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Allison Transmission 3000 MH Series, Operator'S Manual

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Allison Transmission 3000 MH Series Operator'S Manual Download Page 2

 

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

Summary of Contents for 3000 MH Series

Page 1: ...MOTORHOME SERIES OPERATOR S MANUAL 3000 4000...

Page 2: ...r s Manual 2005 FEBRUARY Rev 1 2005 SEPTEMBER OM3349EN Motorhome Series MH Transmissions 3000 and 4000 Product Families WTEC III Controls and Allison 4th Generation Controls 3000 MH 4000 MH Printed in...

Page 3: ...2 NOTES...

Page 4: ...ELECTOR 20 RANGE SELECTION 21 DRIVING TIPS CHECK TRANS LIGHT 26 DIAGNOSTIC CODES 27 ACCELERATOR CONTROL 27 DOWNSHIFT AND DIRECTION CHANGE INHIBITOR FEATURE 27 USING THE ENGINE TO SLOW THE VEHICLE 29 U...

Page 5: ...HANGE INTERVAL RECOMMENDATIONS 52 TRANSMISSION FLUID CONTAMINATION 56 TRANSMISSION FLUID AND FILTER CHANGE PROCEDURE 57 DIAGNOSTICS INTRODUCTION 60 DIAGNOSTIC CODES 60 DIAGNOSTIC CODE DISPLAY PROCEDUR...

Page 6: ...wing 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 tr...

Page 7: ...ll 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 t...

Page 8: ...r 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...

Page 9: ...ONNECTOR 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 CLUT...

Page 10: ...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 Serie...

Page 11: ...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 Fig...

Page 12: ...LATE 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 M...

Page 13: ...nents 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...

Page 14: ...lison 4th 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 EM...

Page 15: ...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...

Page 16: ...er 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 t...

Page 17: ...ODE 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 positio...

Page 18: ...escending 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...

Page 19: ...E 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...

Page 20: ...e 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 se...

Page 21: ...w when in DRIVE to request the next lower range Continuously pressing the Down Arrow will request the lowest range available MODE Button and Display Mode Diagnostic Button This is the same function as...

Page 22: ...MODE 1 2 3 4 5 D N R MODE R N D MODE V07344 Figure 7 Typical Motorhome Series Shift Selectors WTEC III Controls V07344 01 00 6 1 MODE R N D 5 4 3 2 1 6 1 6 1 Figure 8 Typical Motorhome Series Shift Se...

Page 23: ...inhibitor Always apply the service brakes when selecting R Reverse to prevent unexpected vehicle movement and because a service brake inhibit may be present When R is flashing it indicates the shift...

Page 24: ...led see the Operator s Manual for the vehicle WARNING If you let the vehicle coast in N Neutral there is no engine braking and you could lose control Coasting can also cause severe transmission damage...

Page 25: ...ed unless the shift is made with the engine at idle Also be aware of other interlocks that would prevent attaining D Drive or R Reverse Examples are wheelchair lift not stored and service brakes not a...

Page 26: ...d ranges Push the Up or Down arrow for the desired range The digital display shows the range chosen Even though a lower range is selected the transmission may not downshift until vehicle speed is redu...

Page 27: ...light will illuminate then turn off after a few seconds This momentary lighting is to show that the status light circuits are working properly If the CHECK TRANS light does not illuminate during igni...

Page 28: ...If you shift while the throttle pedal is depressed too far the transmission will only engage if the throttle pedal is released in the next three seconds This may cause a sudden movement of the vehicl...

Page 29: ...is three seconds Shifts from N Neutral to D Drive or N Neutral to R Reverse are also inhibited when the TCM ECU has been programmed by input output function to detect that auxiliary equipment is in op...

Page 30: ...wer range If the vehicle is exceeding the maximum speed for this range use the service brakes and or retarder to slow the vehicle When a lower speed is reached the TCM ECU will automatically downshift...

Page 31: ...o torque speed control or electronic retarder control messages received on the vehicle s J1939 Data Link Some types of controls and the amount of retarder application are shown in the Types of Retarde...

Page 32: ...Auto 1 3 on plus two pressure switches 1 3 capacity at closed throttle or 2 3 and Full On with brake pressure Hand lever plus pressure switch 6 levels of modulation with lever or Full On with brake p...

Page 33: ...THE VEHICLE OBSERVE THE RETARDER SUMP OVERTEMP LIGHT to be sure it responds properly to retarder temperature NOTE Transmission fluid level must be set correctly for highest retarder effectiveness As...

Page 34: ...to closed and decelerate to just prior to the Closed Throttle CT 3 2 and perform a Step Thru ST 3 2 by going to WOT Repeat for the WOT 3 4 ST 4 3 WOT 4 5 ST 5 4 WOT 5 6 ST 6 5 4 From a Stop release ve...

Page 35: ...fely attainable range and hold the throttle steady at WOT and allow the vehicle to perform the Powered Downshifts as required to ascend the grade 9 Approach the grade in the highest safely attainable...

Page 36: ...ON FLUID AND VISCOSITY GRADE in the Care And Maintenance section DRIVING ON SNOW OR ICE WARNING Using the retarder on wet or slippery roads may cause loss of traction on the drive wheels your vehicle...

Page 37: ...e at 1200 1500 rpm until it cools 2 3 minutes If the vehicle is stuck in deep sand snow or mud it may be possible to rock it out using the following procedure 1 Shift to D Drive and apply steady light...

Page 38: ...r problem is indicated If high temperature in either the engine or transmission persists stop the engine and have the overheating condition investigated by maintenance personnel PARKING BRAKE WARNING...

Page 39: ...ng conditions Some shift schedules may be inhibited as a result of operating conditions such as engine or transmission fluid temperature Shift schedules may be changed using the MODE button some appli...

Page 40: ...rols or Allison 4th Generation Controls equipped transmission will have the engine brake controlled by the TCM ECU This is done so the transmission will automatically select a lower range when the eng...

Page 41: ...output always powered or clutched drive The output of a clutched drive PTO is powered when the PTO clutch is pressurized Be sure that the limits for PTO engagement speed and operational speed are not...

Page 42: ...aulty oil cooler The breather refer to Figure 1 through Figure 4 to make sure it is clean and free from dirt or debris Report any abnormal condition to your nearest Allison distributor or dealer PREVE...

Page 43: ...f the transmission is known to contain an OLS If an OLS is not detected during a fixed number of engine starts the WTEC III or Allison 4th Generation Controls system concludes that no OLS is present I...

Page 44: ...arrow buttons 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...

Page 45: ...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 flui...

Page 46: ...l diagnostic information two characters at a time Low Fluid Level o L is displayed o L represents Fluid Oil Level Check Mode followed by L o L o represents Low Oil Level and the number of quarts the t...

Page 47: ...rols Display Cause of Code oL 0X Settling time too short oL 50 Engine speed rpm too low oL 59 Engine speed rpm too high oL 65 Neutral must be selected oL 70 Sump fluid temperature too low oL 79 Sump f...

Page 48: ...utral 2 Be sure the engine is at low idle 500 800 rpm 3 Apply the parking brakes and emergency brake and make sure they are properly engaged 4 Chock the wheels and take any other steps necessary to ke...

Page 49: ...t to transmission control module split line and fill tube Scale none Dimension determined by installation Reference dimension only Actual dimension to be determined by installation Reference drawing A...

Page 50: ...ature is then typically 16 49 C 60 120 F To perform a COLD CHECK do the following 1 Start the engine and run it at idle 500 800 rpm in N Neutral for about one minute 2 Shift to D Drive and then to R R...

Page 51: ...ehicle on a level surface and shift to N Neutral Apply the parking brake and allow the engine to idle 500 800 rpm 3 Remove the dipstick and wipe it clean Insert the dipstick into the fill tube pushing...

Page 52: ...ken into consideration The Transmission Fluid Operating Temperature Requirements table lists the minimum fluid temperatures at which the transmission may be safely operated without preheating Preheat...

Page 53: ...the main filter not the lube filter or fluid changed after the first 5000 mile 8000 km or 200 hours of operation whichever comes first Refer to the latest revision of Service Tips 1099 for convenient...

Page 54: ...S 295 Fluid 12 000 Miles 20 000 km 6 Months 500 Hours 12 000 Miles 20 000 km 6 Months 500 Hours Overhaul 12 000 Miles 20 000 km 6 Months 500 Hours 25 000 Miles 40 000 km 12 Months 1000 Hours 25 000 Mi...

Page 55: ...Months 500 Hours 12 000 Miles 20 000 km 6 Months 500 Hours Overhaul 12 000 Miles 20 000 km 6 Months 500 Hours 25 000 Miles 40 000 km 12 Months 1000 Hours 25 000 Miles 40 000 km 12 Months 1000 Hours O...

Page 56: ...RAL VOCATION Fluid Filters Fluid Filters Main Internal Lube Auxiliary Main Internal Lube Auxiliary Schedule 3 TranSynd TES 295 Fluid 2 Inch Control Module 1 75 Inch Approximately Requires Filter Kit P...

Page 57: ...ssium hydroxide KOH to neutralize a gram of fluid TRANSMISSION FLUID CONTAMINATION Fluid Examination At each fluid change examine the drained fluid for evidence of dirt or water A normal amount of con...

Page 58: ...luid NOTE Do not drain the transmission fluid if only filters are being replaced WARNING Avoid contact with the hot fluid or the sump when draining transmission fluid Direct contact with the hot fluid...

Page 59: ...d cover assemblies into the filter compartment Align each filter cover assembly with the holes in the channel plate sump Push the cover assemblies in by hand to seat the seals 4 Install six bolts into...

Page 60: ...uid level Refer to FLUID LEVEL CHECK USING PUSHBUTTON OR LEVER SHIFT SELECTOR paragraph NOTE Quantities listed are approximations and do not include external lines and cooler hose Transmission Fluid C...

Page 61: ...the appropriate publication number DIAGNOSTIC CODES Diagnostic codes are numerical indications relating to a malfunction in transmission operation In WTEC III Controls each code consists of a two dig...

Page 62: ...Historical codes are useful in determining if a problem Is isolated Is intermittent Results from a previous malfunction The TCM ECU may automatically delete a code from memory if it has not recurred...

Page 63: ...re listed second and provide specific areas or conditions within the main code that cause the fault This subcode indicates the problem is caused by low voltage Diagnostic Codes Allison 4th Generation...

Page 64: ...ontrols pushbutton or lever shift selectors 3 Press the MODE button to see the next code repeat for subsequent codes NOTE Be sure to record all codes displayed before they are cleared This is essentia...

Page 65: ...s is essential for troubleshooting To Clear Active Indicators and Inactive Codes then Resume Vehicle Operation 1 Clear active indicators and inactive codes WTEC III Controls To clear active indicators...

Page 66: ...Vehicle manufacturer supplied wiring is correct g ECU connectors are tight clean and undamaged ECU Input Voltage Low 13 13 ECU Input Voltage Medium Low 13 23 ECU Input Voltage High 14 12 23 Check a I...

Page 67: ...r temperature If no check that main transmission connector is tight clean and undamaged b ECU connectors are tight clean and undamaged Sump Fluid Temperature Cold 24 23 Verify the overheat situation C...

Page 68: ...opens shorts between wires or shorts to ground C3 Pressure Switch Open 33 12 23 Check a Main transmission connector is tight clean and undamaged b ECU connectors are tight clean and undamaged c Wirin...

Page 69: ...ts to ground e Unauthorized repairs have not been made f Change harness optional Short to Battery in Solenoid Circuit 44 12 13 14 15 16 21 22 23 24 26 Check a Main transmission connector is tight clea...

Page 70: ...wiring harness has no opens shorts between wires or shorts to ground c Main wiring harness to transmission has no shorts between wires or shorts to ground d Correct dipstick is installed e Fluid leve...

Page 71: ...rect for the transmission Oncoming Ratio Test After Shift 55 07 17 27 87 97 XY Check a Correct dipstick is installed b Fluid level is correct Refer to CARE AND MAINTENANCE section c Output and turbine...

Page 72: ...9 Check a Correct dipstick is installed b Fluid level is correct Refer to CARE AND MAINTENANCE section c Output and turbine speed sensor connectors are tight clean and undamaged d Speed sensor wiring...

Page 73: ...ng switches and connectors to determine why input states are different Input Function Fault 64 12 23 Use diagnostic tool to read retarder counts and identify problem wires Check wiring for short to ba...

Page 74: ...y connected b End of TPS cable is pulled out properly c Engine fuel lever is in idle position d Engine fuel lever provides proper amount of stroke on TPS cable e Wiring harness to TPS has no opens sho...

Page 75: ...e engine software to be compatible with transmission torque requirements a Add necessary engine torque control functions or b Reduce engine power and torque ratings P0634 TCM Internal temperature too...

Page 76: ...tor is tight clean and undamaged b TCM connector is tight clean and undamaged c Wiring harness has no opens shorts between wires or shorts to ground P0701 Transmission Control System Performance 1 Let...

Page 77: ...ensor b Engine speed sensor output speed sensor temperature sensor and oil level sensor working correctly c Wiring harness has no opens shorts between wires or shorts to ground P0711 P0712 P0713 Trans...

Page 78: ...en wires or shorts to ground c Wiring harness has no opens shorts between wires or shorts to ground 2 Let vehicle idle with parking brake applied wheels chocked and vehicle level Check a Correct dipst...

Page 79: ...ON 1 Check a Turbine and output speed sensor connectors are tight clean and undamaged b Speed sensor wiring harness has no opens shorts between wires or shorts to ground 2 Let vehicle idle with parkin...

Page 80: ...ck a Correct dipstick is installed b Fluid level is correct P0960 P0964 P0968 P2727 P2736 P2761 Pressure Control Solenoid Circuit Open 1 Check a Main transmission connector is tight clean and undamage...

Page 81: ...Wiring harness has no opens P0989 P0990 Retarder Pressure Sensor Circuit Fault 1 Check a Retarder pressure sensor connector is tight clean and undamaged b TCM connector is tight clean and undamaged c...

Page 82: ...uately sized for heat load P2742 P2743 Retarder Oil Temperature Sensor Circuit Fault 1 Check a Retarder temperature measured with Allison DOC diagnostic tool is consistent with code or determine if co...

Page 83: ...Ohms U0100 Lost Communica tions with ECM PCM J1587 1 Check a Serial communications interface connections at engine are tight clean and undamaged b TCM connector is tight clean and undamaged c Serial...

Page 84: ...that the shift selector is an Allison supplied shift selector U0404 U0592 Invalid Data Received from Gear Shift Module 1 Check a Shift selector connector is tight clean and undamaged b TCM connector...

Page 85: ...Control Unit also commonly referred to as the computer for WTEC III Controls EMI Electromagnetic Interference FCC Federal Communications Commission J1587 Engine transmission serial data communication...

Page 86: ...lison DOC diagnostic tool PT Part Throttle PTO Power Takeoff RFI Radio Frequency Interference ST Step Thru A downshift forced by applying WOT just prior to a CT downshift TCM Transmission Control Modu...

Page 87: ...and Service Locator tool on the Allison Transmission web site at www allisontransmission com You may also refer to Allison Transmission s Worldwide Sales and Service Directory SA2229EN We recognize ho...

Page 88: ...n delivery date and accumulated miles and or hours of operation Nature of problem Chronological summary of your transmission s history Step Three If you are still not satisfied after contacting the Re...

Page 89: ...FREE 888 666 5799 INTERNATIONAL 317 471 4995 Available Service Literature WTEC III Controls Publication Type 3000 MH 4000 MH Allison DOC For PC User Guide GN3433EN GN3433EN Automatic Transmission Flu...

Page 90: ...T4015EN Operators Manual Motorhome Series OM3349EN OM3349EN Parts Catalog PC2150EN PC2456EN Parts Catalog on CD CD2150EN CD2456EN Principles of Operation PO4016EN PO4016EN Service Manual SM4013EN SM40...

Page 91: ...c 90 Bay State Road Wakefield MA 01880 1095 781 246 1810 CENTRAL REGION Central Detroit Diesel Allison Inc 9200 Liberty Drive Liberty MO 64068 816 781 8070 Inland Detroit Diesel Allison Inc 210 Alexan...

Page 92: ...Reno Street Oklahoma City OK 73127 405 947 3321 WESTERN REGION Detroit Diesel Allison British Columbia Ltd 9300 192nd Street Surrey British Columbia V4N 3R8 604 888 1211 Stewart Stevenson 1755 Adams...

Page 93: ...08022 0400 609 298 2541 SOUTHERN REGION Av Ejercito Nacional No 843 Colonia Granada Mexico D F C P 11520 936 321 4248 CENTRAL REGION PO Box 894 Mail Code 462 470 PF06 Indianapolis IN 46206 0894 317 2...

Page 94: ...OM3349EN 200509 www allisontransmission com Printed in USA 200509...

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