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Allison Transmission Workshop Repair & Service Manual

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US Dollar: $59.00

Complete digital official shop manual contains service, maintenance, and troubleshooting information for the Allison Transmissions. Diagnostic and repair procedures are covered in great detail to repair, maintain, rebuild, refurbish or restore your Allison Transmissions like a professional mechanic in local service/repair workshop. This cost-effective quality manual is 100% complete and intact as should be without any missing pages. It is the same factory shop manual used by dealers that guaranteed to be fully functional to save your precious time.

This manual for Allison Transmissions is divided into different sections. Each section covers a specific component or system and, in addition to the standard service procedures, includes disassembling, inspecting, and assembling instructions. A table of contents is placed at the beginning of each section. Pages are easily found by category, and each page is expandable for great detail. It is in the cross-platform PDF document format so that it works like a charm on all kinds of devices. You do not need to be skilled with a computer to use the manual.

FILELIST:
bonus_material
CD2456EN - Parts Catalog CD-ROM (4000 Product Family Series Transmissions)
GN2055EN - Technician’s Guide (Automatic Transmission Fluid).pdf
GN4008EN - In-Chassis Maintenance (1000 & 2000 Product Families - 4th Gen. Controls).pdf
GN4062EN - Technician's Guide (1000 & 2000 Product Families).pdf
JA3450EN - Quick-Tech Reference (1000 & 2000 Product Families - Pre-4th gen. Controls Data).pdf
JA3664EN - In-Chassis Maintenance (1000 & 2000 Product Families - Vocational Models).pdf
MT3004EN - Mechanic’s Tips (3000 & 4000 Product Families - WTEC III Controls).pdf
MT3190EN - Mechanic's Tips (1000 & 2000 & 2400 On-Highway Transmissions).pdf
MT4007EN - Mechanic's Tips (1000 & 2000 Product Families - 4th gen. Controls).pdf
MT4015EN - Mechanic‘s Tips (3000 & 4000 Product Families - 4th gen. Controls).pdf
MT4108EN - Mechanic’s Tips (Allison 4th gen. Controls - 3700 SP).pdf
OM3349EN - Operator’s Manual (3000 & 4000 Product Families - Vocational Models).pdf
OM3757EN - Operator’s Manual (1000 & 2000 Product Families - Highway Series (HS) Transmissions).pdf
OM4118EN - Operator’s Manual (1000 & 2000 Product Families - International Models).pdf
SM2148EN - Service Manual (3000 Product Family - Vocational Models).pdf
SM2457EN - Service Manual (4000 Product Family On-Highway Transmissions - Vocational Models).pdf
SM3191EN - Service Manual (1000 & 2000 Product Families - Pre-4th gen. Controls - Vocational Models).pdf
SM4006EN - Service Manual (1000 & 2000 Product Families - 4th gen. Controls - Vocational Models).pdf
SM4013EN - Service Manual (3000 Product Family - 4th gen. Controls - Vocational Models).pdf
SM4014EN - Service Manual (4000 Product Family - 4th gen. Controls - Vocational Models).pdf
TS2470EN - Troubleshooting Manual (WTEC II Electronic Controls).pdf
TS2712EN - Troubleshooting Manual (Allison Transmission Electronic Controls).pdf
TS2973EN - Troubleshooting Manual (WTEC III Electronic Controls - 3000 & 4000 Product Families - Vocational Models).pdf
TS3192EN - Troubleshooting Manual (1000 & 2000 & 2400 Product Families Electronic Controls).pdf
TS3353EN - Troubleshooting Manual (5000, 6000, 8000, 9000 Series Transmissions Commercial Electronic Controls 2 (CEC2)).pdf
TS3977EN - Troubleshooting Manual (1000 & 2000 Product Families - 4th gen. Controls).pdf
TS3977FR - Manuel de dépannage (Groupes de produits 1000 et 2000 - Commandes Allison 4. Génération).pdf
TS3989EN - Troubleshooting Manual (3000 & 4000 Product Families - 4th gen. Controls - Vocational Models).pdf
TS3989FR - Manuel de dépannage (Groupes de produits 3000 et 4000).pdf

TS2470EN:
WTEC II ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL
1998 MAY; REV. 1 1999 OCTOBER; REV. 2 2004 JULY; REV. 3 2005 DECEMBER
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)

TS2712EN:
ALLISON TRANSMISSION ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL
This document covers the following on- and off-highway transmission models:
MT(B) 648; CLBT 5962 and 6062
HT(B) 741, 746 and 748; DP 8963
HT(B) 755CR and 755DR; CL(B)T 9681
V 731, V 731RH, VR 731, and VR 731RH; CLT 755 and CL(B)T 755

TS2973EN:
WTEC III ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL
2005 OCTOBER
REV. 1 OCTOBER 2006
VOCATIONAL MODELS
3000 VOCATIONAL MODELS
3000 HS 3500 RDS B 300(P)(R)
3000 RDS 3500 EVS B 400(P)(R)
3000 EVS T 200
3000 MH T 300
3000 PTS
3000 TRV
3200 SP 3500 SP 3700 SP
3200 TRV
MD 3060 MD 3560 MD 3070PT
MD 3066
4000 VOCATIONAL MODELS
4000 EVS 4500 EVS 4700 EVS 4800 EVS B 500
4000 HS 4500 HS 4700 RDS
4000 MH 4500 RDS
4000 RDS 4500 SP
4000 TRV 4500 TRV
HD 4060 HD 4560 HD 4070 HD 4076 B 500P
HD 4060P HD 4560P HD 4070P B 500R
HD 4060R HD 4560R HD 4070R B 500PR
HD 4060PR HD 4560PR HD 4070PR T 425 T 450

TS3192EN:
ALLISON 1000/2000/2400 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL
2003 APRIL
REV. 1 2004 MAY

TS3353EN:
5000, 6000, 8000, 9000 Series Transmissions
COMMERCIAL ELECTRONIC CONTROLS 2 (CEC2) TROUBLESHOOTING MANUAL
2005 DECEMBER
M 5610A M 5610AR
S 5610H S 5610MR S 5610M
M 6610A M 6610AR
S 6610H S 6610HR S6610M S 6610MR
M 8610A M 8610AR
S 8610H S 8610HR S 8610M S 8610MR
M 9610A M 9610AR
S 9610A S 9610AR S 9610M S 9610MR
S 9805M S 9805MR
S 9810A S 9810AR S 9810H S 9810HR
S 9810M S 9810MR

TS3977EN:
2008 FEBRUARY
REV. 2 2008 SEPTEMBER
ALLISON 4th GENERATION CONTROLS
1000 AND 2000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL

TS3977FR:
GROUPES DE PRODUITS 1000 ET 2000 MANUEL DE DÉPANNAGE — COMMANDES ALLISON 4ème GÉNÉRATION
JANVIER 2006

TS3989FR:
FÉVRIER 2005
GROUPES DE PRODUITS 3000 ET 4000 MANUEL DE DÉPANNAGE—COMMANDES ALLISON 4ème GÉNÉRATION
MODÈLES SPÉCIALISÉS Manuel de dépannage FÉVRIER 2005
MODÈLES 3000 SPÉCIALISÉS
3000 HS 3500 RDS B 300(P)(R)
3000 RDS 3500 EVS B 400(P)(R)
3000 EVS T 200
3000 MH T 300
3000 PTS
3000 TRV
3200 SP 3500 SP 3700 SP 3200 TRV
MODÈLES 4000 SPÉCIALISÉS
4000 EVS 4500 EVS 4700 EVS 4800 EVS B 500
4000 HS 4500 HS 4700 RDS B 500P
4000 MH 4500 RDS B 500R
4000 RDS 4500 SP B 500PR
4000 TRV 4500 TRV T 425 T 450

EXCERPT:
Troubleshooting Manual
Allison Transmission
Electronic Control
DEFINITIONS AND ABBREVIATIONS .............................. v
OPERATIONAL OVERVIEW
Introduction .................................................... 1-1
Applications ................................................... 1-2
Electronic Control Unit (ECU) ............................................ 1-3
Programmable Read Only Memory (PROM) ................................. 1-4
Output Speed Sensor ................................................. 1-5
Throttle Position Sensor ............................................ 1-6
Shift Selectors ................................................ 1-8
Reverse and Forward Pressure Switches.............................. 1-9
Oil Pressure Switches/Sensors ............................................. 1-10
Temperature Sensor........................................ 1-12
Chassis Wiring Harness............................................. 1-13
Cab Wiring Harness .................................................. 1-14
Secondary Wiring Harness ........................................ 1-15
Electro-Hydraulic Valve Body ............................................. 1-16
Solenoids ............................................. 1-17
Typical On-Highway Fluid Flows........................................ 1-19
Typical Off-Highway Fluid Flows ....................................... 1-29
COMPONENT INSTALLATION AND ADJUSTMENT
Introduction .................................................... 2-1
Electronic Control Unit (ECU) ............................................ 2-2
Programmable Read Only Memory (PROM) ................................. 2-3
Output Speed Sensor ................................................. 2-4
Throttle Position Sensor ............................................ 2-5
Shift Selectors ................................................ 2-8
Wiring Harnesses ........................................... 2-11
VEHICLE INTERFACE
Introduction .................................................... 3-1
Electronic Control Inquiry System....................................... 3-1
Mandatory Vehicle Interface ..................................... 3-2
Optional Cab Harness Interface ........................................... 3-12
Optional Secondary Harness Interface................................. 3-28
SELF-DIAGNOSTICS ....................................... 4-1
TROUBLESHOOTING–TROUBLE CODES PRESENT ......................... 5-1
TROUBLESHOOTING–INTERMITTENT TROUBLE CODES ....................... 6-1
TROUBLESHOOTING–NO TROUBLE CODES PRESENT .................. 7-1
APPENDIX A–TROUBLESHOOTING STEPS–TROUBLE CODES PRESENT........ A-1
APPENDIX B–TROUBLESHOOTING STEPS–NO TROUBLE CODES PRESENT............ B-1
APPENDIX C–CONNECTOR, TERMINAL, AND WIRE REPAIR .................. C-1
APPENDIX D–ADDITIONAL TERMINAL DESIGNATIONS................ D-1
APPENDIX E–ELECTRICAL SCHEMATICS ............................... E-1
APPENDIX F–HYDRAULIC SCHEMATICS ................................. F-1
APPENDIX G–SPECIAL TOOLS............................... G-1
APPENDIX H–DIAGNOSTIC CODE BACKGROUND INFORMATION................... H-1

DEFINITIONS AND ABBREVIATIONS
Allison Transmission Electronic Control System — The complete electronic control system for the transmission, including all detail components.
Bi-Directional Communication Link (BDCL) — Hard wire connections which allow the Allison Electronic
Control system to communicate with other engine or transmission controls.
Check Transmission Light — Optional instrument panel warning light that alerts the operator that a problem has occurred and the vehicle should be serviced as soon as possible. Also used by the technician to read diagnostic codes when a diagnostic data reader is not used.
Detroit Diesel Electronic Controls (DDEC) — Detroit Diesel’s electronic engine control system.
Diagnostic Codes (Trouble Codes) — Two-digit codes stored in the electronic control ECU memory. These codes are set when system self-diagnostics detects problems. Technicians access codes and use them to help troubleshoot problems.
Diagnostic Data Link (DDL) — Cab harness connector which allows a diagnostic data reader to interface with the Allison Electronic Control system.
Digital Display Unit (DDU) — Optional electronic component that displays various system operating and warning information.
Digital Volt Ohmmeter (DVOM) — Electrical device used for performing voltage, continuity and resistance tests.
Do Not Shift Light — Warning lamp located on the shift selector. This indicator alerts the driver that a potentially serious problem has been detected and shift selection has been limited.
Electronic Control Inquiry System (ECIS) — On-line data base (available through Distributor Parts Departments) that indicates which options are programmed on a particular PROM.
Electronic Control Unit (ECU) — The Allison Electronic Control system onboard microcomputer. This is the electronic “brain” for the system.
Fluidic Oil Level Sensor (FOLS) — One of the three types of switches that signal the ECU when a low lube pressure or low oil level condition exists. The FOLS uses a separate housing that bolts to the bottom of the valve body. It is very similar to the Low Oil Pressure/Level Sensor, but does not use a bi-metal strip.
Infinity (∞) — An indication that circuit or component resistance is so high it can not be measured. Generally, this means continuity is not present (the circuit is open).
Jumper Wire — A short piece of wire used to connect two electrical circuits or bypass a portion of a circuit.
Low Oil Level/Pressure Sensor — One of the three types of switches that signal the ECU when a low lube pressure or low oil level condition exists. The Low Oil Level/Pressure Sensor uses a separate housing that bolts to the bottom of the valve body. It is very similar to the Fluidic Oil Level Sensor and uses a bi-metal strip to compensate for cold oil temperatures until the transmission warms up.
Lube Pressure Switch — One of the three types of switches that signal the ECU when a low lube pressure or low oil level condition exists. The Lube Pressure Switch is configured like the forward and reverse pressure switches. It plumbs directly into the lubrication oil passage.
Ohm (Ω) — A unit of electrical resistance measurement.
Options — Programmed special features. Examples — Bed Hoist Interlock, Loading Hold, Neutral-To-Range
Inhibit, etc. Options must be programmed in the PROM and properly wired.
Programmable Read Only Memory (PROM) — This is the microchip that contains all the transmission shift and control information. The PROM is located in the ECU.
Power Take-Off (PTO) — Transmission-mounted accessory drive unit. PTOs are used to operate pumps and other accessories on specialty vehicles.
Self-Diagnostics — The Allison Transmission Electronic Control’s built-in capability to recognize system problems.
Solenoid — Components in the electro-hydraulic valve body that act as switches to direct hydraulic pressure into specific passages or to exhaust.
Speed Sensor (Output Speed Sensor) — Provides the electronic control system with output speed information.
The speed sensor replaces the conventional hydraulic governor system.
Splice — A connection of two or more wires. When repairing harness wires, they are spliced using special butt connectors.
Temperature Sensor — Monitors sump oil temperature for the ECU. On-highway sensors are mounted on the solenoid control circuit (on the internal wiring harness). Off-highway sensors are mounted in the lock-up valve body.
Throttle Position Sensor (TPS) — Provides the electronic control system with throttle position information. The TPS replaces the conventional hydraulic modulator system.
Transmission Engine Communication Link (TECL) — A type of Bi-Directional Communication Link
(BDCL) that allows the Allison Transmission Electronic Control to communicate with engine controls.
Transmission Test Switch — Vehicle manufacturer-installed switch that places the electronic control system in its diagnostic mode. When the switch is on, trouble codes can be retrieved.
Transmission to Transmission Communication Link (TTCL) — A type of Bi-Directional Communication
Link (BDCL) that allows the Allison Transmission Electronic Control to communicate with other
transmission controls.
Vehicle Interface — Term describing the electrical connections between the vehicle and the Allison
Transmission Electronic Control system.

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