Allison Transmission 5000, 6000, 8000, 9000 SeriesOff-Highway Transmissions

Allison Transmission 5000, 6000, 8000, 9000 SeriesOff-Highway Transmissions Commercial Electronic Controls 2 (CEC2) TS3353EN Troubleshooting Manual

How to Use This Manual
his manual provides troubleshooting information for Allison Transmission Division, 5000, 6000, 8000, and 9000 Series Off-Highway Transmissions which have CEC 2. Service Manuals SM1866EN (5000, 6000), SM1228EN (8000) and SM1833EN (9000), plus Parts Catalogs PC1860EN (5000, 6000), PC1249EN (8000) and PC1830EN (9000) may be used in conjunction with this manual.
This manual includes:

  1. Description of the CEC 2 system.
  2. Description of the electronic control system components.
  3. Description of diagnostic codes, system responses to faults, and troubleshooting.
  4. Wire, terminal, and connector repair information.

Specific instructions for using many of the available or required service tools and equipment are not included in this manual. The service tool manufacturer will furnish instructions for using the tools or equipment.
Additional information may be published from time to time in Service Information Letters (SIL) and will be included in future revisions of this and other manuals. Please use these SILs to obtain up-to-date information concerning Allison Transmission products.

DIAGNOSTIC CODES
C. Manually Clearing Codes and Active Indicators from the Code List. To clear active indicators or all codes:
1. Enter the diagnostic display mode.
2. Press and hold the MODE button for approximately three seconds until the LED indicator flashes. All active indicators are cleared. To remove all inactive codes, press and hold the MODE button for about ten seconds until the LED indicator flashes again. All active indicators will be cleared at ECU power down.
3. Codes that cannot be manually cleared will remain.
D. Exiting the diagnostic display mode. Exit the diagnostic display mode using one of the following procedures:
1. On a pushbutton shift selector, press the ⇑ (Up) and ⇓ (Down) arrow buttons at the same time or press any range button, D, N, or R. The shift (D, N, or R) is commanded if not inhibited by an active code.
2.On a lever shift selector, momentarily press the “display mode” button or move the shift lever to any shift position other than the one it was in when the diagnostic display mode was activated. If the shift is inhibited, the ECU will continue to command the current transmission range attained and the lever should be returned to its original position.
3.Wait until timeout (approximately 10 minutes) and the system will automatically return to the normal operating mode.
4.Turn off power to the ECU (turn off the vehicle engine at the ignition switch).

DIAGNOSTIC CODE RESPONSE
The following ECU responses to a fault provide for safe transmission operation:
Do Not Shift (DNS) Response Release lockup clutch and inhibit lockup operation.
Inhibit all shifts.
Turn on the CHECK TRANS light.
Shift selector display flashes the range selected.
Ignore any range selection inputs from the pushbutton or lever shift selector.
SOLenoid OFF (SOL OFF) Response
All solenoids are commanded off.

SHIFT SELECTOR DISPLAYS RELATED TO ACTIVE CODES
“Cateye” The forward slash segments and the middle horizontal segments (-\-) may be on under the following conditions:
RSI link fault is active (code 23 12 or 23 14)
When two COP timeouts occur within two seconds of each other (reference code 69 33)
Shift selector display line fault is active (23 16)

APPENDIX C - CONNECTOR PART NUMBERS, TERMINAL PART NUMBERS, TOOL PART NUMBERS, AND REPAIR INSTRUCTIONS
C. Terminal Crimping — VIM And Speed Sensor Terminals (Standard Crimping Tool)
1. If a spare wire is used, the wire should be pushed through the proper hole in the strain relief (if used), through the wire seal, and out the other side of the connector before stripping.
2. Carefully strip insulation 0.18 ± 0.02 inch (4.5 mm ± 0.5 mm). Unless insulation crimp is over-tight, Automatic Wire Stripper J 35615 will remove insulation and crimp from old terminal without damaging wire.
3. Place core crimp portion of terminal on bed of anvil “E” and squeeze crimper enough to keep terminal from dropping (Figure C–2, View B).
4. Position wire core in terminal and squeeze crimper tool to complete the core crimp. Be sure to orient the terminal so that it is properly aligned with the terminal cavity in the connector. The terminal should be positioned so that the lock tang is on the side of the cavity which has the notch in the middle (for the remover tool).
5. Position insulation crimp of terminal on anvil “C” so that the entire insulation crimp area and a portion of the terminal between the core and insulation crimp areas are supported by the anvil. Complete the insulation crimp.
6. Be sure lock tang is lifted to allow proper reseating of the terminal.
7. Pull on the wire to pull the terminal completely into the cavity. (A click will be heard and the terminal should stay in place if the wire is pushed.)

D. Terminal Crimping Using Alternate Tool J 35123
1. If a spare wire is used, the wire should be pushed through the proper hole in the strain relief (if used) and the wire seal, and out the other side of the connector prior to stripping.
2. Insert remover tool in front side of connector to release locktab and push terminal out front of connector. Pull the terminal and wire out the front of the connector to complete Steps (3) through (7).
3. Push open the terminal holder on the crimper tool J 35123 and insert a terminal into the opening marked 18–16 (Figure C–2, View C) so that the crimp ends point up. Release the terminal holder.
4. Slightly close the crimping tool (close until one click is heard) but do not start to crimp the terminal. Place the terminal on the wire so it is in the same position as it will be when pulled back into the connector. The terminal should be positioned so that the lock tang is on the side of the cavity which has the notch in the middle (for the remover tool).
5. Insert the wire into the terminal until the wire contacts the holder. (By doing this, the core and insulation should be properly positioned for the core and insulation crimp wings.)
6. Squeeze the crimper fully until it opens when released.
7. Open the terminal holder and remove the wire and terminal from the crimping tool.
8. Pull on the terminal to assure a tight crimp.
9. Be sure lock tang is lifted to allow proper reseating of the terminal.
10. Pull on the wire to pull the terminal completely into the cavity. (A click will be heard and the terminal should stay in place if the wire is pushed.)

Allison Transmission 5000, 6000, 8000, 9000 SeriesOff-Highway Transmissions Commercial Electronic Controls 2 (CEC2) TS3353EN Troubleshooting Manual

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