Allison HD 4560P User Manual

TS2470EN
Printed in the U.S.A. Copyright © 1998 General Motors Corp.
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)

Allison HD 4560P Specifications

General

Brand	Allison
Model	HD 4560P
Category	Microphone system
Language	English

Summary

Troubleshooting Manual

IMPORTANT SAFETY NOTICE

WARNINGS, CAUTIONS, AND NOTES

Defines the types of alerts used in the manual for safety and equipment protection.

SECTION 1. GENERAL DESCRIPTION

1 2. ELECTRONIC CONTROL UNIT (ECU)

Describes the Electronic Control Unit (ECU) as the brain of the WTEC II system.

A. Pushbutton Shift Selector

B. Lever Shift Selector

1 4. THROTTLE POSITION SENSOR (TPS)

1 5. SPEED SENSORS

Describes the engine, turbine, and output speed sensors and their function in shift control.

1 6. CONTROL MODULE

1 7. WIRING HARNESSES

A. External Wiring Harness

B. Internal Wiring Harness

1 8. VEHICLE INTERFACE MODULE (VIM)

1 9. TRANSID FEATURE

Explains the TransID feature for managing component changes and calibrations.

SECTION 2. DEFINITIONS AND ABBREVIATIONS

2 1. DO NOT SHIFT LIGHT

Explains the function and indication of the DO NOT SHIFT light during transmission faults.

2 2. DIAGNOSTIC DATA READER (DDR)

Describes the Pro-Link® 9000 as the diagnostic tool for WTEC II and III controls.

SECTION 3. BASIC KNOWLEDGE

3 1. BASIC KNOWLEDGE REQUIRED

3 3. SYSTEM OVERVIEW

3 4. IMPORTANT INFORMATION IN THE TROUBLESHOOTING PROCESS

Lists crucial precautions and information before starting troubleshooting.

3 5. BEGINNING THE TROUBLESHOOTING PROCESS

SECTION 4. WIRE CHECK PROCEDURES

4 1. CHECKING OPENS, SHORTS BETWEEN WIRES, AND SHORTS-TO-GROUND

Explains procedures for checking wires for opens, shorts between wires, and shorts to ground.

4 2. CHECKING AT TRANSMISSION CONNECTOR AND THE INTERNAL HARNESS FOR OPENS, SHORTS BETWEEN WIRES, AND SHORTS-TO-GROUND

Details checks for opens and shorts at the transmission connector and internal harness.

SECTION 5. OIL LEVEL SENSOR

5 1. ELECTRONIC FLUID LEVEL CHECK (SHIFT SELECTOR)

Describes how to check transmission fluid level using the shift selector display.

A. Fluid Level Check Procedure

5 2. ELECTRONIC FLUID LEVEL CHECK (PRO-LINK® 9000)

Explains how to check transmission fluid level using the Pro-Link® 9000 diagnostic tool.

SECTION 6. DIAGNOSTIC CODES

6 1. DIAGNOSTIC CODE MEMORY

Explains how diagnostic codes are logged and stored in memory.

6 2. CODE READING AND CODE CLEARING

Details methods for reading and clearing diagnostic codes using the shift selector or Pro-Link.

6 3. DIAGNOSTIC CODE RESPONSE

6 5. DIAGNOSTIC CODE LIST AND DESCRIPTION

6 6. DIAGNOSTIC CODE TROUBLESHOOTING

A. Beginning The Troubleshooting Process

Details the initial steps for starting a diagnostic code troubleshooting process.

B. Solenoid Locations

CODE 13 XX — ECU INPUT VOLTAGE

CODE 14 XX — OIL LEVEL SENSOR

CODE 21 XX — THROTTLE POSITION SENSOR FAULT OR ADJUSTMENT

CODE 22 XX — SPEED SENSOR/CIRCUITRY FAULT

CODE 23 XX — SHIFT SELECTOR

CODE 24 XX — SUMP FLUID TEMPERATURE

CODE 25 XX — OUTPUT SPEED SENSOR, DETECTED AT ZERO SPEED, X RANGE

CODE 32 XX — C3 PRESSURE SWITCH

CODE 33 XX — SUMP OIL TEMPERATURE SENSOR

CODE 34 XX — EEPROM COMPATIBILITY OR CHECKSUM FAULT

CODE 35 XX — POWER INTERRUPTION

CODE 36 XX — HARDWARE AND SOFTWARE NOT COMPATIBLE

CODE 41 XX — OPEN OR SHORT-TO-GROUND IN SOLENOID CIRCUIT

CODE 42 XX — SHORT-TO-BATTERY IN SOLENOID CIRCUIT

CODE 43 XX — SOLENOID LOW SIDE CIRCUIT, OPEN DRIVER, OR WIRE SHORTED-TO-GROUND

CODE 44 XX — SHORT-TO-GROUND IN SOLENOID CIRCUIT

CODE 45 XX — OPEN CONDITION IN SOLENOID CIRCUIT

CODE 51 XX — OFFGOING RATIO TEST DURING SHIFT (TIE-UP TEST)

CODE 52 XX — OFFGOING C3 PRESSURE SWITCH TEST DURING SHIFT

CODE 53 XX — OFFGOING SPEED TEST (DURING SHIFT)

CODE 54 XX — ONCOMING RATIO TEST (AFTER SHIFT)

CODE 55 XX — ONCOMING C3 PRESSURE SWITCH (AFTER SHIFT)

CODE 56 XX — RANGE VERIFICATION RATIO TEST (BETWEEN SHIFTS)

CODE 57 XX — RANGE VERIFICATION C3 PRESSURE TEST (BETWEEN SHIFTS)

CODE 61 XX — RETARDER FLUID HOT

CODE 62 XX — RETARDER TEMPERATURE SENSOR

CODE 63 XX — INPUT FUNCTION FAULT

CODE 64 XX — RETARDER MODULATION REQUEST DEVICE FAULT

CODE 65 XX — ENGINE RATING HIGH

CODE 66 XX — SCI (SERIAL COMMUNICATION INTERFACE) FAULT

CODE 69 XX — ECU MALFUNCTION

SECTION 8. GENERAL TROUBLESHOOTING OF PERFORMANCE COMPLAINTS

SHIFT SELECTOR DISPLAYS “CATEYES” AND VEHICLE IS NOT OPERABLE

SHIFT SELECTOR DISPLAY IS BLANK

VEHICLE WILL NOT START (ENGINE WILL NOT CRANK)

DO NOT SHIFT LIGHT WILL NOT GO OUT AT START-UP

DO NOT SHIFT LIGHT FLASHES INTERMITTENTLY

Addresses intermittent issues with the DO NOT SHIFT light.

NO DO NOT SHIFT LIGHT AT IGNITION

Covers troubleshooting when the DO NOT SHIFT light does not illuminate at ignition.

ECU WILL NOT TURN OFF WHEN IGNITION SWITCH OFF

TRANSMISSION WILL NOT SHIFT TO FORWARD OR REVERSE (STAYS IN NEUTRAL)

Provides solutions for the transmission remaining stuck in neutral.

TRANSMISSION WILL NOT STAY IN FORWARD OR REVERSE

Covers troubleshooting for the transmission not staying in the selected forward or reverse gear.

TRANSMISSION WILL NOT MAKE A SPECIFIC SHIFT

TRANSMISSION DOES NOT SHIFT PROPERLY (ROUGH SHIFTS, SHIFTS OCCURRING AT TOO LOW OR TOO HIGH SPEED)

Covers troubleshooting for rough shifts or shifts occurring at incorrect speeds.

RETARDER PERFORMANCE COMPLAINTS

A. Retarder Does Not Apply

Details troubleshooting steps when the retarder fails to engage or apply.

EXCESSIVE FLARE — ENGINE OVERSPEED ON FULL-THROTTLE UPSHIFTS

EXCESSIVE SLIPPAGE AND CLUTCH CHATTER

A. Ranges 1, 2, 3, 4 Only (6-Speed)

Details troubleshooting for clutch slipping issues specific to ranges 1-4 (6-speed).

B. Ranges 4, 5, 6 Only (6-Speed)

Covers troubleshooting for clutch slipping issues specific to ranges 4-6 (6-speed).

C. Ranges 3, 5, R Only (6-Speed)

Details troubleshooting for clutch slipping issues specific to ranges 3, 5, R (6-speed).

D. Ranges 2, 6 Only (6-Speed)

Addresses troubleshooting for clutch slipping issues specific to ranges 2, 6 (6-speed).

LOW PRESSURE SECTION

A. Low Main Pressure in All Ranges (Including C6, T-Case)

Details troubleshooting for low main hydraulic pressure across all transmission ranges.

B. Clutch Pressure Low in Specific Ranges, Normal Pressure in Other Ranges

Covers troubleshooting for clutch pressure issues specific to certain ranges.

C. Low Lubrication Pressure

Addresses troubleshooting for low transmission lubrication pressure.

ABNORMAL STALL SPEEDS (Stall In First Range — 6-Speed) (Stall In Second Range — 7-Speed)

A. High Stall Speeds

Details troubleshooting for high stall speed conditions.

B. Low Stall Speeds

Covers troubleshooting for low stall speed conditions.

OVERHEATING IN ALL RANGES

LEAKING FLUID (OUTPUT SHAFT)

POWER TAKEOFF (PTO)*

TRANSFER CASE (T-CASE)

A. Won’t Go Into First Range

Details troubleshooting steps when the transmission will not engage in first range.

B. Makes Excessive Noise

C. No Front Output Drive

D. Transmission Fluid Leaks

APPENDICES

Appendix A — IDENTIFICATION OF POTENTIAL CIRCUIT PROBLEMS

Appendix B — CHECKING CLUTCH PRESSURES

Details procedures for checking individual clutch pressures.

Appendix D — WIRE/CONNECTOR CHART

Appendix E — CONNECTOR PART NUMBERS, TERMINAL PART NUMBERS, TOOL PART NUMBERS, AND REPAIR INSTRUCTIONS

Appendix F — THROTTLE POSITION SENSOR ADJUSTMENT

Details the procedure for adjusting the Throttle Position Sensor (TPS).

Appendix K — SOLENOID AND TEMPERATURE CHARTS

Appendix M — DIAGNOSTIC TREE — WT SERIES HYDRAULIC SYSTEM

Presents a diagnostic tree for troubleshooting the WT Series hydraulic system.

Appendix N — PRO-LINK® 9000 DIAGNOSTIC DATA READER INFORMATION

Provides information and procedures for using the Pro-Link® 9000 diagnostic tool.

A. Circuit Inspection

B. Finding an Intermittent Fault Condition

Provides methods for diagnosing intermittent faults in wiring and electronic components.

APPENDIX B — CHECKING CLUTCH PRESSURES

C. Comparing Recorded Data to Specifications

APPENDIX D — WIRE/CONNECTOR CHART

ECU CONNECTOR “A” (BLACK/WHITE)

Provides pin-out and wire information for ECU connector "A".

ECU CONNECTOR “B” (BLACK)

THROTTLE POSITION SENSOR CONNECTOR

APPENDIX E — CONNECTOR PART NUMBERS, TERMINAL PART NUMBERS, TOOL PART NUMBERS, AND REPAIR INSTRUCTIONS

LIST OF SPECIAL TOOLS REQUIRED TO SERVICE WTEC II WIRING HARNESSES

1–1. THOMAS & BETTS CONNECTORS (ECU AND RSI)

Details part numbers and repair procedures for Thomas & Betts ECU and RSI connectors.

1–2. PACKARD METRI-PACK 150 SERIES CONNECTORS — PULL-TO-SEAT

Provides part numbers and repair procedures for Packard Metri-Pack 150 Pull-to-Seat connectors.

1–3. PACKARD METRI-PACK 150 SERIES CONNECTORS — PUSH-TO-SEAT (OIL LEVEL SENSOR)

Details part numbers and repair procedures for Packard Metri-Pack 150 Push-to-Seat connectors.

1–4. PACKARD METRI-PACK 280 SERIES CONNECTORS — PULL-TO-SEAT

1–5. PACKARD METRI-PACK 280 SERIES CONNECTORS — PUSH-TO-SEAT (DDR)

1–6. PACKARD WEATHER 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))

1–7. AMP PRODUCTS CONNECTORS (16-WAY VIW; 8-WAY RMR DEVICE (HAND LEVER))

B. Terminal Removal

1–8. DEUTSCH IPD/ECD CONNECTORS (31-WAY BULKHEAD, 31-WAY FEEDTHROUGH HARNESS; 16-WAY OPTIONAL SENSOR HARNESS; 6-WAY OPTIONAL DDR)

A. Connector/Terminal Repairs (cont’d)

B. Terminal Removal (refer to Figure E–9, View A)

1–9. ITT CANNON CONNECTORS — CRIMPED (37-WAY FMTV BULKHEAD; 6-WAY TRANSFER CASE; 8-WAY MD RETARDER)

B. Terminal Removal (refer to Figure E–10, Views A and B)

C. Terminal Crimping (refer to Figure E–10, View C)

1–10. ITT CANNON CONNECTORS — SOLDERED (2-WAY HD RETARDER)

A. Connector Terminal Repair (refer to Figure E–11)

C. Wire Removal — Desoldering

D. Soldering Wire Into Terminal

1–11. DEUTSCH DT SERIES CONNECTORS (12-WAY NAVISTAR VIW)

A. Connector/Terminal Repair

B. Terminal Removal (refer to Figure E–12, Views A and B)

C. Terminal Crimping (refer to Figure E–11, View C)

D. Terminal Insertion

1–12. DILL CONNECTORS (FREIGHTLINER 4-WAY FUSE AND 5-WAY RELAY VIW)

B. Terminal Removal (refer to Figure E–13, Views A and B)

1–13. EPC CONNECTORS (FORD 16-WAY BULKHEAD)

A. Connector/Terminal Repairs

B. Terminal Removal (refer to Figure E–14, View A)

C. Terminal Crimping

1–14. REPAIR OF A BROKEN WIRE WITH IN-LINE BUTT SPLICE

A. Connector Check Before Repair

B. Special Tools

C. Straight Lead Repair Procedure

APPENDIX F — THROTTLE POSITION SENSOR ADJUSTMENT

A. Description of Operation (Figure F–1)

B. Throttle Position Sensor (TPS) Adjustment

Provides detailed instructions for adjusting the throttle position sensor.

APPENDIX M — DIAGNOSTIC TREE — WT HYDRAULIC SYSTEM

APPENDIX N — PRO-LINK® 9000 DIAGNOSTIC DATA READER INFORMATION

A. Preparing to Use the Pro-Link® 9000 Diagnostic Data Reader

B. Checking Transmission Fluid Level (covered in Section 5–2 of this Manual)

C. Checking for Diagnostic Codes (use of the Pro-Link® 9000 mentioned, but not explained in Section 6)

Details procedures for checking diagnostic codes via the Pro-Link® 9000.

D. Clearing Diagnostic Codes (covered in Section 6 of this Manual)

Explains how to clear diagnostic codes using the Pro-Link® 9000.

E. Checking Other Troubleshooting Parameters

F. Performing a Clutch Test (covered in Appendix B)

APPENDIX P — INPUT/OUTPUT FUNCTIONS

PTO ENABLE (USING “PTO” SWITCH)

Details how to engage PTO using the PTO switch based on speed and throttle conditions.

PTO ENABLE (USING “MODE” BUTTON)

Explains PTO engagement using the MODE button based on speed and throttle conditions.

AUXILIARY FUNCTION RANGE INHIBIT (STANDARD)

AUXILIARY FUNCTION RANGE INHIBIT (SPECIAL)

ENGINE BRAKE/PRESELECT REQUEST AND ENGINE BRAKE ENABLE (STANDARD)

ENGINE BRAKE/PRESELECT REQUEST AND ENGINE BRAKE ENABLE (EUROPEAN)

FIRE TRUCK PUMP MODE

FIRE TRUCK PUMP MODE (OPTIONAL)

QUICK-TO-NEUTRAL PUMP

AUTOMATIC NEUTRAL FOR PTO (STANDARD)

AUTOMATIC NEUTRAL FOR REFUSE PACKER AND PTO ENABLE WITH SERVICE BRAKE STATUS

MANUAL LOCKUP

SHIFT IN PROCESS/SHIFT ENABLE

RETARDER ENABLE

KICKDOWN

FOURTH LOCKUP PUMP MODE

NEUTRAL INDICATOR FOR PTO AND PTO ENABLE

AUTOMATIC NEUTRAL FOR REFUSE PACKER AND PTO ENABLE