PDF Operator’s Manual Allison Transmission 3000 & 4000 Series WTEC III Controls - 718 KB
Master the operation of your Allison 3000 and 4000 series transmissions equipped with WTEC III controls.
This operator's manual covers all aspects of daily use, from shifting procedures to understanding diagnostic codes.
It is essential reading for any driver or fleet manager to ensure proper handling and long-term reliability.
Get the knowledge you need to operate your Allison transmission effectively.
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EMERGENCY VEHICLE SERIES
3000/4000
OPERATOR’S
MANUAL
--- Page 3 ---
4000 EVS
4500 EVS
3000 EVS
3500 EVS
4700 EVS
4800 EVS V06299.04.00
Figure 2. Emergency Vehicle Series Transmissions
(Allison 4th Generation Controls)
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--- Page 4 ---
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.
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PUSHBUTTON AND LEVER SHIFT SELECTORS
WITH DIGITAL DISPLAY (cont’d)
Description of Available Ranges (refer to Figure 11 and Figure 12)
7+ Lower ranges provide greater engine braking for going down
6* grades (the lower the range, the greater the braking effect).
5* Occasionally, it may be desirable to restrict automatic shifting to a
4*
3 lower range because of:
2 • Road conditions.
• Load.
• Traffic conditions.
• Etc.
The pushbutton shift selector arrow buttons access individual
forward 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 reduced (this prevents excessive engine speed in
the lower range).
1 First-range provides the vehicle with its maximum driving torque
and engine braking effect. Use first-range when:
• Pulling through mud and deep snow.
• Maneuvering in tight spaces.
• Driving up or down steep grades.
For vehicles equipped with the pushbutton selector, push the
↓ (Down) arrow until first-range appears in the select window.
+ Only available in 4700/4800 EVS.
* Actual ranges available depend on programming by vehicle manufacturer.
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--- Page 6 ---
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 “ 1/3 on” plus 1/3, capacity at closed throttle or 2/3
two pressure and “Full On” with brake pressure
switches *
Hand lever plus 6 levels of modulation with lever, or
pressure switch * “Full On” with brake pressure
Foot pedal plus Full modulation with separate pedal,
pressure switch or “Full On” with brake pressure
Hand lever plus 6 levels of modulation with lever, or 3
interface for levels of modulation based on pedal
special pedal * position
* These control systems may apply the retarder at high speed on grades when the vehicle has road
speed limiting and the retarder is enabled.
** For retarder apply systems integrated with the service brake system, the retarder is most effective
when applied with light brake pedal pressure for 1–2 seconds to allow the retarder to fully
charge. Added pedal pressure can be applied when more aggressive braking is desired.
NOTE: When the transmission fluid or engine water temperature
(engine water is an OEM option) exceeds programmed limits, retarder
capacity is automatically gradually reduced to minimize or avoid
possible system overheating.
Contact your vehicle manufacturer to understand how the retarder controls have
been integrated into your vehicle.
CAUTION: Observe the following cautions when driving a vehicle
equipped with a retarder:
• THE RETARDER WORKS ONLY WHEN THE ENGINE IS AT
CLOSED THROTTLE.
• OBSERVE TRANSMISSION AND ENGINE TEMPERATURE
LIMITS AT ALL TIMES. Select the lowest possible transmission
range to increase the cooling system capacity and total retardation
available.
• In the event of OVERHEATING, DECREASE THE USE OF THE
RETARDER; USE THE SERVICE BRAKES TO SLOW THE
VEHICLE.
• OBSERVE THE RETARDER/SUMP “OVERTEMP” LIGHT to be
sure it responds properly to retarder temperature.
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--- Page 7 ---
IMPORTANCE OF PROPER FLUID LEVEL
It is important that the proper fluid level be maintained at all times because the
transmission fluid cools, lubricates, and transmits hydraulic power. If the fluid
level is too low, the converter and clutches do not receive an adequate supply of
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.
However, no oil level sensor diagnostics take place unless the OLS is
“autodetected” by Allison 4th Generation Controls or WTEC III Controls.
Frequently check for the presence of oil level diagnostics if 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. If an OLS is known to be present, but has not been
detected, then troubleshooting of the OLS circuit is required. After the OLS circuit
is repaired, reset “autodetect” or manually select the OLS function using Allison
DOC™ For PC–Service Tool. For detailed troubleshooting procedures refer to the
Troubleshooting Manual. Refer to the SERVICE LITERATURE section for
specific publication numbers.
NOTE: To correctly check the transmission fluid level using the
dipstick, the transmission fluid must be at operating temperature.
The oil level sensor method of checking the fluid level compensates for
transmission fluid temperature between 60°C–104°C (140°F–220°F).
Any temperature below 60°C (140°F) or above 104°C (220°F) will
result in an Invalid for Display condition.
FLUID LEVEL CHECK USING PUSHBUTTON OR LEVER
SHIFT SELECTOR
The transmission must be equipped with the oil level sensor to be able to read
fluid level information.
NOTE: WTEC III Controls pushbutton and lever selectors display fluid
level diagnostic information one character at a time. Allison 4th
Generation Controls pushbutton and lever selectors display fluid level
diagnostic information two characters at a time.
1. Park the vehicle on a level surface, shift to N (Neutral), and apply the
parking brake.
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--- Page 8 ---
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.
Allison requires all 3000 and 4000 Product Families transmissions to have 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 kit and fluid information. Refer to Mechanic’s
Tips, latest version, for location of the main filter and the filter change procedure.
Service Tips #1099 and Mechanic’s Tips are available online at
www.allisontransmission.com.
Refer to the following Recommended Fluid/Filter Change tables for guidelines for
fluid and filter change intervals.
NOTE: Change fluid/filters at or before recommended mileage, months,
or hours have elapsed, whichever comes first. In some cases, operating
hours may represent a more reliable measure of oil life; therefore, fluid
change intervals should not be based on mileage alone.
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