MOTORHOME SERIES 3000/4000 - RV Tech Library

1 MOTOR HOME SE RIESOPERATOR S MANUAL3000/ 4000 Allison Transmission VOCATIONAL MODELS Operator sManual 2005 FEBRUARY Rev. 1 2005 SEPTEMBER OM3349EN MOTORHOME SERIES (MH) Transmissions3000 and 4000 Product FamiliesWTEC III Controls and Allison 4 th Generation Controls3000 MH4000 MH Printed in USAC opyright 2005 General Motors Corporation2 NOTESTABLE OF CONTENTSINTRODUCTIONKEEPINGTHATALLISONAD VANTAGE .. 7A BRIEF DESCRIPTION OF THE ALLISON MOTORHOME 12 ELECTRONIC CONTROL 12 TORQUE 13 PLANETARYGEARSANDCLUTCHES .. 14 COOLER 14 RETARDER .. 15 SHIFT SELECTORSDESCRIPTION OF AVAILABLE 17 LEVER SHIFT 18 PUSHBUTTON SHIFT 20 RANGE 21 DRIVING TIPSCHECKTRANSLIGHT .. 26 DIAGNOSTIC 27 ACCELERATOR 27 DOWNSHIFT AND DIRECTION CHANGE INHIBITOR 27 USINGTHEENGINETOSLOWTHEVEHICLE .. 29 USING THE HYDRAULIC 29 ADAPTING 32 RANGE 34 COLDWEATHERSTARTS.

2 34 DRIVING ON SNOW OR 35 ROCKINGOUT .. 36 HIGHFLUIDTEMPERATURE .. 36 PARKINGBRAKE .. 37 TOWING OR 38 PRIMARY/SECONDARY SHIFT 38 CRUISECONTROLOPERATION .. 38 TURNINGOFFTHEVEHICLE .. 39 POWER TAKEOFF OPERATIONENGINE-DRIVENPOWERTAKEOFF(PTO) .. 403 CARE AND MAINTENANCEPERIODIC 41 PREVENT MAJOR 41 IMPORTANCE OF PROPER FLUID 42 FLUID LEVEL CHECK USING PUSHBUTTON OR LEVER 43 MANUAL FLUID CHECK 47 COLDCHECK .. 49 HOTCHECK .. 50 RECOMMENDED AUTOMATIC TRANSMISSION FLUID AND VISCOSITYGRADE .. 50 KEEPINGFLUIDCLEAN .. 51 FLUID AND INTERNAL FILTER CHANGE 52 TRANSMISSION FLUID 56 TRANSMISSION FLUID AND FILTER CHANGE 60 DIAGNOSTIC 60 DIAGNOSTIC CODE DISPLAY 63 DIAGNOSTIC CODE LISTINGS AND PROCEDURES(WTECIIICONTROLS) .. 65 DIAGNOSTIC CODE LISTINGS AND PROCEDURES (ALLISON 4thGENERATIONCONTROLS).

3 73 ABBREVIATIONS AND DEFINITIONSABBREVIATIONS AND 84 CUSTOMER SERVICEOWNER 86 SERVICELITERATURE .. 88 ALLISON TRANSMISSION 90 ALLISON TRANSMISSION REGIONAL 924 TRADEMARK USAGEThe following trademarks are the property of the companies indicated: Allison DOC is a trademark of General Motors Corporation. DEXRON is a registered trademark of the General Motors Corporation. TranSynd is a trademark of Castrol , CAUTIONS, NOTESIT IS YOUR RESPONSIBILITYto be completely familiar with the warningsand cautions described in this manual. It is, however, important to understand thatthese warnings and cautions are not exhaustive. Allison Transmission could notpossibly know, evaluate, and advise the service trade of all conceivable ways inwhich service might be done or of the possible hazardous consequences of eachway.

4 The vehicle manufacturer is responsible for providing information related tothe operation of vehicle systems (including appropriate warnings, cautions, andnotes). Consequently, Allison Transmission has not undertaken any such broadevaluation. Accordingly,ANYONE WHO USES A SERVICE PROCEDUREOR TOOL WHICH IS NOT RECOMMENDED BY ALLISONTRANSMISSION OR THE VEHICLE MANUFACTURER MUST first bethoroughly satisfied that neither personal safety nor equipment safety will bejeopardized by the service methods service and repair is important to the safe, reliable operation of theequipment. The service procedures recommended by Allison Transmission (or thevehicle manufacturer) and described in this manual are effective methods forperforming service operations. Some of these service operations require the use oftools specially designed for the purpose.

5 The special tools should be used whenand as types of headings are used in this manual to attract your attention. Thesewarnings and cautions advise of specific methods or actions that can result inpersonal injury, damage to the equipment, or cause the equipment to :A warning is used when an operating procedure, practice,etc., if not correctly followed, could result in personal injury or loss :A caution is used when an operating procedure, practice,etc., if not strictly observed, could result in damage to or destruction :A note is used when an operating procedure, practice, etc., isessential to THAT ALLISON ADVANTAGEA llisonMotorhome SERIES (MH) transmissionsprovide many advantages for thedriver who must stop and go or change speeds frequently. Driving is easier,safer, and more MOTORHOME SERIES transmissions are rugged and designed to provide long,trouble-free service.

6 This manual will help you gain maximum benefits from yourALLISON-equipped PADSMAIN-PRESSURE TAPNOTE: Inch SERIES ThreadsBREATHERFEEDTHROUGHHARNESSCONNECT ORCOOLER PORTSNOTE: Inch SERIES (BOTH SIDES)BREATHERMAIN-PRESSURE TAPNOTE: Inch SERIES ThreadsFEEDTHROUGHHARNESSCONNECTORTORQUE CONVERTERWITH LOCKUP CLUTCHAND TORSIONAL DAMPERFILL TUBEAND DIPSTICK(Available on both sides)Figure 1. Typical 3000 MH SERIES Transmission(WTEC III Controls) (BOTH SIDES)BREATHERMAIN-PRESSURE TAPNOTE: Inch SERIES ThreadsTORQUE CONVERTERWITH LOCKUP CLUTCHAND TORSIONAL DAMPERFILL TUBEAND DIPSTICK(Available on both sides)FILL TUBEAND DIPSTICK(Available on both sides)MAIN-PRESSURE TAPNOTE: Inch SERIES ThreadsNAMEPLATEFEEDTHROUGHHARNESS CONNECTORCOOLER PORTSNOTE: Inch SERIES ThreadsOUTPUTSPEEDSENSORINPUTSPEEDSENSOR ASSEMBLY PADSBREATHERF igure 2.

7 Typical 3000 MH SERIES Transmission(Allison 4thGeneration Controls)9 TURBINE SPEEDSENSORMOUNTINGPADINPUT SPEEDSENSORNAMEPLATEFILL TUBE AND DIPSTICKOUTPUT SPEEDSENSORFEEDTHROUGHHARNESSCONNECTORV0 6342 COOLER PORTSMAIN-PRESSURE TAPMOUNTING PAD(BOTH SIDES)COOLER PORTSFEEDTHROUGHHARNESSCONNECTORBREATHER BREATHERF igure 3. Typical 4000 MH SERIES Transmission(WTEC III Controls)10 TURBINE SPEEDSENSORMOUNTINGPADINPUT SPEEDSENSORNAMEPLATEFILL TUBE AND DIPSTICKOUTPUT PORTSMAIN-PRESSURE TAPMOUNTING PAD(BOTH SIDES)COOLER PORTSBREATHERBREATHERFEEDTHROUGHHARNESS CONNECTORF igure 4. Typical 4000 MH SERIES Transmission(Allison 4thGeneration Controls)11A BRIEF DESCRIPTION OF THE ALLISON MOTORHOMESERIES TRANSMISSIONSI ncluded in the Allison On-Highway Transmission family are the MotorhomeSeries transmissions.

8 The transmissions described in this manual include: WTEC III Controls or Allison 4thGeneration Controls A torque converter with lockup and torsion damper Three planetary gear setsMotorhome SERIES transmissions may contain an integral retarder or a provision tomount a Power Takeoff (PTO).ELECTRONIC CONTROL SYSTEMAll MOTORHOME SERIES transmissions come standard with WTEC III Controls orAllison 4thGeneration Controls. These systems consist offive major componentsconnected by OEM-furnished wiring harnesses. Thefive major components are: Transmission Control Module (TCM) or Electronic Control Unit (ECU) Three speed sensors Remote shift selector Control module (which contains solenoid valves, a pressure switch, and anoptional oil level sensor) Engine Electronic Control Module (ECM) or Engine Throttle PositionSensor (TPS), if installedThe TCM/ECU receives information from the following: Throttle position sensor, if installed Speed sensors Pressure switch Shift selectorThe TCM/ECU processes information and then sends signals to actuate specificsolenoids located in the control valve module.

9 These solenoids control bothoncoming and offgoing clutch pressures to provide closed-loop shift control bymatching input rpm during a shift to a desired profile programmed into feature of both Allison 4thGeneration Controls and WTEC III controls is autodetect. Autodetect is active within thefirst several engine starts, dependingupon the component or sensor being detected. These engine start cycles beginwhen the transmission is installed during vehicle manufacture. Autodetect searchesfor the presence of the following transmission components or data inputs:Transmission ComponentsRetarderPresent, Not PresentOil Level Sensor (OLS)Present, Not PresentThrottleAnalog, J1587, J1939 Engine Coolant TemperatureAnalog, J1939, J1587 Seek help from the nearest Allison Transmission service outlet when any of theabove components are present, but are not responding feature of the MOTORHOME SERIES transmission is its ability to adapt or learn as it operates.

10 Each shift is measured electronically, stored, and used bythe TCM/ECU to adapt or learn the optimum control for future :Allison 4thGeneration Controls and WTEC III Controls aredesigned and manufactured to comply with all FCC and other guidelinesregarding radio frequency interference/electromagnetic interference(RFI/EMI) for transportation electronics. Manufacturers, assemblers, andinstallers of radio-telephone or other two-way communication radioshave the sole responsibility to correctly install and integrate thosedevices into Allison MOTORHOME SERIES transmission-equipped vehiclesto customer TCM/ECU is programmed to provide the most suitable operatingcharacteristics for a specific application. This manual does not attempt to describeall of the possible combinations. The information contained herein describes onlythe operating characteristics most frequently requested by the CONVERTERThe torque converter consists of the following four elements: Pump input element driven directly by the engine Turbine output element hydraulically driven by the pump Stator reaction (torque multiplying) element Lockup Clutch mechanically couples the pump and turbine when engaged;controlled by TCM/ECU13 When the pump turns faster than the turbine, the torque converter is multiplyingtorque.