . . . . . . . ……………. 2-2
2-3 SHIFT SELECTOR ……………… … . . . . . . . …… . . . . . . . …… . . . . . . . …. … 2-4
A. Selector Classification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
B. Select and Monitor Display(s) .. . . …… . . . . . . . …… . . . . . . . …… . . . . . . . …… . . … 2-6
C. MODE Button …………………. . . . …….. . …….. . . . …….. . …….. 2-7
D. Trans Service lndicator (Wrench lcon) .. . . . . . . . . ……………… . . . . . . . . . . . . . . . . . . … 2-7
E. Backlighting ………………….. . …….. . . . …….. . . . …….. . …….. 2-7
F. Keypad Pushbutton Shift Selector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
G. Lever Shift Selector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
H. Strip Pushbutton Shift Selector ……….. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . … 2-8
1. Dual Stations or Multiple Transmission Contrai . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
2-4 THROTTLE POSITION SENSOR (TPS) …. . . . . . .. . . . .. . . . . . .. . . . .. . . . . . .. . . . .. . . . . . .. . . 2-9
2-5 SPEED SENSORS ……………………………………………………. 2-10
2-6 ELECTRO-HYDRAULIC VALVE COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . … 2-11
A. Oil Levei Sensor (OLS) ……………………………………………….. 2-13
2-7 WIRING HARNESSES .. . . . …. . . . . . . . .. . . . . . .. . . . . . .. . . . . . . . .. . . . . . .. . . . . . . . .. . 2-14
A. Extemal Wiring Harness (Figure 2-13) ………………………………………… 2-14
B. Internai Wiring Harnesses (Figure 2-14) . . . . . . . . ………. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
2-8 VEHICLE INTERFACE MODULE (VIM) …………………………………………. 2-19
2-9 AUTODETECT FEATURE . …….. . . . . . . . …. . . . . . . . . . . . …. . . . . . . . . . . . …. . . . . . . . 2-19
A. Oil Levei Sensor (OLS) ……. . . . …… . . . …… . …….. . …… . . . …… . ….. 2-19
SECTION 3 FLUID CHECK PROCEDURES
3-1 TRANSMISSION FLUID (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 FLUID LEVEL CHECKS …. . …… . …… . …… . . . …… . …… . …… 3-2
A. Cold Check Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
B. Hot Check Procedure …. . . . ……………….. . . . . . . . . . …………………. 3-7
C. Electronic Fluid Check …….. . . . . . …….. . . . . . …….. . . . . . …….. . . . . . …… 3-8
D. Fluid Levei Check using Universal Allison DOC® …….. . …… . …… . …… . …… . . . … 3-10
3-3 TRANSMISSION FLUID CAPACITY . ………. . . . . . . . …….. . . . . . . . ………. . . . . . . . . 3-11
SECTION 4 DIAGNOSTIC CODES
4-1 OVERVIEW ………………………. . . . ………. . . . …….. . . . ………. 4-1
4-2 BEGINNING THE TROUBLESHOOTING PROCESS ………. . …… . . . …… . …… . . . …… 4-1
Copyright© 2016 Allison Transmission, lnc. AII Rights Reserved. ix
Allison 5000, 6000, 8000 and 9000 Product Families
4-3 CHECK TRANS LIGHT ………………………………………………….. 4-2
4-4 TYPES OF SYSTEM RESPONSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4-5 USING SELECTOR FOR DIAGNOSTIC TROUBLE CODE (DTC) DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
A. Display Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
B. Mode lndicator Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
C. Reading DTCs with Strip Shift Selector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
D. Reading DTCs with Lever Shift Selector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
4-6 DIAGNOSTICS IN UNIVERSAL ALLISON DOc® …………………………………….. 4-6
A. Viewing DTCs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
B. Clearing DTCs …………………………………………………….. 4-7
4-7 SELECTOR DISPLAY DESCRIPTIONS FOR ACTIVE DIAGNOSTIC TROUBLE CODES (DTCs) AND INHIBITS ……… 4-8
4-8 CEC5 DTC LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
4-9 DTC LIST AND DESCRIPTION INDEX …………………………………………. 4-14
SECTION 5 VEHICLE INTERFACE WIRING-MANDATORY (VIW-M)
5-1 TCM POWER ………………………………………………………. 5-1
5-2 SYSTEM GROUNDS …………………………………………………… 5-1
5-3 POWER AND GROUND USING A BUS BAR ……………………………………….. 5-2
5-4 INSTALLING A MASTER DISCONNECT SWITCH …………………………………….. 5-2
5-5 IGNITION POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5-6 CHECK TRANS LIGHT ………………………………………………….. 5-3
5-7 NEUTRAL START …………………………………………………….. 5-4
5-8 SPEEDOMETER SIGNAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
5-9 REVERSE WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
SECTION 6 GENERAL TROUBLESHOOTING OF PERFORMANCE COMPLAINTS
6-1 GENERAL TROUBLESHOOTING OF PERFORMANCE COMPLAINTS ………………………….. 6-1
APPENDICES
A. TOWING, JUMP STARTING, WELDING AND PAINTING …………………………………. A-1
B. TRAINING AND REQUIRED SKILLS …………………………………………… 8-1
C. FIRST STEPS AND TIPS FOR TROUBLESHOOTING ………………………………….. C-1
D. TROUBLESHOOTING WITH A DIGITAL MULTIMETER (DMM) ……………………………… D-1
E. TROUBLESHOOTING TRANSMISSION AND VEHICLE CIRCUITS ……………………………. E-1
F. STANDARD WIRING CHECKS ……………………………………………… F-1
G. ADVANCED TROUBLESHOOTING ……………………………………………. G-1
H. SPEED SENSOR TIPS ………………………………………………….. H-1
1. NON-APPROVED WIRE CHECKS …………………………………………….. 1-1
J. CLUTCHES AND SOLENOIDS ……………………………………………… J-1
K. PRESSURE TAP LOCATIONS ………………………………………………. K-1
L. CONNECTOR, TERMINAL AND TOOL PART NUMBERS AND REPAIR INSTRUCTIONS ………………… L-1
M. THROTTLE POSITION SENSOR ADJUSTMENT …………………………………….. M-1
N. EXTERNALLY-GENERATED ELECTRONIC INTERFERENCE ……………………………… N-1
O. CEC5 SYSTEM!TCM INTERFACE ……………………………………………. 0-1
P. HYDRAULIC SCHEMATICS ……………………………………………….. P-1

IMAGES PREVIEW OF THE MANUAL:

ALLISON TRANSMISSION 5000 6000 8000 & 9000 PRODUCT FAMILIES (CEC5) TROUBLESHOOTING 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 dealersinorder to diagnose your vehicle of its faults.
• Require some other service manual or have any queries: please WRITE to us at [email protected]

S.V