Allison Transmission 5000 6000 8000 9000 SeriesOff-Highway Transmissions Commercial Electronic Controls 2 (CEC2) TS3353EN Troubleshooting Manual

Description

Allison Transmission 5000 6000 8000 9000 SeriesOff-Highway Transmissions Commercial Electronic Controls 2 (CEC2) TS3353EN Troubleshooting Manual

DESCRIPTION:

Allison Transmission 5000 6000 8000 9000 SeriesOff-Highway Transmissions Commercial Electronic Controls 2 (CEC2) TS3353EN Troubleshooting Manual 

M 5610A, M 5610AR
S 5610H, S 5610NR, S 5610M
M 6610A, M 6610AR
S 6610H, S 6610HR, S 6610M
M 8610A, M 8610AR
S 8610H, S 8610HR, S 8610M, S 8610MR
M 9610A, M 9610AR
S 9610A, S 9610AR, S 9610M, S 9610MR
S 9810A, S 9810AR, S 9810H, S 9810HR, S 9810M, S 9810MR

FOREWORD — How to Use This Manual :

This manual provides troubleshooting information for Allison Transmission Division, 5000, 6000, 8000, and
9000 Series Off-Highway Transmissions which have CEC 2. Service Manuals SM1866EN (5000, 6000),
SM1228EN (8000) and SM1833EN (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 CEC 2 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 letter suffix added to the publication number.

TABLE OF CONTENTS:

Allison Transmission 5000 6000 8000 9000 SeriesOff-Highway Transmissions Commercial Electronic Controls 2 (CEC2) TS3353EN Troubleshooting Manual 

TS3353EN…………………………………………………………………………………………………. 2
TITLE PAGE……………………………………………………………………………………………. 2
FOREWORD — How to Use This Manual……………………………………………………………………….. 3
IMPORTANT SAFETY NOTICE………………………………………………………………………………… 4
WARNINGS, CAUTIONS, AND NOTES…………………………………………………………………………… 4
INTRODUCTION………………………………………………………………………………………….. 5
TRADEMARKS……………………………………………………………………………………………. 5
TABLE OF CONTENTS……………………………………………………………………………………… 6
Section1— GENERAL DESCRIPTION………………………………………………………………………… 10
1–1. TRANSMISSION………………………………………………………………………………….. 10
Figure 1–1. Electronic Control Unit Block Diagram………………………………………………….. 10
Figure 1–2. CEC 2 Components…………………………………………………………………….. 11
1–2. ELECTRONIC CONTROL UNIT (ECU)…………………………………………………………………… 12
Figure 1–3. Electronic Control Unit (ECU)…………………………………………………………. 12
1–3. SHIFT SELECTOR………………………………………………………………………………… 12
Figure 1–4. Pushbutton Shift Selector…………………………………………………………….. 12
Figure 1–5. Typical Lever Shift Selector………………………………………………………….. 13
1–4. THROTTLE POSITION SENSOR……………………………………………………………………….. 13
Figure 1–6. Throttle Position Sensor……………………………………………………………… 13
1–5. SPEED SENSORS…………………………………………………………………………………. 14
Figure 1–7. Speed Sensors……………………………………………………………………….. 14
1–6. ELECTRO-HYDRAULIC VALVE COMPONENTS ……………………………………………………………… 14
Figure 1–8. CEC 2 Control Module ………………………………………………………………… 14
1–7. WIRING HARNESSES………………………………………………………………………………. 15
Figure 1–9. CEC 2 External Wiring Harnesses……………………………………………………….. 16
Figure 1–10. CEC 2 Internal Wiring Harnesses ……………………………………………………… 17
1–8. VEHICLE INTERFACE MODULE……………………………………………………………………….. 18
Figure 1–11. Vehicle Interface Module (VIM)……………………………………………………….. 18
1–9. AUTODETECT FEATURE…………………………………………………………………………….. 18
Section2— DEFINITIONS AND ABBREVIATIONS……………………………………………………………….. 20
2–1. CHECK TRANS LIGHT……………………………………………………………………………… 20
2–2. DIAGNOSTIC DATA READER…………………………………………………………………………. 20
Figure 2–1. Pro-Link® 9000 Diagnostic Tool……………………………………………………….. 21
2–3. ABBREVIATIONS ………………………………………………………………………………… 21
Section3— BASIC KNOWLEDGE……………………………………………………………………………. 24
3–1. BASIC KNOWLEDGE REQUIRED……………………………………………………………………….. 24
3–2. USING THE TROUBLESHOOTING MANUAL………………………………………………………………… 25
3–3. SYSTEM OVERVIEW……………………………………………………………………………….. 25
3–4. IMPORTANT INFORMATION IN THE TROUBLESHOOTING PROCESS………………………………………………. 25
3–5. BEGINNING THE TROUBLESHOOTING PROCESS……………………………………………………………. 26
Section4— WIRE CHECK PROCEDURES………………………………………………………………………. 28
4–1. CHECKING OPENS, SHORTS BETWEEN WIRES, AND SHORTS-TO-GROUND (Use Digital Volt/Ohmmeter J3452…………… 28
Figure 4–1. Open Circuit……………………………………………………………………….. 28
Figure 4–2. Short Between Wires or to Ground……………………………………………………… 29
4–2. CHECKING AT TRANSMISSION CONNECTOR AND THE INTERNAL HARNESS FOR OPENS, SHORTS BETWEEN WIRES,…………… 29
Figure 4–3. Checking Continuity…………………………………………………………………. 30
Figure 4–4. Short Between Wires or to Ground……………………………………………………… 31
Section5— DIAGNOSTIC CODES…………………………………………………………………………… 32
5–1. DIAGNOSTIC CODE MEMORY…………………………………………………………………………. 32
Table 5–1. Code List…………………………………………………………………………… 32
5–2. CODE READING AND CODE CLEARING………………………………………………………………….. 32
5–3. DIAGNOSTIC CODE RESPONSE……………………………………………………………………….. 34
5–4. SHIFT SELECTOR DISPLAYS RELATED TO ACTIVE CODES…………………………………………………… 34
5–5. DIAGNOSTIC CODE LIST AND DESCRIPTION…………………………………………………………….. 35
Table 5–2. CEC 2 Diagnostic Codes (cont’d)……………………………………………………….. 35
5–6. DIAGNOSTIC CODE TROUBLESHOOTING…………………………………………………………………. 42
CODE 13 XX – ECU INPUT VOLTAGE…………………………………………………………………… 43
Figure 5–1. Code 13 Schematic Drawing………………………………………………………… 43
CODE 21 XX – THROTTLE FAULT……………………………………………………………………… 47
Figure 5–2. Code 21 Schematic Drawing………………………………………………………… 47
Table 5–3. Voltage Chart……………………………………………………………………. 45
CODE 22 XX – SPEED SENSOR/CIRCUITRY FAULT…………………………………………………………. 51
Figure 5–3. Code 22 Schematic Drawing………………………………………………………… 51
CODE 23 XX – SHIFT SELECTOR……………………………………………………………………… 55
Figure 5–4. Code 23 Schematic Drawing………………………………………………………… 55
CODE 24 XX – SUMP FUID TEMPERATURE……………………………………………………………….. 57
Figure 5–5. Code 24 Schematic Drawing………………………………………………………… 57
Table 5–4. Transmission Operation as a Function of Temperature………………………………….. 59
Figure 5–6. Temperature Sensor Chart…………………………………………………………. 59
TRANSMISSION COMPONENT WIRING DIAGRAMS AND DIAGNOSTICS…………………………………………………. 40
CODE 25 XX – OUTPUT SPEED SENSOR, DETECTED AT ZERO SPEED, X RANGE……………………………………. 61
Figure 5–7. Code 25 Schematic Drawing………………………………………………………… 61
CODE 26 XX – THROTTLE SOURCE NOT DETECTED…………………………………………………………. 64
CODE 33 XX – SUMP FLUID TEMPERATURE SENSOR………………………………………………………… 65
Figure 5–8. Code 33 Schematic Drawing………………………………………………………… 65
Figure 5–9. Temperature Sensor Chart…………………………………………………………. 67
CODE 34 XX – CALIBRATION COMPATIBILITY OR CHECKSUM FAULT……………………………………………. 68
CODE 35 XX – POWER INTERRUPTION………………………………………………………………….. 69
Figure 5–10. Code 35 Schematic Drawing……………………………………………………….. 69
CODE 36 XX – HARDWARE AND SOFTWARE NOT COMPATIBLE………………………………………………….. 72
CODE 45 XX – GENERAL SOLENOID FAILURE…………………………………………………………….. 73
Figure 5–11. Code 45 Schematic Drawing……………………………………………………….. 73
CODE 46 XX – HI SIDE OVERCURRENT FAULT……………………………………………………………. 77
Figure 5–12. Code 46 Schematic Drawing……………………………………………………….. 77
CODE 56 XX – RANGE VERIVERCATION RATIO TEST (Between Shifts)………………………………………. 79
CODE 65 00 – ENGINE RATING HIGH………………………………………………………………….. 81
CODE 66 00 – SCI (SERIAL COMMUNICATION INTERFACE) FAULT…………………………………………….. 83
Figure 5–13. Code 66 Schematic Drawing……………………………………………………….. 83
CODE 69 XX – ECE MALFUNCTION…………………………………………………………………….. 85
Section6— VEHICLE INTERFACE WIRING……………………………………………………………………. 86
6–1. ECU POWER…………………………………………………………………………………….. 86
6–2. SYSTEM GROUNDS………………………………………………………………………………… 87
6–3. POWER AND GROUND USING A BUS BAR………………………………………………………………… 88
6–4. INSTALLING A MASTER DISCONNECT SWITCH……………………………………………………………. 89
6–5. IGNITION POWER………………………………………………………………………………… 90
6–6. CHECK TRANS LIGHT……………………………………………………………………………… 91
6–7. NEUTRAL START…………………………………………………………………………………. 92
6–8. SPEEDOMETER SIGNAL…………………………………………………………………………….. 93
6–9. REVERSE WARNING……………………………………………………………………………….. 94
6–10. SHIFT SELECTOR / DISPLAY DIMMER………………………………………………………………… 95
6-11. SERIAL COMMUNICATION INTERFACE (SCI)……………………………………………………………. 96
6–12. COMMUNICATION INTERFACE — SAE j1939…………………………………………………………….. 97
Section7— INPUT AND OUTPUT FUNCTIONS………………………………………………………………….. 98
7–1. INPUT FUNCTIONS……………………………………………………………………………….. 98
Table 7–1. Input Functions………………………………………………………………………. 98
7–2. OUTPUT FUNCTIONS………………………………………………………………………………. 99
Table 7–2. Output Functions…………………………………………………………………….. 99
Section8— GENERAL TROUBLESHOOTING OF PERFORMANCE COMPLAINTS………………………………………………100
Table 8–1. Troubleshooting Performance Complaints……………………………………………………..101
APPENDICES…………………………………………………………………………………………….106
APPENDIX A – IDENTIFICATION OF POTENTIAL CIRCUIT PROBLEMS……………………………………………….108
APPENDIX B – WIRE/CONNECTOR CHART…………………………………………………………………….110
Table B–1. Appendix B Abbreviation Guide (cont’d)………………………………………………….110
Figure B–1. ECU Connector “S”……………………………………………………………………112
Figure B–2. ECU Connector “T”……………………………………………………………………113
Figure B–3. ECU Connector “V”……………………………………………………………………114
Figure B–4. ITT Cannon Bulkhead Connector…………………………………………………………115
Figure B–5. Main Valve Body Cover Connector……………………………………………………….117
Figure B–6. Lockup Valve Body Cover Connector……………………………………………………..118
Figure B–7. Trim Boost or Low Valve Body Cover Connector……………………………………………119
Figure B–8. Remote Selector Connector…………………………………………………………….120
Figure B–9. Speed Sensor Connector……………………………………………………………….122
Figure B–10. Diagnostic Connector (Packard)……………………………………………………….123
Figure B–11. Optional Deutsch DDR Connector or Optional DDU Connector………………………………..124
Figure B–12. VIW Connector (Packard Micro-Pack)……………………………………………………125
Figure B–13. TPS Connector………………………………………………………………………127
Figure B–14. VIM Connector (Harness)……………………………………………………………..128
Figure B–15. VIM Connector (Harness)……………………………………………………………..129
Figure B–16. SCI Interface Connector……………………………………………………………..130
Figure B–17. J1939 Interface Connector……………………………………………………………131
APPENDIX C – CONNECTOR PART NUMBERS, TERMINAL PART NUMBERS, TOOL PART NUMBERS, AND REPAIR INSTRUCTIONS……….132
Figure C–1A. Delphi-Packard Micro-Pack Connector (ECU)……………………………………………..134
Figure C–1B. Delphi-Packard Micro-Pack Connector (VIWV, VIWS, Shift Selector)…………………………135
1–1. DELPHI-PACKARD MICRO-PACK 100W CONNECTORS (ECU, VIWV, VIWS, SHIFT SELECTORS)………………………136
Figure C–2. Delphi-Packard Metri-Pack 150 Series Connectors — Pull-to-Seat (Speed Sensor, 30-Way…….139
1–2. DELPHI-PACKARD METRI-PACK 150 SERIES CONNECTORS — PULL-TO-SEAT (Speed Sensor, 30-Way and 18-……….140
Figure C–3. Delphi-Packard Metri-Pack 150 Series Connector — Push-To-Seat (Sump Temperature Ther…….143
1–3. DELPHI-PACKARD METRI-PACK 150 SERIES CONNECTORS — PUSH-TO-SEAT (SUMP TEMPERATURE THERMISTOR)………..144
Figure C–4. Delphi-Packard Metri-Pack 280 Series Connectors — Push-to-Seat (DDR and SCI)……………145
1–4. DELPHI-PACKARD METRI-PACK 280 SERIES CONNECTORS — PUSH-TO-SEAT (DDR and SCI)………………………146
Figure C–5. Delphi-Packard WeatherPack Connector (TPS)…………………………………………. 43
1–5. DELPHI-PACKARD WEATHERPACK CONNECTORS (TPS)……………………………………………………150
Figure C–6. Terminal Crimping With Tool J35606………………………………………………..151
Figure C–7. Deutsch Connector (6-Way Optional DDR or Optional DDU)……………………………….153
1–6. DEUTSCH CONNECTOR (6-WAY OPTIONAL DDR OR OPTIONAL DDU)………………………………………….154
Figure C–8. ITT Cannon Connector — Crimped (35-Way T-Harness Bulkhead)……………………………155
1–7. ITT CANNON CONNECTOR — CRIMPED (35-WAY HARNESS BULKHEAD)……………………………………….156
Figure C–9. ITT Cannon Connectors — Soldered (Main Valve Body Internal Harness, Main Valve Body …….159
1–8. ITT CANNON CONNECTORS — SOLDERED (Main Valve Body Internal Harness, Main Valve Body Harness,………..160
Figure C–10. Deutsch DT Series Connector (3-Way J1939 Interface)…………………………………163
1–9. Deutsch DT Series Connector (3-Way J1939 Interface)…………………………………………….164
1–10. REPAIR OF A BROKEN WIRE WITH IN-LINE BUTT SPLICE………………………………………………166
Figure C–11. Crimper J38125-8……………………………………………………………….167
APPENDIX D – THROTTLE POSITION SENSOR ADJUSTMENT……………………………………………………….170
Figure D–1. Throttle Position to Voltage Conversion………………………………………………..170
Figure D–2. Throttle Position Determination Diagram………………………………………………..170
Table D–1. Volts Versus Count for Throttle Sensor Display Reading…………………………………….172
Figure D–3. Throttle Position Sensor Adjustment……………………………………………………173
APPENDIX E – WELDING ON VEHICLE/VEHICLE INTERFACE MODULE………………………………………………..174
1–1. WELDING ON VEHICLE………………………………………………………………………….174
1–2. VEHICLE INTERFACE MODULE…………………………………………………………………….174
Figure E–1. Vehicle Interface Module………………………………………………………….174
Figure E–2. VIM Components Location and Pin-Out Diagram…………………………………………175
APPENDIX F – HYDRAULIC SCHEMATICS…………………………………………………………………….176
Figure F–1. 5610, 6610 Models — Hydraulic Schematic………………………………………………..178
Figure F–2. 8610 Models — Hydraulic Schematic……………………………………………………..179
Figure F–3. M 9610 Models — Hydraulic Schematic……………………………………………………180
Figure F–4. S 9810 Models — Hydraulic Schematic……………………………………………………181
APPENDIX G – CEC 2 SYSTEM/ECU WIRING SCHEMATICS………………………………………………………..182
Figure G–2. CEC 2 Solenoid Function By Model……………………………………………………….183
Figure G–3. ECU Schematic — 5610, 6610, 9610……………………………………………………….184
Figure G–4. ECU Schematic — 8610………………………………………………………………….185
Figure G–5. ECU Schematic — 9810………………………………………………………………….186
APPENDIX H – EXTERNALLY-GENERATED ELECTRONIC INTERFACE………………………………………………….188
1–1. ELECTROMAGNETIC/RADIO FREQUENCY INTERFERENCE…………………………………………………..188
1–2. GENERAL GUIDELINES FOR RADIO EQUIPMENT INSTALLATION……………………………………………188
1–3. EXTERNALLY-GENERATED SPEED SENSOR SIGNALS……………………………………………………..189
APPENDIX J _ PRO-LINK® 9000 DIAGNOSTIC DATA READER INFORMATION…………………………………………..190
1–1. PRO-LINK® 9000 DIAGNOSTIC TOOLS………………………………………………………………190
APPENDIX K – WIRING SCHEMATICS SPECIFIC INPUT/OUTPUT FUNCTIONS…………………………………………..192
Figure K–1. Secondary Shift Schedule……………………………………………………………..192
Figure K–2. Two Speed Axle Input and Output……………………………………………………….193
Figure K–3. Hold In Range……………………………………………………………………….194
Figure K–4. D1 Select…………………………………………………………………………..195
Figure K–5. Stall Check…………………………………………………………………………196
Figure K–6. Manual Lockup……………………………………………………………………….197
Figure K–7. Shift Selector Transition…………………………………………………………….198
Figure K–8. Neutral To Range Inhibit……………………………………………………………..199
Figure K–9. Quick To Neutral…………………………………………………………………….200
Figure K–10. Manual Lockup Enable………………………………………………………………..201
Figure K–11. Automatic Lockup Off………………………………………………………………..202
Figure K–12. Retarder Enable…………………………………………………………………….203
Figure K–13. Park Brake Enable…………………………………………………………………..204
Figure K–14. Load Dump Brake Enable………………………………………………………………205
Figure K–15. ÆP (“Delta-P”) Hold…………………………………………………………………206
Figure K–16. R1 and R2 Reverse Operation With Single-Reverse Shift Selector…………………………..207
Figure K–17. Manual Mode………………………………………………………………………..208
Figure K–18. Bed Hoist Interlock…………………………………………………………………209
Figure K–19. Lockup Indicator……………………………………………………………………210
Figure K–20. Range Commanded Indicator……………………………………………………………211
Figure K–21. Output Speed Indicator — A…………………………………………………………..212
Figure K–22. Output Speed Indicator — B…………………………………………………………..213
Figure K–23. Engine Overspeed Indicator…………………………………………………………..214
Figure K–24. Retarder Indicators…………………………………………………………………215
Figure K–25. Secondary Mode Indicator…………………………………………………………….216
Figure K–26. Two-Speed Axle Output……………………………………………………………….217
Figure K–27. Park Brake Output…………………………………………………………………..218
Figure K–28. Load Dump Brake Output………………………………………………………………219
Figure K–29. Manual Mode Indicator……………………………………………………………….220
APPENDIX L – SUMP THERMISTOR TROUBLESHOOTING INFORMATION………………………………………………..222
Graph L–1………………………………………………………………………………………222

IMAGES PREVIEW OF THE MANUAL:

ALLISON TRANSMISSION 5000 6000 8000 9000 SERIESOFF-HIGHWAY TRANSMISSIONS COMMERCIAL ELECTRONIC CONTROLS 2 (CEC2) TS3353EN TROUBLESHOOTING MANUAL:

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