Allison Transmission 3000 & 4000 Product Families Troubleshooting Manual – PDF DOWNLOAD
DESCRIPTION:
Allison Transmission 3000 & 4000 Product Families 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
TS3989EN
4500 TRV*
4700 EVS
4700 OFS
4700 RDS
4800 EVS
B 300PR
B 500
B 500P
B 500PR
B 500R
T425
T450
FOREWORD-How to Use This Manual :
Welcome to the TS3989EN Traubleshooting 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 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 Praduct Families Allison 4th 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 Troubleshooting Manual – PDF DOWNLOAD
FOREWORD-How to Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii
IMPORTANT SAFETY INFORMATION …………………………………………………. iii
ABBREVIATIONS ANO ACRONYMS ………………………………………………….. iv
TRADEMARK USAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . viii
LITERATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . viii
LIST OF WARNINGS ………………………………………………………….. ix
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
A. Software Features …………………………………………………… 1-2
B. PC Requirements …………………………………………………… 1-3
SECTION 2 ALLISON 4TH GENERATION CONTROL SYSTEM OPERATION
2-1 GENERAL SYSTEMS OVERVIEW ……………………………………………. 2-1
2-2 ELECTRONIC TRANSMISSION CONTROL MODULE (TCM) ………………………………. 2-3
2-3 SHIFT SELECTORS …………………………………………………… 2-4
A. Selector Classification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
B. Select and Monitor Display(s) ……………………………………………… 2-7
C. Mode lndicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
D. MODE Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
E. Trans Service lndicator (Wrench lcon) …………………………………………. 2-9
F. Backlighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
G. Keypad Pushbutton Shift Selector ………………………………………….. 2-10
H. Levar Shift Selector …………………………………………………. 2-10
1. Strip Pushbutton Shift Selector ……………………………………………. 2-10
J. Dual Stations or Multiple Transmission Contrai ……………………………………. 2-11
K. Dual Allison Shift Selector Capability on CAN2 ……………………………………. 2-12
2-4 THROTTLE POSITION SENSOR (TPS) …………………………………………. 2-12
2-5 SPEED SENSORS ……………………………………………………. 2-13
2-6 CONTROL VALVE MODULE (ELECTROHYDRAULIC) …………………………………. 2-13
A. Assembly Overview …………………………………………………. 2-13
B. C6 Valva Body Assembly (7-speed) …………………………………………. 2-18
C. Filter Life Valve Body Assembly ……………………………………………. 2-18
D. Main Pressure Modulation Solenoid …………………………………………. 2-18
E. Temperatura Fluid Temperatura (TFT) Sensor …………………………………….. 2-19
F. Oil Levei Sensor (OLS) ……………………………………………….. 2-19
G. Diagnostic Pressure Switch 1 (PS1) …………………………………………. 2-21
H. Turbina Speed Sensor (3000 Family) …………………………………………. 2-21
2-7 WIRE HARNESSES …………………………………………………… 2-21
A. Extemal Hamess . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
B. Internai Wiring Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24
2-8 OPTIONAL VEHICLE INTERFACE MODULE (VIM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25
2-9 AUTO-DETECT LOGIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26
A. Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26
B. Reset Auto-Detect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26
C. Override Auto-Detect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27
D. Retardar Auto-Detect Logic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27
E. Oil Levei Sensor (OLS) Auto-Detect Logic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27
F. Throttle Source Auto-Detect Logic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28
G. Engine Coolant Temperatura Source Auto-Detect Logic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28
Copyright© 2016 Allison Transmission, lnc. AII Rights Reserved. xiii
Allison 3000 and 4000 Product Families
H. TRANSID (TI □) Auto-Detect Logic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29
2-10 Adaptive Contrais ……………………………………………………. 2-29
A. Adapt Shifts Report Patterns and Regions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30
2-11 Shift Schedules ……………………………………………………… 2-30
A. Overview ………………………………………………………. 2-30
B. Shift Calibrations …………………………………………………… 2-31
2-12 PRIMARY ANO SECONDARY SHIFT SCHEDULES …………………………………… 2-31
A. Selection ………………………………………………………. 2-31
B. Common Shift Schedule Types ……………………………………………. 2-31
2-13 HOLD SCHEDULE FOR UPSHIFTS …………………………………………… 2-32
2-14 PRESELECT SCHEDULE FOR DOWNSHIFTS …………………………………….. 2-32
A. During Non-Engine Brake Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32
B. During Engine Brake Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32
2-15 CRUISE MODE SHIFT SCHEDULE …………………………………………… 2-33
2-16 OVER-TEMPERATURE SHIFT SCHEDULE ………………………………………. 2-33
2-17 UNDER-TEMPERATURE (COLO) SHIFT SCHEDULE ………………………………….. 2-33
2-18 KICKDOWN SHIFT SCHEDULE …………………………………………….. 2-34
2-19 OUTPUT RETARDER SHIFT SCHEDULE ……………………………………….. 2-34
A. High Retardar Fluid Temperatura . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34
B. Retardar Cruise Contrai lnteractions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34
2-20 SHIFT ENERGY MANAGEMENT (SEM), LOWER RANGE TORQUE PROTECTION (LRTP), ANO AUTOSELECT LOGIC … 2-34
A. Shift Energy Management (SEM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34
B. Lower Range Torque Protection (LRTP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35
C. Autoselect Logic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35
2-21 LOAD BASE □ SHIFT SCHEDULING (LBSS) ………………………………………. 2-35
A. Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35
B. Load Based Shift Scheduling (LBSS) Torque-Based . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-37
C. Super Economy Shift Schedule (SESS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-37
D. Accel-Based Shift Scheduling (ABSS)/Accel-Based MODE Selection (ABMS) . . . . . . . . . . . . . . . . . . . . . . . . . . 2-37
E. Load Based Shift Scheduling (LBSS) lnhibits/Delays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-37
2-22 VEHICLE ACCELERATION CONTROL (VAC) ……………………………………… 2-38
2-23 VEHICLE ACCELERATION RATE LIMITING ………………………………………. 2-38
2-24 INPUT ANO OUTPUT (1/0) FUNCTIONS ………………………………………… 2-39
2-25 CUSTOMER MODIFIABLE CONSTANTS (CMCs) ……………………………………. 2-39
2-26 SHIFT INHIBIT LOGIC ………………………………………………….. 2-40
A. Engine Speed lnhibit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40
B. Direction Change lnhibit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40
C. Auxiliary Function Range lnhibit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40
□. Notification in Shifl Selector Display …………………………………………. 2-41
E. Reset (Clearing) …………………………………………………… 2-41
F. Viewing lnhibits in Universal Allison DOC® . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-41
G. Transfer Case lnhibit from Universal Allison DOC® Action Requests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-41
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
xiv Copyright © 2016 Allison Transmission, lnc. AII Rights Reserved.
TABLE OF CONTENTS
C. Checking Dipstick Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
D. Electronic Fluid Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
E. Fluid Levei Check using Universal Allison DOC® . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
3-3 TRANSMISSION FLUID 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
4-4 PROGNOSTICS FEATURES AVAILABILITY ……………………………………….. 4-3
4-5 TURNING PROGNOSTICS PACKAGE ON OR OFF ……………………………………. 4-4
4-6 PROGNOSTICS INDICATION AT ENGINE START ……………………………………. 4-5
4-7 SETTING FLUI □ TYPE ………………………………………………….. 4-6
4-8 OIL LIFE MONITOR (OM) ………………………………………………… 4-6
A. Percentage Fluid Life Remaining Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
B. Maintenance Required Notification …………………………………………… 4-7
C. OM Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
D. OM Maintenance History ……………………………………………….. 4-7
4-9 FILTER LIFE MONITOR (FM) ………………………………………………. 4-7
A. Filter Life Status Display ……………………………………………….. 4-7
B. Maintenance Required Notification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
C. FM Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
D. FM Maintenance History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
E. Filter Life lndicator (FLI) Switch (PS2) Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
4-10 TRANSMISSION HEALTH MONITOR (TM) ………………………………………… 4-8
A. Clutch System Status Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
B. Maintenance Required Notification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
C. TM Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
D. TM Maintenance History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
4-11 PROGNOSTICS IN UNIVERSAL ALLISON DOC® …………………………………….. 4-9
A. Viewing History ……………………………………………………. 4-9
B. Enabling/Disabling Prognostics Package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
C. Reset Prognostics Monitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
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. Mode lndicator Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
C. Read/Clear DTC with Keypad Pushbutton Selector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
D. 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 SELECTOR DISPLAY DESCRIPTIONS FOR ACTIVE DIAGNOSTIC TROUBLE CODES (DTCs) ANO INHIBITS ……… 5-9
5-8 DTC LIST AND DESCRIPTION INDEX …………………………………………. 5-10
SECTION 6 CONTROL SYSTEM AND TRANSMISSION SPECIFICATIONS
6-1 MEASURING TRANSMISSION PRESSURES ………………………………………. 6-1
Copyright© 2016 Allison Transmission, lnc. AII Rights Reserved. XV
Allison 3000 and 4000 Product Families
6-2 TRANSMISSION AND VEHICLE PREPARATION …………………………………….. 6-1
6-3 COMPARING RECORDED 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 AND 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 AND CLUTCH CHART ……………………………………………. 6-11
6-12 DIAGNOSTIC FLOW CHARTS USING CLUTCH TEST …………………………………. 6-15
6-13 SPEED SENSOR DATA …………………………………………………. 6-18
6-14 SOLENOID DATA ……………………………………………………. 6-19
6-15 TRANSMISSION FLUI □ TEMPERATURE (TFT) SENSORS ………………………………. 6-20
6-16 PRESSURE SWITCH DATA, PS1 AND PS2 ………………………………………. 6-20
6-17 RETARDER MODULATION REQUEST (RMR) RESISTANCE MODULE DATA ……………………… 6-21
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 AND TIPS FOR TROUBLESHOOTING ………………………………….. C-1
D. TROUBLESHOOTING WITH A DIGITAL MULTIMETER (DMM) ……………………………… D-1
E. TROUBLESHOOTING TRANSMISSION AND 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 AND 4000 TCM DIAGRAM ……………………………………………… L-1
M. HYDRAULIC SCHEMATICS ……………………………………………….. M-1
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