Allison HD 4560

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WTEC II ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC CODES

NOTESNOTES

Main Page

How to Use this Manual2
Safety Notice3
Shift Selector Terms and Display Indications4
Table of Contents5
General Description7
Transmission7
Electronic Control Components View7
Electronic Control Unit Block Diagram8
Electronic Control Unit (ECU) Description9
Shift Selector9
B. Lever Shift Selector10
Throttle Position Sensor11
Speed Sensors11
Control Module12
Wiring Harnesses13
B. Internal Wiring Harness14
Vehicle Interface Module16
Transid Feature16
Transmission Changes Versus Transid Number17
Transid 1 S/N Breakpoint17
Compatibility between Transid Level and ECU Calibration Level18
Definitions and Abbreviations19
Do Not Shift Light19
Diagnostic Data Reader19
Abbreviations List20
Using the Troubleshooting Manual23
Basic Knowledge Required23
System Overview24
Important Information in the Troubleshooting Process24
Beginning the Troubleshooting Process25
Wire Check Procedures27
Checking Opens, Shorts between Wires, and Shorts-To-Ground27
Checking at Transmission Connector and the Internal Harness28
For Opens, Shorts between Wires, and Shorts-To-Ground28
Feedthrough Connector, “Green Seal,” and Internal Harness View29
Checking Continuity30
Short between Wires and to Ground31
Oil Level Sensor33
Electronic Fluid Level Check (Shift Selector)33
Electronic Fluid Level Check (Pro-Link 9000)36
A. Fluid Level Check Procedure36
Diagnostic Code Memory37
Code Reading and Code Clearing37
Reading Codes37
Clearing Active Indicators38
Manually Clearing Codes and Active Indicators from the Code List38
Diagnostic Code Response39
Exiting the Diagnostic Display Mode39
Shift Selector Displays Related to Active Codes39
Diagnostic Code List and Description40
WT Series Diagnostic Codes40
Transmission Component Wiring Diagrams and Diagnostics51
Diagnostic Code Troubleshooting53
Solenoid Locations53
Diagnostic Code 13 and 35 Schematics54
C. Diagnostic Code Schematics54
Code 13 XX - ECU Input Voltage55
Voltage Chart57
Code 14 XX - Oil Level Sensor59
Code 21 XX - Throttle Position Sensor Fault or Adjustment63
Code 22 XX - Speed Sensor/Circuitry Fault67
Code 23 XX - Shift Selector72
Code 24 XX - Sump Fluid Temperature75
Temperature Sensor Chart78
External Hydraulic Circuit Characteristics79
Converter Operation Maximum Cooler Flow79
Converter Operation Maximum Allowable Pressure Drop79
Lockup Operation Maximum Cooler Flow80
Lockup Operation Maximum Allowable Pressure Drop80
Code 25 XX - Output Speed Sensor, Detected at Zero Speed, X Range81
Code 32 XX - C3 Pressure Switch85
Input Functions85
Code 33 XX - Sump Oil Temperature Sensor89
Code 34 XX - EEPROM Compatibility or Checksum Fault93
Code 35 XX - Power Interruption94
Code 36 XX - Hardware and Software Not Compatible96
Code 41 XX - Open or Short-To-Ground in Solenoid Circuit97
Probing the Connector100
Solenoid Resistance Vs. Temperature100
Code 42 XX - Short-To-Battery in Solenoid Circuit103
Code 43 XX Solenoid Low Side Circuit/Open Driver/Wire Shored-To-Ground109
Code 44 XX - Short-To-Ground in Solenoid Circuit113
Code 45 XX - Open Condition in Solenoid Circuit119
Code 51 XX - Offgoing Ratio Test During Shift (Tie-Up Test)124
Code 52 XX - Offgoing C3 Pressure Switch Test During Shift126
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 Hot138
Transmission Retarder Operation as a Function of Temperature138
Code 61 XX - Retarder over Temperature139
Code 62 XX - Retarder Temperature Sensor141
Code 63 XX - Input Function Fault145
Code 64 XX - Retarder Modulation Request Device Fault147
Code 65 XX - Engine Rating High153
Code 65 XX - SCI (Serial Communication Interface) Fault154
Code 69 XX - ECU Malfunction157
Input and Output Functions160
General Troubleshooting of Performance Complaints164
Electronic and Hydraulic Troubleshooting180
Resistance Module Troubleshooting Data180
Appendices182
Tool Part Numbers, and Repair Instructions182
Identification of Potential Circuit Problems184
Circuit Inspection184
Finding an Intermittent Fault Condition184
Recurring Conditions185
Checking Clutch Pressures186
Recording Data187
Clutch Pressure Test Conditions187
Comparing Recorded Data to Speciﬁcations188
Main Pressure and Clutch Pressure Speciﬁcations189
Solenoid and Clutch Chart194
Wire/Connector Chart196
ECU Connector "A" (Black/White)197
ECU Connector "B" (Black)198
Bulkhead Connector Cross-Reference Chart200
31-Way Deutsch IPD Bulkhead Connector201
Deutsch Bulkhead Connector (Male/Female)202
Cannon 37-Way FMTV Bulkhead Connector203
Deutsch Transmission Connector, (Male/Female)204
Transmission Connector205
Remote Serial Interface Connector206
Optional Deutsch Sensor Harness Connector207
Speed Sensor Connector208
Diagnostic Connector209
Optional Deutsch DDR Connector210
VIW (Amp) Connector211
Throttle Position Sensor Connector212
Transfer Case Connector213
Retarder Connector (MD/B 300/B 400)214
Retarder Connector (HD/B 500)215
Retarder Resistance Module/Interface Connector216
Retarder Temperature Sensor Connector (HD/B 500)217
Customer-Furnished VIW/VIM Connector Cross-Reference Chart219
VIM Connector (Harness)220
Ford 16-Way Transmission Bulkhead Connector222
Bulkhead a (Gray)222
Bulkhead B (Black)222
Packard Metri-Pack VIM Connectors223
Packard Weather Pack VIM Connectors224
Navistar Deutsch DT Series VIW Connector225
Dill VIW Connectors227
Packard Metri-Pack Cab and Chassis Harness Connectors229
Resistance Module Type 2 — Single Pressure Switch230
Resistance Module Type 3 — Bendix E-10R Pedal231
Resistance Module Type 5 — Hand Lever232
Resistance Module Type 7 — Dedicated Pedal233
Resistance Module Type 8 — Three Pressure Switch234
Resistance Module Type 9 — Two Pressure Switch235
Oil Level Sensor Connector236
Spare Wires237
Connector Part Numbers, Terminal Part Numbers, and Repair Instructions238
List of Special Tools Required for Servicing of the Wiring Harnesses239
Thomas & Betts ECU Connector, RSI Connector241
Thomas & Betts Connectors (ECU and RSI)242
Connector/Terminal Repairs242
Terminal Removal242
Terminal Crimping / Deletion of RSI Jumper Wire242
Packard Metri-Pack 150 Series Connectors243
Terminal Crimping245
Packard Metri-Pack 150 Series Connectors — Push-To-Seat247
Packard Metri-Pack 150 Series Connectors - Push-To-Seat248
Terminal Crimping Using Alternate Tool J 35123249
Packard Metri-Pack 280 Series Connectors — Pull-To-Seat251
Packard Metri-Pack 280 Series Connectors — Push-To-Seat (DDR)255
Packard Weather Pack Connectors259
Terminal Crimping Using Crimping Tool J 38125-6261
Terminal Crimping Using Alternate Crimper Pliers J 35606 or J 38852261
Amp Products Connectors263
Deutsch IPD/ECD Connectors265
Terminal Insertion (ECD Bulkhead)269
Terminal Insertion (All Connectors Except ECD Bulkhead)269
ITT Cannon Connectors — Crimped271
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 Splice289
Straight Lead Repair Procedure290
List of World Transmission Connector Parts291
External Harness Parts291
Internal Harness Parts298
RVI Parts300
New Flyer Parts301
Iveco Parts302
Throttle Position Sensor Adjustment310
Throttle Position to Voltage Conversion310
Throttle Position Determination Diagram310
Volts Versus Count for Throttle Sensor Display Reading313
Welding on Vehicle316
VIM Components Location and Pin-Out Diagram317
Hydraulic Schematics318
C2 Latch Valve Detail318
WT Hydraulic Schematic - Neutral319
WT Hydraulic Schematic - Reverse320
WT Hydraulic Schematic - 1St Range321
WT Hydraulic Schematic - 2Nd Range322
WT Hydraulic Schematic - 3Rd Range323
WT Hydraulic Schematic - 4Th Range324
WT Hydraulic Schematic - 5Th Range325
WT Hydraulic Schematic - 6Th Range326
MD 3070 Hydraulic Schematic - Neutral, Power on327
MD 3070 Hydraulic Schematic - Reverse, Power on328
MD 3070 Hydraulic Schematic - lo MD, Power on329
MD 3070 Hydraulic Schematic - 1St, Power on330
MD 3070 Hydraulic Schematic - 2Nd, Power on331
MD 3070 Hydraulic Schematic - 3Rd, Power on332
MD 3070 Hydraulic Schematic - 4Th, Power on333
MD 3070 Hydraulic Schematic - 5Th, Power on334
MD 3070 Hydraulic Schematic - 6Th, Power on335
MD/B 300/B 400 Retarder Hydraulic Schematic, Retarder on336
MD/B 300/B 400 Retarder Hydraulic Schematic, Retarder off337
HD/B 500 Retarder Hydraulic Schematic - Retarder on341
WT Wiring Schematics343
General Notes343
Solenoid and Temperature Charts345
Solenoid Resistance Vs.temperature Chart346
Electromagnetic/Radio Frequency Interference347
General Guidelines for Radio Equipment Installation347
Externally-Generated Speed Sensor Signals348
Diagnostic Tree — WT Series Hydraulic System with Gauges349
Diagnostic Tree — WT Series Hydraulic System Without Gauges350
Pro-Link 9000 Diagnostic Data Reader Information351
Pro-Link 9000 Menu Selections352
Input/Output Functions357
Secondary Shift Schedule357
D1 Selection358
PTO Enable (Using “PTO” Switch)359
PTO Enable (Using “MODE” Button)360
Shift Selector Transition361
Auxiliary Function Range Inhibit (Standard)362
Auxiliary Hold364
Engine Brake/Preselect Request and Engine Brake Enable (Standard)365
Engine Brake/Preselect Request and Engine Brake Enable (European)366
Fire Truck Pump Mode367
Quick-To-Neutral Pump369
Automatic Neutral for PTO370
Automatic Neutral372
Two Speed Axle Input and Output373
Manual Lockup374
Reverse Enable375
Shift in Process/Shift Enable376
Anti-Lock Brake Response377
Retarder Enable378
Service Brake Status379
Differential Clutch Request380
Automatic Neutral for Refuse Packer and PTO Enable381
Kickdown383
Fourth Lockup Pump Mode384
Automatic Neutral for Refuse Packer/Pto Enable W Service Brake Status385
Sump/Retarder Temperature Indicator387
Range Indicator388
Output Speed Indicator389
PTO Overspeed Indicator391
Engine Overspeed Indicator392
Lockup Indicator393
Secondary Mode Indicator394
Retarder Indicator395
Neutral Indicator for PTO and PTO Enable396

Allison HD 4560 - Page 58

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