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ALLISON MD-HD WTEC 3 TROUBLESHOOTING MANUAL

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ALLISON MD-HD WTEC 3 TROUBLESHOOTING MANUAL

Format: PDF

Language: EN

Size: 6.71 MB

Pages: 396

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ALLISON MD-HD WTEC 3 TROUBLESHOOTING MANUAL

What does this catalog contain?

ALLISON MD-HD WTEC 3 TROUBLESHOOTING MANUAL contains high quality images, diagrams, instructions to help you to operate, maintenance, diagnostic, and repair your machine. This document is printable, without restrictions, contains searchable text and bookmarks for easy navigation.

ALLISON MD-HD WTEC 3 TROUBLESHOOTING MANUAL includes:

  • Numbered table of contents easy to use so that you can find the information you need fast.
  • Detailed sub-steps expand on repair procedure information.
  • Numbered instructions guide you through every repair procedure step by step.
  • Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
  • Notes, cautions and warnings throughout each chapter pinpoint critical information.
  • Bold figure number help you quickly match illustrations with instructions.
  • Detailed illustrations, drawings and photos guide you through every procedure.
  • Enlarged inset helps you identify and examine parts in detail.

What will you get when you get this service catalog?

  • After payment has been received, a few minutes later.
  • Lifetime PDF and Access To Download (By Request).
  • Compatible With Windows, Mac, IOS, Android and Other Systems.
  • Searchable Text and Built-in Index For Instant Information Search Bookmarks.
  • Printable – Pages Or Entire Manual.
  • Zoomable – Detailed Exploded Diagrams, Picture.

TABLE OF CONTENT OF THE ALLISON MD-HD WTEC 3 TROUBLESHOOTING MANUAL

Foreword. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii
SAFETY INFORMATION
Important Safety Notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .iii
Warnings, Cautions, and Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .iii
Trademarks Used in This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .iv
Shift Selector Terms and Display Indications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .iv
SECTION 1. GENERAL DESCRIPTION
1–1. TRANSMISSION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1
1–2. ELECTRONIC CONTROL UNIT (ECU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3
1–3. SHIFT SELECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3
A. Pushbutton Shift Selector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3
B. Lever Shift Selector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–4
1–4. THROTTLE POSITION SENSOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–5
1–5. SPEED SENSORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–5
1–6. CONTROL MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–6
1–7. WIRING HARNESSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–7
A. External Wiring Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–7
B. Internal Wiring Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–9
1–8. VEHICLE INTERFACE MODULE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–9
1–9. AUTODETECT FEATURE (V9A SOFTWARE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–10
A. Retarder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–10
B. Oil Level Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–10
C. Throttle Source (Also Applies to V9 Software). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–10
D. Engine Coolant Temperature Sensor Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–10
1–10. AUTODETECT FEATURE (V8, V8A, V9 SOFTWARE). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–10
A. Retarder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–11
B. Oil Level Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–11
C. Throttle Source (V8, V8A Software — See Paragraph 1–9C for V9 and 9A) . . . . . . . . . . . . . 1–11
D. Engine Coolant Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–12
1–11. TRANSID FEATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–12
A. General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–12
B. Transmission Changes Versus TransID Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–12
C. Compatibility Between TransID Level and ECU Calibration Level . . . . . . . . . . . . . . . . . . . . 1–15
SECTION 2. DEFINITIONS AND ABBREVIATIONS
2–1. CHECK TRANS LIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1
2–2. ALLISON TRANSMISSION DIAGNOSTIC TOOL J-44950 (ATDT™) . . . . . . . . . . . . . . . . . . . 2–1
2–3. DIAGNOSTIC DATA READER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–2
2–4. ABBREVIATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–3

SECTION 3. BASIC KNOWLEDGE
3–1. BASIC KNOWLEDGE REQUIRED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1
3–2. USING THE TROUBLESHOOTING MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–2
3–3. SYSTEM OVERVIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–2
3–4. IMPORTANT INFORMATION IN THE TROUBLESHOOTING PROCESS . . . . . . . . . . . . . . . . 3–2
3–5. BEGINNING THE TROUBLESHOOTING PROCESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–3
SECTION 4. WIRE CHECK PROCEDURES
4–1. CHECKING OPENS, SHORTS BETWEEN WIRES, AND SHORTS-TO-GROUND . . . . . . . . . 4–1
4–2. CHECKING AT TRANSMISSION CONNECTOR AND THE INTERNAL HARNESS
FOR OPENS, SHORTS BETWEEN WIRES, AND SHORTS-TO-GROUND . . . . . . . . . . . . . . . . 4–2
SECTION 5. OIL LEVEL SENSOR
5–1. INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1
5–2. ELECTRONIC FLUID LEVEL CHECK (SHIFT SELECTOR). . . . . . . . . . . . . . . . . . . . . . . . . . . 5–3
A. Fluid Level Check Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–3
5–3. ELECTRONIC FLUID LEVEL CHECK (ATDT™ or PRO-LINK® 9000) . . . . . . . . . . . . . . . . . . 5–5
A. Fluid Level Check Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–5
SECTION 6. DIAGNOSTIC CODES
6–1. DIAGNOSTIC CODE MEMORY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1
6–2. CODE READING AND CODE CLEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1
6–3. DIAGNOSTIC CODE RESPONSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–3
6–4. SHIFT SELECTOR DISPLAYS RELATED TO ACTIVE CODES . . . . . . . . . . . . . . . . . . . . . . . . 6–4
6–5. DIAGNOSTIC CODE LIST AND DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–4
6–6. DIAGNOSTIC CODE TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–17
A. Beginning the Troubleshooting Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–17
B. Solenoid Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–17
C. Diagnostic Code Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–17
D. Wire/Terminal Numbering Scheme . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–17
SECTION 7. INPUT AND OUTPUT FUNCTIONS
7–1. INPUT FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1
7–2. OUTPUT FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–3

APPENDICES
A. IDENTIFICATION OF POTENTIAL CIRCUIT PROBLEMS. . . . . . . . . . . . . . . . . . . . . . . . . . . .A–1
B. CHECKING CLUTCH AND RETARDER PRESSURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B–1
C. SOLENOID AND CLUTCH CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C–1
D. WIRE/CONNECTOR CHART. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D–1
E. CONNECTOR PART NUMBERS, TERMINAL PART NUMBERS,
TOOL PART NUMBERS, AND REPAIR INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E–1
F. THROTTLE POSITION SENSOR ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F–1
G. WELDING ON VEHICLE/VEHICLE INTERFACE MODULE . . . . . . . . . . . . . . . . . . . . . . . . . .G–1
H. HYDRAULIC SCHEMATICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H–1
J. WT WIRING SCHEMATIC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J–1
K. TRANSID 1 TEMPERATURE SENSOR AND SOLENOID RESISTANCE CHARTS . . . . . . . .K–1
L. EXTERNALLY-GENERATED ELECTRONIC INTERFERENCE . . . . . . . . . . . . . . . . . . . . . . . . L–1
M. DIAGNOSTIC TREE — WT SERIES HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . M–1
N. DIAGNOSTIC TOOL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .N–1
P. INPUT/OUTPUT FUNCTION WIRING SCHEMATICS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P–1
Q. TRANSID 2 THERMISTOR TROUBLESHOOTING INFORMATION . . . . . . . . . . . . . . . . . . . .Q–1

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