Allison Transmission Emergency Vehicle Series User manual

EMERGENCY VEHICLE SERIES
OPERATOR’S
MANUAL
3000/4000

Allison Transmission
VOCATIONAL MODELS
Operator’s
Manual
2005 FEBRUARY
Rev. 1 2005 SEPTEMBER
OM3656EN
Emergency Vehicle Series (EVS) Transmissions
3000 and 4000 Product Families
WTEC III Controls and Allison 4
th
Generation Controls
3000 EVS
3500 EVS
4000 EVS
4500 EVS
4700 EVS
4800 EVS
Printed in USA Copyright © 2005 General Motors Corporation

2
NOTES

TABLE OF CONTENTS
INTRODUCTION
KEEPINGTHATALLISONADVANTAGE ........................ 7
A BRIEF DESCRIPTION OF THE ALLISON EMERGENCY VEHICLE SERIES
TRANSMISSIONS ...................................... 17
ELECTRONIC CONTROL SYSTEM ........................... 17
TORQUE CONVERTER ................................... 18
PLANETARYGEARSANDCLUTCHES ........................ 19
COOLER CIRCUIT ...................................... 19
RETARDER...........................................20
SHIFT SELECTORS
DESCRIPTION OF AVAILABLE TYPES .........................21
INTRODUCTION ....................................... 22
LEVER SHIFT SELECTOR ................................. 23
PUSHBUTTON SHIFT SELECTOR ............................ 25
RANGE SELECTION .....................................26
DRIVING TIPS
CHECKTRANSLIGHT ................................... 31
DIAGNOSTIC CODES .................................... 32
DIAGNOSTIC CODE DISPLAY PROCEDURE .....................34
ACCELERATOR CONTROL ................................ 36
DOWNSHIFT AND DIRECTION CHANGE INHIBITOR FEATURE ....... 36
USINGTHEENGINETOSLOWTHEVEHICLE ................... 37
USING THE HYDRAULIC RETARDER ......................... 38
RANGE PRESELECTION .................................. 41
COLDWEATHERSTARTS ................................. 41
DRIVING ON SNOW OR ICE ............................... 42
ROCKINGOUT ........................................ 42
HIGHFLUIDTEMPERATURE .............................. 43
PARKINGBRAKE ...................................... 44
TOWING OR PUSHING ................................... 44
TURNINGOFFTHEVEHICLE .............................. 45
PRIMARY/SECONDARY SHIFT SCHEDULES .................... 45
CRUISECONTROLOPERATION.............................45
POWER TAKEOFF OPERATION
ENGINE-DRIVENPOWERTAKEOFF(PTO) ..................... 47
3

CARE AND MAINTENANCE
PERIODIC INSPECTIONS ................................. 49
PREVENT MAJOR PROBLEMS ..............................49
IMPORTANCE OF PROPER FLUID LEVEL ...................... 50
FLUID LEVEL CHECK USING PUSHBUTTON OR LEVER SHIFT
SELECTOR ........................................... 50
FLUID LEVEL CHECK USING DIAGNOSTIC TOOLS ............... 54
MANUAL FLUID CHECK PROCEDURE ....................... 55
COLDCHECK ......................................... 57
HOTCHECK .......................................... 58
RECOMMENDED AUTOMATIC TRANSMISSION FLUID AND VISCOSITY
GRADE ............................................. 58
KEEPINGFLUIDCLEAN..................................59
FLUID AND INTERNAL FILTER CHANGE INTERVAL
RECOMMENDATIONS ................................... 60
DIAGNOSTICS
DIAGNOSTIC CODES .................................... 65
CUSTOMER SERVICE
OWNER ASSISTANCE ................................... 66
SERVICELITERATURE................................... 68
ALLISON TRANSMISSION DISTRIBUTORS ..................... 70
ALLISON TRANSMISSION REGIONAL OFFICES .................. 72
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
Emergency Vehicle Series (EVS) transmissions are rugged and designed to
provide long, trouble-free service. All Emergency Vehicle Series transmissions are
available with engine driven PTO provisions and optional retarders.
This manual will help you gain maximum benefits from your ALLISON-equipped
vehicle.
INTRODUCTION
7

Abbreviations
ABS Anti-lock Brake System
DOC Diagnostic Optimized Connection
DTC Diagnostic Trouble Code
ECM Electronic Control Module
ECU Electronic Control Unit
EMI Electromagnetic Interference
EVS Emergency Vehicle Series
FCC Federal Communications Commission
KOH Potassium Hydroxide
MIL Military Specifications
OEM Original Equipment Manufacturer
OLS Oil Level Sensor
PTO Power Takeoff
RFI Radio Frequency Interference
TAN Total Acid Number
TCM Transmission Control Module
TPS Throttle Position Sensor
WTEC World Transmission Electronic Control
8

3000 EVS
3500 EVS
4000 EVS
4500 EVS
4700 EVS
4800 EVS
V06299.03.00
Figure 1. Emergency Vehicle Series Transmissions
(WTEC III Controls)
9

3000 EVS
3500 EVS
4000 EVS
4500 EVS
4700 EVS
4800 EVS
V06299.04.00
Figure 2. Emergency Vehicle Series Transmissions
(Allison 4
th
Generation Controls)
10

ASSEMBLY PADS
(BOTH SIDES)
TO RETARDER
ACCUMULATOR
OIL FILL TUBE AND
DIPSTICK
(AVAILABLE ON
BOTH SIDES
)
OUTPUT
RETARDER
TORQUE CONVERTER
WITH LOCKUP CLUTCH
AND TORSIONAL DAMPER
BREATHER
MAIN-PRESSURE TAP
NOTE: Inch series threads
FEEDTHROUGH
HARNESS
CONNECTOR
RETARDER
VALVE BODY
CONNECTOR
OUTPUT
SPEED
SENSOR
ASSEMBLY PADS
MAIN-PRESSURE TAP
NOTE: Inch Series Threads
BREATHER
COOLER PORTS
NOTE: Inch Series Threads
LEFT-REAR VIEW
LEFT-FRONT VIEW
V07307.03.00
TACHOGRAPH PROVISION
NOTE: Metric Series Threads
Figure 3. 3000/3500 EVS With Retarder
(WTEC III Controls)
11

ASSEMBLY PADS
(BOTH SIDES)
TO RETARDER
ACCUMULATOR
OIL FILL TUBE AND
DIPSTICK
(AVAILABLE ON
BOTH SIDES
)
OUTPUT
RETARDER
TORQUE CONVERTER
WITH LOCKUP CLUTCH
AND TORSIONAL DAMPER
BREATHER
MAIN-PRESSURE TAP
NOTE: Inch series threads
RETARDER
VALVE BODY
CONNECTOR
OUTPUT
SPEED
SENSOR
ASSEMBLY PADS
MAIN-PRESSURE TAP
NOTE: Inch Series Threads
BREATHER
COOLER PORTS
NOTE: Inch Series Threads
V07307.02.00
TACHOGRAPH PROVISION
NOTE: Metric Series Threads
Figure 4. 3000/3500 EVS With Retarder
(Allison 4
th
Generation Controls)
12

V07309.00.02
RIGHT-FRONT VIEW
LEFT-REAR VIEW
PTO (TOP RIGHT POSITION)
RETARDER
FEEDTHROUGH
HARNESS
CONNECTOR
COOLER PORTS
PTO (TOP RIGHT POSITION)
MOUNTING PADS
(BOTH SIDES)
MOUNTING PADS
(BOTH SIDES)
FILL TUBE
TURBINE
SPEED
SENSOR
ENGINE SPEED SENSOR
PTO (BOTTOM LEFT
POSITION)
MAIN-PRESSURE TAP
NAMEPLATE
FEEDTHROUGH
HARNESS
CONNECTOR
RETARDER
Figure 5. 4000/4500 EVS With PTO And Retarder
(WTEC III Controls)
13

V07309.02.00
RIGHT-FRONT VIEW
LEFT-REAR VIEW
PTO PROVISION
(TOP RIGHT POSITION)
TORQUE
CONVERTER
MODULE
STANDARD
REAR
COVER
COOLER PORTS
PTO PROVISION
MOUNTING PAD
MOUNTING PADS
(BOTH SIDES)
FILL TUBE
TURBINE-SPEED
SENSOR ENGINE-SPEED SENSOR
PTO PROVISION
MAIN-PRESSURE TAP
NAMEPLATE
SOLENOID
CONNECTOR
RETARDER
TEMPERATURE
CONNECTOR
Figure 6. 4000/4500 EVS With PTO
(Allison 4
th
Generation Controls)
14

MOUNTING
PAD
MOUNTING PAD
PTO PROVISION
PTO
PROVISION
C6 ADAPTER
HOUSING
RETARDER
OUTPUT
FLANGE
BREATHER
LEFT-REAR VIEW
RIGHT-REAR VIEW
V08619.00.01
TURBINE
SPEED
SENSOR
MOUNTING
PAD
C6 ADAPTER
HOUSING
FEEDTHROUGH
HARNESS CONNECTOR
INPUT
SPEED
SENSOR
NAMEPLATE
FILL TUBE
PTO PROVISION
(TOP RIGHT
POSITION)
OUTPUT
SPEED SENSOR
Figure 7. 4700/4800 EVS With PTO And Retarder
(WTEC III Controls)
15

MOUNTING
PAD
MOUNTING PAD
PTO PROVISION
PTO
PROVISION
C6 ADAPTER
HOUSING
RETARDER
OUTPUT
FLANGE
BREATHER
LEFT-REAR VIEW
RIGHT-REAR VIEW
V08619.01.00
TURBINE
SPEED
SENSOR
MOUNTING
PAD
C6 ADAPTER
HOUSING
INPUT
SPEED
SENSOR
NAMEPLATE
FILL TUBE
PTO PROVISION
(TOP RIGHT
POSITION)
OUTPUT
SPEED SENSOR
FEEDTHROUGH
HARNESS CONNECTOR
Figure 8. 4700/4800 EVS With PTO And Retarder
(Allison 4
th
Generation Controls)
16

A BRIEF DESCRIPTION OF THE ALLISON EMERGENCY
VEHICLE SERIES TRANSMISSIONS
Included in the Allison On-Highway Transmission family are the Emergency
Vehicle 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 (four for 4700/4800 EVS)
A provision to mount a Power Takeoff (PTO) is available on all transmissions.
The integral retarder feature is optional.
ELECTRONIC CONTROL SYSTEM
All Emergency Vehicle 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.
17

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 Emergency Vehicle 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 Emergency Vehicle 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
18

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 (four for 4700/4800 EVS) and shafts
provides the mechanical gear ratios and direction of travel for the vehicle. The
planetary gear sets are controlled by five multiplate clutches (six for
4700/4800 EVS) that work in pairs to produce up to six forward speeds (seven for
4700/4800 EVS) 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 3
through Figure 8).
19