User Manuals: Allison HD 4560 Transmission System

Manuals and User Guides for Allison HD 4560 Transmission System. We have 1 Allison HD 4560 Transmission System manual available for free PDF download: Troubleshooting Manual

Allison HD 4560 Troubleshooting Manual (397 pages)

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

Brand: Allison | Category: Microphone system | Size: 4 MB

How to Use this Manual
2
Safety Notice
3
Shift Selector Terms and Display Indications
4
Table of Contents
5
General Description
7
Transmission
7
Electronic Control Components View
7
Electronic Control Unit Block Diagram
8
Electronic Control Unit (ECU) Description
9
Shift Selector
9
B. Lever Shift Selector
10
Throttle Position Sensor
11
Speed Sensors
11
Control Module
12
Wiring Harnesses
13
B. Internal Wiring Harness
14
Vehicle Interface Module
16
Transid Feature
16
Transmission Changes Versus Transid Number
17
Transid 1 S/N Breakpoint
17
Compatibility between Transid Level and ECU Calibration Level
18
Definitions and Abbreviations
19
Do Not Shift Light
19
Diagnostic Data Reader
19
Abbreviations List
20
Using the Troubleshooting Manual
23
Basic Knowledge Required
23
System Overview
24
Important Information in the Troubleshooting Process
24
Beginning the Troubleshooting Process
25
Wire Check Procedures
27
Checking Opens, Shorts between Wires, and Shorts-To-Ground
27
Checking at Transmission Connector and the Internal Harness
28
For Opens, Shorts between Wires, and Shorts-To-Ground
28
Feedthrough Connector, “Green Seal,” and Internal Harness View
29
Checking Continuity
30
Short between Wires and to Ground
31
Oil Level Sensor
33
Electronic Fluid Level Check (Shift Selector)
33
Electronic Fluid Level Check (Pro-Link 9000)
36
A. Fluid Level Check Procedure
36
Diagnostic Code Memory
37
Code Reading and Code Clearing
37
Reading Codes
37
Clearing Active Indicators
38
Manually Clearing Codes and Active Indicators from the Code List
38
Diagnostic Code Response
39
Exiting the Diagnostic Display Mode
39
Shift Selector Displays Related to Active Codes
39
Diagnostic Code List and Description
40
WT Series Diagnostic Codes
40
Transmission Component Wiring Diagrams and Diagnostics
51
Diagnostic Code Troubleshooting
53
Solenoid Locations
53
Diagnostic Code 13 and 35 Schematics
54
C. Diagnostic Code Schematics
54
Code 13 XX - ECU Input Voltage
55
Voltage Chart
57
Code 14 XX - Oil Level Sensor
59
Code 21 XX - Throttle Position Sensor Fault or Adjustment
63
Code 22 XX - Speed Sensor/Circuitry Fault
67
Code 23 XX - Shift Selector
72
Code 24 XX - Sump Fluid Temperature
75
Temperature Sensor Chart
78
External Hydraulic Circuit Characteristics
79
Converter Operation Maximum Cooler Flow
79
Converter Operation Maximum Allowable Pressure Drop
79
Lockup Operation Maximum Cooler Flow
80
Lockup Operation Maximum Allowable Pressure Drop
80
Code 25 XX - Output Speed Sensor, Detected at Zero Speed, X Range
81
Code 32 XX - C3 Pressure Switch
85
Input Functions
85
Code 33 XX - Sump Oil Temperature Sensor
89
Code 34 XX - EEPROM Compatibility or Checksum Fault
93
Code 35 XX - Power Interruption
94
Code 36 XX - Hardware and Software Not Compatible
96
Code 41 XX - Open or Short-To-Ground in Solenoid Circuit
97
Probing the Connector
100
Solenoid Resistance Vs. Temperature
100
Code 42 XX - Short-To-Battery in Solenoid Circuit
103
Code 43 XX Solenoid Low Side Circuit/Open Driver/Wire Shored-To-Ground
109
Code 44 XX - Short-To-Ground in Solenoid Circuit
113
Code 45 XX - Open Condition in Solenoid Circuit
119
Code 51 XX - Offgoing Ratio Test During Shift (Tie-Up Test)
124
Code 52 XX - Offgoing C3 Pressure Switch Test During Shift
126
Code 53 XX - Offgoing Speed Test (During Shift)
128
Code 54 XX - Oncoming Ratio Test (after Shift)
130
Code 55 XX - Oncoming C3 Pressure Switch (after Shift)
132
Code 56 XX - Range Verification Ratio Test (between Shifts)
134
Code 57 XX - Range Verification C3 Pressure Test (between Shifts)
137
Code 61 XX - Retarder Fluid Hot
138
Transmission Retarder Operation as a Function of Temperature
138
Code 61 XX - Retarder over Temperature
139
Code 62 XX - Retarder Temperature Sensor
141
Code 63 XX - Input Function Fault
145
Code 64 XX - Retarder Modulation Request Device Fault
147
Code 65 XX - Engine Rating High
153
Code 65 XX - SCI (Serial Communication Interface) Fault
154
Code 69 XX - ECU Malfunction
157
Input and Output Functions
160
General Troubleshooting of Performance Complaints
164
Electronic and Hydraulic Troubleshooting
180
Resistance Module Troubleshooting Data
180
Appendices
182
Tool Part Numbers, and Repair Instructions
182
Identification of Potential Circuit Problems
184
Circuit Inspection
184
Finding an Intermittent Fault Condition
184
Recurring Conditions
185
Checking Clutch Pressures
186
Recording Data
187
Clutch Pressure Test Conditions
187
Comparing Recorded Data to Speciﬁcations
188
Main Pressure and Clutch Pressure Speciﬁcations
189
Solenoid and Clutch Chart
194
Wire/Connector Chart
196
ECU Connector "A" (Black/White)
197
ECU Connector "B" (Black)
198
Bulkhead Connector Cross-Reference Chart
200
31-Way Deutsch IPD Bulkhead Connector
201
Deutsch Bulkhead Connector (Male/Female)
202
Cannon 37-Way FMTV Bulkhead Connector
203
Deutsch Transmission Connector, (Male/Female)
204
Transmission Connector
205
Remote Serial Interface Connector
206
Optional Deutsch Sensor Harness Connector
207
Speed Sensor Connector
208
Diagnostic Connector
209
Optional Deutsch DDR Connector
210
VIW (Amp) Connector
211
Throttle Position Sensor Connector
212
Transfer Case Connector
213
Retarder Connector (MD/B 300/B 400)
214
Retarder Connector (HD/B 500)
215
Retarder Resistance Module/Interface Connector
216
Retarder Temperature Sensor Connector (HD/B 500)
217
Customer-Furnished VIW/VIM Connector Cross-Reference Chart
219
VIM Connector (Harness)
220
Ford 16-Way Transmission Bulkhead Connector
222
Bulkhead a (Gray)
222
Bulkhead B (Black)
222
Packard Metri-Pack VIM Connectors
223
Packard Weather Pack VIM Connectors
224
Navistar Deutsch DT Series VIW Connector
225
Dill VIW Connectors
227
Packard Metri-Pack Cab and Chassis Harness Connectors
229
Resistance Module Type 2 — Single Pressure Switch
230
Resistance Module Type 3 — Bendix E-10R Pedal
231
Resistance Module Type 5 — Hand Lever
232
Resistance Module Type 7 — Dedicated Pedal
233
Resistance Module Type 8 — Three Pressure Switch
234
Resistance Module Type 9 — Two Pressure Switch
235
Oil Level Sensor Connector
236
Spare Wires
237
Connector Part Numbers, Terminal Part Numbers, and Repair Instructions
238
List of Special Tools Required for Servicing of the Wiring Harnesses
239
Thomas & Betts ECU Connector, RSI Connector
241
Thomas & Betts Connectors (ECU and RSI)
242
Connector/Terminal Repairs
242
Terminal Removal
242
Terminal Crimping / Deletion of RSI Jumper Wire
242
Packard Metri-Pack 150 Series Connectors
243
Terminal Crimping
245
Packard Metri-Pack 150 Series Connectors — Push-To-Seat
247
Packard Metri-Pack 150 Series Connectors - Push-To-Seat
248
Terminal Crimping Using Alternate Tool J 35123
249
Packard Metri-Pack 280 Series Connectors — Pull-To-Seat
251
Packard Metri-Pack 280 Series Connectors — Push-To-Seat (DDR)
255
Packard Weather Pack Connectors
259
Terminal Crimping Using Crimping Tool J 38125-6
261
Terminal Crimping Using Alternate Crimper Pliers J 35606 or J 38852
261
Amp Products Connectors
263
Deutsch IPD/ECD Connectors
265
Terminal Insertion (ECD Bulkhead)
269
Terminal Insertion (All Connectors Except ECD Bulkhead)
269
ITT Cannon Connectors — Crimped
271
ITT Cannon Connectors — Soldered (2-Way HD Retarder)
275
Deutsch DT Series Connectors (12-Way Navistar VIW)
279
Dill Connectors (Freightliner 4-Way Fuse and 5-Way Relay VIW)
283
EPC Connectors (Ford 16-Way Bulkhead)
287
Repair of a Broken Wire with In-Line Butt Splice
289
Straight Lead Repair Procedure
290
List of World Transmission Connector Parts
291
External Harness Parts
291
Internal Harness Parts
298
RVI Parts
300
New Flyer Parts
301
Iveco Parts
302
Throttle Position Sensor Adjustment
310
Throttle Position to Voltage Conversion
310
Throttle Position Determination Diagram
310
Volts Versus Count for Throttle Sensor Display Reading
313
Welding on Vehicle
316
VIM Components Location and Pin-Out Diagram
317
Hydraulic Schematics
318
C2 Latch Valve Detail
318
WT Hydraulic Schematic - Neutral
319
WT Hydraulic Schematic - Reverse
320
WT Hydraulic Schematic - 1St Range
321
WT Hydraulic Schematic - 2Nd Range
322
WT Hydraulic Schematic - 3Rd Range
323
WT Hydraulic Schematic - 4Th Range
324
WT Hydraulic Schematic - 5Th Range
325
WT Hydraulic Schematic - 6Th Range
326
MD 3070 Hydraulic Schematic - Neutral, Power on
327
MD 3070 Hydraulic Schematic - Reverse, Power on
328
MD 3070 Hydraulic Schematic - lo MD, Power on
329
MD 3070 Hydraulic Schematic - 1St, Power on
330
MD 3070 Hydraulic Schematic - 2Nd, Power on
331
MD 3070 Hydraulic Schematic - 3Rd, Power on
332
MD 3070 Hydraulic Schematic - 4Th, Power on
333
MD 3070 Hydraulic Schematic - 5Th, Power on
334
MD 3070 Hydraulic Schematic - 6Th, Power on
335
MD/B 300/B 400 Retarder Hydraulic Schematic, Retarder on
336
MD/B 300/B 400 Retarder Hydraulic Schematic, Retarder off
337
HD/B 500 Retarder Hydraulic Schematic - Retarder on
341
WT Wiring Schematics
343
General Notes
343
Solenoid and Temperature Charts
345
Solenoid Resistance Vs.temperature Chart
346
Electromagnetic/Radio Frequency Interference
347
General Guidelines for Radio Equipment Installation
347
Externally-Generated Speed Sensor Signals
348
Diagnostic Tree — WT Series Hydraulic System with Gauges
349
Diagnostic Tree — WT Series Hydraulic System Without Gauges
350
Pro-Link 9000 Diagnostic Data Reader Information
351
Pro-Link 9000 Menu Selections
352
Input/Output Functions
357
Secondary Shift Schedule
357
D1 Selection
358
PTO Enable (Using “PTO” Switch)
359
PTO Enable (Using “MODE” Button)
360
Shift Selector Transition
361
Auxiliary Function Range Inhibit (Standard)
362
Auxiliary Hold
364
Engine Brake/Preselect Request and Engine Brake Enable (Standard)
365
Engine Brake/Preselect Request and Engine Brake Enable (European)
366
Fire Truck Pump Mode
367
Quick-To-Neutral Pump
369
Automatic Neutral for PTO
370
Automatic Neutral
372
Two Speed Axle Input and Output
373
Manual Lockup
374
Reverse Enable
375
Shift in Process/Shift Enable
376
Anti-Lock Brake Response
377
Retarder Enable
378
Service Brake Status
379
Differential Clutch Request
380
Automatic Neutral for Refuse Packer and PTO Enable
381
Kickdown
383
Fourth Lockup Pump Mode
384
Automatic Neutral for Refuse Packer/Pto Enable W Service Brake Status
385
Sump/Retarder Temperature Indicator
387
Range Indicator
388
Output Speed Indicator
389
PTO Overspeed Indicator
391
Engine Overspeed Indicator
392
Lockup Indicator
393
Secondary Mode Indicator
394
Retarder Indicator
395
Neutral Indicator for PTO and PTO Enable
396

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User Manuals: Allison HD 4560 Transmission System

Allison HD 4560 Troubleshooting Manual (397 pages)

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