Allison B 300 Troubleshooting Manual Download Page 1

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TS2470EN

Printed in the U.S.A.

Troubleshooting
Manual

Division of General Motors Corporation

P.O. Box 894 Indianapolis, Indiana 46206-0894

May 1998

Revision 1, 199910

Allison Transmission

MD/HD/B Series Transmissions
WTEC II Controls
(Pre-TransID and TID 1)

MD 3060/MD 3066/MD 3560(P)(R)
MD 3070PT
HD 4060/HD 4560(P)(R)
B 300/B 400/ B 500(P)(R)

Summary of Contents for B 300

Page 1: ...nual Division of General Motors Corporation P O Box 894 Indianapolis Indiana 46206 0894 May 1998 Revision 1 199910 Allison Transmission MD HD B Series Transmissions WTEC II Controls Pre TransID and TI...

Page 2: ...ice 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...

Page 3: ...e system information provided by the vehicle manufacturer and or body builder at all times the Allison transmission is being serviced IMPORTANT SAFETY NOTICE IT IS YOUR RESPONSIBILITY to be completely...

Page 4: ...MIL L 46002 ORD and MIL I 23310 WEP under the designation of Nucle Oil Biobor JF is the registered trademark for a biological inhibitor manufactured by Hammonds Fuel Additives Corporation Loctite is...

Page 5: ...ng Harness 1 7 B Internal Wiring Harness 1 8 1 8 VEHICLE INTERFACE MODULE 1 10 1 9 TRANSID FEATURE 1 10 SECTION 2 DEFINITIONS AND ABBREVIATIONS 2 1 DO NOT SHIFT LIGHT 2 1 2 2 DIAGNOSTIC DATA READER 2...

Page 6: ...SECTION 7 INPUT AND OUTPUT FUNCTIONS 7 1 INPUT FUNCTIONS 7 1 7 2 OUTPUT FUNCTIONS 7 3 SECTION 8 GENERAL TROUBLESHOOTING OF PERFORMANCE COMPLAINTS 8 1 GENERAL NOTES 8 1 8 2 TROUBLESHOOTING PERFORMANCE...

Page 7: ...er or converter to supply 12V to the electronic control system Model Year 95 and later transmissions operating on 24VDC require a 24V VIM and a 24V wiring harness which includes shielding for the turb...

Page 8: ...OR TURBINE SPEED SENSOR CONNECTOR HD B 500 HD B 500 RETARDER TEMPERATURE SENSOR CONNECTOR REMOTE SERIAL INTERFACE CONNECTOR RETARDER K CONNECTOR HD B 500 HD MD B RETARDER ACCUMULATOR H SOLENOID CONNEC...

Page 9: ...its is a MODE ON indicator position During normal transmission operation MODE ON indicates that a secondary or special operating condition has been selected by pressing the MODE button In diagnostic d...

Page 10: ...position or when moving into or out of N Neutral or R Reverse The digital display on the lever selector indicates the selected range at the top and the range monitored attained at the bottom A MODE b...

Page 11: ...The engine speed signal is generated by ribs on the shell of the torque converter pump The turbine speed signal is generated by the rotating clutch housing spline contours The output speed signal is g...

Page 12: ...ocated in the internal wiring harness Changes in sump fluid temperature are indicated by changes in sensor resistance which changes the signal sent to the ECU see chart in Section 6 Code 24 The oil le...

Page 13: ...ovides parts to any Allison customer or OEM and is responsible for warranty on these parts SCTI recognizes ATD manufacturers and SCTI part numbers SCTI provides a technical HELPLINE at 519 627 1673 Wa...

Page 14: ...NNECTOR ENGINE SPEED SENSOR CONNECTOR V01592 TPS CONNECTOR TURBINE SPEED SENSOR CONNECTOR HD B 500 REMOTE SERIAL INTERFACE CONNECTOR RETARDER K CONNECTOR HD B 500 HD MD B RETARDER ACCUMULATOR H SOLENO...

Page 15: ...NOID E C3 SOLENOID C MD OIL LEVEL SENSOR C3 PRESSURE SWITCH TEMPERATURE SENSOR HD OIL LEVEL SENSOR TURBINE SPEED SENSOR MD B 300 B 400 OMITTED IN HD B 500 C4 SOLENOID D MD 3070 C6 SOLENOID J MD 3070 L...

Page 16: ...nsmission A Ns and calibrated ECU A Ns and receive all changes made to the transmission and all of the corresponding calibrations This will reduce the number of A N changeovers with which an OEM must...

Page 17: ...ess Adapter harness P N 200100 can be ordered from St Clair Technologies to provide the same connection outside the transmission and allow a pre TransID transmission to be converted to a TransID 1 tra...

Page 18: ...began in September 1996 see Table 1 2 A TransID level 1 transmission is compatible with V6E V7 V7A V8 and V8A ECUs TransID level 2 transmissions were produced beginning in late December 1997 and all w...

Page 19: ...8538 D diagnostic tool which is available through Kent Moore Heavy Duty Division A portable microcomputer based receiver transmitter display unit the Pro Link transmits and receives data to and from t...

Page 20: ...DVOM Digital Volt Ohmmeter ECU Electronic Control Unit also commonly referred to as the computer EEPROM Electronically Erasable Programmable Read Only Memory This is the microchip that contains the tr...

Page 21: ...hich the transmission is commanded to return to previously commanded range RSI Remote Serial Interface Communications lines between remote shift selector and the ECU SCI Serial Communication Interface...

Page 22: ...eneral Motors Corp DEFINITIONS AND ABBREVIATIONS Volt Unit of electrical force VOM Volt Ohmmeter WOT Wide Open Throttle WT World Transmission Infinity Condition of a circuit with higher resistance tha...

Page 23: ...of WTEC II wiring harnesses and wiring harness components as follows See Service Information Letter 1 WT 97 for further information Repair parts for the internal wiring harness and for wiring harness...

Page 24: ...oving the harnesses may eliminate the problem Wiggle connectors harnesses and splices when looking for opens This simulates vehicle move ments which occur during actual operation When disconnecting a...

Page 25: ...nd remedies 3 If a diagnostic code is found in the ECU memory record all available code information and clear the active indicator refer to Section 6 4 Test drive the vehicle to confirm a diagnostic c...

Page 27: ...s using jumper wire kit J 39197 connect wire 102 and 120 to each other being careful not to distort the terminals Jumping the wires together creates a circuit between wires 102 and 120 2 On the opposi...

Page 28: ...ND 1 Disconnect the external wiring harness from the transmission a For MD B 300 and B 400 transmissions prior to S N 6510015259 refer to SIL 11 WT 94 Rev A b Water and white film contamination have b...

Page 29: ...th wire seals Figure 4 3 Figure 4 3 Feedthrough Connector Green Seal And Internal Harness CAUTION The cleaning solvent must not be chlorine based contain petroleum distillates or conduct electricity T...

Page 30: ...place the feedthrough connector or replace the solenoid Figure 4 4 Checking Continuity b If the resistance check is good check the harness for shorts between wires and to ground by per forming the fol...

Page 31: ...m when switch is closed and 20 000 Ohms minimum when switch is open 0 0 WIRING HARNESS Two wires have frayed and are shorted together Continuity beeper of VOM will sound or reading will go to zero Ohm...

Page 33: ...evel Check Procedure 1 Park the vehicle on a level surface and shift to N Neutral Apply the parking brake 2 On the Pushbutton shift selector simultaneously press the Up and Down arrow buttons once 3 O...

Page 34: ...on is reported when O L is displayed followed by and a number display The displayed number is a fault code and indicates improper conditions or a system malfunction Example O L 70 Indicates an Invalid...

Page 35: ...y illuminated A constant tone will sound until the fluid level mode is exited Reasons for Invalid for Display are the same as those shown in Table 5 1 under Cause of Code f To exit the fluid level dis...

Page 36: ...evel check until the following conditions are met The fluid temperature is above 60 C 140 F or below 104 C 220 F The transmission is in neutral The vehicle has been stationary for approximately two mi...

Page 37: ...mal ECU powerdown occurs ignition turned off Inactive codes are cleared from the code list after the counter exceeds 25 F Event Counter Counts the number of occurrences of a diagnostic code If a code...

Page 38: ...displayed In the normal operating mode the MODE ON display indicates secondary mode operation Any code position which does not have a diagnostic code logged will display for both the main and Subcode...

Page 39: ...for 8 seconds when the fault is first detected Blank the select digit in the display Ignore any range selection inputs and disable the button feedback tone for the pushbutton shift selector On the le...

Page 40: ...draulic default 14 12 Oil level sensor failed low No None 23 Oil level sensor failed high not used No None 21 12 Throttle position sensor failed low No Use full throttle default DNA 23 Throttle positi...

Page 41: ...ange R DNA 32 00 C3 pressure switch open Yes DNS Lock in current Low DNA 33 C3 pressure switch open 3rd range Yes DNS Lock in current range 3rd DNA 55 C3 pressure switch open 5th range Yes DNS Lock in...

Page 42: ...pen or short to ground F solenoid circuit No Lockup inhibited DNA 22 Open or short to ground G solenoid circuit Yes DNS SOL OFF Hydraulic default DNA 23 Open or short to ground H solenoid circuit No R...

Page 43: ...aulic default DNA 14 Short to ground C solenoid circuit Yes DNS SOL OFF Hydraulic default DNA 15 Short to ground D solenoid circuit Yes DNS SOL OFF Hydraulic default DNA 16 Short to ground E solenoid...

Page 44: ...st inhibited 51 01 Offgoing ratio test during shift L to 1 Yes DNS RPR DNA 10 Offgoing ratio test during shift 1 to L Yes DNS RPR DNA 12 Offgoing ratio test during shift 1 to 2 Yes DNS RPR DNA 21 Offg...

Page 45: ...ing shift 5 to 6 Yes DNS RPR DNA 71 Offgoing C3PS test during shift R to 1 Yes DNS NNC DNA 72 Offgoing C3PS test during shift R to 2 Yes DNS NNC DNA 78 Offgoing C3PS test during shift R to N1 Yes DNS...

Page 46: ...t 6 to N4 Yes 1 DNS RPR DNA 78 Offgoing speed test during shift R to N1 Yes DNS NNC DNA 99 Offgoing speed test during shift N2 to N3 or N3 to N2 Yes DNS RPR DNA XY Offgoing speed test X to Y 4 54 01 O...

Page 47: ...4 to 6 Yes DNS RPR DNA 53 Oncoming ratio test during shift 5 to 3 Yes DNS RPR DNA 54 Oncoming ratio test after shift 5 to 4 Yes DNS RPR DNA 56 Oncoming ratio test after shift 5 to 6 Yes DNS RPR DNA 6...

Page 48: ...3PS test after shift 1 to R Yes 1 DNS NNC DNA 27 Oncoming C3PS test after shift 2 to R Yes 1 DNS NNC DNA 87 Oncoming C3PS test after shift N1 to R Yes DNS RPR DNA 97 Oncoming C3PS test after shift NVL...

Page 49: ...l to drive shifts for refuse packer I O package 41 41 Pump pack and a neutral general purpose input No No auto Neutral to drive shifts for refuse packer I O package 41 64 12 Retarder modulation reques...

Page 50: ...s DNS SOL OFF Hydraulic default DNA 35 ECU EEPROM checksum test No 5 Induce COP timeout reset ECU DNA 36 ECU RAM self test No 5 Induce COP timeout reset ECU DNA 41 ECU I O ASIC addressing test No 5 In...

Page 53: ...Diagnostic Code section lists diagnostic codes and their description Locate the appropriate troubleshooting chart and follow the instructions If the code does not reappear it may be an intermittent p...

Page 54: ...applicable If your transmission is not equipped with an oil level sensor or retarder disregard the portions of the schematic pertaining to those optional pieces of equipment Refer to the appropriate...

Page 55: ...ECTOR RSI CONNECTOR A 1 L 1 12V OR 24V BATTERY BATTERY POWER IGNITION ECU A 2 L 2 E 2 R 2 VIM B 9 B 18 B 2 B 11 K 1 K 2 J 1 J 2 H A C E 1 7 E 1 R 1 F1 S1 B 12 C1 ALT DDR CONNECTOR 7 1 A H J 2 K 2 E 2...

Page 56: ...stic Data to find input voltage Record reading 2 Turn off vehicle ignition and remove the connectors from the ECU 3 Check system voltage at wire 136A and 136C pin B2 and B11 If power is low or high at...

Page 57: ...ires that are chafed and touching other components 6 If no other cause is found replace the ECU If replacing the ECU corrects the problem reinstall the original bad ECU to confirm that the problem is...

Page 59: ...A GREEN 135 B GREEN 135 B GREEN 156 BLUE 124 RED 164 YELLOW 133 WHITE B 3 SUMP TEMP SENSOR TPS 165 BLUE G 3 G 2 B 3 RED BLACK G 3 106 WHITE SUMP TEMP SENSOR AND OIL LEVEL SENSOR GROUND OIL LEVEL POWE...

Page 60: ...B GREEN 156 BLUE 124 RED 164 YELLOW 133 WHITE SUMP TEMP SENSOR TPS 165 BLUE 162 WHITE B 28 RED RED BLACK BLUE BLACK A B 106 WHITE 161 YELLOW SUMP TEMP SENSOR AND OIL LEVEL SENSOR GROUND OIL LEVEL POWE...

Page 61: ...with Pro Link version 3 0 or later For complete description of oil level checking procedures using the oil level sensor see Section 5 Normal operation of the OLS can be checked as follows Attach the D...

Page 62: ...been normal the problem is either in the OLS itself the internal harness wires or the transmission side of the feedthrough harness connection Inspect the transmission feedthrough harness connector to...

Page 63: ...GREEN 135 B GREEN 156 BLUE 124 RED 164 YELLOW 133 WHITE B 3 SUMP TEMP SENSOR TPS 165 BLUE G 3 G 2 B 3 RED BLACK G 3 106 WHITE SUMP TEMP SENSOR AND OIL LEVEL SENSOR GROUND OIL LEVEL POWER OIL LEVEL SI...

Page 64: ...UE 124 RED 164 YELLOW 133 WHITE SUMP TEMP SENSOR TPS 165 BLUE 162 WHITE B 28 RED RED BLACK BLUE BLACK A B 106 WHITE 161 YELLOW SUMP TEMP SENSOR AND OIL LEVEL SENSOR GROUND OIL LEVEL POWER OIL LEVEL SI...

Page 65: ...d of the TPS travel 2 If counts are high but the percentage never reaches 100 percent TPS linkage may have bound up and overstroked the TPS to set a false 100 percent reading After TPS overstroking ce...

Page 66: ...If the original problem reoccurs reinstall the replacement ECU 8 The only troubleshooting necessary for a PWM fault is to check for an open short to ground or short to battery in the signal wire from...

Page 67: ...B 140 BLUE B 6 TURBINE SPEED HI TURBINE SPEED LO A 141 VIOLET B 7 B 150 ORANGE B 16 ENGINE SPEED HI ENGINE SPEED LO TRANSMISSION E 3 E 2 E 3 E 2 A B ENGINE SPEED SENSOR HD B 500 TURBINE SPEED SENSOR O...

Page 68: ...B 7 B 150 ORANGE B 16 ENGINE SPEED HI ENGINE SPEED LO TRANSMISSION V U A B ENGINE SPEED SENSOR HD B 500 TURBINE SPEED SENSOR OUTPUT SPEED SENSOR ECU SPEED SENSOR CIRCUITS USE TWISTED PAIRS OF WIRE B...

Page 69: ...terminals for dirt corrosion or damage If resistance is not correct replace the sensor 2 Remove the connectors from the ECU Check the sensor circuit in the external harness for open wires shorts betwe...

Page 70: ...s see Sales Tech Data Book SA2404EN Part II Section C Recheck the sensor wiring for intermittent conditions see Appendix A 6 If the condition persists replace the ECU If replacing the ECU corrects the...

Page 72: ...ELLOW 4 E 1 R 1 ECU A 1 L 1 VIM B 2 B 9 A 8 B 34 RSI CONNECTOR BATTERY GROUND REMOTE WAKEUP REMOTE SERIAL INTERFACE B 26 160 VIOLET 5 6 7 1 REMOTE SERIAL INTERFACE 136 B 143 B CUT WIRE BETWEEN TERMINA...

Page 73: ...place the shift selector 5 Use care in separating and disconnecting the shift selector head from the ECU If this is a remote shift selector replace the shift selector assembly 6 If the condition persi...

Page 75: ...wing Units Produced Prior To 9 94 F 3 ANALOG GROUND TPS LO SUMP TEMP ECU B A G 2 GREEN B 1 B 13 VIOLET C 135 A 135 B F 3 SUMP TEMP SENSOR TPS 147 FEEDTHROUGH CONNECTOR TRANSMISSION G 2 A B C G 2 F 3 B...

Page 76: ...OG GROUND TPS LO SUMP TEMP SIGNAL GROUND C3PS INPUT ECU B A W GREEN B 1 B 13 VIOLET C 135 A 161 N 135 B P B 27 B 28 X SUMP TEMP SENSOR TPS 147 YELLOW WHITE 162 FEEDTHROUGH HARNESS CONNECTOR TRANSMISSI...

Page 77: ...ion See Table 6 4 on next page The sump must be preheated to an acceptable temperature to avoid logging codes and transmission diagnostic response NOTE Medium cold fluid 29 C 20 F to 7 C 20 F will all...

Page 78: ...onableness and speed tie up tests turned off 0 32 0 32 Medium cold fluid R N D allowed 2nd gear start hold override upshifts only 7 19 7 19 All C3 Pressure Switch tests turned off Neutral operation on...

Page 79: ...smission the problem is with the engine or its cooling system 4 If the transmission became hot before the engine allow the vehicle to idle for 3 5 minutes and check the transmission fluid level Correc...

Page 80: ...9 8 2400 0 85 13 5 549 79 6 3200 0 85 13 5 549 79 6 LOCKUP OPERATION MAXIMUM COOLER FLOW Input rpm Flow Pressure Drop L s gpm kPa psi 600 0 10 1 6 0 0 800 0 23 3 7 0 0 1200 0 50 7 9 0 0 1400 0 63 10 0...

Page 81: ...141 VIOLET B 7 B 150 ORANGE B 16 ENGINE SPEED HI ENGINE SPEED LO TRANSMISSION E 3 E 2 E 3 E 2 A B ENGINE SPEED SENSOR HD B 500 TURBINE SPEED SENSOR OUTPUT SPEED SENSOR ECU SPEED SENSOR CIRCUITS USE TW...

Page 82: ...ORANGE B 16 ENGINE SPEED HI ENGINE SPEED LO TRANSMISSION V U A B ENGINE SPEED SENSOR HD B 500 TURBINE SPEED SENSOR OUTPUT SPEED SENSOR ECU SPEED SENSOR CIRCUITS USE TWISTED PAIRS OF WIRE B 9 B 27 B 18...

Page 83: ...de 22 16 3 Connect the Pro Link 9000 with ignition on engine off check for indication of turbine speed If turbine speed is indicated refer to Section 4 2 for corrective action 4 If the output speed se...

Page 84: ...or damage at the tone wheel end Check for looseness of the tone wheel Refer to the appropriate Service Manual if repair of a loose tone wheel is necessary Replace the sensor if it is damaged or if its...

Page 85: ...ced Prior To 9 94 FOR INPUT FUNCTIONS SIGNAL GROUND C 3 F 2 C 3 TRANSMISSION F 2 161A YELLOW 162 WHITE ECU B 27 C3 PS B 28 13 C3 PRESSURE SWITCH SIGNAL GROUND VIW CONNECTOR 161B B 28 B 27 F 2 C 3 B A...

Page 86: ...94 12 97 FOR INPUT FUNCTIONS SIGNAL GROUND N W X TRANSMISSION 135 GREEN 161 YELLOW 162 WHITE ECU B 1 B 27 C3 PS B 28 13 C3 PRESSURE SWITCH ANALOG GROUND SIGNAL GROUND VIW CONNECTOR 161 B TID1 B 28 B 2...

Page 87: ...proper transmission Service Manual If wiring problems are found isolate and repair see Appendix E Paragraph 1 9 3 If no wiring problems are found replace the C3 pressure switch refer to transmission S...

Page 89: ...g Units Produced Prior To 9 94 F 3 ANALOG GROUND TPS LO SUMP TEMP ECU B A G 2 GREEN B 1 B 13 VIOLET C 135 A 135 B F 3 SUMP TEMP SENSOR TPS 147 FEEDTHROUGH CONNECTOR TRANSMISSION G 2 A B C G 2 F 3 B 1...

Page 90: ...GROUND TPS LO SUMP TEMP SIGNAL GROUND C3PS INPUT ECU B A W GREEN B 1 B 13 VIOLET C 135 A 161 N 135 B P B 27 B 28 X SUMP TEMP SENSOR TPS 147 YELLOW WHITE 162 FEEDTHROUGH HARNESS CONNECTOR TRANSMISSION...

Page 91: ...es Also you may be experiencing an intermittent problem and the code will not be active Proceed cautiously it is unlikely there is a sensor hardware fault 3 Disconnect the external harness at the tran...

Page 92: ...2 361 OHMS 525 577 632 691 754 820 889 962 1039 1118 1202 1288 1379 1472 1569 1670 1774 1882 1993 2107 2225 2628 1 6 C 60 500 700 900 1100 1300 1500 1700 1900 2100 2300 2500 2700 2900 40 20 0 20 40 60...

Page 93: ...has been corrected drive the vehicle to see if Code 34 14 recurs If Code 34 14 recurs proceed to Step 3 3 Reprogram the correct calibration into the EEPROM Contact your nearest Allison distributor de...

Page 94: ...OOL CONNECTOR RSI CONNECTOR A 1 L 1 12V OR 24V BATTERY BATTERY POWER IGNITION ECU A 2 L 2 E 2 R 2 VIM B 9 B 18 B 2 B 11 K 1 K 2 J 1 J 2 H A C E 1 7 E 1 R 1 F1 S1 B 12 C1 ALT DDR CONNECTOR 7 1 A H J 2...

Page 95: ...ground connections can cause this code A defective charging system or open battery fuse or fusible link can also cause this code The battery fuse or fusible link may be at the battery or in the VIM Di...

Page 96: ...orrection for subcode 36 00 requires the installation of EPROM software that is compatible with the ECU hardware involved If a different EEPROM calibration is required update the ECU hardware to be co...

Page 97: ...A 134 YELLOW A 34 B 109 BLUE A 9 A SOL SOLENOID GROUND 1 D SOL J SOL B SOL SOLENOID GROUND 2 E SOL C SOL SOLENOID GROUND 3 G SOL F SOL LO K SOL HI K SOL LO A 1 A 2 D 1 B 1 B 2 E 1 C 1 C 2 F 1 D 2 A B...

Page 98: ...110 WHITE A 10 A 134 YELLOW A 34 B 109 BLUE A 9 A SOL SOLENOID GROUND 1 D SOL J SOL B SOL SOLENOID GROUND 2 E SOL C SOL SOLENOID GROUND 3 G SOL F SOL LO K SOL HI K SOL LO A B M 131 BLUE A 31 A B A B F...

Page 99: ...oubleshooting procedure for 69 XX codes Active Indicator Clearing Procedure Power down Manual NOTE Intermittent connections or lack of battery direct power and ground connections may cause this and ot...

Page 100: ...17 and 6 18 of Section 6 5 Also check battery and ECU input voltages NOTE The retarder accumulator solenoid H has a 30 Ohm coil Since H solenoid is not mounted in the sump no relationship between temp...

Page 101: ...the terminals in the connectors and the ECU for damage or contamination Clean or replace as necessary If the terminals are satisfactory check the wires of the solenoid circuit in the external harness...

Page 103: ...10 A 134 YELLOW A 34 B 109 BLUE A 9 A SOL SOLENOID GROUND 1 D SOL J SOL B SOL SOLENOID GROUND 2 E SOL C SOL SOLENOID GROUND 3 G SOL F SOL LO K SOL HI K SOL LO A 1 A 2 D 1 B 1 B 2 E 1 C 1 C 2 F 1 D 2...

Page 104: ...F 110 WHITE A 10 A 134 YELLOW A 34 B 109 BLUE A 9 A SOL SOLENOID GROUND 1 D SOL J SOL B SOL SOLENOID GROUND 2 E SOL C SOL SOLENOID GROUND 3 G SOL F SOL LO K SOL HI K SOL LO A B M 131 BLUE A 31 A B A...

Page 105: ...rned out solenoid driver in the ECU Replace the solenoid when this occurs see appropriate transmission Service Manual for replacement procedure If the solenoid driver is burned out 69 XX codes will be...

Page 106: ...ion and for corroded or damaged terminals Clean or replace as necessary 2 Test solenoid circuit at the transmission connector for shorts between the solenoid circuit being diagnosed and all other term...

Page 107: ...d remove the control module see the transmission Service Manual and replace the internal harness 6 If the condition recurs use spare wire s in the external harness for the solenoid circuit indicated b...

Page 109: ...9 BLUE A 9 A SOL SOLENOID GROUND 1 D SOL J SOL B SOL SOLENOID GROUND 2 E SOL C SOL SOLENOID GROUND 3 G SOL F SOL LO K SOL HI K SOL LO A 1 A 2 D 1 B 1 B 2 E 1 C 1 C 2 F 1 D 2 A B D 1 131 BLUE A 31 A B...

Page 110: ...A 30 A 4 G 120 WHITE TRANSMISSION A 20 A 102 ORANGE A 2 e 111 GREEN A 11 J 128 ORANGE A 28 H 121 VIOLET A 21 K 129 VIOLET A 29 B 103 GREEN L 130 YELLOW C 104 WHITE F 110 WHITE A 10 A 134 YELLOW A 34...

Page 111: ...Tool J 38850 may be useful in making this test If a short is found drain the fluid remove the control module refer to the Service Manual isolate and repair the short The short will probably be in the...

Page 113: ...10 A 134 YELLOW A 34 B 109 BLUE A 9 A SOL SOLENOID GROUND 1 D SOL J SOL B SOL SOLENOID GROUND 2 E SOL C SOL SOLENOID GROUND 3 G SOL F SOL LO K SOL HI K SOL LO A 1 A 2 D 1 B 1 B 2 E 1 C 1 C 2 F 1 D 2...

Page 114: ...E F 110 WHITE A 10 A 134 YELLOW A 34 B 109 BLUE A 9 A SOL SOLENOID GROUND 1 D SOL J SOL B SOL SOLENOID GROUND 2 E SOL C SOL SOLENOID GROUND 3 G SOL F SOL LO K SOL HI K SOL LO A B M 131 BLUE A 31 A B A...

Page 115: ...dicator Clearing Procedure Power down Manual NOTE Intermittent connections or lack of battery direct power and ground connections may cause this and other codes NOTE The retarder accumulator solenoid...

Page 116: ...be twice that of a single solenoid Refer to Figure 6 31 for resistance values versus temperature Figure 6 31 Solenoid Resistance vs Temperature Terminals Solenoids Which Share Ground A1 D1 A D B1 E1 B...

Page 117: ...CU and inspect their terminals for damage or contamination Clean or replace as necessary If the terminals are satisfactory check the wires of the solenoid circuit in the external harness for shorts to...

Page 119: ...A 10 A 134 YELLOW A 34 B 109 BLUE A 9 A SOL SOLENOID GROUND 1 D SOL J SOL B SOL SOLENOID GROUND 2 E SOL C SOL SOLENOID GROUND 3 G SOL F SOL LO K SOL HI K SOL LO A 1 A 2 D 1 B 1 B 2 E 1 C 1 C 2 F 1 D 2...

Page 120: ...E F 110 WHITE A 10 A 134 YELLOW A 34 B 109 BLUE A 9 A SOL SOLENOID GROUND 1 D SOL J SOL B SOL SOLENOID GROUND 2 E SOL C SOL SOLENOID GROUND 3 G SOL F SOL LO K SOL HI K SOL LO A B M 131 BLUE A 31 A B A...

Page 121: ...ing procedure for 69 XX codes Active Indicator Clearing Procedure Power down Manual NOTE Intermittent connections or lack of battery direct power and ground connections may cause this and other codes...

Page 122: ...wice that of a single solenoid Refer to Figure 6 34 for solenoid resistance values versus temperature Figure 6 34 Solenoid Resistance vs Temperature Terminals Solenoids Which Share Ground A1 D1 A D B1...

Page 123: ...tamination Clean or replace as necessary If the terminals are satisfactory check the wires of the solenoid circuit in the external harness for continuity If the open is found in one of the wires isola...

Page 124: ...the transmission to the previous range Additional codes could be logged for other shifts where X indicates the range from and Y indicates the range to NOTE This test is not performed below a calibrat...

Page 125: ...n the fluid remove the control module disassemble the control module and clean it inspecting for damaged valve body gaskets and stuck or sticky valves Inspect the transmission for signs of clutch dama...

Page 126: ...e transmission is commanded to the previous range Additional codes could be logged for other shifts where X indicates the range from and Y indicates the range to NOTE C3 tests are turned off below a c...

Page 127: ...tions in Appendix B 5 If C3 is being held on hydraulically C3 remains pressurized drain the fluid remove the control module disassemble and clean the control module checking for damaged valve body gas...

Page 128: ...tral output is below 200 rpm or when temperatures are below a calibrated 0 C 32 F Active Indicator Clearing Procedure Power down Manual subcodes 78 and 99 only NOTE Before troubleshooting read Pages 6...

Page 129: ...and check for damaged valve body gaskets and stuck or sticky valves particularly latch valves and solenoid second stage valves 4 If excessive clutch pressure is not remaining in the offgoing clutch r...

Page 130: ...ide ratio transmission or vice versa Additional codes could be logged for other shifts where X indicates the range from and Y indicates the range to there have been occurrences of Code 54 87 N1 R for...

Page 131: ...ng the diagnostic tool s clutch test mode 5 If the clutch pressure does not show on the gauge s the control module is probably not commanding the clutch on Drain the fluid and remove the control modul...

Page 132: ...ittent connections or lack of battery direct power and ground connections may cause this and other codes NOTE Check battery and ECU input voltages before troubleshooting NOTE Energizing the solenoids...

Page 133: ...he control module gaskets are damaged See Appendix B for clutch pressure specification Drain the fluid remove the control module and inspect the face seals and valve body gaskets If the face seals or...

Page 134: ...useful in troubleshooting Troubleshooting 1 After the transmission is at operating temperature allow vehicle to idle on level ground for 3 4 minutes Check the transmission fluid level If improper flui...

Page 135: ...noisy sensor is found check the resistance of the sensor 300 30 Ohms refer to the Code 22 XX temperature variation chart and its wiring for opens shorts and shorts to ground refer to Code 22 XX Carefu...

Page 137: ...external harness for shorts Use the system wiring diagram to identify wires which are connected If a shorted C3 pressure switch circuit in the external harness is found isolate and repair 4 If the C3...

Page 138: ...tion of Temperature Description Version 6 501 and 502 Version 7 D70 Version 7A P01 MD Retarder Light On MD Retarder Light Off 166 C 330 F 159 C 318 F 141 C 285 F 135 C 275 F 166 C 330 F 159 C 318 F MD...

Page 139: ...266 284 302 361 OHMS 525 577 632 691 754 820 889 962 1039 1118 1202 1288 1379 1472 1569 1670 1774 1882 1993 2107 2225 2628 1 6 C 60 500 700 900 1100 1300 1500 1700 1900 2100 2300 2500 2700 2900 40 20...

Page 141: ...S LO RTDR TEMP ECU B A B GREEN B 1 B 4 C 135 A 135 C A TPS 138 ORANGE RETARDER TEMP SENSOR A B B 1 B C B 4 RETARDER CONNECTOR BULKHEAD CONNECTOR SENSOR CONNECTOR MD B 300 B 400 HD B 500 ECU V01668 B B...

Page 142: ...NNECTOR MD B 300 B 400 HD B 500 ECU V04935 B BLACK NOTE 1 This wire may pass through a bulkhead connector NOTE 2 These wires may pass through a sensor connector SEE NOTE 2 TO OLS SEE NOTE 1 ANALOG GRO...

Page 143: ...or hardware fault 3 Remove the connector at the ECU Measure resistance between B1 and B4 Compare resistance value to chart see Figure 6 35 to see if reading is within expected operating range 4 Discon...

Page 145: ...icle acceleration event is defined as an increase in transmission output speed from 1 rpm to a calibration value The operation of the Automatic Neutral For Refuse Packer will be limited when this code...

Page 146: ...Use the DDR to identify the two wires associated with the input functions for Pump Pack Enable and Automatic Neutral For Refuse Packer Inspect the input wiring connectors and switches to determine why...

Page 147: ...5 B GREEN 135 B GREEN 156 BLUE 124 RED 164 YELLOW 133 WHITE B 3 SUMP TEMP SENSOR TPS 165 BLUE G 3 G 2 B 3 RED BLACK G 3 106 WHITE SUMP TEMP SENSOR AND OIL LEVEL SENSOR GROUND OIL LEVEL POWER OIL LEVEL...

Page 148: ...BLUE 124 RED 164 YELLOW 133 WHITE SUMP TEMP SENSOR TPS 165 BLUE 162 WHITE B 28 RED RED BLACK BLUE BLACK A B 106 WHITE 161 YELLOW SUMP TEMP SENSOR AND OIL LEVEL SENSOR GROUND OIL LEVEL POWER OIL LEVEL...

Page 149: ...wn NOTE Before troubleshooting read Pages 6 17 and 6 18 of Section 6 5 Also check battery and ECU input voltages NOTE Intermittent connections or lack of battery direct power and ground connections ca...

Page 150: ...ion 3 Position 4 Position 5 Position 6 A to C 32 K 0 14 28 45 65 82 100 1 1 1 5 1 9 2 3 2 8 3 2 3 6 1 2 3 4 5 6 White Blue Orange Violet Green Yellow Red Auto 1 2 On A to C 12 K 50 2 4 No connections...

Page 151: ...reen Violet Orange Blue White Dedicated Pedal A B C 135D 164 133 Green Yellow White 3 Pressure Switch Hi 3 Pressure Switch Med 3 Pressure Switch Lo A B A B A B 133 173 133 172 133 171 White Violet Whi...

Page 153: ...t match the transmission shift calibration When a code 65 is set no shifts out of neutral are allowed It is possible the transmission calibration selected for this engine is improper Contact local All...

Page 154: ...g 151B VIW CONNECTOR B 8 B 17 ECU 142A WHITE 151A BLUE STANDARD DIAGNOSTIC TOOL CONNECTOR 7 142B 6 OPTIONAL DEUTSCH DIAGNOSTIC CONNECTOR A K J SERIAL COMMUNICATIONS INTERFACE SERIAL COMMUNICATIONS INT...

Page 155: ...n link failure NOTE If a Code 66 00 is set and the ECU was programmed after 9 26 94 the SERVICE icon on the shift selector will be illuminated Active Indicator Clearing Procedure Power down Manual Sel...

Page 157: ...subcodes 32 33 35 36 41 Self clearing subcode 32 after an ECU reset NOTE Subcode 34 cannot be cleared Main Code Subcode Meaning 69 12 ECU open driver A solenoid circuit 69 13 ECU open driver B soleno...

Page 158: ...tart the ECU If the code recurs replace the ECU For subcodes 33 through 41 except 34 and 36 1 Remove the ECU core cover or shift selector 2 Reseat the EPROM 3 Reinstall the core cover or shift selecto...

Page 160: ...tic tool Operator s Manual for further information regarding special input functions and other inhibits NOTE The schematic in Appendix J shows the intended use of the control features specified These...

Page 161: ...tions preselect a lower range Engine Brake and Preselect Request Standard Engine Brake and Preselect Request Special The following input functions inhibit upshifts D1 Selection Auxiliary Hold The foll...

Page 162: ...function information references The wiring schematics in Appendix J illustrate installation requirements for output functions as well as input functions and designate specific wire numbers in the tra...

Page 164: ...o the engine correct Are wheel chocks in place Is air flow to the cooler and radiator unrestricted Is the driveline properly connected Are there signs of fluid leakage under the vehicle What is the or...

Page 165: ...L NOT CRANK Lever shift selector not in neutral Select N Neutral and restart Dead battery Recharge battery Disconnected battery Reconnect battery No display Faulty ignition circuit wire 146 Repair wir...

Page 166: ...iring See Appendix E Fluid temperature too low Warm transmission fluid Faulty fluid temperature sensor circuit Repair sensor or circuits Faulty ECU Replace the ECU DO NOT SHIFT LIGHT FLASHES INTERMITT...

Page 167: ...e battery and charging system Shift selector is not functioning properly Replace shift selector Disconnected or dirty connectors Perform connector checkout Appendix E Faulty wiring harnesses Repair ha...

Page 168: ...DOES NOT SHIFT PROPERLY ROUGH SHIFTS SHIFTS OCCUR RING AT TOO LOW OR TOO HIGH SPEED Engine idle speed too fast neutral to range shift Adjust engine idle speed refer to Vehicle Service Manual Faulty t...

Page 169: ...enable switch if present ABS input is active if vehicle is equipped with ABS None This is normal If ABS is active retarder will not apply Retarder request below 10 2 percent Use DDR to determine count...

Page 170: ...Stays On Autoflow valve not returning to off position Autoflow valve spring weak or broken Autoflow valve stuck on K solenoid stuck on ABNORMAL ACTIVITIES OR RESPONSES A Excessive Creep in First and...

Page 171: ...el refer to transmission Mechanic s Tips for proper dipstick calibration Low main pressure See Low Pressure section Erratic speed sensor signal See Code 22 XX Sticking stage 2 solenoid valve see Solen...

Page 172: ...fer to transmission Service Manual C Ranges 3 5 R Only 6 Speed Ranges 1 4 6 R only 7 Speed C3 clutch slipping leaks at face seals leaks at piston seals C3 clutch plates worn Inspect control module fac...

Page 173: ...f necessary refer to transmission Service Manual Control module body leakage separator plate not flat separator plate gasket leakage loose control valve body bolts Replace or rebuild control module as...

Page 174: ...6 Speed Stall In Second Range 7 Speed A High Stall Speeds Not in gear Select D Drive Low fluid level aerated fluid Add fluid to proper level refer to Mechanic s Tips for proper dipstick calibration In...

Page 175: ...ansmission Service Manual Air flow to cooler obstructed Remove air flow obstruction Engine overheat Correct overheat situation refer to Vehicle Service Manual Inaccurate temperature gauge or sending u...

Page 176: ...o transmission Service Manual if repair is needed Dipstick or fill tube seal worn Replace seals or dipstick Incorrect dipstick marking Calibrate dipstick refer to transmission Mechanic s Tips NOISE OC...

Page 177: ...ls cracked converter pump tangs converter cover or converter housing porosity replace parts as required refer to transmission Service Manual PTO driveline out of specification Bring driveline into spe...

Page 178: ...d or missing Rebuild clutch assembly Inadequate fluid pressure to PTO Inspect and repair fluid pressure supply line kinked loose or plugged orifice too small Engine speed outside operating band Increa...

Page 179: ...t Drive Differential clutch bad C7 piston seals C7 rotating seals C7 clutch plates C7 check ball C7 electrical wires solenoids terminals connectors Rebuild differential clutch refer to transmission Se...

Page 180: ...p Hand Lever Off Position 1 Position 2 Position 3 Position 4 Position 5 Position 6 A to C 32 K 0 16 28 48 65 84 100 1 1 1 5 1 9 2 3 2 8 3 2 3 6 1 2 3 4 5 6 White Blue Orange Violet Green Yellow Red Au...

Page 182: ...art Numbers Terminal Part Numbers Tool Part Numbers and Repair Instructions Appendix F Throttle Position Sensor Adjustment Appendix G Miscellaneous Items Appendix H Hydraulic Schematics Appendix J WT...

Page 184: ...ete harness However it is important to check the entire harness for chafed or damaged areas Road vibrations and bumps can damage a poorly installed harness by moving it against sharp edges and cause s...

Page 185: ...or below a certain temperature Only on right hand or left hand turns When the vehicle hits a bump etc If such a condition can be related to the code it is easier to find the cause If the time between...

Page 186: ...lugs from the pressure tap locations where measurement is desired refer to Figure B 1 Figure B 1 Clutch Pressure Check Points 2 Install hydraulic fittings suitable for attaching pressure gauges or tra...

Page 187: ...range where lockup can be obtained Record the pressure values at the engine speed and sump fluid temperature values shown in Table B 1 The lockup clutch is functioning correctly when engine speed and...

Page 188: ...ication take corrective action to replace the internal parts of the transmission necessary to correct the problem Refer to the Transmission Service Manual for the model being checked 5 Recheck pressur...

Page 189: ...C5 1300 1900 189 276 2C C1 C4 1300 1900 189 276 MD 3070 Idle Neutral C5 1500 1900 218 276 1480 1900 215 276 Reverse C3 C5 1500 1900 218 276 1480 1900 215 276 LowC C3 C6 1500 1900 218 276 1480 1900 21...

Page 190: ...3 0 5 850 1300 124 189 6C C2 C4 1150 1650 167 239 0 80 C2 0 11 6 0 35 C4 0 5 6L C2 C4 LU 900 1300 131 189 0 80 C2 0 11 6 0 35 C4 0 5 850 1300 124 189 MD 3070 High Speed Neutral C5 1500 2300 218 334 14...

Page 191: ...980 1400 142 203 1400 1600 200 232 5C C2 C3 1150 1650 167 239 1130 1650 164 239 1400 1600 200 232 5L C2 C3 LU 900 1300 131 189 880 1300 128 189 880 1300 128 189 1400 1600 200 232 6C C2 C4 1150 1650 1...

Page 192: ...61 0 70 C1 0 10 0 70 C2 0 10 4L C1 C2 LU 1050 1400 152 203 0 70 C1 0 10 0 70 C2 0 10 950 1400 138 203 5C C2 C3 1190 1380 173 200 0 70 C2 0 10 0 70 C3 0 10 5L C2 C3 LU 900 1250 131 181 0 70 C2 0 10 0 7...

Page 194: ...LU 6 X X 0 X X 0 5 X X 0 X X X 0 4 0 X X X 0 3 X X 0 X X X 0 2 X X 0 X X X 0 1 X X 0 X X 0 N1 X X X 0 X 0 N2 X X X X N3 X X X X N4 X X X X R X X X X X X Range Solenoid Non Latching Modulating Clutche...

Page 195: ...ank Electrically OFF with respect to solenoids hydraulically OFF with respect to clutches 0 Optional ON or OFF If diagnostics indicate that turbine speed is below a calibration value typically less th...

Page 196: ...Allison Transmission components are the ECU speed sensors retarder connectors transmission connectors and shift selectors Other kinds of connectors for optional or customer furnished components are p...

Page 197: ...A13 White 113 Reverse Warning VIM Conn F2 A14 White 114 Output Function 1 VIM Conn F3 A15 Green 115 DO NOT SHIFT Light VIM Conn A3 A16 Reserved A17 Green 117 Input Function 8 VIW 16 A18 Blue 118 Inpu...

Page 198: ...Sump Temp Signal Trans Conn F3 B14 Green 148 Output Speed Sensor Lo Output Speed Sensor B Rtdr Conn D B15 Orange 149 Turbine Speed Sensor Hi Trans Conn E3 B16 Orange 150 Engine Speed Sensor Lo Engine...

Page 200: ...K 120 White G 8 M 7 121 Violet H 9 8 122 Violet d 7 P 143C Black 124 Red a 10 R 135B Green 9 127 White c 18 S 136B Red 313CM Yellow 128 Orange J 11 T 9 129 Violet K 12 U 10 130 Yellow L 13 V 11 131 Bl...

Page 201: ...ECU A22 8 White 120 ASOL A 1 G ECU A20 9 Violet 121 SG02 B 2 H ECU A21 10 Red 124 TPHI ECU A24 11 Orange 128 BSOL B 1 J ECU A28 12 Violet 129 FSOL E 1 K ECU A29 13 Yellow 130 SG03 C 2 L ECU A30 14 Blu...

Page 202: ...SGD4 ECU A22 a Red 124 TPHI ECU A24 c White 127 HSOL ECU A27 J Orange 128 BSOL ECU A28 K Violet 129 FSOL ECU A29 L Yellow 130 SGD3 ECU A30 M Blue 131 DSOL ECU A31 e Yellow Green 134 111 KSHI JSOL ECU...

Page 203: ...let 121 SG02 B 2 H ECU A21 P Violet 122 SG04 ECU A22 R Red 124 TPHI ECU A24 S White 127 HSOL ECU A27 T Orange 128 BSOL B 1 J ECU A28 U Violet 129 ESOL E 1 K ECU A29 V Yellow 130 SG03 C 2 L ECU A30 W B...

Page 204: ...wer ECU A6 E Green 107 FSHI ECU A7 f Blue 101 NSLO ECU A1 F White 110 FSOL ECU A10 G White 120 ASOL ECU A20 H Violet 121 SGD2 ECU B21 J Orange 128 BSOL ECU A28 K Violet 129 ESOL ECU A29 L Yellow 130 S...

Page 205: ...Level ECU B31 C1 Green 103 C C3 Solenoid Hi ECU A3 C2 Yellow 130 Solenoid Ground 3 C G ECU A30 C3 White 162 C3 Pressure Switch Power ECU B28 D1 Blue 131 D C4 Solenoid Hi ECU A31 D2 White 110 F Lockup...

Page 206: ...No Description Termination Point s 1 Red 136 Battery ECU B2 VIM Conn E1 2 Orange Jumper RSI Conn 3 Clip Jumper Wire When Remote Selector is Primary 3 Orange Jumper RSI Conn 2 4 Yellow 168 Remote Seri...

Page 207: ...SS CONNECTOR Terminal No Color Wire No Description Termination Point s C Green 135C TPLO ECU B1 D Orange 138 RETT ECU B4 E Blue 109 KSLO ECU A9 F Yellow 134 KSHI ECU A34 G Violet 122 SGD4 ECU A22 H Wh...

Page 208: ...500 ONLY Terminal No Color Wire No Description Termination Point s A Orange 149 Turbine Speed Sensor Hi ECU B15 B Blue 140 Turbine Speed Sensor Lo ECU B6 OUTPUT SPEED SENSOR CONNECTOR Terminal No Col...

Page 209: ...OSTIC CONNECTOR Terminal No Color Wire No Description Termination Point s A Black 143 Battery ECU B18 VIM Conn A2 H Yellow 146B Ignition Signal ECU B12 VIM Conn F1 H Red 136D Battery ECU B12 VIM Conn...

Page 210: ...TIONAL DEUTSCH DDR CONNECTOR Terminal No Color Wire No Description Termination Point s A White 142A Serial Communication ECU B8 VIW 6 B Blue 151A Serial Communication ECU B17 VIW 7 C Yellow 146B Ignit...

Page 211: ...ved 5 Orange 137 Spec Function Input 7 ECU B3 6 White 142B Serial Communication ECU B8 DDR J 7 Blue 151B Serial Communication ECU B17 DDR K 8 Yellow 153 Spec Function Input 2 ECU B19 9 Green 155 Spec...

Page 212: ...s Corp APPENDIX D WIRE CONNECTOR CHART Figure D 14 TPS Connector THROTTLE POSITION SENSOR CONNECTOR Terminal No Color Wire No Description Termination Point s A Green 135A Analog Ground ECU B1 Trans Co...

Page 213: ...CHART Figure D 15 Transfer Case Connector TRANSFER CASE CONNECTOR Terminal No Color Wire No Description Termination Point s A White 127 H Diff Lock Solenoid Hi ECU A27 B Violet 122 H Diff Lock Solenoi...

Page 214: ...NNECTOR MD B 300 B 400 Terminal No Color Wire No Description Termination Point s A Yellow 134 K Rtdr Enable Solenoid Hi ECU A34 B Blue 109 K Rtdr Enable Solenoid Lo ECU A9 C Yellow 139 Output Speed Se...

Page 215: ...SHOOTING MANUAL APPENDIX D WIRE CONNECTOR CHART Figure D 17 Retarder Connector HD B 500 RETARDER CONNECTOR HD B 500 Terminal No Color Wire No Description Termination Point s A Yellow 134 K Rtdr Enable...

Page 216: ...Resistance Module Interface Connector RETARDER RESISTANCE MODULE INTERFACE CONNECTOR Terminal No Color Wire No Description Termination Point s A Green 135D Analog Ground ECU B1 Trans Conn G2 Rtdr Res...

Page 217: ...E CONNECTOR CHART Figure D 19 Retarder Temperature Sensor Connector HD B 500 RETARDER TEMPERATURE SENSOR CONNECTOR HD B 500 Terminal No Color Wire No Description Termination Point s A Orange 138 Retar...

Page 219: ...r Navistar 29516972 Navistar 29516972 Ford 29515707 8 Ford 29515704 Gillig 29511644 Gillig 29511644 Description Rev Warn Neut Start Power Ground Fuse 12033769 Fuse 12033769 6 Way Shroud 47 6 Way Tower...

Page 220: ...15 DO NOT SHIFT Light ECU A15 B1 Orange 132 Output Function 2 ECU A32 B2 Violet 157 Speedometer Signal ECU B23 B3 Reserved C1 Reserved C2 White 125 Output Function 4 ECU A25 C3 Orange 158 Dimmer Input...

Page 221: ...ition Power C2 Green 312NC Output Wire 112 Relay Normally Closed C3 Reserved D1 Green 325NC Output Wire 125 Relay Normally Closed D2 Green 332NC Output Wire 132 Relay Normally Closed D3 Reserved E1 Ye...

Page 222: ...E 1 ECU A29 11 Yellow 130 SGD3 C 2 ECU A30 12 Blue 131 DSOL D 1 ECU A31 13 Red 136B 12 24V Splice to 136E Splice to 136A 14 Red 136C 12 24V Splice to 136E ECU B11 15 Black 143B BTGD Splice to 143F Sp...

Page 223: ...S ECU A15 B Orange 132 SFO2 ECU A32 C White 125 SFO4 ECU A25 D Violet 112 SFO3 ECU A12 E White 113 RVWN ECU A13 F White 114 SFO1 ECU A14 G H VIM B 8 WAY FEMALE P N 12064998 FREIGHTLINER HARNESS P N 29...

Page 224: ...Wire No Description Termination Point s A Red 136A 12 24V ECU B2 B Red 136C 12 24V ECU B11 C Yellow 146A IGSN ECU B12 D E Black 143C BTGD ECU B18 F Black 143A BTGD ECU B9 6 WAY TOWER P N 12015799 GILL...

Page 225: ...O2Com 315 SFO1Com VIM B E2 7 Green 332NC SFO2NC 316 SFO1NC VIM B D2 8 Blue 332NO SFO2NO 317 SFO1NO VIM B E3 9 Green 105 SFO5 105 Same as Current ECU A5 10 Blue 151B SCI 151B Same as Current Splice to...

Page 226: ...ire No Description Wire No Description Termination Point s 1 Yellow 161B Signal Ground 161B Same as Current Splice to 161A 2 Green 155 SFI1 155 Same as Current ECU B21 3 Green 117 SFI 137 SFI7 ECU A17...

Page 227: ...Description Termination Point s 30 White GND GND SP Splice Area C 85 Green 115 DNS ECU A15 86 White 305 ACC IGTN CIW A D 87 White 223 DNS LIGHT CIW B F 87A Relay Holder B P N 29509583 Terminal No Col...

Page 228: ...136D 12 24V Splice Area A 2A White 306 Ignition Fused CIW B D 2B Yellow 146A IGSN ECU B12 Relay Holder A P N 29509583 Terminal No Color Wire No Description Termination Point s 30 Black 15E IG SRT CIW...

Page 229: ...VIM B G1 POWER GROUND P N 15300002 NAVISTAR HARNESS P N 29516972 Terminal No Color Wire No Description Termination Point s A Red 336B 12 24 UNF Splice to 336A C B Black 343B BTGND Splice to 343A B FUS...

Page 230: ...C II ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL APPENDIX D WIRE CONNECTOR CHART Figure D 28 Resistance Module Type 2 Single Pressure Switch RESISTANCE MODULE TYPE 2 Terminal No Color A White B Blue LA...

Page 231: ...TING MANUAL D 38 Copyright 1998 General Motors Corp APPENDIX D WIRE CONNECTOR CHART Figure D 29 Resistance Module Type 3 Bendix E 10R Pedal RESISTANCE MODULE TYPE 3 Terminal No Color A Blue B Violet C...

Page 232: ...NTROLS TROUBLESHOOTING MANUAL APPENDIX D WIRE CONNECTOR CHART Figure D 30 Resistance Module Type 5 Hand Lever RESISTANCE MODULE TYPE 5 Terminal No Color White 1 Blue 2 Orange 3 Violet 4 Green 5 Yellow...

Page 233: ...OTING MANUAL D 40 Copyright 1998 General Motors Corp APPENDIX D WIRE CONNECTOR CHART Figure D 31 Resistance Module Type 7 Dedicated Pedal RESISTANCE MODULE TYPE 7 Terminal No Color A Green B Yellow C...

Page 234: ...stance Module Type 8 Three Pressure Switch RESISTANCE MODULE TYPE 8 LOW PRESSURE Terminal No Color A White B Blue MEDIUM PRESSURE Terminal No Color A White B Orange HIGH PRESSURE Terminal No Color A W...

Page 235: ...ENDIX D WIRE CONNECTOR CHART Figure D 33 Resistance Module Type 9 Two Pressure Switch RESISTANCE MODULE TYPE 9 MEDIUM PRESSURE Terminal No Color A White B Orange HIGH PRESSURE Terminal No Color A Whit...

Page 236: ...WIRE CONNECTOR CHART Figure D 34 End View of Oil Level Sensor Plug OIL LEVEL SENSOR CONNECTOR Termination Point s Terminal No Color Wire No Description 24 Way Transmission Connector 31 Way Feedthroug...

Page 237: ...1998 General Motors Corp APPENDIX D WIRE CONNECTOR CHART SPARE WIRES Color Wire No From To Orange 201 ECU Trans Connector Yellow 202 ECU Trans Connector Green 203 ECU TPS Connector Violet 204 ECU RSI...

Page 238: ...star VIW E 41 1 12 Dill Connectors 4 Way Fuse and 5 Way Relay VIW E 45 1 13 EPC Connectors 16 Way Ford Bulkhead E 49 1 14 Repair of a Broken Wire with In Line Butt Splice E 50 1 15 List of World Trans...

Page 239: ...Crimper alternate 1 6 J 35615 Wire Stripper 1 14 J 35689 A Remover 1 2 1 3 J 38125 6 Crimper 1 5 1 6 J 38125 7 Crimper 1 2 1 3 1 4 1 5 1 7 1 12 1 13 J 38125 8 Crimper 1 12 J 38125 10 Remover 1 6 J 38...

Page 240: ...NOTES WTEC II ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL Copyright 1998 General Motors Corp E 3 APPENDIX E CONNECTOR PART NUMBERS TERMINAL PART NUMBERS TOOL PART NUMBERS AND REPAIR INSTRUCTIONS...

Page 241: ...NNECTOR PART NUMBERS TERMINAL PART NUMBERS TOOL PART NUMBERS AND REPAIR INSTRUCTIONS Figure E 1 Thomas Betts ECU Connector RSI Connector VIEW A CONNECTOR WIRING AND TERMINAL TERMINAL FINGER UP OR DOWN...

Page 242: ...rminal without damaging the wire unless the insulation crimp is overtight 2 Insert a terminal into Crimp Nest No 2 of crimping tool J 38687 Figure E 1 View B 3 Properly position the stripped wire in t...

Page 243: ...umulator Solenoid 30 Way and 18 Way VIM A C E B D 22 20 18 1 6 WIRE SIDE 2 2 2 0 18 1 6 WIRE SIDE SEALING PLUG VIEW A STRAIN RELIEF SPECIAL BOLT 12 WAY SEAL PLUG HARNESS CONNECTOR REMOVE IN THIS DIREC...

Page 244: ...2129426 12034236 12110234 12110236 12034413 Internal Harness to Transmission Feedthrough Connector Connector Assembly Terminal 12 Way Seal x2 Internal 12092197 12110236 29514675 Turbine Speed Nt Senso...

Page 245: ...ief and push it through the front of the connector 5 Install the retainer ring on the bolt 6 Insert the harness wires in the proper connector positions and pull out the front of the connector 7 Strip...

Page 246: ...the crimper tool J 35123 and insert a terminal into the opening marked 18 16 Figure E 2 View C so that the crimp ends point up Release the terminal holder 4 Slightly close the crimping tool close unt...

Page 247: ...rs Push to Seat Oil Level Sensor A C E B D 22 20 18 1 6 WIRE SIDE 2 2 2 0 18 1 6 WIRE SIDE C D VIEW A Remove in this direction Install in this direction Butt wire against terminal holder TERMINAL Use...

Page 248: ...imping 1 Carefully strip insulation 4 5 mm 0 5 mm 0 18 0 02 inch Unless insulation crimp is overtight Automatic Wire Stripper J 35615 will remove insulation and crimp from old terminal without damagin...

Page 249: ...iew C so that the crimp ends point up Release the terminal holder 3 Slightly close the crimping tool close until one click is heard but do not start to crimp the terminal Place the terminal on the wir...

Page 250: ...NOTES WTEC II ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL Copyright 1998 General Motors Corp E 13 APPENDIX E CONNECTOR PART NUMBERS TERMINAL PART NUMBERS TOOL PART NUMBERS AND REPAIR INSTRUCTIONS...

Page 251: ...ri Pack 280 Series Connectors Pull to Seat 8 Way Freightliner 5 Way Navistar Cab Harness 2 Way Navistar and Ford Cab Harness Internal Harness Solenoid and C3 Pressure Switch A C E B D VIEW B VIEW A J...

Page 252: ...eceptacle Terminal Socket Use crimping anvils 2 and A Secondary Lock 12066195 12034047 12065141 12064998 12034046 12064999 5 Way Navistar Cab Harness 5 Pin Plug Terminal Socket Use crimping anvils 2 a...

Page 253: ...ld terminal without damaging wire 2 Place core crimp portion of terminal on bed of anvil indicated and squeeze crimper enough to hold terminal from dropping Figure E 7 View B 3 Position wire core in t...

Page 254: ...NOTES WTEC II ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL Copyright 1998 General Motors Corp E 17 APPENDIX E CONNECTOR PART NUMBERS TERMINAL PART NUMBERS TOOL PART NUMBERS AND REPAIR INSTRUCTIONS...

Page 255: ...PART NUMBERS TOOL PART NUMBERS AND REPAIR INSTRUCTIONS Figure E 5 Packard Metri Pack 280 Series Connectors Push to Seat DDR A C E B D VIEW D VIEW B VIEW C VIEW A V00651 01 J 38125 7 WIRE CONNECTOR J...

Page 256: ...ing 1 Strip wire to approximately 6 0 0 25 mm 0 24 0 01 inch 2 Insert terminal into crimping tool Figure E 5 View D anvil 2 3 Slightly close crimping tool to hold the terminal steady 4 Align the termi...

Page 257: ...ART NUMBERS AND REPAIR INSTRUCTIONS C Terminal Crimping cont d 10 Tug on terminal and assure the crimp is tight 11 Insert terminal into connector with the lock tab toward the center line of the connec...

Page 258: ...NOTES WTEC II ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL Copyright 1998 General Motors Corp E 21 APPENDIX E CONNECTOR PART NUMBERS TERMINAL PART NUMBERS TOOL PART NUMBERS AND REPAIR INSTRUCTIONS...

Page 259: ...r Pack Connectors TPS 3 Way RMR Sensor HD Retarder Temperature 6 Way Gillig VIM 4 Way RMR Device Type 3 3 Way RMR Device Dedicated Pedal 1 3 5 2 4 1 3 5 2 4 WIRE SEAL TERMINAL THROTTLE POSITION SENSOR...

Page 260: ...If terminal is to be replaced cut terminal between core and insulation crimp this minimizes wire loss NOTE Two special tools are available for this operation tool J 38125 6 Paragraph C tool J 35606 or...

Page 261: ...gs together to fit in anvil 5 10 Crimp wire seal in anvil 5 11 Tug on terminal and be sure the crimp is tight 12 Insert the terminal into the connector The terminal will click into place and should no...

Page 262: ...eral Motors Corp E 25 WTEC II ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL APPENDIX E CONNECTOR PART NUMBERS TERMINAL PART NUMBERS TOOL PART NUMBERS AND REPAIR INSTRUCTIONS Figure E 7 Terminal Crimping...

Page 263: ...NDIX E CONNECTOR PART NUMBERS TERMINAL PART NUMBERS TOOL PART NUMBERS AND REPAIR INSTRUCTIONS Figure E 8 Amp Products Connectors 16 Way VIW 8 Way RMR Device Hand Lever A C E B D V01690 VIEW A VIEW B V...

Page 264: ...terminal steady 4 Insert the wire so that the stripped portion of the wire is in the core crimp area and the insulated portion of the wire is in the insulation crimping area 5 Crimp the stripped sect...

Page 265: ...R A ISE TO ROTA T E SEL NO CONVOLUTE CONDUIT BACKSHELL PLUG NUT LOCKWASHER RECEPTACLE GROMMET BACKSHELL FOLLOWER GROMMET BACKSHELL FOLLOWER CONVOLUTE CONDUIT BACKSHELL TAPE WRAPPED WIRE BUNDLE TAPE W...

Page 266: ...in Cavity Plug Panel Nut Lockwasher 29509616 23018768 23016504 23016302 23016303 31 Way Plug M M Terminal Pin Cavity Plug 29509617 23018768 23016504 31 Way Receptacle F F Terminal Socket Cavity Plug P...

Page 267: ...or ECD Connector Receptacle 31 Way 31 Pin Receptacle Terminal socket Cavity Plug Panel Nut O ring Seal Lockwasher Backshell Assembly Backshell Housing Backshell Follower Backshell Grommet Female Femal...

Page 268: ...insulation from the wire 2 Set the crimping tool wire size to number 18 for the ECD or IPD connector For the optional DDR connector set the wire size to number 12 To set the wire size remove the reta...

Page 269: ...outer grommet aligns with the A terminal ID on the inner grommet Reversing PIN and SKT or SOC sides of the grommet will cause the grommet holes to be misaligned with the holes in either the receptacle...

Page 270: ...NOTES WTEC II ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL Copyright 1998 General Motors Corp E 33 APPENDIX E CONNECTOR PART NUMBERS TERMINAL PART NUMBERS TOOL PART NUMBERS AND REPAIR INSTRUCTIONS...

Page 271: ...onnectors Crimped 37 Way FMTV Bulkhead 6 Way Transfer Case 8 Way MD Retarder R A ISE TO ROTA T E SEL NO DEPTH ADJUSTMENT SCREW J 34182 CRIMPER LOCKING RING J 41193 2 INSTALLER J 39841 INSTALLER J 3984...

Page 272: ...he rear of the connector using slow even pressure 4 Pull the wire and terminal out the back of the connector 5 If replacing the terminal cut the wire through the middle of the terminal crimp to minimi...

Page 273: ...he lock ring to retain the adjustment 4 Fully insert the wire into the terminal so that the stripped portion of the wire is in the crimp area A small section 0 5 1 0 mm 0 020 0 040 inch of wire will b...

Page 274: ...NOTES WTEC II ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL Copyright 1998 General Motors Corp E 37 APPENDIX E CONNECTOR PART NUMBERS TERMINAL PART NUMBERS TOOL PART NUMBERS AND REPAIR INSTRUCTIONS...

Page 275: ...re E 11 ITT Cannon Connectors Soldered 2 Way HD Retarder SOLDERING IRON Tinning stripped wire Soldering iron on side of cup Fill cup half full Soldering iron on side of cup Flow solder in cup Insert w...

Page 276: ...to allow access to the terminals and wire ends If the grommet is hard to slide lubricate the wires with isopropyl alcohol If necessary move some of the harness covering If no solder is present proceed...

Page 277: ...apply heat to the side of the cup until the solder melts NOTE Do not overheat the connector while soldering If the connector gets too hot stop work until it cools 7 Carefully insert the stripped end o...

Page 278: ...NOTES WTEC II ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL Copyright 1998 General Motors Corp E 41 APPENDIX E CONNECTOR PART NUMBERS TERMINAL PART NUMBERS TOOL PART NUMBERS AND REPAIR INSTRUCTIONS...

Page 279: ...tsch DT Series Connectors 12 Way Navistar VIW R A ISE TO ROTA T E SEL NO DEUTSCH DEUTSCH DEPTH ADJUSTMENT SCREW J 34182 CRIMPER LOCKING RING TERMINAL WIRE SIZE INDICATOR VIEW C VIEW A V01692 CRIMP PIN...

Page 280: ...re E 11 View C 1 Strip approximately 6 8 mm 0 236 0 315 inch of insulation from the wire 2 Set the crimping tool wire size to number 18 To set the wire size remove the retainer pin Lift and rotate the...

Page 281: ...ol handle until it releases The terminal is now crimped onto the wire 6 Remove the terminal and wire from the crimping tool 7 Tug on the terminal to ensure the crimp is tight D Terminal Insertion 1 Sl...

Page 282: ...NOTES WTEC II ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL Copyright 1998 General Motors Corp E 45 APPENDIX E CONNECTOR PART NUMBERS TERMINAL PART NUMBERS TOOL PART NUMBERS AND REPAIR INSTRUCTIONS...

Page 283: ...STRUCTIONS Figure E 13 Dill Connectors Freightliner 4 Way Fuse and 5 Way Relay VIW A C E B D V01693 J 38125 7 WEDGE LOCK RELEASE SECONDARY LOCK RELEASE VIEW A VIEW B FUSE BLOCK REAR VIEW SECONDARY LOC...

Page 284: ...al Pull on the wire at the rear of the fuse block to remove the terminal NOTE If servicing relay holders that are connected with a wedge lock separate the relay blocks by using Remover Tool J 38125 13...

Page 285: ...anvil and squeeze crimper enough to hold terminal from dropping Figure E 13 View C 3 Position wire core in terminal and squeeze the crimper tool to complete the core crimp Be sure to orient the termi...

Page 286: ...NOTES WTEC II ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL Copyright 1998 General Motors Corp E 49 APPENDIX E CONNECTOR PART NUMBERS TERMINAL PART NUMBERS TOOL PART NUMBERS AND REPAIR INSTRUCTIONS...

Page 287: ...ERMINAL PART NUMBERS TOOL PART NUMBERS AND REPAIR INSTRUCTIONS Figure E 14 EPC Connectors Ford 16 Way Bulkhead A C E B D V01695 J 38125 7 VIEW B VIEW A RECEPTACLE SECONDARY LOCK J 38125 13 WIRE AND TE...

Page 288: ...the terminal on the bed of the designated crimping anvil and squeeze crimper enough to hold terminal from dropping Figure E 14 View B 3 Position wire core in terminal and squeeze the crimper tool to c...

Page 289: ...n of mating terminals Ensure that terminals are secure in the connector Clean straighten or replace parts as required 2 Reconnect all previous unmated connectors Ensure connectors are fully inserted o...

Page 290: ...e the splice Insulation piercing splice clips should not be used C Straight Lead Repair Procedure 1 Locate damaged wire 2 Remove insulation 8 0 mm 0 31 inch 3 Insert one wire into crimp barrel and cri...

Page 291: ...07 O ring Seal 29503055 Thomas Betts 750001 Cavity Plug 29500919 Thomas Betts 7B282 34 Pin B Plug 29500914 Thomas Betts 400133 Terminal Socket 29500917 Thomas Betts 6D871 2 1 T Locking Bar 29503057 Th...

Page 292: ...2 Backshell Grommet 29514043 Deutsch ECD WTA10 24 03 MAIN TRANSMISSION PRIOR TO 8 15 94 24 Pin Plug 12092201 Packard Electric Terminal Socket BeCu 12110236 Packard Electric Seal 2 12092200 Packard Ele...

Page 293: ...1 Panel Nut 29516989 Deutsch ECD 0926 207 2087 O ring Seal 29516994 Deutsch ECD 9013 3 0201 Lockwasher 29519126 Deutsch ECD 0914 212 2086 Backshell Housing 29520394 Deutsch ECD WTA10 20 01 19 Backshel...

Page 294: ...63 90 Lockwasher 23016303 Deutsch IPD 112264 37 Pin Plug Assembly 29502375 ITT Cannon FMTV CA3106E28 21P B 37 Pin Receptacle Assembly 29502374 ITT Cannon FMTV CA3100E28 21S B 31 Pin Plug 29511365 Deut...

Page 295: ...043 Deutsch ECD WTA10 24 03 TRANSFER CASE 6 Pin Plug Assembly 29506418 ITT Cannon KPSE06E10 6S Terminal Socket ITT Cannon 031 9174 004 Cavity Plug 29517132 ITT Cannon 225 0070 000 6 Pin Receptacle Ass...

Page 296: ...Pin Plug Seal 12015795 Packard Electric Connector Seal 12010718 Packard Electric Terminal Pin 12089040 Packard Electric Wire Seal 12015284 Packard Electric 3 Pin Receptacle 12015092 Packard Electric...

Page 297: ...Seal 12010718 Packard Electric Terminal Pin 12089040 Packard Electric Wire Seal 12015284 Packard Electric PTO PRESSURE SWITCH 2 Pin Plug Seal 12015378 Packard Electric Connector Seal 12010155 Packard...

Page 298: ...9 Packard Electric Terminal Socket Becu 12110236 Packard Electric C3 PRESSURE SWITCH 2 Pin Plug 12092420 Packard Electric Terminal Socket 12110237 Packard Electric 2 Pin Receptacle 12110139 Packard El...

Page 299: ...00 Backshell Housing 29514041 Deutsch ECD WTA10 24 01 Backshell Follower 29514042 Deutsch ECD WTA10 24 02 Backshell Grommet 29514043 Deutsch ECD WTA10 24 03 MD MAIN INTERNAL CONNECTOR PRIOR TO 8 15 94...

Page 300: ...1690 Cavity Plug 23016504 Deutsch 114017 21 Pin Receptacle 29516187 Deutsch IPD HDP24 24 21PN Terminal Pin 29511369 Deutsch 3660 201 1690 Cavity Plug 23016504 Deutsch 114017 BULKHEAD 31 Pin Plug 2951...

Page 301: ...NSTRUCTIONS NEW FLYER DESCRIPTION ATD P N MANUFACTURER MFR P N OTHER CONNECTORS 4 Pin Plug Seal 12015798 Packard Electric Connector Seal 12020220 Packard Electric Terminal Socket 12089188 Packard Elec...

Page 302: ...UFACTURER MFR P N 19 Pin Plug A 29516947 Amp 281923 6 Terminal Socket 29516944 Amp 281938 1 Wire Seal 29516945 Amp 281934 2 19 Pin Receptacle A 29516949 Amp 281921 6 Terminal Pin 29516943 Amp 281937 1...

Page 303: ...MINAL PART NUMBERS TOOL PART NUMBERS AND REPAIR INSTRUCTIONS SCANIA DESCRIPTION ATD P N MANUFACTURER MFR P N OTHER CONNECTORS 9 Pin Plug 29520275 Amp 206708 1 Terminal Socket 23015204 Amp 66101 2 Back...

Page 304: ...PTION ATD P N MANUFACTURER MFR P N OTHER CONNECTORS 6 Pin Plug 12015799 Packard Electric Connector Seal 12010227 Packard Electric Terminal Socket 12089188 Packard Electric Wire Seal 12015323 Packard E...

Page 305: ...9 Packard Electric OTHER CONNECTORS 1 Pin Receptacle 12015987 Packard Electric Terminal Pin 12020119 Packard Electric 6 Pin Plug 12015344 Packard Electric Terminal Socket 12034046 Packard Electric Ter...

Page 306: ...4A468 BA BULKHEAD BLACK 16 Pin Plug 29516150 EPC F2AB 14A464 RA Terminal Socket 29516152 Cardell E7EB 14487 AA Connector Spacer 29516151 EPC F2AB 14A468 CA 16 Pin Receptacle 29516153 EPC F2AB 14A624 E...

Page 307: ...nal Socket 12089188 Packard Electric REVERSE WARNING NON RETARDER 2 Pin Plug Seal 12015792 Packard Electric Connector Seal 12010155 Packard Electric Terminal Socket 12089188 Packard Electric Wire Seal...

Page 308: ...B Terminal Pin 23018768 Deutsch 0460 202 16141 Wedge Lock 29511401 Deutsch W12P Cavity Plug 23016504 Deutsch 114017 12 Pin Plug Gray 29511372 Deutsch DT0612SA Terminal Socket 23016502 Deutsch 0462 201...

Page 309: ...NOTES E 72 Copyright 1998 General Motors Corp APPENDIX E CONNECTOR PART NUMBERS TERMINAL PART NUMBERS TOOL PART NUMBERS AND REPAIR INSTRUCTIONS WTEC II ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL...

Page 310: ...Conversion 2 Each position gives a different voltage The ECU then converts the voltage to counts Each count corresponds to approximately 179 mm 007 inch of throttle sensor movement Figure F 2 diagram...

Page 311: ...new counts are read from the current sensor position the idle and wide open throttle count set points are continually readjusted to the lowest and highest counts respectively This compensates for fue...

Page 312: ...t be maintained Watch the movement of the throttle sensor as the controls move it through its full stroke Be sure there is no misalignment or obstruction to smooth movement through the full stroke Mak...

Page 313: ...3 173 213 13 54 94 134 174 214 14 55 1 078 95 1 863 135 2 647 175 3 431 215 4 215 15 0 276 56 96 136 176 216 16 57 97 137 177 217 17 58 98 138 178 218 18 59 99 139 179 219 19 60 1 176 100 1 96 140 2 7...

Page 314: ...CONNECTION REMOVAL WIRING HARNESS OPERATING BAND 22 9 mm 0 9 in 47 5 mm 1 87 in 118 1 mm 4 65 in 95 2 mm 3 75 in 93 45 mm 3 679 in 87 15 mm 3 431 in HITCH PIN CLIP ENGINE FUEL LEVER Attach to engine o...

Page 316: ...nents and wiring to protect them from hot sparks etc 4 Do not connect welding cables to electronic control components 1 2 VEHICLE INTERFACE MODULE The Allison Vehicle Interface Module VIM containing a...

Page 317: ...OTTOM OF RELAY Ignition fuse position in early VIM 18 WAY CONNECTOR PIN ID 18 See page D 24 for wire terminal usage See page D 25 for wire terminal usage F G H J K L M N P R S A B C D E F 3 2 1 M1 18...

Page 318: ...OTING MANUAL APPENDIX H HYDRAULIC SCHEMATICS Figure H 1 C2 Latch Valve Detail C2 LATCH VALVE C2 TO CLUTCH C2 LATCH VALVE DETAIL C1 TO CLUTCH CONTROL MAIN EBF C2 FROM SOL C1 FROM SOL C3 TO CLUTCH C3 FR...

Page 319: ...C4 N C FWD N C ON OFF C2 Latch C1 C4 C1 Latch Lube Regulator Ctl Main Reg EX EX B D G C3 C2 C1 N O C3 N C C5 N C A C E C1 C3 Pressure Switch C3 C2 Accumulator Relay Valve MAIN CONTROL MAIN EXHAUST SU...

Page 320: ...ube Regulator Main Regulator Ctl Main Reg EX EX WT HYDRAULIC SCHEMATIC REVERSE F B D G C4 C5 C3 C2 C1 N O C3 N C C5 N C A C E EX Conv Regulator C1 Lockup Lube Lube C3 Pressure Switch C2 Accumulator Re...

Page 321: ...C SCHEMATIC 1st RANGE F D G C1 N O C3 N C A C EX C2 Latch C1 C4 Exhaust Backfill C1 Latch Main Regulator Ctl Main Reg C2 C1 C3 C2 Main Filter Pressure Relief Suction Filter Main Main MD B 300 and B 40...

Page 322: ...Lockup Lube Lube C3 Pressure Switch C5 C3 C2 Accumulator Relay Valve Main Filter Pressure Relief Pump Sump Suction Filter Main MAIN CONTROL MAIN EXHAUST SUCTION COOLER LUBE EX BACKFILL CONVERTER FWD...

Page 323: ...EX WT HYDRAULIC SCHEMATIC 3rd RANGE D C4 C5 C3 C2 C1 N O C5 N C A E EX Conv Regulator C1 Lockup Lube Lube C3 Pressure Switch C5 C3 C2 Accumulator Relay Valve Main Filter Pressure Relief Pump Sump Suct...

Page 324: ...Lube Overdrive Knockdown Conv Flow Main Regulator Main Filter Pressure Relief Pump Sump Suction Filter Main MD B 300 and B 400 models only Lube Regulator EX EX EX C1 C4 Exhaust Backfill C4 C5 C2 C1 C...

Page 325: ...C2 N O C4 N C FWD N C ON OFF C2 Latch C1 C4 Exhaust Backfill C1 Latch Main Regulator EX EX F B D G C4 C5 C2 C1 N O C3 N C C5 N C A C E EX C1 C3 Pressure Switch C5 C3 C2 MAIN CONTROL MAIN EXHAUST SUCTI...

Page 326: ...3 N C C5 N C A C E EX Conv Regulator C1 Lockup Lube Lube C3 Pressure Switch C5 C3 C2 Accumulator Relay Valve MAIN CONTROL MAIN EXHAUST SUCTION COOLER LUBE EX BACKFILL CONVERTER FWD KDN SOLENOIDS ENERG...

Page 327: ...DRAULIC SCHEMATICS C1 LATCH C2 LATCH C6 INTERLOCK VALVE Main Control Main Exhaust Backfill Exhaust MD 3070 HYDRAULIC SCHEMATIC PARTIAL NEUTRAL POWER ON MAIN EBF EBF EBF P S C1 C3 C5 C2 B FEED C FEED E...

Page 328: ...eneral Motors Corp C1 LATCH C2 LATCH C6 INTERLOCK VALVE Main Control Main Exhaust Backfill Exhaust MD 3070 HYDRAULIC SCHEMATIC PARTIAL REVERSE POWER ON MAIN EBF EBF EBF P S C1 C3 C5 C2 B FEED C FEED E...

Page 329: ...HYDRAULIC SCHEMATICS C1 LATCH C2 LATCH C6 INTERLOCK VALVE Main Control Main Exhaust Backfill Exhaust MD 3070 HYDRAULIC SCHEMATIC PARTIAL LO MD POWER ON MAIN EBF EBF EBF P S C1 C3 C5 C2 B FEED C FEED E...

Page 330: ...98 General Motors Corp C1 LATCH C2 LATCH C6 INTERLOCK VALVE Main Control Main Exhaust Backfill Exhaust MD 3070 HYDRAULIC SCHEMATIC PARTIAL 1ST POWER ON MAIN EBF EBF EBF P S C1 C3 C5 C2 B FEED C FEED E...

Page 331: ...H HYDRAULIC SCHEMATICS C1 LATCH C2 LATCH C6 INTERLOCK VALVE Main Control Main Exhaust Backfill Exhaust MD 3070 HYDRAULIC SCHEMATIC PARTIAL 2ND POWER ON MAIN EBF EBF EBF P S C1 C3 C5 C2 B FEED C FEED E...

Page 332: ...98 General Motors Corp C1 LATCH C2 LATCH C6 INTERLOCK VALVE Main Control Main Exhaust Backfill Exhaust MD 3070 HYDRAULIC SCHEMATIC PARTIAL 3RD POWER ON MAIN EBF EBF EBF P S C1 C3 C5 C2 B FEED C FEED E...

Page 333: ...H HYDRAULIC SCHEMATICS C1 LATCH C2 LATCH C6 INTERLOCK VALVE Main Control Main Exhaust Backfill Exhaust MD 3070 HYDRAULIC SCHEMATIC PARTIAL 4TH POWER ON MAIN EBF EBF EBF P S C1 C3 C5 C2 B FEED C FEED E...

Page 334: ...98 General Motors Corp C1 LATCH C2 LATCH C6 INTERLOCK VALVE Main Control Main Exhaust Backfill Exhaust MD 3070 HYDRAULIC SCHEMATIC PARTIAL 5TH POWER ON MAIN EBF EBF EBF P S C1 C3 C5 C2 B FEED C FEED E...

Page 335: ...H HYDRAULIC SCHEMATICS C1 LATCH C2 LATCH C6 INTERLOCK VALVE Main Control Main Exhaust Backfill Exhaust MD 3070 HYDRAULIC SCHEMATIC PARTIAL 6TH POWER ON MAIN EBF EBF EBF P S C1 C3 C5 C2 B FEED C FEED E...

Page 336: ...RIOR TO S N 6510021203 CONTROL MAIN MAIN PRESSURE RETARDER OUT CONVERTER OUT EXHAUST TO RETARDER LUBE FROM COOLER TO COOLER VEHICLE AIR V01519 Air Protection Valve OEM supplied Accumulator ON OFF Sole...

Page 337: ...400 RETARDER HYDRAULIC SCHEMATIC RETARDER OFF PRIOR TO S N 6510021203 EX Air Accumulator EX Retarder Temp Sensor Flow Valve Retarder Control Valve CONTROL MAIN MAIN PRESSURE CONVERTER OUT EXHAUST ORIF...

Page 338: ...RDER ON CONTROL MAIN MAIN PRESSURE RETARDER OUT CONVERTER OUT EXHAUST TO RETARDER LUBE FROM COOLER TO COOLER VEHICLE AIR V01539 01 Air Protection Valve OEM supplied Accumulator ON OFF Solenoid N EX Ai...

Page 339: ...ied MD B 300 B 400 RETARDER HYDRAULIC SCHEMATIC RETARDER OFF EX Air Accumulator EX Retarder Temp Sensor Flow Valve Retarder Control Valve CONTROL MAIN MAIN PRESSURE CONVERTER OUT EXHAUST ORIFICE LUBE...

Page 340: ...der Charge Pressure HD B 500 RETARDER HYDRAULIC SCHEMATIC RETARDER ON CONTROL MAIN MAIN PRESSURE RETARDER OUT CONVERTER OUT EXHAUST TO RETARDER LUBE FROM COOLER TO COOLER VEHICLE AIR V01131 01 Air Pro...

Page 341: ...SCHEMATIC RETARDER OFF CONTROL MAIN MAIN PRESSURE CONVERTER OUT ORIFICE LUBE EXHAUST LUBE FROM COOLER TO COOLER VEHICLE AIR V01132 01 Air Protection Valve OEM supplied Accumulator ON OFF Solenoid N EX...

Page 343: ...H SOL H SOL K SOL HI K SOL LO OUTPUT SPEED LO B 31 A 6 B 32 B 27 B 6 A 10 A 30 A 21 A 2 A 11 A 4 A 29 A 31 A 3 A 28 A 20 B 7 RTDR TEMP RETARDER MODULATION SIGNAL RETARDER MODULATION HI NOT USED J SOL...

Page 344: ...31 A B A B ECU B A V04680 ECU A A 9 A 1 A 18 A 27 A W D B 27 OLS POWER SUMP TEMP INPUT C3PS INPUT A 6 N B 1 Y B 31 X B 28 P B 13 B A B A C3 PRESSURE SWITCH SIGNAL GROUND ANALOG GROUND OIL LEVEL C E B...

Page 345: ...86 104 122 140 158 176 194 212 230 248 266 284 302 361 OHMS 525 577 632 691 754 820 889 962 1039 1118 1202 1288 1379 1472 1569 1670 1774 1882 1993 2107 2225 2628 1 6 C 60 500 700 900 1100 1300 1500 17...

Page 346: ...igure K 2 Solenoid Resistance vs Temperature Chart V00719 01 MAXIMUM OHMS WT SOLENOID RESISTANCE SPEC VALUE 3 26 2 OHMS AT 20 C MINIMUM OHMS SOLENOID RESISTANCE IN OHMS 4 8 5 2 4 6 5 4 4 4 2 4 3 8 3 6...

Page 347: ...io equipment manufacturer Detailed installation instructions are the sole responsibility of the radio equipment manufacturer Experience has shown that most EMI RFI problems can be prevented or elimina...

Page 348: ...LS A Checking for Externally Generated Speed Sensor Signals Use the following procedures to determine if speed sensor signals generated by a source external to the transmission or wiring harness are p...

Page 349: ...N 150 PSI HOT MAIN CIRCUIT LEAK C3 CLUTCH APPLIED C1 CLUTCH APPLIED C5 CLUTCH APPLIED C4 CLUTCH APPLIED LOW CONTROL MAIN CTL 1 3 CL PR C1 C2 PRESSURE LOW C2 PRESSURE LOW C2 SOLENOID INOPERATIVE C1 SOL...

Page 350: ...INED RANGE C3 SWITCH INOPERATIVE C3 SW ON ATTAINED RANGE SELECT NEUTRAL RANGE ENGINE IDLE ENABLE CLUTCH TEST MODE C3 SW ON IN GEAR C3 SOLENOID INOPERATIVE C3 SW ON IN NEUTRAL C3 SWITCH INOPERATIVE INS...

Page 351: ...Allison Transmission wiring harness Refer to the vehicle manufacturer s manual for location of the connector 2 Be sure that the vehicle ignition key is on Check to see that the Pro Link 9000 has been...

Page 352: ...reen explaining why the fluid level is not being displayed 4 The fluid level is correct when a 0 zero appears in front of QT quarts or LT liters Press the FUNCtion key to return to the menu of choice...

Page 353: ...f the screen display an English explanation of the code is displayed for example code 24 12 s message would read OIL TEMPERATURE COLD If there are arrows at the side of line four of the display this m...

Page 354: ...the test is complete 4 Press ENTER to select ENABLE The display will show ENABLING CLUTCH TEST PLEASE WAIT Once the test is enabled the following display screen appears CLUTCH TEST ENABLED TEST MAY D...

Page 355: ...LUTCH TEST is also useful for selecting higher ranges to conduct a torque converter stall test Using a higher range reduces torque loads on internal transmission components 6 During clutch testing it...

Page 357: ...es Can be used for performance economy loaded empty or other shift schedule combinations VARIABLES TO SPECIFY None VOCATIONS Various Figure P 1 Secondary Shift Schedule WARNING These schematics show t...

Page 358: ...or property personal injury or loss of life ALLISON TRANSMISSION IS NOT LIABLE FOR THE CONSEQUENCES ASSOCIATED WITH MISWIRING OR UNINTENDED USE OF THESE FEATURES D1 SELECTION USES Provides a convenien...

Page 359: ...SPECIFY Minimum and maximum engine speed for engagement maximum engine speed for allowable operation minimum and maximum output speed for engagement maximum output speed for allowable operation VOCATI...

Page 360: ...CIFY Minimum and maximum engine speed for engagement maximum engine speed for allowable operation minimum and maximum output speed for engagement maximum output speed for allowable operation VOCATIONS...

Page 361: ...to select which one is active VARIABLES TO SPECIFY None VOCATIONS Various Figure P 5 Shift Selector Transition WARNING If this function is enabled in the shift calibration the function MUST be integr...

Page 362: ...Inhibit Standard WARNING If this function is enabled in the shift calibration the function MUST be integrated into the vehicle wiring If the function is available in the shift calibration but will not...

Page 363: ...HIBIT INPUT 1 WIRE 161B SIGNAL GROUND WIRE 155 AUX FUNCTION RANGE INHIBIT INPUT 2 BATTERY GROUND WIRE 143A AUXILIARY FUNCTION SWITCH 1 AUXILIARY FUNCTION SWITCH 2 SERVICE TRANS SWITCHED POWER VIM K1 N...

Page 364: ...njury or loss of life ALLISON TRANSMISSION IS NOT LIABLE FOR THE CONSEQUENCES ASSOCIATED WITH MISWIRING OR UNINTENDED USE OF THESE FEATURES AUXILIARY HOLD USES Provide a discrete input to hold the tra...

Page 365: ...selecting a lower range Also prevents engagement of engine brake with throttle 0 or lockup OFF VARIABLES TO SPECIFY Preselect range Standard value is second range for exhaust style brakes and fourth r...

Page 366: ...to the ECU that the brake is active and to provide increased braking by preselecting a lower range Also prevents engagement of engine brake with throttle 0 or lockup OFF VARIABLES TO SPECIFY Preselect...

Page 367: ...haft rotation When split shaft engages PPE signal and Pump Engaged light are turned on Transmission output unlocks 4 SELECT DRIVE Transmission shifts to fourth lockup OK To Pump light is turned on TO...

Page 368: ...ested light Turns on both input signals to ECU wires 117 and 118 which activates fire truck mode When split shaft shifts Pump Engaged light is turned on 4 SELECT DRIVE Transmission shifts to fourth lo...

Page 369: ...the function MUST be integrated into the vehicle wiring If the function is available in the shift calibration but will not be used in the vehicle it MUST be disabled in the calibration WIRE 119 QUICK...

Page 370: ...ge of PTO Figure P 14 Automatic Neutral for PTO Standard WARNING If this function is enabled in the shift calibration the function MUST be integrated into the vehicle wiring If the function is availab...

Page 371: ...ST be integrated into the vehicle wiring If the function is available in the shift calibration but will not be used in the vehicle it MUST be disabled in the calibration V05020 WIRE 161B SIGNAL GROUND...

Page 372: ...If the function is available in the shift calibration but will not be used in the vehicle it MUST be disabled in the calibration DOOR CONTROL SWITCH TO DOOR CONTROLS WIRE 118 AUTOMATIC NEUTRAL SWITCHE...

Page 373: ...ENDED USE OF THESE FEATURES TWO SPEED AXLE INPUT AND OUTPUT USES Provides output speed interlock for axle engagement input to ECU and input to speedometer to adjust for axle ratio change VARIABLES TO...

Page 374: ...ift mode and the second as the switching mechanism to command the lockup clutch on and off VARIABLES TO SPECIFY None VOCATIONS Oil field pumping mud pumps hoists drilling Figure P 18 Manual Lockup WAR...

Page 375: ...RIABLES TO SPECIFY None VOCATIONS European transit buses and tour buses Figure P 19 Reverse Enable WARNING If this function is enabled in the shift calibration the function MUST be integrated into the...

Page 376: ...al Shift in Process to powertrain module that a shift is being requested 2 Powertrain module reduces engine power and sends a signal to ECU Shift Enable indicating that it is OK to shift 3 ECU command...

Page 377: ...CK BRAKE RESPONSE USES Signals the ECU when ABS function is active so that lockup clutch and retarder will be disabled VARIABLES TO SPECIFY None VOCATIONS Various Figure P 21 Anti Lock Brake Response...

Page 378: ...ication and brake lights during retarder operation USES None VOCATIONS Various This function is required for retarder equipped transmissions Figure P 22 Retarder Enable V05027 WIRE 163 RETARDER ENABLE...

Page 379: ...personal injury or loss of life ALLISON TRANSMISSION IS NOT LIABLE FOR THE CONSEQUENCES ASSOCIATED WITH MISWIRING OR UNINTENDED USE OF THESE FEATURES SERVICE BRAKE STATUS USES Indicates to the ECU whe...

Page 380: ...S NOT LIABLE FOR THE CONSEQUENCES ASSOCIATED WITH MISWIRING OR UNINTENDED USE OF THESE FEATURES DIFFERENTIAL CLUTCH REQUEST USES Provides for operator ON OFF control of the differential locking clutch...

Page 381: ...er recycling truck Figure P 24 Automatic Neutral for Refuse Packer and PTO Enable V05029 WIRE 161B SIGNAL GROUND WIRE 117 PACK ENABLE WIRE 112 PTO ENABLE OUTPUT WIRE 114 NEUTRAL INDICATOR FOR PTO WIRE...

Page 382: ...ker recycling truck Figure P 25 Automatic Neutral for Refuse Packer and PTO Enable Optional V05029 01 WIRE 161B SIGNAL GROUND WIRE 117 PACK ENABLE WIRE 112 PTO ENABLE OUTPUT WIRE 114 NEUTRAL INDICATOR...

Page 383: ...ON TRANSMISSION IS NOT LIABLE FOR THE CONSEQUENCES ASSOCIATED WITH MISWIRING OR UNINTENDED USE OF THESE FEATURES KICKDOWN USES Provides both economy and performance shift points at full throttle Opera...

Page 384: ...E None 3 SELECT PUMP Turns on Pump Mode Requested light Turns on both input signals to ECU wires 117 and 118 which activates pump mode When split shaft shifts Pump Engaged light is turned on 4 SELECT...

Page 385: ...d and Neutral must be selected prior to the operator exiting the cab In addition vehicles using this feature must have the following Warning sticker visible in the vehicle cab WARNING Set Park Brake a...

Page 386: ...park brake must be engaged and Neutral must be selected prior to the operator exiting the cab In addition vehicles using this feature must have the following Warning sticker visible in the vehicle ca...

Page 387: ...SOCIATED WITH MISWIRING OR UNINTENDED USE OF THESE FEATURES SUMP RETARDER TEMPERATURE INDICATOR USES Turn on dash indicator when transmission sump or retarder out temperature has exceeded specified li...

Page 388: ...or property personal injury or loss of life ALLISON TRANSMISSION IS NOT LIABLE FOR THE CONSEQUENCES ASSOCIATED WITH MISWIRING OR UNINTENDED USE OF THESE FEATURES RANGE INDICATOR USES Used with auxili...

Page 389: ...erty personal injury or loss of life ALLISON TRANSMISSION IS NOT LIABLE FOR THE CONSEQUENCES ASSOCIATED WITH MISWIRING OR UNINTENDED USE OF THESE FEATURES OUTPUT SPEED INDICATOR A USES To signal that...

Page 390: ...the transmission output shaft has exceeded a specified value VARIABLES TO SPECIFY Rpm to turn output ON and to turn output OFF The ON value must be higher than the OFF value VOCATIONS Various Figure P...

Page 391: ...ONSEQUENCES ASSOCIATED WITH MISWIRING OR UNINTENDED USE OF THESE FEATURES PTO OVERSPEED INDICATOR USES Turn on dash light when PTO reaches an overspeed condition VARIABLES TO SPECIFY Rpm to turn ON rp...

Page 392: ...r loss of life ALLISON TRANSMISSION IS NOT LIABLE FOR THE CONSEQUENCES ASSOCIATED WITH MISWIRING OR UNINTENDED USE OF THESE FEATURES ENGINE OVERSPEED INDICATOR USES To turn on dash light when engine r...

Page 393: ...erty personal injury or loss of life ALLISON TRANSMISSION IS NOT LIABLE FOR THE CONSEQUENCES ASSOCIATED WITH MISWIRING OR UNINTENDED USE OF THESE FEATURES LOCKUP INDICATOR USES Turn on dash indicator...

Page 394: ...SION IS NOT LIABLE FOR THE CONSEQUENCES ASSOCIATED WITH MISWIRING OR UNINTENDED USE OF THESE FEATURES SECONDARY MODE INDICATOR USES To indicate that Secondary Mode is active VARIABLES TO SPECIFY None...

Page 395: ...ld result in damage to equipment or property personal injury or loss of life ALLISON TRANSMISSION IS NOT LIABLE FOR THE CONSEQUENCES ASSOCIATED WITH MISWIRING OR UNINTENDED USE OF THESE FEATURES RETAR...

Page 396: ...ON Operator selects NEUTRAL to enable fast idle Transmission shifts to neutral if throttle and output speed are low When DRIVE is re selected fast idle is interrupted and transmission shifts to drive...

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Allison B 300, Troubleshooting Manual

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