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EMERGENCY VEHICLE SERIES
3000/4000
OPERATOR'S
MANUAL

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Summary of Contents for Allison Transmission Emergency Vehicle Series

  • Page 1 EMERGENCY VEHICLE SERIES 3000/4000 OPERATOR’S MANUAL...
  • Page 2 Operator’s 2005 FEBRUARY Rev. 1 2005 SEPTEMBER Manual OM3656EN Allison Transmission VOCATIONAL MODELS Emergency Vehicle Series (EVS) Transmissions 3000 and 4000 Product Families WTEC III Controls and Allison 4 Generation Controls 3000 EVS 3500 EVS 4000 EVS 4500 EVS 4700 EVS...
  • Page 3 NOTES...
  • Page 4: Table Of Contents

    KEEPING THAT ALLISON ADVANTAGE ......7 A BRIEF DESCRIPTION OF THE ALLISON EMERGENCY VEHICLE SERIES TRANSMISSIONS ........17 ELECTRONIC CONTROL SYSTEM .
  • Page 5 SERVICE LITERATURE ........68 ALLISON TRANSMISSION DISTRIBUTORS ..... 70...
  • Page 6 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.
  • Page 7 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.
  • Page 8: Introduction

    INTRODUCTION 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...
  • Page 9 Abbreviations Anti-lock Brake System Diagnostic Optimized Connection Diagnostic Trouble Code Electronic Control Module Electronic Control Unit Electromagnetic Interference Emergency Vehicle Series Federal Communications Commission Potassium Hydroxide Military Specifications Original Equipment Manufacturer Oil Level Sensor Power Takeoff Radio Frequency Interference Total Acid Number...
  • Page 10 4000 EVS 4500 EVS 3000 EVS 3500 EVS 4700 EVS 4800 EVS V06299.03.00 Figure 1. Emergency Vehicle Series Transmissions (WTEC III Controls)
  • Page 11 4000 EVS 4500 EVS 3000 EVS 3500 EVS 4700 EVS 4800 EVS V06299.04.00 Figure 2. Emergency Vehicle Series Transmissions (Allison 4 Generation Controls)
  • Page 12 BREATHER ASSEMBLY PADS FEEDTHROUGH HARNESS CONNECTOR OUTPUT SPEED SENSOR RETARDER VALVE BODY CONNECTOR MAIN-PRESSURE TAP NOTE: Inch Series Threads TACHOGRAPH PROVISION COOLER PORTS NOTE: Metric Series Threads NOTE: Inch Series Threads LEFT-REAR VIEW BREATHER ASSEMBLY PADS (BOTH SIDES) TORQUE CONVERTER OUTPUT WITH LOCKUP CLUTCH RETARDER...
  • Page 13 BREATHER ASSEMBLY PADS OUTPUT SPEED SENSOR RETARDER VALVE BODY CONNECTOR MAIN-PRESSURE TAP NOTE: Inch Series Threads TACHOGRAPH PROVISIO N COOLER PORTS NOTE: Metric Series Threads NOTE: Inch Series Threads BREATHER ASSEMBLY PADS (BOTH SIDES) TORQUE CONVERTER OUTPUT WITH LOCKUP CLUTCH RETARDER AND TORSIONAL DAMPER TO RETARDER...
  • Page 14 RETARDER PTO (TOP RIGHT POSITION) FEEDTHROUGH MOUNTING PADS HARNESS (BOTH SIDES) CONNECTOR NAMEPLATE FILL TUBE TURBINE SPEED SENSOR ENGINE SPEED SENSOR RIGHT-FRONT VIEW MOUNTING PADS (BOTH SIDES) PTO (TOP RIGHT POSITION) FEEDTHROUGH HARNESS CONNECTOR RETARDER PTO (BOTTOM LEFT POSITION) MAIN-PRESSURE TAP COOLER PORTS LEFT-REAR VIEW V07309.00.02...
  • Page 15 PTO PROVISION (TOP RIGHT POSITION) FILL TUBE RETARDER TEMPERATURE CONNECTOR TORQUE SOLENOID CONVERTER CONNECTOR MODULE NAMEPLATE TURBINE-SPEED SENSOR ENGINE-SPEED SENSOR MOUNTING PAD RIGHT-FRONT VIEW MOUNTING PADS (BOTH SIDES) PTO PROVISION STANDARD REAR COVER PTO PROVISION MAIN-PRESSURE TAP COOLER PORTS LEFT-REAR VIEW V07309.02.00 Figure 6.
  • Page 16 BREATHER PROVISION C6 ADAPTER HOUSING RETARDER OUTPUT MOUNTING FLANGE PTO PROVISION MOUNTING PAD LEFT-REAR VIEW PTO PROVISION (TOP RIGHT POSITION) FEEDTHROUGH HARNESS CONNECTOR C6 ADAPTER HOUSING MOUNTING INPUT SPEED SENSOR TURBINE SPEED SENSOR FILL TUBE NAMEPLATE OUTPUT SPEED SENSOR RIGHT-REAR VIEW V08619.00.01 Figure 7.
  • Page 17 BREATHER PROVISION C6 ADAPTER HOUSING RETARDER OUTPUT MOUNTING FLANGE PTO PROVISION MOUNTING PAD LEFT-REAR VIEW PTO PROVISION (TOP RIGHT POSITION) C6 ADAPTER HOUSING MOUNTING INPUT SPEED SENSOR TURBINE SPEED SENSOR FILL TUBE OUTPUT SPEED SENSOR NAMEPLATE FEEDTHROUGH HARNESS CONNECTOR RIGHT-REAR VIEW V08619.01.00 Figure 8.
  • Page 18: A Brief Description Of The Allison Emergency Vehicle Series Transmissions

    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 Generation Controls. These systems consist of five major components connected by OEM-furnished wiring harnesses.
  • Page 19: Torque Converter

    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”...
  • Page 20: Planetary Gears And Clutches

    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: •...
  • Page 21: Retarder

    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.
  • Page 22: Shift Selectors

    SHIFT SELECTORS DESCRIPTION OF AVAILABLE TYPES HOLD OVERRIDE BUTTON HOLD OVERRIDE BUTTON MODE INDICATOR MODE INDICATOR (LED) (LED) MODE BUTTON MODE MODE MODE MODE BUTTON MODE ID MODE ID DIGITAL DISPLAY DIGITAL DISPLAY DISPLAY MODE/ DISPLAY MODE/ DIAGNOSTIC BUTTON DIAGNOSTIC BUTTON SIX-SPEED, SEVEN-SPEED, CONTOURED...
  • Page 23: Introduction

    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 Emergency Vehicle 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.
  • Page 24: Lever Shift Selector

    • D (Drive) • Some number of lower forward range positions Emergency Vehicle Series transmissions can be programmed to have up to six forward ranges (seven for the 4700/4800 EVS). Shift selector positions should agree with the programming of the TCM/ECU unit.
  • Page 25 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.
  • Page 26: Pushbutton Shift Selector

    PUSHBUTTON SHIFT SELECTOR General Description. The pushbutton shift selector (refer to Figure 9 and Figure 10) has the following: • R (Reverse)—Press this button to select Reverse. • N (Neutral)—Press this button to select Neutral. • D (Drive)—Press this button to select Drive. The highest forward range available will appear in the digital display window.
  • Page 27: Range Selection

    DIAGNOSTIC CODE DISPLAY PROCEDURE, for more information about diagnostic codes and display procedure. RANGE SELECTION MODE MODE MODE MODE V07344 Figure 11. Typical Emergency Vehicle Series Shift Selectors (WTEC III Controls) MODE V07344.01.00 Figure 12. Typical Emergency Vehicle Series Shift Selectors (Allison 4 Generation Controls)
  • Page 28 PUSHBUTTON AND LEVER SHIFT SELECTORS WITH DIGITAL DISPLAY Description of Available Ranges (refer to Figure 11 and Figure 12) WARNING: If you leave the vehicle and the engine is running, the vehicle can move unexpectedly and you or others could be injured.
  • Page 29 PUSHBUTTON AND LEVER SHIFT SELECTORS WITH DIGITAL DISPLAY (cont’d) Description of Available Ranges (refer to Figure 11 and Figure 12) Completely stop the vehicle and let the engine return to idle before shifting from a forward range to R (Reverse) or from R (Reverse) to a forward range.
  • Page 30 PUSHBUTTON AND LEVER SHIFT SELECTORS WITH DIGITAL DISPLAY (cont’d) Description of Available Ranges (refer to Figure 11 and Figure 12) WARNING: D (Drive) may not be attained due to an active inhibitor. Always apply the service brakes when selecting D (Drive) to prevent unexpected vehicle movement and because a service inhibit may be present.
  • Page 31 PUSHBUTTON AND LEVER SHIFT SELECTORS WITH DIGITAL DISPLAY (cont’d) Description of Available Ranges (refer to Figure 11 and Figure 12) Lower ranges provide greater engine braking for going down grades (the lower the range, the greater the braking effect). Occasionally, it may be desirable to restrict automatic shifting to a lower range because of: •...
  • Page 32: Driving Tips

    DRIVING TIPS CHECK TRANS LIGHT The electronic control system is programmed to inform the operator of a problem with the transmission system and automatically take action to protect the operator, vehicle, and transmission. When the Electronic Control Unit (ECU) or the Transmission Control Module (TCM) detects a problem condition, the TCM/ECU: •...
  • Page 33: Diagnostic Codes

    When the CHECK TRANS light comes on and the ignition switch is turned off, the transmission will remain in N (Neutral) until the condition causing the CHECK TRANS light is corrected. Generally, while the CHECK TRANS light is on, upshifts and downshifts will be restricted and direction changes will not occur.
  • Page 34 Diagnostic Codes—WTEC III Controls. When the diagnostic mode is entered, the first code (position d1) is displayed as follows: Example—Code 1312: Displayed as: d, 1, 1, 3, 1, 2 (each item appears for about one second) • d1 (code position)—Code position indicates that this is the first diagnostic code listed in the ECU memory.
  • Page 35: Diagnostic Code Display Procedure

    — Allison 4 Generation Controls—Press and hold the MODE button for 10 seconds to clear both active indicators and inactive codes. 2. Begin operating as normal—have the transmission checked at the earliest opportunity by an Allison Transmission distributor or dealer.
  • Page 36 10 seconds to clear both active indicators and inactive codes. 2. Begin operating as normal—have the transmission checked at the earliest opportunity by an Allison Transmission distributor or dealer. NOTE: If the condition that caused the code is still present, the code...
  • Page 37: Accelerator Control

    ACCELERATOR CONTROL WARNING: To help avoid injury or property damage caused by sudden movement of the vehicle, do not make shifts from N (Neutral) to D (Drive) or R (Reverse) when the throttle pedal is depressed. 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.
  • Page 38: Using The Engine To Slow The Vehicle

    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 operation and the shift should not be allowed. When directional change shifts are inhibited, the TCM/ECU will put the transmission in N (Neutral) and the digital display, if present, will flash the letter of the range selected (D or R).
  • Page 39: Using The Hydraulic Retarder

    USING THE HYDRAULIC RETARDER WARNING: DO NOT USE THE RETARDER DURING INCLEMENT WEATHER OR WHEN ROAD SURFACES ARE SLIPPERY. De-energize the retarder at the master control switch. To help avoid injury or property damage caused by loss of vehicle control, be ready to apply vehicle brakes or other retarding device if the transmission retarder does not apply.
  • Page 40 NOTE: If your transmission has a retarder but it is not functioning, it may not have been “autodetected” during vehicle manufacture. Go immediately to your nearest Allison Transmission service outlet to have “autodetect” reset or the retarder enabled using the Allison DOC™ For PC–Service Tool.
  • Page 41 Types of Retarder Control (cont’d) Type Description Amount of Application Combinations of Auto “half-on” Half capacity at closed throttle or the above plus pressure “Full On” with brake pressure systems ** switch * Auto “ on” plus , capacity at closed throttle or two pressure and “Full On”...
  • Page 42: Range Preselection

    COLD WEATHER STARTS All Emergency Vehicle Series transmissions are programmed to restrict full operation until specific fluid temperatures are reached. Refer to the following table for temperature restrictions.
  • Page 43: Driving On Snow Or Ice

    Transmission operation at cold ambient temperatures may require preheating or the use of a lower viscosity transmission fluid. Refer to RECOMMENDED AUTOMATIC TRANSMISSION 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 may slide out of control.
  • Page 44: High Fluid Temperature

    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 throttle (never full throttle). 2. When the vehicle has rocked forward as far as it will go, apply and hold the vehicle service brakes.
  • Page 45: Parking Brake

    If the engine temperature indicates a high temperature, an engine or radiator 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: If you leave the vehicle and the engine is running, the vehicle can move unexpectedly and you or others could be injured.
  • Page 46: Turning Off The Vehicle

    TURNING OFF THE VEHICLE Always select N (Neutral) prior to turning off the vehicle engine. PRIMARY/SECONDARY SHIFT SCHEDULES The points at which shifts occur depend upon predetermined speeds and other operating conditions. A transmission “shift calibration” includes several sets of shift points which may be used according to current or anticipated operating conditions.
  • Page 47 Operating a vehicle on cruise control with the engine brake turned on and controlled by the transmission TCM/ECU, may cause an unwanted application of the engine brake when the cruise control decelerates for downhill grades. Eliminate this condition by turning off the engine brake while operating the vehicle on cruise control.
  • Page 48: Power Takeoff Operation

    POWER TAKEOFF OPERATION ENGINE-DRIVEN POWER TAKEOFF (PTO) CAUTION: Do not exceed the engagement and operational speed limits imposed on the driven equipment during the operation of the PTO. Exceeding the speed limits produces high hydraulic pressure in the PTO that can damage the PTO components. Consult the vehicle manufacturer’s literature for these speed limits.
  • Page 49 When the programmed engagement speed is exceeded, the PTO will not engage. The PTO engagement must be retried after the speed has been reduced. When operational speeds (either engine or transmission output) are exceeded, the PTO will deactivate and the PTO engagement process must be repeated.
  • Page 50: Care And Maintenance

    Generation Controls or WTEC III Controls oversee the operation of the transmission. Minor problems can be kept from becoming major problems if an Allison Transmission distributor or dealer is notified when one of these conditions occur: • Shifting feels odd.
  • Page 51: Importance Of Proper Fluid Level

    fluid. If fluid level is too high, the fluid can aerate. Aerated fluid can cause the transmission to shift erratically or overheat. Emergency Vehicle Series transmissions have an oil level sensor (OLS) that allows the operator to obtain an indication of fluid level from the shift selector.
  • Page 52 HOLD OVERRIDE BUTTON HOLD OVERRIDE BUTTON MODE INDICATOR MODE INDICATOR (LED) (LED) MODE BUTTON MODE MODE MODE MODE BUTTON MODE ID MODE ID DIGITAL DISPLAY DIGITAL DISPLAY DISPLAY MODE/ DISPLAY MODE/ DIAGNOSTIC BUTTON DIAGNOSTIC BUTTON SIX-SPEED, SEVEN-SPEED, CONTOURED LEFT-HAND RIGHT-HAND BEZEL LEVER SELECTOR LEVER SELECTOR...
  • Page 53 HOLD OVERRIDE HOLD OVERRIDE BUTTON BUTTON MODE INDICATOR MODE INDICATOR (LED) (LED) MODE BUTTON MODE BUTTON MODE ID MODE ID DIGITAL DISPLAY DIGITAL DISPLAY DISPLAY MODE DISPLAY MODE DIAGNOSTIC BUTTON DIAGNOSTIC BUTTON SIX-SPEED, SEVEN-SPEED, CONTOURED LEFT-HAND RIGHT-HAND BEZEL LEVER SELECTOR LEVER SELECTOR WITH REVERSE WITH REVERSE...
  • Page 54 Sump fluid temperature too high o,L, —, 8, 9 Output shaft rotation o,L, —, 9, 5 Sensor failure * Report sensor failure display to a distributor or dealer in your area (check the telephone directory for an Allison Transmission distributor or dealer).
  • Page 55: Fluid Level Check Using Diagnostic Tools

    Sensor failure * Report sensor failure display to a distributor or dealer in your area (check the telephone directory for an Allison Transmission distributor or dealer). CAUTION: A low or high fluid level can cause overheating and irregular shift patterns. Incorrect fluid level can damage the transmission.
  • Page 56: Manual Fluid Check Procedure

    — Sump fluid temperature too high (above 104°C or 220°F) — Output shaft rotation MANUAL FLUID CHECK PROCEDURE Refer to Figure 3 through Figure 6 for the location of the fill tube and dipstick. WARNING: If you leave the vehicle and the engine is running, the vehicle can move unexpectedly and you or others could be injured.
  • Page 57 NOTE: Calibrate level marking locations with respect 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 AS66-60. ****Reference drawing AS67-60. V07301.00.01 Figure 15. Standard Emergency Vehicle Series Transmission Dipstick Markings...
  • Page 58: Cold Check

    COLD CHECK The Cold Check determines if the transmission has enough fluid to be operated safely until a Hot Check can be made. NOTE: The correct fluid level can not be determined unless the transmission is in a level position. CAUTION: DO NOT start the engine until the presence of sufficient transmission fluid has been confirmed.
  • Page 59: Hot Check

    CAUTION: DO NOT operate the transmission for extended periods of time until a Hot Check has verified proper fluid level. Transmission damage can result from extended operation at improper fluid level conditions. CAUTION: Obtain an accurate fluid level by imposing the following conditions: •...
  • Page 60: Keeping Fluid Clean

    ® DEXRON -III license numbers on the container or consult the lubricant manufacturer. Consult your Allison Transmission dealer or distributor before using other fluid types. CAUTION: Disregarding minimum fluid temperature limits can result in transmission malfunction or reduced transmission life.
  • Page 61: Fluid And Internal Filter Change Interval Recommendations

    FLUID AND INTERNAL FILTER CHANGE INTERVAL RECOMMENDATIONS CAUTION: Transmission fluid and filter change frequency is determined by the severity of transmission service. To help avoid transmission damage, more frequent changes can be necessary than recommended in the general guidelines when operating conditions create high levels of contamination or overheating.
  • Page 65 CAUTION: Transmission fluid and filters must be changed whenever there is evidence of dirt or a high temperature condition. A high temperature condition is indicated when the transmission fluid is discolored, has a strong odor, or has exceeded oil analysis limits. Fluid Analysis Transmission protection and fluid change intervals may be optimized by monitoring fluid oxidation according to the tests and limits shown in the Fluid...
  • Page 66: Diagnostic Codes

    DIAGNOSTICS DIAGNOSTIC CODES MODE MODE SHIFT ALLISON DOC™ SELECTORS V07952.00.00 Figure 16. Shift Selectors, Allison DOC™ For PDA–Service Tool, and Allison DOC™ For PC–Service Tool Poor performance may activate a code without illuminating the CHECK TRANS light. Continued illumination of the CHECK TRANS light during vehicle operation (not start-up) indicates the TCM/ECU has signaled a diagnostic code.
  • Page 67: Customer Service

    The satisfaction and goodwill of the owners of Allison transmissions are of primary concern to Allison Transmission, its distributors, and their dealers. As an owner of an Allison transmission, you have service locations throughout the world that are eager to meet your parts and service needs with: •...
  • Page 68 Therefore, it is suggested that Step One be followed when experiencing a problem. Your purchase of an Allison Transmission product is greatly appreciated, and it is our sincere desire to assure complete satisfaction.
  • Page 69: Service Literature

    Parts Catalog* PC2150EN PC2456EN Parts Catalog CD-ROM CD2150EN CD2456EN Principles of Operation PO2454EN PO2454EN Service Manual SM2148EN SM2457EN Troubleshooting Manual TS2973EN TS2973EN Worldwide Sales and Service SA2229EN SA2229EN Directory* * Also available on the Allison Transmission web site at www.allisontransmission.com...
  • Page 70 Parts Catalog PC2150EN PC2456EN Parts Catalog on CD CD2150EN CD2456EN Principles of Operation PO4016EN PO4016EN Service Manual SM4013EN SM4014EN Troubleshooting Manual TS3989EN TS3989EN Worldwide Sales and Service SA2229EN SA2229EN Directory* * Also available on the Allison Transmission web site at www.allisontransmission.com...
  • Page 71: Allison Transmission Distributors

    ALLISON TRANSMISSION DISTRIBUTORS EASTERN REGION Atlantic Detroit Diesel-Allison, LLC Penn Detroit Diesel-Allison, Inc. 180 Route 17 South 8330 State Road Lodi, NJ 07644 Philadelphia, PA 19136-2986 201-489-5800 215-335-0500 Covington Detroit Diesel-Allison Western Branch Diesel, Inc. 8015 Piedmont Triad Parkway 3504 Shipwright Street...
  • Page 72 SOUTHERN REGION Caribe Detroit Diesel-Allison Stewart & Stevenson Power, Inc. 5840 Dahlia Street Division of GT Corporation Ceramic Ind. Park Commerce City, CO 80022 Campo Rico Ave., Block C 303-287-7441 Carolina, Puerto Rico 00982 787-750-5000 Detroit Diesel-Allison de Mexico S.A. Stewart &...
  • Page 73: Allison Transmission Regional Offices

    ALLISON TRANSMISSION REGIONAL OFFICES EASTERN REGION SOUTHERN REGION 19 Oaklynn Drive Av. Ejercito Nacional No. 843 PO Box 400 Colonia Granada Columbus, NJ 08022-0400 Mexico, D.F. C.P. 11520 609-298-2541 936-321-4248 CENTRAL REGION WESTERN REGION PO Box 894, Mail Code 462-470-PF06...
  • Page 74 OM3656EN 200509 www.allisontransmission.com Printed in USA 200509...

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