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Second level
Product Training
Third level Rigid Dump Truck (RDT)
Fourth level TR70 : TR100
TEREX Equipment Limited Detroit Diesel S2000
Fifth level
TEREX Equipment Limited

Level 2 –
Product
AllisonTraining
Transmission
- Detroit
C.E.C.
Diesel DDEC IVControls
2 Controls
Electronic Controls(IV)

170708

Terex Centre of Excellence


TEREX CENTRE OF EXCELLENCE
Terex Equipment Limited
TEREX Equipment
Newhouse IndustrialLimited
Estate
TEREX Equipment Limited
Newhouse Industrial
Motherwell, ML1 Estate
5RY
Motherwell,
Newhouse ML1
Industrial
United Kingdom 5RY
Estate

See Us At - www.terex.co.uk 1 United Kingdom


Technical Online Assistance: http://constructionsupport.terex.com
2

Allison Transmission
Detroit Diesel C.E.C. 2
Series 2000

TR70 T913 – 12V2000


TR100 T883 – 16V2000

S2000 – DDEC IV

Detroit Diesel Electronic Controlled Engines (Version 4)


2
3

Allison
DDEC IVTransmission C.E.C. 2

DETROIT DIESEL ELECTRONIC CONTROLS (IV)


An advanced electronic fuel injection control system.

DDEC Consists of:


• Sensors and switches
• Conductors and connections
• ECM (computer)
– Hardware
– Software
• Injectors

3
4

Allison Transmission
Electronic C.E.C. 2
Engine Advantages

• Engine Protection
• Engine Diagnostics
• Reduced Maintenance
• Improved Engine Governing
• Fuel Economy Optimization
• Enhanced Cold Starting
• Smoke Control
• Reduced Emission Levels

4
5

Allison Transmission
Wire / Cable Colours C.E.C. 2

5
N - BROWN
U - BLUE
R - RED
P - PURPLE
EXAMPLE;
R/W - RED/WHITE G - GREEN
•MAIN COLOUR RED
•WITH WHITE TRACER L - LIGHT GREEN
W - WHITE
Y - YELLOW
B - BLACK
S - SLATE (GREY)
O - ORANGE
K - PINK
5
6

Allison
WeldingTransmission
Precautions C.E.C. 2

6
Before welding on truck:
• Turn key-switch off
• Turn master switch off
Disconnect:
• Battery supply & earth cables
• Alternator earth & supply cables
• Transmission ECU
• Engine ECM
• Any other electronic options ie. rear view TV, lube
systems, etc.

6
7

Allison Transmission C.E.C. 2

Main Components

7
8

Allison Transmission C.E.C. 2


DDEC Necessities

8
ENGINE MOUNTED
CTS COOLANT TEMP. SENSOR
TBS TURBO BOOST SENSOR
FTS FUEL TEMP. SENSOR DATA
ATS AIR INTAKE SENSOR LINK
FPS FUEL PRESSURE SENSOR
CPS COOLANT PRESSURE SENSOR
OTS OIL TEMP. SENSOR
OPS OIL PRESSURE SENSOR
SRS SYNCRONOUS REF. SENSOR
TRS TIMING REF. SENSOR
CLS COOLANT LEVEL SENSOR
TPS THROTTLE POSITION

VEHICLE MOUNTED 8
9

Allison
DDEC ECMTransmission C.E.C. 2
Connections

VEHICLE CONNECTIONS
ENGINE CONNECTIONS

9
10

Allison Transmission
S2000 DDEC ECMs C.E.C. 2

10
Master ECM

Receiver ECM

DDEC
10 (IV)
11

Allison
DDEC ECMTransmission
Design C.E.C. 2

11

• 1 ECM has capacity to power up to 8 electronic unit pumps (EUP).


• 12V2000 master & receiver ECMs powers 6 EUPs each.
• 16V2000 master & receiver ECMs powers 8 EUPs each.
• S2000 master ECM is hardwired for all sensor data + TRS/SRS.
• S2000 receiver ECM is hardwired for TRS/SRS only.

11
12

Allison
DDEC ECMTransmission C.E.C. 2
Connectors

12

Power Connector

Vehicle Interface Connector - VIH


Communication Connector 12
13

Allison
DDEC ECMTransmission C.E.C. 2
Connectors

13

Injector Harness Connector M

Sensor Harness Connector


Injector Harness Connector R
13
14

Allison Transmission
Power Module – TR70C.E.C. 2

14
K23 A – Engine ECM Battery Power
K23 B – Engine ECM Battery Power

F42

F43
F41

F44

F46
F40

F45
K23 C – Trans. ECU Ignition Power
K59
K23 D – Trans. ECU Battery Power
K59 – Timer Relay
F40 – Main Battery Fuse
F41 – Engine ECM Battery Fuse M
F42 – Engine ECM Battery Fuse R K23 K23 K23 K23
F43 – Engine ECM Battery Fuse M A B C D

F44 – Engine ECM Battery Fuse R


F45 – Trans. ECU Battery Fuse
F46 – Trans. ECU Battery Fuse

14
15

Allison Transmission
Timer Relay – K59 C.E.C. 2

Control Fuse to Timer (15)


15
Ignition Signal (B2)

Control Fuse to Timer (A1)

30 Second Shut-Down Delay

Timer Output to Relays (18) Timer Earth (A2)


15
16

Allison Transmission
Interface Module C.E.C. 2

16
K60 - Check Transmission K60 K14 K17 K14 K17
Aux Aux
K14 - Neutral Start
K17 - Reverse
K14 Aux – On Board Weighing
K52
K17 Aux – Reverse Camera
K52 – Body Hoist Hold in Range
K39 - Delta () P K39

K25 – Lock Up Drop Out


F60
(TR100 F64) K25
K20 – Converter Drive
F60 - Ignition Signal 10A
S52 - Manual/Automatic Key
K20
S53 - Power/Economy Key

S52 S53
To Shift Control
(S & V) Harness (VIW) To Console Harness
16
17

Allison Transmission
Main Fuse Box C.E.C. 2

17

A B C
K23 K4

K43

K34 K56

K15 K38 K57

Relay Definition
K4 Flasher K15 Dipped Beam K56 Sound Power Body Raise
K23 Ignition K34 Horn K57 Sound Power 1st / Rev Gr.
K38 Main Beam K43 Radio
17
18

Allison Transmission C.E.C. 2

18

Power Up

18
19

Allison Transmission C.E.C. 2


DDEC Schematic

19

Electronic
Control
Module
(ECM)

EEPROM

- +
Battery

Ignition
19
20

Allison
Typical Transmission
Power Start UpC.E.C. 2
Circuit
MAIN FUSE BOX POWER MODULE
20
N - Gear

AR
GE TER
ENGINE ECM IF
SH
K23 F3

V
To K59

E.C.U.
Ignition Sense

S
Battery Power
From F40

K14
K1 - ENGINE
STARTER RELAY

INTERFACE
MODULE

S2 - KEY SWITCH
20
21

Allison Transmission C.E.C. 2


Power Harness

21

* Cavity B on Master ECM Only

21
22

Allison Transmission
Power Start Up CircuitC.E.C.
– TR702 (T913)

22

Keyswitch

Master Disconnect
Solenoid
Neutral Start Relay

Starter
Solenoid
Batteries

Ignition
Alternator Sense Relay
Main Fuse
Starter Motor Box

22
23

Allison Transmission
Power Start Up CircuitC.E.C.
– TR702 (T913)

23
From Batteries

To Keyswitch

Timer Relay

23
H2
To Tachometer M Engine Diagnostic Stop Lamp
P Engine Diagnostic Check Lamp
Allison

Diagnostic Switch
Power Start
Transmission

Accelerator Pedal
Up CircuitC.E.C.

24
2
– Ignition

Coolant Level Sensor


Sense

Diagnostic Switch
24
24
25

Allison Transmission
Power Start Up CircuitC.E.C.
– TR702 (T913)

25
K23 A – Engine ECM Battery Power
K23 B – Engine ECM Battery Power

F42

F43
F41

F44

F46
F40

F45
K23 C – Trans. ECU Ignition Power
K59
K23 D – Trans. ECU Battery Power
K59 – Timer Relay
F40 – Main Battery Fuse
F41 – Engine ECM Battery Fuse M
F42 – Engine ECM Battery Fuse R K23 K23 K23 K23
F43 – Engine ECM Battery Fuse M A B C D

F44 – Engine ECM Battery Fuse R


F45 – Trans. ECU Battery Fuse
F46 – Trans. ECU Battery Fuse

Engine VIH Main Power Harness


25
26

Allison Transmission
Main Power ConnectorC.E.C. 2 Module
at Power

26
A - 150 (M) B
B - 150 (M) B
C - 150 (R) B
D - 150 (R) B
E - Spare
F - Spare
G - 240 (M) R
H - 241 (M) R
J - 240 (R) R
K - 241 (R) R
L - Spare
M - Spare
N - Spare
P - 150 (M) B
R - Spare
S - Spare
Cavity - Wire# (Master/Receiver) Colour

26
27

Allison Transmission
VIH at Power Module C.E.C. 2

27

1 - W/K
1 Ignition Signal
8
2 - 439 K
2 7 Ignition Signal to DDEC
3 - 953 B/W
DDEC Common Earth
4 - Spare
3 6 5 - Spare
6 - Spare
7 - Spare
4 5
8 - Spare

Cavity - Wire# (Master/Receiver) Colour


27
28

Allison Transmission
VIH at ECM – Ignition C.E.C.
Sense 2

28

28
29

Allison Transmission C.E.C. 2

29

Injector Harness

29
30

Allison Transmission
Electronic Unit Pump C.E.C.
Power 2Harness

30

Electronic EUP

Control
Module Electronic Unit Pump
(ECM)

EEPROM

- +
Battery

Ignition
30
31

Allison
InjectorTransmission C.E.C. 2
Harness Connector

31

31
32

Allison Transmission
Electronic Unit Pump C.E.C.
Harness2

RIGHT HAND BANK


32

Receiver ECM
Master ECM

LEFT HAND
32 BANK
33

Allison
InjectorTransmission C.E.C. 2
Bank Identification

33

A1-B2-A5-B4-A3-B1-A6-B5-A2-B3-A4-B6
33
34

Allison Transmission
EUP & Injector C.E.C. 2
Schematic

34

1 FUEL FILTER
2 FUEL PUMP
3 FUEL FILTER
4 REGULATOR/RELIEF VALVE
5 JUNCTION BOX
6 INJECTION NOZZLE
7 HIGH PRESSURE FUEL LINE
8 ELECTRONIC UNIT PUMP (EUP)

SCHEMATIC BASED
34 ON 16V2000
35

Allison Transmission
S2000 Typical C.E.C. 2Nozzle
EUP & Injector

35

35
36

Allison Transmission
EUP Drive C.E.C. 2
off Camshaft

36

• EUPs on Camshaft
– Near EUI Performance
Yet Less Space
• Injection Nozzles in Head
– Pumping Forces in Block
– Lower Engine Height
• Roller Cam Followers
– Reduced Friction & Wear
• Short Pre-Stressed
Fuel Lines
– Increased Fatigue Strength

36
37

Allison Transmission
S2000 EUP InstallationC.E.C. 2

37

Inje
Pre ctor H
ssu i
EUP re F gh
Pip uel
e

Injector
Nozzle

37
38

Allison Transmission
S2000 EUP InstallationC.E.C. 2

38

 1. CAMSHAFT ROLLER4. SOL. PLUNGER  1. EUP 3. FUEL LINE NUT 5. INJECTION NOZZLE CLAMP
2. EUP BODY 5. SPRING 2. INJECTION LINE 4. INJECTION NOZZLE
3. SOLENOID 6. PLUNGER 38
39

Allison Transmission
S2000 EUP C.E.C. 2
Injection Cycle
Injection Line
39
Solenoid

EUP

Cam Injection
Nozzle

39
40

Allison Transmission
S2000 EUP CalibrationC.E.C.
Code 2

40

40
41

Allison Transmission C.E.C. 2

41

Sensors

41
42

Allison Transmission
DDEC Sensor Wiring C.E.C. 2

42

• Common Return Circuit. #452


• Thermistor

• Piezoresistive Pressure sensor


• Voltage is Proportional to Pressure

42
43

Allison Transmission
DDEC Sensor Rating C.E.C. 2

43

0.25V - 4.75V
Working Range

Fail Fail

0 Volt 5 Volt

43
44

Allison Transmission
DDEC Sensor Rating C.E.C. 2
DDEC Sensor Electrical Terms 44

• Open Circuit
An “open” describes a complete break in the path of current at some
point in the circuit.

• Short Circuit
A “short” occurs when a load in the circuit is accidentally bypassed.
Electricity will always take the path of least resistance.

• Grounded Circuit
A “ground” is similar to a “short” because current accidentally bypasses
a load in the circuit. The difference is that the bypass connects directly
to the negative terminal of the power source by way of the chassis
ground path.

44
45

Allison
DDEC 2Transmission
Wire Sensor C.E.C. 2

45

5V Supply

Signal

Return

ECM Sensor
Open = HI VOLTAGE
Short = LO VOLTAGE

45
46

Allison
DDEC 3Transmission
Wire Sensor C.E.C. 2

46

ECM Sensor
5V Supply

Signal

Return

Open Supply = LO VOLTAGE


Open Signal = LO VOLTAGE
Open Return = HI VOLTAGE
Supply short to Signal = HI VOLTAGE
Supply short to Return = LO VOLTAGE
Signal short to Return = LO VOLTAGE

46
47

Allison Transmission
S2000 Sensor HarnessC.E.C. 2

47

47
48

Allison
Sensor Transmission
Locations C.E.C. 2

48
1 OIL TEMP. SENSOR (OTS)
2 OIL PRESS. SENSOR (OPS)
3 TIMING REFERENCE SENSOR (TRS)
4 FUEL TEMP. SENSOR (FTS)
5 CHARGE AIR TEMP. SENSOR (ATS)
6 TURBO BOOST SENSOR (TBS)
7 FUEL PRESSURE SENSOR (FPS)
8 COOLANT TEMP. SENSOR (CTS)
9 COOLANT PRESS. SENSOR (CPS)
10 SYNCHRONOUS REFERENCE SENSOR (SRS)

48
49

Allison Transmission
Synchronous / TimingC.E.C. 2
Reference Sensors
DDEC Schematic Diagram 49

Synch Reference

Electronic EUI
Timing Reference
Control
Module
(ECM)

EEPROM

- +
Battery

Ignition
49
50

Allison Transmission
Synchronous / TimingC.E.C. 2
Reference Sensors
(TRS / SRS) 50
 SRS/TRS: Magnetic pickup sensors generate alternating current (AC). The frequency will
change dependent on the speed of the pulse wheel (RPM of Engine).
SRS
Camshaft
Timing
Pins

SRS/TRS

Cam Gear/
SRS
36
1
50 TRS Crank Timing Wheel
51

Allison Transmission
Synchronous / TimingC.E.C. 2
Reference Sensors
S2000 SRS/TRS 51
Synchronous Reference Sensor
1/Cam Revolution

SRS

TRS

Timing Reference Sensor


36/Crankshaft Revolution 51
52

Allison Transmission
Electronic Foot Pedal C.E.C. 2

52
Synch Reference
EUI
Timing Reference Electronic
Electronic Foot
Pedal Assembly Control
Module
(ECM)

EEPROM

- +
Battery
Ignition

52
53

Allison Transmission
Electronic Foot Pedal C.E.C. 2
Assembly

53

Terex ID
B19

Supply - Red & White = 5V±1%


Idle - White & Black = 10 - 20% of Input (i.e. 5V Input = 0.5 - 1V)
Full Throttle - White & Black = 70 - 85% of Input (i.e. 5V Input = 3.5 - 4.25V)
Wired 53via VIH
54

Allison
ThrottleTransmission C.E.C.
Position Sensor 2 TR70
– TPS

54

54
55

Allison Transmission
Electronic Foot Pedal C.E.C. 2
Assembly

55
0 VOLTS 0.25 VOLTS 4.75 VOLTS 5 VOLTS

LO
VOLT BUFFER 0% BUFFER
100% Hi VOLT
CODE ZONE THROTTLE THROTTLE ZONE CODE

OPERATING RANGE

0 48 102 205 717 871 968 1025


(10%) (20%) (70%) (85%) (100%)
COUNTS

DDEC IV

55 Counts can be read using DDR only


56

Allison Transmission
Turbo Boost Sensor - C.E.C.
TBS 2

56
Synch Reference
EUI
Timing Reference Electronic
Electronic Foot
Pedal Assembly Control
Module
Turbo Boost Pressure
(ECM)

EEPROM

- +
Battery
Ignition

56
57

Allison Transmission
Turbo Boost Sensor - C.E.C.
TBS 2

57

TBS

57
58

Allison Transmission
Temperature C.E.C.
& Pressure 2
Sensors

58
Synch Reference
EUI
Timing Reference Electronic
Electronic Foot
Pedal Assembly Control
Module
Turbo Boost Pressure
(ECM)
Fuel / Oil / Coolant/ Air
Temperature

Oil / Fuel Pressure


EEPROM

- +
Battery
Ignition

58
59

Allison Transmission
Temperature C.E.C.
& Pressure 2
Sensors

59
AIR INTAKE TEMPERATURE SENSOR

ATS

ATS

59
60

Allison Transmission
Temperature C.E.C.
& Pressure 2
Sensors

60

FTS FPS

FTS - Fuel Temperature Sensor


FPS - Fuel Pressure Sensor
60
61

Allison Transmission
Temperature C.E.C.
& Pressure 2
Sensors

61

OTS - Oil Temp. Sensor


CTS
CTS - Engine Coolant Temp. Sensor
T - Engine Coolant Temp. Sender
CPS - Engine Coolant Press.
Sensor
OPS - Oil Pressure Sensor

CPS

OPS

OTS

61
62

Allison
PressureTransmission
Sensors C.E.C. 2

62

Coolant
Oil / Fuel
Pressure
Pressure

Series 60

Series 2000
Different Harness Connectors

Series 2000

62
63

Allison
CoolantTransmission
Level Sensor C.E.C. 2

63
Synch Reference
EUI
Timing Reference Electronic
Electronic Foot
Pedal Assembly Control
Module
Turbo Boost Pressure
(ECM)
Fuel / Oil / Coolant
Temperature
Oil / Fuel Pressure

EEPROM

Coolant Level

- +
Battery
Ignition

63
64

Allison
CoolantTransmission
Level Sensor C.E.C. 2

64

DDEC IV
Coolant Level Sensor

OEM Responsible - Coolant level sensor (S47) signal to VIH connector 115-H3
64
65

Allison Transmission C.E.C. 2

65

Diagnostics

65
66

Allison Transmission C.E.C. 2


Diagnostics

66
Synch Reference
EUI
Timing Reference Electronic
Electronic Foot
Pedal Assembly Control
Module DDR Interface/ DDDL/
Reprogramming
Turbo Boost Pressure
(ECM)
Stop
Fuel / Oil / Coolant Engine
Temperature

Oil / Fuel Pressure


Check
EEPROM Engine

Coolant Level

- +
Ignition Battery
Diagnostic Stop Engine
Request Override

66
67

Allison
On BoardTransmission
DiagnosticsC.E.C. 2
Engine Diagnostic / Engine Override Switch 67
10. Master Diagnostic Request & Engine
Override Switch (S68)
11. Receiver Diagnostic Request Switch (S68)

10 11

A - Stop Engine Light (SEL)


B - Check Engine Light (CEL)
67
H2
M Engine Diagnostic Stop Lamp
P Engine Diagnostic Check Lamp
Allison
On BoardTransmission

68
DiagnosticsC.E.C. 2

68
68
69

Allison
On BoardTransmission
DiagnosticsC.E.C. 2
Diagnostic Lights 69

 ECM will detect a fault on the engine.


 Either engine warning or stop lamp will illuminate depending on severity of fault.
 With ignition ON, select diagnostic request switch.
 The red warning lamp will flash out any active fault codes followed by the amber warning lamp
flashing out any inactive fault codes.
 Once all the active and inactive codes have been shown it will begin the sequence again.
 Note: Code 25 = All clear.
 Press the diagnostic switch again to exit diagnostic mode.

2 FLASHES 5 FLASHES

SHORT PAUSE LONG PAUSE


69
70

Allison Transmission
Diagnostic C.E.C. 2
Code Summary

13 COOLANT LEVEL CIRCUIT LOW 43


70
COOLANT LEVEL TOO LOW
14 INTERCOOLER, COOLANT OR OIL TEMP CIRCUIT HIGH 44 IN/COOLER, COOLANT OR OIL TEMP HIGH
15 INTERCOOLER, COOLANT OR OIL TEMP CIRCUIT LOW 45 LOW OIL PRESSURE
16 COOLANT LEVEL CIRCUIT HIGH 46 BATTERY VOLTAGE LOW
21 TPS CIRCUIT HIGH 47 FUEL PRESSURE HIGH
22 TPS CIRCUIT LOW 48 FUEL PRESSURE LOW
23 FUEL TEMP CIRCUIT HIGH 53 EEPROM WRITE OR NON VOLATILE FAIL
24 FUEL TEMP CIRCUIT LOW 55 J1939 DATA LINK FAULT
25 NO CODES (ALL CLEAR) 58 TORQUE OVERLOAD
27 AIR TEMP CIRCUIT HIGH 61 INJECTOR RESPONSE TIME TOO LONG
28 AIR TEMP CIRCUIT LOW 63 PWM OPEN OR SHORT TO BATTERY
32 SEL SHORT OR OPEN CIRCUIT 64 TURBO SPEED CIRCUIT FAILED
33 BOOST PRESSURE CIRCUIT HIGH 67 COOLANT PRESSURE CIRCUIT HIGH/LOW
34 BOOST PRESSURE CIRCUIT LOW 71 INJECTOR RESPONSE TIME TOO SHORT
35 OIL PRESSURE CIRCUIT HIGH 72 VEHICLE OVERSPEED
36 OIL PRESSURE CIRCUIT LOW 75 BATTERY VOLTAGE HIGH
37 FUEL PRESSURE CIRCUIT HIGH 76 ENGINE OVERSPEED WITH ENGINE BRAKE
38 FUEL PRESSURE CIRCUIT LOW 85 ENGINE OVERSPEED
41 TOO MANY SRS (MISSING TRS) 86 WATER PUMP PRESSURE CIRCUIT HIGH
42 TOO MANY TRS (MISSING SRS) 88 COOLANT PRESSURE LOW
70
71

Allison Transmission C.E.C. 2


DDR Interface

71

Diagnostic Connector

S2000

Located Below Dash


Terex Tooling #
Multi-Kit (DDR, Cartridge & Cables) ; 15275098
DDEC III/IV Card ; 15275096
Spare DDR ; 15268971
Spare Multi Cartridge ; 15273084
Spare Adaptor Cable ; 15270310 71
72

Allison
D.D.D.L.Transmission
Interface C.E.C. 2

Detroit Diesel Diagnostic Link - D.D.D.L.


72

Diagnostic Link and DDEC Reports

DDDL Package

DDEC Reports DDDL

Operating Report Tool Troubleshooting &


Maintenance Tool

Comprehensive Engine Maintenance &


Information Management Troubleshooting Software
Software Programme That Performs All
of The Same Functions As
DDR and MORE

72
73

Allison
D.D.D.L.Transmission
Interface C.E.C. 2
DDDL Interface Tool No.s 73
15501306 DDDL Complete Kit - Includes Software, Cables,
Translator box
Spares
15501455 Translator Box
15501458 PC to Translator Box Cable
15501460 Translator Box to Vehicle Cable
15501457 Vehicle Cable
15501454 Extension Cable
15501379 6 to 9 Pin Adaptor Cable - DDEC V Engines Only

73
74

Allison Transmission
Engine Protection C.E.C.
/ Ramp 2
Down

74

 Warning- Illumination of CEL, SEL only.

 Rampdown- Immediate reduction to 70% power, ramping down to 40%


over 30 seconds and maintains 40% power.

Typical Parameters:
LOW COOLANT LEVEL
HIGH COOLANT TEMPERATURE
LOW OIL PRESSURE
HIGH OIL TEMPERATURE

74
75

Allison Transmission C.E.C. 2

75

Communication

75
76

Allison Transmission C.E.C. 2


Communication

76
Synch Reference
EUI
Timing Reference Electronic
Electronic Foot Communication
Pedal Assembly Control
Module DDR Interface/ DDDL/
Reprogramming
Turbo Boost Pressure
(ECM)
Stop
Fuel / Oil / Coolant Engine
Temperature

Oil / Fuel Pressure


Check
EEPROM Engine

Coolant Level

- +
Ignition Battery
Diagnostic Stop Engine
Request Override

76
77

Allison Transmission C.E.C. 2


Communication

77

• J1587/J1708
– 9600 Baud Rate, used to transmit sensor and engine data to diagnostic
tools ie. DDR, DDDL

• J1939
– 250k Baud Rate, communication link between engine and transmission.

77
78

Allison Transmission C.E.C. 2


Communication

78

A - Spare
B - Spare
C - Spare
D - 927 G J1939 (S)
E - 926 B J1939 (-)
F - 925 R J1939 (+)

Cavity - Wire# (Master/Receiver) Colour

Common for both Master


78 and Receiver ECMs’
79

Allison
CANBUS Transmission C.E.C.
Communication 2
– TR70

79

79
80

Allison Transmission C.E.C. 2

80

Tachometer Calibration

80
81

Allison Transmission
(P2) Tachometer C.E.C. 2
Calibration

Tachometer Calibration Input 81


TR70 (T913) 12.00 Pulses
TR100 (T883) 12.00 Pulses (70 Amp Alternator)
18.34 Pulses (100 Amp Alternator – 14 poles)
20.96 Pulses (100 Amp Alternator – 16 poles)
PULSE
The tachometer when installed as new or replaced will
require calibration prior to being put to work.

On the rear of the tachometer there is a pressure pad.

1. Hold down pressure pad.


2. Turn on ignition - Do not start engine.
3. Hold pressure pad until the word ‘PULSE’ appears
on the tachometer display.
4. Release pressure pad and a calibration figure will be
displayed, similar to above.
5. Each digit will flash for 4-5 seconds each, prior to
advancing to the next digit.
6. To alter a digit, press the pressure pad.
7. Once calibration is complete, turn off ignition.

81
82

Allison Transmission C.E.C. 2

82

General Troubleshooting

82
83

Allison
GeneralTransmission C.E.C. 2
Troubleshooting
Fuel System Troubleshooting 83
Low Power

Inspect the following:


• Fuel Supply
• Restricted Filters
• Obstructed Fuel Lines
• Fuel Pump

83
84

Allison
GeneralTransmission C.E.C. 2
Troubleshooting
Air System Troubleshooting 84
Low Power

Inspect The Following:


• Intake
– Air Cleaner
– Charge Cooler
– Piping
– Turbocharger
• Exhaust
– Faulty Piping
– Obstructed Muffler
• Turbo Boost Sensor
• Low Compression

84
85

Allison
GeneralTransmission C.E.C. 2
Troubleshooting
Lube System Troubleshooting 85
Low Oil Pressure

Inspect the following:


• Supply
– Low Oil Level
– Oil Quality
• Mechanical
– Stuck Regulator or Relief Valve
• Temperature
– High Coolant Temp.
– High Ambient Load

85
86

Allison
GeneralTransmission C.E.C. 2
Troubleshooting

Lube System Troubleshooting 86


High Oil Consumption

• High Consumption
– Leaks
– Worn Components
– Checking and Filling Procedures
• Pump Speed
• Restriction to flow (worn parts)

86
87

Allison
GeneralTransmission C.E.C. 2
Troubleshooting

Lube System Troubleshooting 87


High Oil Consumption

• External Leaks
– Oil Lines or connections leaking
– Gaskets or oil seal leaks
– High crank case pressure
• Internal Leaks
– Oil Cooler Leaking
– Turbocharger
– Air compressor
– Worn Valve Guides/Seats

87
88

Allison
GeneralTransmission C.E.C. 2
Troubleshooting

Lube System Troubleshooting 88


High Oil Pressure

• Oil Control At Cylinder


– Oil Control rings worn, broken, or improperly
installed
– Scored liners, Pistons, or oil rings
– Excessive oil in Crankcase

88
89

Allison
GeneralTransmission C.E.C. 2
Troubleshooting
Blue Smoke Troubleshooting 89

• Air Cleaner
• Turbocharger seals
• Turbocharger Oil Drain
• Exhaust Valve Guides and Seals
• Piston Rings
• Oil Level

BLUE SMOKE IS CAUSED BY EXCESSIVE OIL IN THE CYLINDER

89
90

Allison
GeneralTransmission C.E.C. 2
Troubleshooting
Black Smoke Troubleshooting 90

• Air Cleaner
• Turbocharger
• Exhaust Manifold Gaskets
• Muffler
• Exhaust Piping
• Charge Cooler
• Turbo Boost Sensor

BLACK SMOKE OCCURS WHEN FUEL IS NOT COMPLETELY BURNED

90
91

Allison
GeneralTransmission C.E.C. 2
Troubleshooting
Black Smoke Troubleshooting 91

• Grade of Fuel
• Injector Output
• Avoid Lugging the Engine

BLACK SMOKE OCCURS WHEN FUEL IS NOT COMPLETELY BURNED

91
92

Allison
GeneralTransmission C.E.C. 2
Troubleshooting

White Smoke Troubleshooting 92


• Air Cleaner
• Connections
• Grade of Fuel
• Injector Output
• Aerated Fuel
• Burnt Exhaust Valves
• Exhaust Valve Adjustment
• Compression Rings

WHITE SMOKE IS CAUSED BY MISFIRING CYLINDER

92
93

Allison
GeneralTransmission C.E.C. 2
Troubleshooting

Cooling System Troubleshooting 93


Temperature Problems

• HIGH TEMP.
– Coolant level
– Fan Operation
– Hoses
– Pump Failure
– Ambient/Load
• LOW TEMP.
– Thermostats
– System Cooling Capacity

93
94

Allison
GeneralTransmission C.E.C. 2
Troubleshooting

Cooling System Troubleshooting 94


Temperature Problems

• Cavitation
• Corrosion
• Scale
• Silicate Drop-out

94
95

Terex Equipment Limited


Motherwell, ML1 5RY
Scotland
+44 (0)1698 732121
+44 (0)1698 734046

Web
www.terex.com

Technical Online Assistance


http://constructionsupport.terex.com