Allison TC10 5th Generation Controls Trooubleshooting Manual – PDF DOWNLOAD
DESCRIPTION:
Allison TC10 5th Generation Controls Trooubleshooting Manual – PDF DOWNLOAD
FOREWORD-How to Use This Manual:
Welcome to the Troubleshooting Manual TS7116EN. This manual providas troubleshooting information for
the TC10 Transmission. Service Manual SM7117EN and the Parts Catalog PC7120EN may be used in
conjunction with this manual.
This manual includes:
• Description of the TC1 O Allison 5th Generation Electronic Contrai system.
• Description of Diagnostic Trouble Codes (DTCs), system responses to faults, and troubleshooting
steps for active DTCs.
• Wire, terminal, and connector repair information.
• System schematics.
• Troubleshooting complaints without DTCs.
• lnpuUOutput Wiring Diagrams.
lnstructions for proper use of the service toais used to troubleshoot active DTCs and making connector
repairs are included in this manual. Refer to the appropriate service manuais for procedures and instructions
to service toais used to overhaul the transmission.
Additional information may be published periodically in Service lnformation Letters (SIL) and will be included
in future revisions of Allison Service Publications. Please review all Slls to obtain up-to-date information
concerning Allison Transmission products.
TABLE OF CONTENTS:
Allison TC10 5th Generation Controls Trooubleshooting Manual – PDF DOWNLOAD
FOREWORD-How to Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii
IMPORTANT SAFETY INFORMATION …………………………………………………. iii
ABBREVIATIONS ANO ACRONYMS ………………………………………………….. iv
TRADEMARK USAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii
LITERATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii
LIST OF WARNINGS …………………………………………………………. viii
SECTION 1 ESSENTIAL TOOLS FOR TROUBLESHOOTING AND CALIBRATION
1-1 GENERAL TOOLS INFORMATION ……………………………………………. 1-1
1-2 ESSENTIAL TOOLS LIST ………………………………………………… 1-1
1-3 UNIVERSAL ALLISON DOC® ………………………………………………. 1-2
SECTION 2 ALLISON 5th GENERATION CONTROL SYSTEM OPERATION
2-1 GENERAL SYSTEMS OVERVIEW ……………………………………………. 2-1
2-2 ELECTRONIC TRANSMISSION CONTROL MODULE (TCM) ………………………………. 2-4
2-3 SHIFT SELECTORS …………………………………………………… 2-6
A. Normal Operation Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
B. lnhibited Operation Display ………………………………………………. 2-7
C. Oil Levei Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
D. Diagnostic Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
E. Push Button Shift Selector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
F. Bump Levar Shift Selector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
G. Preselect Downshift Shift Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
H. MODE lndicator ……………………………………………………. 2-9
1. MODE Button …………………………………………………….. 2-10
J. Trans Service lndicator (Wrench lcon) ………………………………………… 2-10
K. Backlighting ……………………………………………………… 2-10
2-4 SPEED SENSORS ……………………………………………………. 2-11
2-5 CONTROL VALVE BODY MODULE …………………………………………… 2-11
A. Assembly Overview …………………………………………………. 2-11
B. Main Pressure Modulation (MM) Solenoid ………………………………………. 2-16
C. Transmission Fluid Temperatura (TFT) Sensor (Sump Temperatura Sensor) ……………………… 2-17
D. Oil Levei Sensor (OLS) ……………………………………………….. 2-17
E. Pressure Switch Manifolds ……………………………………………… 2-17
F. Turbina Shaft Speed Sensor …………………………………………….. 2-17
G. Countershaft Speed Sensor ……………………………………………… 2-18
2-6 WIRING HARNESSES …………………………………………………. 2-18
A. Extemal Wiring Harness ……………………………………………….. 2-18
B. Internai Wiring Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
2-7 OPTIONAL VEHICLE INTERFACE MODULE (VIM) …………………………………… 2-20
2-8 ADAPTIVE CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
A. Adapt Shifls Repor! Patterns and Regions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
2-9 SHIFT SCHEDULES …………………………………………………… 2-21
A. Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
B. Shift Calibrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
2-10 PRIMARY ANO SECONDARY SHIFT SCHEDULES …………………………………… 2-22
A. Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
B. Common Shift Schedule Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
2-11 HOLD SCHEDULE FOR UPSHIFTS …………………………………………… 2-23
2-12 PRESELECT SCHEDULE FOR DOWNSHIFTS …………………………………….. 2-23
A. During Non-Engine Brake Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23
B. During Engine Brake Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23
Copyright© 2014 Allison Transmission, lnc. AII Rights Reserved. xi
Allison TC10
2-13 CRUISE MODE SHIFT SCHEDULE …………………………………………… 2-24
2-14 UNDER-TEMPERATURE (COLD) SHIFT SCHEDULE ………………………………….. 2-24
2-15 KICKDOWN SHIFT SCHEDULE …………………………………………….. 2-24
2-16 LOW RANGE TORQUE PROTECTION (LRTP) ……………………………………… 2-24
2-17 LOAD BASED SHIFT SCHEDULING (LBSS) ………………………………………. 2-25
A. Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25
B. Types of LBSS are the following: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26
2-18 VEHICLE ACCELERATION CONTROL (VAC) ……………………………………… 2-26
2-19 VEHICLE ACCELERATION RATE LIMITING ………………………………………. 2-27
2-20 INPUT ANO OUTPUT (1/0) FUNCTIONS ………………………………………… 2-27
2-21 CUSTOMER MODIFIABLE CONSTANTS (CMCs) ……………………………………. 2-28
2-22 SHIFT INHIBIT LOGIC ………………………………………………….. 2-28
A. Engine Speed lnhibit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28
B. Direction Change lnhibit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29
C. Auxiliary Function Range lnhibit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29
D. Notification in Shift Selector Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29
E. Reset (Clearing) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29
F. Viewing lnhibits in Universal Allison DOC® . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29
SECTION 3 FLUID CHECK PROCEDURES
3-1 TRANSMISSION FLUI □ (OIL) ………………………………………………. 3-1
A. lmportance of Transmission Fluids …………………………………………… 3-1
B. Approved Fluid Types …………………………………………………. 3-1
C. Keeping Fluid Clean ………………………………………………….. 3-1
D. Preheating Requirements ……………………………………………….. 3-1
3-2 TRANSMISSION FLUI □ LEVEL CHECKS ………………………………………… 3-2
A. Cold Check Procedure (Dipstick Method) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
B. Hot Check Procedure (Dipstick Method) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
C. Checking Dipstick Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
D. Electronic Fluid Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
E. Fluid Levei Check using Universal Allison DOC® . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
3-3 TRANSMISSION FLUI □ CAPACITY ……………………………………………. 3-6
SECTION 4 PROGNOSTICS PACKAGE AND FEATURES
4-1 OVERVIEW ……………………………………………………….. 4-1
4-2 TRANS SERVICE INDICATOR (WRENCH ICON) …………………………………….. 4-1
4-3 PROGNOSTICS PREREQUISITES ……………………………………………. 4-1
4-4 PROGNOSTICS FEATURES AVAILABILITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4-5 TURNING PROGNOSTICS PACKAGE ON OR OFF ……………………………………. 4-2
4-6 PROGNOSTICS INDICATION AT ENGINE START ……………………………………. 4-3
4-7 OIL LIFE MONITOR (OM) ………………………………………………… 4-3
A. Percentage Fluid Life Remaining Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
B. Maintenance Required Notification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
C. OM Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
D. OM Maintenance History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
4-8 FILTER LIFE MONITOR (FM) ………………………………………………. 4-5
A. Filter Life Status Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
B. Filter Life Monitor (FM) Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
C. FM Maintenance History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
4-9 PROGNOSTICS IN UNIVERSAL ALLISON DOC® …………………………………….. 4-6
A. Viewing History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
B. Enabling/Disabling Prognostics Package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
xii Copyright© 2014 Allison Transmission, lnc. AII Rights Reserved.
TABLE OF CONTENTS
C. Reset Prognostics Monitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
SECTION 5 DIAGNOSTIC CODES
5-1 OVERVIEW ……………………………………………………….. 5-1
5-2 TYPES OF SYSTEM RESPONSE …………………………………………….. 5-1
5-3 HYDRAULIC OPERATION DURING ELECTRICAL INTERRUPTION …………………………… 5-2
5-4 CHECK TRANS LIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5-5 USING SELECTOR FOR DIAGNOSTIC TROUBLE CODE (DTC) DISPLAY ……………………….. 5-3
A. Display Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
B. Read/Clear DTCs with Pushbutton Selector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
C. Read/Clear DTCs with Bump Lever Shift Selector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
5-6 DIAGNOSTICS IN UNIVERSAL ALLISON DOC® …………………………………….. 5-6
A. Viewing DTCs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
B. Clearing DTCs …………………………………………………….. 5-7
5-7 DTC LIST ANO DESCRIPTION INDEX ………………………………………….. 5-8
SECTION 6 CONTROL SYSTEM AND TRANSMISSION SPECIFICATIONS
6-1 MECHANICAL GEAR RATIOS ………………………………………………. 6-1
6-2 MEASURING TRANSMISSION PRESSURES ………………………………………. 6-1
6-3 TRANSMISSION ANO VEHICLE PREPARATION …………………………………….. 6-1
6-4 COMPARING RECORDE □ DATA TO SPECIFICATIONS …………………………………. 6-3
6-5 UNIVERSAL ALLISON DOC® CLUTCH TEST ACTION REQUEST ……………………………. 6-3
6-6 MAIN MODULATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6-7 TCC ANO CLUTCH PRESSURES …………………………………………….. 6-4
6-8 TORQUE CONVERTER PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
6-9 PRESSURE SPECIFICATIONS ……………………………………………… 6-4
6-10 CLUTCH, SOLENOID ANO PRESSURE SWITCH OPERATION TABLES …………………………. 6-7
6-11 SOLENOID DATA ……………………………………………………. 6-11
6-12 TRANSMISSION FLUI □ TEMPERATURE (TFT) SENSOR ……………………………….. 6-12
6-13 PRESSURE SWITCH DATA, PRESSURE SWITCH MANIFOLD 1 ANO PRESSURE SWITCH MANIFOLD 2 ………. 6-12
SECTION 7 GENERAL TROUBLESHOOTING OF PERFORMANCE COMPLAINTS
7-1 GENERAL TROUBLESHOOTING OF PERFORMANCE COMPLAINTS ………………………….. 7-1
APPENDICES
A. TOWING, JUMP STARTING, WELDING ANO PAINTING …………………………………. A-1
B. TRAINING ANO REQUIRED SKILLS …………………………………………… B-1
C. FIRST STEPS ANO TIPS FOR TROUBLESHOOTING ………………………………….. C-1
D. TROUBLESHOOTING WITH A DIGITAL MULTIMETER (DMM) ……………………………… D-1
E. TROUBLESHOOTING TRANSMISSION ANO VEHICLE CIRCUITS ……………………………. E-1
F. WIRE/CONNECTOR/VIM CHARTS ……………………………………………. F-1
G. CONNECTOR PART NUMBERS …………………………………………….. G-1
H. TRANSMISSION STALL TEST ……………………………………………… H-1
1. TC10 TCM DIAGRAM …………………………………………………… 1-1
J. HYDRAULIC SCHEMATICS ……………………………………………….. J-1
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