Allison Transmission Motorhome Series User manual

MOTORHOME SERIES
OPERATOR’S
MANUAL
3000/4000

Allison Transmission
VOCATIONAL MODELS
Operator’s
Manual
2005 FEBRUARY
Rev. 1 2005 SEPTEMBER
OM3349EN
Motorhome Series (MH) Transmissions
3000 and 4000 Product Families
WTEC III Controls and Allison 4
th
Generation Controls
3000 MH
4000 MH
Printed in USA Copyright © 2005 General Motors Corporation

2
NOTES

TABLE OF CONTENTS
INTRODUCTION
KEEPINGTHATALLISONADVANTAGE ........................ 7
A BRIEF DESCRIPTION OF THE ALLISON MOTORHOME SERIES
TRANSMISSIONS ...................................... 12
ELECTRONIC CONTROL SYSTEM ........................... 12
TORQUE CONVERTER ................................... 13
PLANETARYGEARSANDCLUTCHES ........................ 14
COOLER CIRCUIT ...................................... 14
RETARDER...........................................15
SHIFT SELECTORS
DESCRIPTION OF AVAILABLE TYPES .........................16
INTRODUCTION ....................................... 17
LEVER SHIFT SELECTOR ................................. 18
PUSHBUTTON SHIFT SELECTOR ............................ 20
RANGE SELECTION .....................................21
DRIVING TIPS
CHECKTRANSLIGHT ................................... 26
DIAGNOSTIC CODES .................................... 27
ACCELERATOR CONTROL ................................ 27
DOWNSHIFT AND DIRECTION CHANGE INHIBITOR FEATURE ....... 27
USINGTHEENGINETOSLOWTHEVEHICLE ................... 29
USING THE HYDRAULIC RETARDER ......................... 29
ADAPTING SHIFTS ..................................... 32
RANGE PRESELECTION .................................. 34
COLDWEATHERSTARTS ................................. 34
DRIVING ON SNOW OR ICE ............................... 35
ROCKINGOUT ........................................ 36
HIGHFLUIDTEMPERATURE .............................. 36
PARKINGBRAKE ...................................... 37
TOWING OR PUSHING ................................... 38
PRIMARY/SECONDARY SHIFT SCHEDULES .................... 38
CRUISECONTROLOPERATION............................. 38
TURNINGOFFTHEVEHICLE .............................. 39
POWER TAKEOFF OPERATION
ENGINE-DRIVENPOWERTAKEOFF(PTO) ..................... 40
3

CARE AND MAINTENANCE
PERIODIC INSPECTIONS ................................. 41
PREVENT MAJOR PROBLEMS ..............................41
IMPORTANCE OF PROPER FLUID LEVEL ...................... 42
FLUID LEVEL CHECK USING PUSHBUTTON OR LEVER SHIFT
SELECTOR ........................................... 43
MANUAL FLUID CHECK PROCEDURE ....................... 47
COLDCHECK ......................................... 49
HOTCHECK .......................................... 50
RECOMMENDED AUTOMATIC TRANSMISSION FLUID AND VISCOSITY
GRADE ............................................. 50
KEEPINGFLUIDCLEAN..................................51
FLUID AND INTERNAL FILTER CHANGE INTERVAL
RECOMMENDATIONS ................................... 52
TRANSMISSION FLUID CONTAMINATION ..................... 56
TRANSMISSION FLUID AND FILTER CHANGE PROCEDURE ......... 57
DIAGNOSTICS
INTRODUCTION ....................................... 60
DIAGNOSTIC CODES .................................... 60
DIAGNOSTIC CODE DISPLAY PROCEDURE .....................63
DIAGNOSTIC CODE LISTINGS AND PROCEDURES
(WTECIIICONTROLS) ................................... 65
DIAGNOSTIC CODE LISTINGS AND PROCEDURES (ALLISON 4
th
GENERATIONCONTROLS) ................................ 73
ABBREVIATIONS AND DEFINITIONS
ABBREVIATIONS AND DEFINITIONS ......................... 84
CUSTOMER SERVICE
OWNER ASSISTANCE ................................... 86
SERVICELITERATURE...................................88
ALLISON TRANSMISSION DISTRIBUTORS ..................... 90
ALLISON TRANSMISSION REGIONAL OFFICES .................. 92
4

TRADEMARK USAGE
The 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 Ltd.
5

WARNINGS, CAUTIONS, NOTES
IT IS YOUR RESPONSIBILITY to be completely familiar with the warnings
and cautions described in this manual. It is, however, important to understand that
these warnings and cautions are not exhaustive. Allison Transmission could not
possibly know, evaluate, and advise the service trade of all conceivable ways in
which service might be done or of the possible hazardous consequences of each
way. The vehicle manufacturer is responsible for providing information related to
the operation of vehicle systems (including appropriate warnings, cautions, and
notes). Consequently, Allison Transmission has not undertaken any such broad
evaluation. Accordingly, ANYONE WHO USES A SERVICE PROCEDURE
OR TOOL WHICH IS NOT RECOMMENDED BY ALLISON
TRANSMISSION OR THE VEHICLE MANUFACTURER MUST first be
thoroughly satisfied that neither personal safety nor equipment safety will be
jeopardized by the service methods selected.
Proper service and repair is important to the safe, reliable operation of the
equipment. The service procedures recommended by Allison Transmission (or the
vehicle manufacturer) and described in this manual are effective methods for
performing service operations. Some of these service operations require the use of
tools specially designed for the purpose. The special tools should be used when
and as recommended.
Three types of headings are used in this manual to attract your attention. These
warnings and cautions advise of specific methods or actions that can result in
personal injury, damage to the equipment, or cause the equipment to become
unsafe.
WARNING: A warning is used when an operating procedure, practice,
etc., if not correctly followed, could result in personal injury or loss of
life.
CAUTION: A caution is used when an operating procedure, practice,
etc., if not strictly observed, could result in damage to or destruction of
equipment.
NOTE: A note is used when an operating procedure, practice, etc., is
essential to highlight.
6

KEEPING THAT ALLISON ADVANTAGE
Allison Motorhome Series (MH) transmissions provide many advantages for the
driver who must “stop and go” or change speeds frequently. Driving is easier,
safer, and more efficient.
The Motorhome Series transmissions are rugged and designed to provide long,
trouble-free service. This manual will help you gain maximum benefits from your
ALLISON-equipped vehicle.
INTRODUCTION
7

OUTPUT
SPEED
SENSOR
NAMEPLATE
INPUT
SPEED
SENSOR
ASSEMBLY PADS
MAIN-PRESSURE TAP
NOTE: Inch Series Threads
BREATHER
FEEDTHROUGH
HARNESS
CONNECTOR
COOLER PORTS
NOTE: Inch Series Threads
V06341.02.00
ASSEMBLY
PADS
(BOTH SIDES)
BREATHER
MAIN-PRESSURE TAP
NOTE: Inch Series Threads
FEEDTHROUGH
HARNESS
CONNECTOR
TORQUE CONVERTER
WITH LOCKUP CLUTCH
AND TORSIONAL DAMPER
FILL TUBE
AND DIPSTICK
(Available on
both sides)
Figure 1. Typical 3000 MH Series Transmission
(WTEC III Controls)
8

V06341.03.01
ASSEMBLY
PADS
(BOTH SIDES)
BREATHER
MAIN-PRESSURE TAP
NOTE: Inch Series Threads
TORQUE CONVERTER
WITH LOCKUP CLUTCH
AND TORSIONAL DAMPER
FILL TUBE
AND DIPSTICK
(Available on
both sides)
FILL TUBE
AND DIPSTICK
(Available on
both sides)
MAIN-PRESSURE TAP
NOTE: Inch Series Threads
NAMEPLATE
FEEDTHROUGH
HARNESS CONNECTOR
COOLER PORTS
NOTE: Inch Series Threads
OUTPUT
SPEED
SENSOR
INPUT
SPEED
SENSOR
ASSEMBLY PADS
BREATHER
Figure 2. Typical 3000 MH Series Transmission
(Allison 4
th
Generation Controls)
9

TURBINE SPEED
SENSOR
MOUNTING
PAD
INPUT SPEED
SENSOR
NAMEPLATE
FILL TUBE AND DIPSTICK
OUTPUT SPEED
SENSOR
FEEDTHROUGH
HARNESS
CONNECTOR
V06342
COOLER PORTS
MAIN-PRESSURE TAP
MOUNTING PAD
(BOTH SIDES)
COOLER PORTS
FEEDTHROUGH
HARNESS
CONNECTOR
BREATHER
BREATHER
Figure 3. Typical 4000 MH Series Transmission
(WTEC III Controls)
10

TURBINE SPEED
SENSOR
MOUNTING
PAD
INPUT SPEED
SENSOR
NAMEPLATE
FILL TUBE AND DIPSTICK
OUTPUT SPEED
SENSOR
V06342.01.00
COOLER PORTS
MAIN-PRESSURE TAP
MOUNTING PAD
(BOTH SIDES)
COOLER PORTS
BREATHER
BREATHER
FEEDTHROUGH
HARNESS CONNECTOR
Figure 4. Typical 4000 MH Series Transmission
(Allison 4
th
Generation Controls)
11

A BRIEF DESCRIPTION OF THE ALLISON MOTORHOME
SERIES TRANSMISSIONS
Included in the Allison On-Highway Transmission family are the Motorhome
Series transmissions. The transmissions described in this manual include:
•WTEC III Controls or Allison 4
th
Generation Controls
•A torque converter with lockup and torsion damper
•Three planetary gear sets
Motorhome Series transmissions may contain an integral retarder or a provision to
mount a Power Takeoff (PTO).
ELECTRONIC CONTROL SYSTEM
All Motorhome Series transmissions come standard with WTEC III Controls or
Allison 4
th
Generation Controls. These systems consist of five major components
connected by OEM-furnished wiring harnesses. The five 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 an
optional oil level sensor)
•Engine Electronic Control Module (ECM) or Engine Throttle Position
Sensor (TPS), if installed
The TCM/ECU receives information from the following:
•Throttle position sensor, if installed
•Speed sensors
•Pressure switch
•Shift selector
The TCM/ECU processes information and then sends signals to actuate specific
solenoids located in the control valve module. These solenoids control both
oncoming and offgoing clutch pressures to provide closed-loop shift control by
matching input rpm during a shift to a desired profile programmed into the
TCM/ECU.
12

A feature of both Allison 4
th
Generation Controls and WTEC III controls is
“autodetect.” Autodetect is active within the first several engine starts, depending
upon the component or sensor being detected. These engine start cycles begin
when the transmission is installed during vehicle manufacture. Autodetect searches
for the presence of the following transmission components or data inputs:
Transmission Components
Retarder Present, Not Present
Oil Level Sensor (OLS) Present, Not Present
Throttle Analog, J1587, J1939
Engine Coolant Temperature Analog, J1939, J1587
Seek help from the nearest Allison Transmission service outlet when any of the
above components are present, but are not responding properly.
Another feature of the Motorhome Series transmission is its ability to adapt or
“learn” as it operates. Each shift is measured electronically, stored, and used by
the TCM/ECU to adapt or “learn” the optimum control for future shifts.
NOTE: Allison 4
th
Generation Controls and WTEC III Controls are
designed and manufactured to comply with all FCC and other guidelines
regarding radio frequency interference/electromagnetic interference
(RFI/EMI) for transportation electronics. Manufacturers, assemblers, and
installers of radio-telephone or other two-way communication radios
have the sole responsibility to correctly install and integrate those
devices into Allison Motorhome Series transmission-equipped vehicles
to customer satisfaction.
The TCM/ECU is programmed to provide the most suitable operating
characteristics for a specific application. This manual does not attempt to describe
all of the possible combinations. The information contained herein describes only
the operating characteristics most frequently requested by the vehicle
manufacturer.
TORQUE CONVERTER
The 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/ECU
13

When the pump turns faster than the turbine, the torque converter is multiplying
torque. When the turbine approaches the speed of the pump, the stator starts to
rotate with the pump and turbine. When this occurs, torque multiplication stops
and the torque converter functions as a fluid coupling.
The lockup clutch is located inside the torque converter and consists of the
following elements:
•Piston and backplate—driven by the engine
•Clutch plate/damper (located between the piston and the
backplate)—splined to the converter turbine
The lockup clutch/torsional damper is engaged and released in response to
electronic signals from the TCM/ECU. Lockup clutch engagement provides a
direct drive from the engine to the transmission gearing. This eliminates converter
slippage and maximizes fuel economy and vehicle speed. The lockup clutch
releases at lower speeds or when the TCM/ECU detects conditions requiring it to
be released.
The torsional damper absorbs engine torsional vibration to prevent transmitting
vibrations through the powertrain.
PLANETARY GEARS AND CLUTCHES
A series of three helical planetary gear sets and shafts provides the mechanical
gear ratios and direction of travel for the vehicle. The planetary gear sets are
controlled by five multiplate clutches that work in pairs to produce up to six
forward speeds and one reverse speed. The clutches are applied and released
hydraulically in response to electronic signals from the TCM/ECU to the
appropriate solenoids.
COOLER CIRCUIT
The transmission fluid is cooled by an integral (transmission-mounted) or
remote-mounted oil cooler. Connections to the cooling circuit are located at the
front or rear of the transmission to facilitate installation of remote cooler lines. On
retarder models, only the rear cooler ports may be used. The integral cooler is
mounted on the lower rear portion of the transmission, replacing the remote cooler
manifold. Integral cooler oil ports are internal requiring coolant to be routed to
and from the cooler.
A new feature has been added on all retarder-equipped transmissions. The retarder
housing now allows addition of either a remote or integral cooler for transmission
sump fluid in addition to retarder out fluid. A by-pass cover is placed over the
sump cooling ports when the provision is not used. The sump cooler ports are
located on the lower right rear face of the retarder housing (refer to Figure 1
through Figure 4).
14

RETARDER
The self-contained retarder is at the output of the transmission and consists of a
vaned rotor which rotates in a vaned cavity. The rotor is splined to and driven by
the output shaft. An external accumulator holds transmission fluid until the
retarder is activated. When the retarder is activated, the fluid in the accumulator is
pressurized by the vehicle air system and directed into the retarder cavity. The
interaction of the fluid with the rotating and stationary vanes causes the retarder
rotor and output shaft to reduce speed, slowing the vehicle or limiting speed on a
downhill grade. Refer to USING THE HYDRAULIC RETARDER for additional
information.
When the retarder is deactivated, the retarder cavity is evacuated and the
accumulator is recharged with fluid.
15

DESCRIPTION OF AVAILABLE TYPES
1
2
3
4
5
D
N
R
MODE
R
N
D
5
4
3
2
1
MODE
R
N
D
MODE
1
2
3
4
5
D
N
R
MODE
R
N
D
MODE
V07343.01.02
SIX-SPEED,
LEFT-HAND
LEVER
SELECTOR
SIX-SPEED,
RIGHT-HAND
LEVER SELECTOR
WITH REVERSE TO FRONT
HOLD OVERRIDE BUTTON
DISPLAY MODE/
DIAGNOSTIC BUTTON
MODE ID
DIGITAL DISPLAY*
MODE BUTTON
MODE INDICATOR
(LED)
MODE ID
MODE
INDICATOR (LED)
Push simultaneously
to enter diagnostic
mode and fluid
level check
NOTE: Number displayed is highest forward range available in selected position.
Visually check to confirm range selected. If display is flashing, shift is inhibited.
*
DIGITAL DISPLAY*
PUSHBUTTON SELECTORS
HOLD OVERRIDE
BUTTON
DISPLAY MODE/
DIAGNOSTIC BUTTON
DIGITAL DISPLAY*
MODE BUTTON
MODE ID
MODE INDICATOR
(LED)
CONTOURED
VERSION
Figure 5. WTEC III Shift Selectors
SHIFT SELECTORS
16

INTRODUCTION
Vehicle manufacturers may choose different types of shift selectors for their
vehicles. The shift selector in your Allison-equipped vehicle will be similar to one
of the pushbutton or lever styles shown above.
With an Allison-equipped vehicle, it is not necessary to select the right moment to
upshift or downshift during changing road and traffic conditions. The Allison
Motorhome Series transmission does it for you. However, knowledge of the shift
selector positions, available ranges, and when to select them, make vehicle control
and your job even easier. Select lower ranges when descending long grades (with
or without retarder) to reduce wear on service brakes. Refer to the Range
Selection table at the end of this section for related information.
6
1
6
1
6
1
MODE
6
1
V07343.03.01
HOLD OVERRIDE
BUTTON HOLD OVERRIDE BUTTON
MODE ID MODE ID
*
MODE INDICATOR
(LED) MODE INDICATOR
(LED)
MODE ID
MODE
INDICATOR (LED)
Push simultaneously
to enter diagnostic
mode and fluid
level check
NOTE:
The first number displayed is highest forward range available and second number is range
attained in selected position.
Visually check to confirm range selected. If display is flashing, shift is inhibited.
*
DIGITAL DISPLAY*
*
MODE BUTTON MODE BUTTON
DIGITAL DISPLAY
DIGITAL DISPLAY
DISPLAY MODE
DIAGNOSTIC BUTTON DISPLAY MODE
DIAGNOSTIC BUTTON
Figure 6. Allison 4
th
Generation Controls Shift Selectors
17

LEVER SHIFT SELECTOR
General Description. The lever shift selector (refer to Figure 5 and Figure 6) is
an electro-mechanical control. Typical lever positions are:
•R(Reverse)
•N(Neutral)
•D(Drive)
•Some number of lower forward range positions
Motorhome Series transmissions can be programmed to have four, five,orsix
forward ranges. Shift selector positions should agree with the programming of the
TCM/ECU unit.
The lever selector includes the following:
•HOLD OVERRIDE button
•MODE button
•Digital display
•DISPLAY MODE/DIAGNOSTIC button
HOLD OVERRIDE Button. The lever shift selector has three locked positions to
prevent accidentally selecting R(Reverse), N(Neutral), or D(Drive). Select
R(Reverse), N(Neutral), or D(Drive) by pressing the HOLD OVERRIDE
button and moving the lever to the desired position. Once D(Drive) is selected,
lower forward range positions may be selected without pressing the
HOLD OVERRIDE button.
MODE Button. The MODE button can allow the driver to enable a secondary
shift schedule, PTO, or other special functions that have been programmed into
the TCM/ECU unit at the request of the OEM. For example, a motorhome OEM
may have provided a secondary shift schedule for improved fuel economy. The
name of the special function (ECONOMY) appears on the MODE ID label
adjacent to the MODE button. Pressing the MODE button activates the
ECONOMY shift schedule and illuminates the MODE INDICATOR (LED).
When the Diagnostic Display Mode has been entered, the MODE button is used
to view and toggle through diagnostic code information. After viewing the first
diagnostic code which appears in the digital display, press the MODE button to
view the 2
nd
diagnostic code logged. Repeat this procedure to view the 3
rd
,4
th
,
and 5
th
code positions. The code displayed is active if the MODE INDICATOR
(LED) is illuminated.
NOTE: Visually check the digital display whenever the lever is moved
to be sure the range selected is shown. Nshould appear in the digital
displayiftheN(Neutral) button is pressed.
18

Digital Display. During normal operation, if D(Drive) is selected, the digital
display shows the highest forward range attainable for the shift schedule in use.
Abnormal operation is indicated by the WTEC III digital display as follows:
•When all segments of the digital display are illuminated for more than
12 seconds, the ECU did not complete initialization.
•When the digital display is blank, there is no power to the selector.
•When the display shows a “
\
/
\
” (cateye), a selector-related fault code has
been logged.
•Conditions which illuminate the CHECK TRANS light disable the shift
selector and the digital display displays the range actually attained. For a
detailed explanation, refer to the CHECK TRANS LIGHT paragraph in the
DRIVING TIPS section.
Abnormal operation is indicated by the Allison 4
th
Generation Controls digital
display as follows:
•When all segments of the digital display are illuminated, the shift selector
did not complete initialization.
•When both digital displays remain blank for 10 seconds after initialization
and then show a “
\
/
\
” (cateye), the shift selector is unable to communicate
with the TCM or has experienced an internal fault.
•When the display shows a “
\
/
\
” (cateye), a selector-related fault code has
been logged.
•Conditions which illuminate the CHECK TRANS light disable the shift
selector. The SELECT digit is blank and the MONITOR digit displays the
range actually attained. For a detailed explanation, refer to the CHECK
TRANS LIGHT paragraph in the DRIVING TIPS section.
The transmission will not shift into range if a CHECK TRANS code is active.
When the display shows Ror Dhas been requested and the display is flashing,
the requested range has not been achieved due to an inhibit function.
Some inhibit functions are vehicle-related and do not result in diagnostic codes.
Some examples are mentioned in the Range Selection tables at the end of this
Section.
Check for active codes if no other inhibit function has been located. Once
D(Drive) is attained, the transmission will shift into the lowest range programmed
for the D(Drive) position, usually first-range.
Display Mode/Diagnostic Button. The DISPLAY MODE/DIAGNOSTIC button
allows access to optional fluid level check information and diagnostic code
information. Press the DISPLAY MODE/DIAGNOSTIC button once to obtain
transmission fluid level information and a second time to obtain diagnostic code
information.
19