Allison 5000 Series Workshop Service Repair Manual

Copyright© 2005 General Motors Corp. Welcome to the TS3353EN Troubleshooting Manual. We make every effort to keep our service information current and accurate. Because of the time lag involved with writing and printing processes, the transmission TCM may report a code that has not yet been added to this document. If you encounter a code that is not yet in this publication, please call the Allison Transmission Technical Assistance Center at 1-800-252-5283. Go to the Table of Contents. PREFACE CEC2 ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

Printed in USA Copyright © 2005 General Motors Corp. Allison Transmission, General Motors Corporation P.O. Box 894 Indianapolis, Indiana 46206-0894 www.allisontransmission.com Allison Transmission Troubleshooting Manual 2005 DECEMBER TS3353EN 5000, 6000, 8000, 9000 Series Transmissions Commercial Electronic Controls 2 (CEC2) M 5610A M 5610AR S 5610H S 5610MR S 5610M M 6610A M 6610AR S 6610H S 6610HR S6610M S 6610MR 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 9805M S 9805MR S 9810A S 9810AR S 9810H S 9810HR S 9810M S 9810MR

COMMERCIAL ELECTRONIC CONTROLS 2 (CEC2) TROUBLESHOOTING MANUAL ii Copyright © 2005 General Motors Corp. This manual provides troubleshooting information for Allison Transmission (AT), 5000, 6000, 8000, and 9000 Series Off-Highway Transmissions which have CEC2. 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 CEC2 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. Check with your Allison Transmission service outlet for the currently applicable publication. Additional copies of this publication may be purchased from authorized Allison Transmission service outlets or from: SGI, Inc. Attn: Allison Literature Fulfillment Desk 8350 Allison Avenue Indianapolis, IN 46268 TOLL FREE: 888-666-5799 INTERNATIONAL: 317-471-4995 Take time to review the Table of Contents and the manual. Reviewing the Table of Contents will aid you in quickly locating information. NOTE: Allison Transmission provides service of wiring harnesses and wiring harness components as follows: • Repair parts for the internal wiring harness and for wiring harness components attached to the shift selector will be available through the Allison Transmission Parts Distribution Center (PDC). Use the P/N from your appropriate parts catalog or from Appendix C in this manual. Allison Transmission is responsible for warranty on these parts. • Repair parts for the external harnesses and external harness components must be obtained from St. Clair Technologies Inc. (SCTI). SCTI provides parts to any Allison customer or OEM and is responsible for warranty on these parts. SCTI recognizes AT, manufacturers, and SCTI part numbers. SCTI provides a technical HELPLINE at 519-627-1673 (Wallaceburg). SCTI will have parts catalogs available. The SCTI addresses and phone numbers for parts outlets are: • St. Clair Technologies, Inc. stocks an external harness repair kit as a source for some external harness repair parts. SCTI is the source for external harness repair parts. St. Clair Technologies, Inc 920 Old Glass Road Wallaceburg, Ontario N8A 4L8 Phone: 519-627-1673 Fax: 519-627-4227 St. Clair Technologies, Inc. Calle Damanti S/N Col Guadalupe–Guaymas Sonora, Mexico 85440 Phone: 011-526-2222-43834 Fax: 011-526-2222-43553 FOREWORD—How to Use This Manual

Copyright © 2005 General Motors Corp. iii IT IS YOUR RESPONSIBILITY to be completely familiar with the warnings and cautions used in this manual. These warnings and cautions advise against using specific service procedures that can result in personal injury, equipment damage, or cause the equipment to become unsafe. These warnings and cautions are not exhaustive. Allison Transmission could not possibly know, evaluate, or advise the service trade of all conceivable procedures by which service might be performed or of the possible hazardous consequences of each procedure. Consequently, Allison Transmission has not undertaken any such broad evaluation. Accordingly, ANYONE WHO USES A SERVICE PROCEDURE OR TOOL WHICH IS NOT RECOMMENDED BY ALLISON TRANSMISSION MUST first be thoroughly satisfied that neither personal safety nor equipment safety will be jeopardized by the service procedures used. Also, be sure to review and observe WARNINGS, CAUTIONS, and NOTES provided by the vehicle manufacturer and/or body builder before servicing the Allison transmission in that vehicle. Proper service and repair is important to the safe and reliable operation of the equipment. The service procedures recommended by Allison Transmission and described in this manual are effective methods for performing troubleshooting operations. Some procedures require using specially designed tools. Use special tools when and in the manner recommended. WARNINGS, CAUTIONS, AND NOTES Three types of headings are used in this manual to attract your attention: NOTE: Is used when an operating procedure, practice, etc., is essential to highlight. WARNING! Is used when an operating procedure, practice, etc., which, if not correctly followed, could result in injury or loss of life. CAUTION: Is used when an operating procedure, practice, etc., which, if not strictly observed, could result in damage to or destruction of equipment. COMMERCIAL ELECTRONIC CONTROLS 2 (CEC2) TROUBLESHOOTING MANUAL The WARNINGS, CAUTIONS, and NOTES in this manual apply only to the Allison transmission and not to other vehicle systems which may interact with the transmission. Be sure to review and observe any vehicle system information provided by the vehicle manufacturer and/or body builder at all times the Allison transmission is being serviced. IMPORTANT SAFETY NOTICE

COMMERCIAL ELECTRONIC CONTROLS 2 (CEC2) TROUBLESHOOTING MANUAL iv Copyright © 2005 General Motors Corp. TRADEMARKS USED IN THIS MANUAL The following trademarks are the property of the companies indicated: • LPS ® Cleaner is a registered trademark of LPS Laboratories. • Loctite ® is a registered trademark of the Loctite Corporation. • Teﬂon ® is a registered trademark of the DuPont Corporation. • Pro-Link ® is a registered trademark of MicroProcessor Systems, Inc. • Allison DOC™ For PC–Service Tool is a trademark for General Motors Corporation INTRODUCTION

Copyright © 2005 General Motors Corp. v Page Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii SAFETY INFORMATION Important Safety Notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .iii Warnings, Cautions, and Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .iii Trademarks Used in This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv SECTION 1. GENERAL DESCRIPTION 1–1. TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1 1–2. ELECTRONIC CONTROL UNIT (ECU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3 1–3. SHIFT SELECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3 A. Pushbutton Shift Selector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3 B. Lever Shift Selector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–4 1–4. THROTTLE POSITION SENSOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–4 1–5. SPEED SENSORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–5 1–6. ELECTRO-HYDRAULIC VALVE COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–5 1–7. WIRING HARNESSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–6 A. External Wiring Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–6 B. Internal Wiring Harnesses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–8 1–8. VEHICLE INTERFACE MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–9 1–9. AUTODETECT FEATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–9 SECTION 2. DEFINITIONS AND ABBREVIATIONS 2–1. CHECK TRANS LIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1 2–2. DIAGNOSTIC DATA READER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1 2–3. ABBREVIATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–2 SECTION 3. BASIC KNOWLEDGE 3–1. BASIC KNOWLEDGE REQUIRED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1 3–2. USING THE TROUBLESHOOTING MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–2 3–3. SYSTEM OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–2 3–4. IMPORTANT INFORMATION IN THE TROUBLESHOOTING PROCESS . . . . . . . . . . . . . . . . 3–2 3–5. TESTING FOR OPENS, SHORTS BETWEEN WIRES, AND SHORTS-TO-GROUND . . . . . . . 3–3 3–6. TESTING AT TRANSMISSION CONNECTOR AND THE INTERNAL HARNESS FOR OPENS, SHORTS BETWEEN WIRES, AND SHORTS-TO-GROUND . . . . . . . . . . . . . . . . 3–5 SECTION 4. WIRE TESTING PROCEDURES 4–1. BEGINNING THE TROUBLESHOOTING PROCESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–1 4–2. GENERAL TROUBLESHOOTING OF PERFORMANCE COMPLAINTS . . . . . . . . . . . . . . . . . 4–1 4–3. SHIFT INHIBITS—NO DIAGNOSTIC CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–7 TABLE OF CONTENTS CEC2 ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

vi Copyright © 2005 General Motors Corp. TABLE OF CONTENTS ( C o n t ' d) CEC2 ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL Page SECTION 5. DIAGNOSTIC CODES 5–1. DIAGNOSTIC CODE MEMORY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1 5–2. CODE READING AND CODE CLEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1 5–3. DIAGNOSTIC CODE RESPONSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–3 5–4. SHIFT SELECTOR DISPLAYS RELATED TO ACTIVE CODES . . . . . . . . . . . . . . . . . . . . . . . . 5–3 5–5. DIAGNOSTIC CODE LIST AND DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–4 SECTION 6. VEHICLE INTERFACE WIRING—MANDATORY (VIW-M) 6–1. ECU POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1 6–2. SYSTEM GROUNDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–2 6–3. POWER AND GROUND USING A BUS BAR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–3 6–4. INSTALLING A MASTER DISCONNECT SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–4 6–5. IGNITION POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–5 6–6. CHECK TRANS LIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–6 6–7. NEUTRAL START . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–7 6–8. SPEEDOMETER SIGNAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–8 6–9. REVERSE WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–9 6–10. SHIFT SELECTOR/DISPLAY DIMMER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–10 6–11. SERIAL COMMUNICATION INTERFACE (SCI)—J1587/J1708. . . . . . . . . . . . . . . . . . . . . . . . 6–11 6–12. COMMUNICATION INTERFACE—SAE J1939 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–12 SECTION 7. WIRING SCHEMATICS−OPTIONAL INPUT AND OUTPUT FUNCTIONS 7–1. CALIBRATION COMPATIBILITY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–2 7–2. INPUT FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–3 7–3. OUTPUT FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–27 SECTION 8. CUTOMER MODIFIABLE CONSTANTS (CMC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–1 APPENDICES A. IDENTIFICATION OF POTENTIAL CIRCUIT PROBLEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . A–1 B. WIRE/CONNECTOR CHART. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B–1 C. CONNECTOR PART NUMBERS, TERMINAL PART NUMBERS, TOOL PART NUMBERS, AND REPAIR INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C–1 D. THROTTLE POSITION SENSOR ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D–1 E. WELDING ON VEHICLE/VEHICLE INTERFACE MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . E–1 F. HYDRAULIC SCHEMATICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F–1 G. CEC2 WIRING SYSTEM/ECU WIRING SCHEMATICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G–1 H. EXTERNALLY-GENERATED ELECTRONIC INTERFERENCE . . . . . . . . . . . . . . . . . . . . . . . . H–1 J. DIAGNOSTIC DATA READER INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J–1

Copyright © 2005 General Motors Corp. 1–1 COMMERCIAL ELECTRONIC CONTROLS 2 (CEC2) TROUBLESHOOTING MANUAL SECTION 1—GENERAL DESCRIPTION 1–1. TRANSMISSION The Commercial Electronic Controls 2 (CEC2) system features clutch control to provide superior shift quality over a wide range of operating conditions. The ranges available in CEC2-equipped Off-Highway transmissions are as follows. • 5610, 6610, 9610—six forward, neutral, two reverses • 8610—six forward, neutral, reverse • 9805—eight forward, neutral • 9810—eight forward, neutral Figure 1–1 is a block diagram of the basic transmission system inputs and outputs. Figure 1–1. Electronic Control Unit Block Diagram Figure 1–2 shows the CEC2 electronic control components. CEC2 consists of the following elements: • Remote 12/24V Max Feature Sealed Electronic Control Unit (ECU) • Remote Pushbutton or Lever Shift Selector • Optional Secondary Shift Selector • Throttle Position Sensor (TPS) (or electronic engine throttle data) • Input, Turbine, and Output Speed Sensors • Electro-Hydraulic Valve Bodies • Wiring Harnesses • Vehicle Interface Module (VIM) NOTE: • All external harnesses are OEM supplied. • The VIM is an OEM option. SHIFT SELECTOR RANGE AND MODE SWITCH DISPLAY VIM INPUTS OUTPUTS ECU SPEED SENSORS THROTTLE POSITION SENSOR V03469.01 TEMPERATURE SENSOR (SUMP) VEHICLE/ENGINE COMMUNICATION LINKS SOLENOIDS

COMMERCIAL ELECTRONIC CONTROLS 2 (CEC2) TROUBLESHOOTING MANUAL 1–2 Copyright © 2005 General Motors Corp. GENERAL DESCRIPTION . Figure 1–2. CEC2 Components BLUE BLUE BLUE BLUE BLACK BLACK GRA GRAY R N D MODE SELECT TRANSMISSION MAIN VALVE BODY CONNECTOR VEHICLE INTERFACE MODULE (VIM) VEHICLE (V) HARNESS TRANSMISSION (T) HARNESS ELECTRONIC CONTROL UNIT (ECU) TPS CONNECTOR (OPTIONAL) REMOTE LEVER SELECTOR REMOTE PUSHBUTTON SELECTOR SHIFT SELECTOR CONNECTOR VIW–V CONNECTOR VIW–S CONNECTOR VIM CONNECTORS PRO-LINK ® DIAGNOSTIC TOOL DIAGNOSTIC TOOL CONNECTOR Bulkhead Connector (Optional) THROTTLE POSITION SENSOR (TPS) THROTTLE POSITION SENSOR (TPS) CONNECTOR OUTPUT SPEED SENSOR CONNECTOR TEMP SENSOR/ LOCKUP CONNECTOR TRIM BOOST CONNECTOR TURBINE SPEED SENSOR CONNECTOR INPUT (ENGINE) SPEED SENSOR CONNECTOR V06587.01.00 NOTE: Illustration is not to scale. Actual harness configuration may differ from this illustration. “S” CONNECTOR (BLACK) “T” CONNECTOR (BLUE) “V” CONNECTOR (GRAY) SELECTOR (S) HARNESS J 1939 CONNECTOR (OPTIONAL) DEUTSCH DIAGNOSTIC TOOL CONNECTOR (OPTIONAL) SCI (J 1587) CONNECTOR (OPTIONAL) ALLISON DOC ™ FOR PC — SERVICE TOOL

Copyright © 2005 General Motors Corp. 1–3 GENERAL DESCRIPTION COMMERCIAL ELECTRONIC CONTROLS 2 (CEC2) TROUBLESHOOTING MANUAL 1–2. ELECTRONIC CONTROL UNIT (ECU) The ECU (Figure 1–3) contains the microcomputer which is the brain of the control system. The ECU receives and processes information defining: The ECU uses the information to: • Control transmission solenoids and valves. • Supply system status. • Provide diagnostic information. Each ECU has a date code stamped on the label which is attached to the outer case of the ECU. This is the date when the ECU passed final test. This date is commonly used to denote the change configuration level of the ECU. It is normal for the ECU date displayed electronically to be a few days prior to the date shown on the label. Figure 1–3. Electronic Control Unit (ECU) 1–3. SHIFT SELECTOR Pushbutton and lever shift selectors for CEC2 are remote mounted from the ECU and connected to the ECU by a wiring harness. Both of these shift selectors have a single digit LED display and a mode indicator LED. During normal transmission operation, illumination of the LED indicator shows that a secondary or special operating condition has been selected by pressing the MODE button. During diagnostic display mode, illumination of the LED indicator shows that the displayed diagnostic code is active. Display brightness is regulated by the same vehicle potentiometer that controls dash light display brightness. More information on both types of shift selectors is continued below. A. Pushbutton Shift Selector (Figure 1–4) The full-function pushbutton shift selector has a MODE button and diagnostic display capability through the single digit LED display. The full-function pushbutton shift selector has the following six (6) pushbuttons: Figure 1–4. Typical Full-Function Pushbutton Shift Selector • Shift selector position • Sump temperature • Turbine speed • Throttle position • Input speed • Transmission output speed • R (Reverse) • D (Drive) • MODE • N (Neutral) • ↓ (Down) and ↑ (Up) arrows V03352.00.02 BLUE BLUE BLUE BLUE BLACK BLACK GRAY ECU NOTE: ECU wiring harness connector retainers are individually keyed and color-coded to make sure that the proper connector is attached to the correct ECU socket. The color of the connector retainer should match the color of the connector strain relief (see Appendix C, Paragraph C–1). R N D MODE V06588.01.00 MODE ID MODE INDICATOR (LED) PUSHBUTTON SELECTOR

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Allison 5000 Series Workshop Service Repair Manual

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