Workhorse Motorhome & Commercial Chassis Service Repair Manual 1999-2005
Complete workshop repair service manual with electrical wiring diagrams for Workhorse Motorhome and Commercial Chassis 1999-2005. It's the same service manual used by dealers that guaranteed to be fully functional and intact without any missing page.
This Workhorse Custom Chassis service repair manual (including maintenance, overhaul, disassembling & assembling, adjustment, tune-up, operation, inspecting, diagnostic & troubleshooting…) is divided into different sections. Each section covers a specific component or system with detailed illustrations. A table of contents is placed at the beginning of each section. Pages are easily found by category, and each page is expandable for great detail. The printer-ready PDF documents work like a charm on all kinds of devices.
“’99-'03 Workhorse Service Manual.pdf”
Workhorse Custom Chassis (Motorhome and Commercial Chassis) Electronic Service Manual ’99-'03 + Wiring; 8,512 pages
“'04-'05 Workhorse Service Manual Supplement.pdf”
Workhorse Custom Chassis (Motorhome and Commercial Chassis) Electronic Service Manual Supplement '04-'05; 1,625 pages
“'04 Workhorse Electrical Schematics”
'04 Electrical Schematics/FE20-L18.pdf
'04 Electrical Schematics/P32-L18.pdf
'04 Electrical Schematics/P32-L31.pdf
'04 Electrical Schematics/P42-L4B.pdf
'04 Electrical Schematics/P42-L31.pdf
'04 Electrical Schematics/P42-L35.pdf
'04 Electrical Schematics/P42-L57.pdf
'04 Electrical Schematics/P42-LQ4-LR4.pdf
'04 Electrical Schematics/P42-LU3.pdf
'04 Electrical Schematics/W22-L18.pdf
'04 Electrical Schematics/W24-L18.pdf
'04 Electrical Schematics/W52-L18.pdf
“'05 Workhorse Electrical Schematics”
'05 Electrical Schematics/FE20.pdf
'05 Electrical Schematics/P32-L18.pdf
'05 Electrical Schematics/P42-L4B.pdf
'05 Electrical Schematics/P42-LQ4-LR4.pdf
'05 Electrical Schematics/P42-LU3.pdf
'05 Electrical Schematics/W22-L18-web.pdf
'05 Electrical Schematics/W24-L18.pdf
'05 Electrical Schematics/W52-L18.pdf
'04-'05 Service Manual Supplement....2
2004Intro.pdf....0
2004-2005 Service Manual Supplement.pdf....0
Section 5 - Brakes.pdf....0
Section 5 - Brakes.pdf....0
Section 6 Engine.pdf....0
4.8-6.0 Engine Mechanical.pdf....0
4.8-6.0 Engine Mechanical.pdf....0
Untitled....273
Untitled....273
Cummins ISB4 Electronic Tech Package.pdf....0
Cummins Inc. 1460 National Road Columbus, Indiana 47201....1127
This document, and the information herein, is CONFIDENTIAL and PROPRIETARY, and shall not be disc....1127
1.1 TECHNICAL PACKAGE INTRODUCTION....1133
1.2 About the ISB4/ISBE engines....1133
1.3 AUTOMOTIVE FEATURES....1133
2.1 ACCELERATOR INTERLOCK....1135
2.2 AUXILIARY PROTECTION SYSTEM....1135
2.3 BATTERY VOLTAGE MONITOR....1135
2.4 CAB SWITCHABLE GOVERNOR....1135
2.5 CRUISE CONTROL....1135
2.6 CRUISE CONTROL GOVERNOR TAILORING....1136
2.7 DIAGNOSTICS....1136
2.7.1 ON BOARD DIAGNOSTICS....1136
2.7.2 Offboard Diagnostics....1136
2.8 ENGINE PROTECTION SYSTEM....1137
2.8.1 Torque Derate....1137
2.8.2 Speed Derate....1137
2.8.3 Engine Protection Shutdown....1137
2.9 ENGINE WARM-UP PROTECTION....1137
2.10 EXHAUST BRAKE....1137
2.10.1 Exhaust Brake/Cruise Control Interaction....1138
2.10.2 Exhaust Brake / Automatic Transmission Interaction....1138
2.10.3 Exhaust Brake / Driveline Retarder....1138
2.11 FAN CLUTCH CONTROL....1138
2.12 GEAR DOWN PROTECTION....1139
2.13 FUEL HEATER CONTROL....1139
2.14 GRID HEATER CONTROLS....1139
2.15 IDLE SHUTDOWN....1140
2.16 INFORMATION LOG....1140
2.17 KEY SWITCH ON....1141
2.18 Limp Home Throttle Operation....1141
2.19 LOW IDLE SPEED ADJUSTABILITY....1142
2.20 MAINTENANCE MONITOR....1142
2.21 MULTILEVEL SECURITY....1142
2.22 POWER TAKEOFF (PTO) GOVERNOR....1143
2.23 POWER TRAIN PROTECTION....1146
2.24 REMOTE THROTTLE....1147
2.25 ROAD SPEED GOVERNOR....1148
2.25.1 Smart RSG....1148
2.25.2 RSG Increment / Decrement Values....1148
2.25.3 Switched RSG....1148
2.25.4 RSG ‘Set’....1148
2.25.5 Kick-down Throttle....1148
2.25.6 Switched RSG Low Speed Application....1149
2.26 STARTER LOCKOUT....1149
2.27 SWITCHED MAX OPERATING SPEEDS....1149
2.27.1 Two Position Switch....1149
2.28 TACHOGRAPH (ISBe)....1149
2.29 TACHOMETER OUTPUTS....1149
2.30 TRANSMISSION SHIFT MODULATION (Analog Torque) LOAD SIGNAL....1149
2.31 TWO SPEED AXLE (Rear Axle Ratio)....1149
2.32 VEHICLE ACCELERATION RATE LIMITER (Rate Management)....1150
2.33 VEHICLE ANTI-THEFT PROTECTION....1150
2.34 VEHICLE SPEED SENSOR (VSS) ANTI - TAMPERING....1150
2.35 WATER-IN-FUEL WARNING....1150
3.1 ELECTRIC CONTROL MODULE....1152
Figure 3-1: Electronic Control Module....1153
3.2 HARNESSES....1153
3.3 ENGINE POSITION SENSOR....1153
3.4 ENGINE SPEED SENSOR....1153
3.5 INTAKE MANIFOLD pressure/AIR TEMPERATURE SENSOR....1153
3.6 COOLANT TEMPERATURE SENSOR....1154
3.7 OIL PRESSURE/TEMPERATURE SENSOR (OPTIONAL)....1154
3.8 Oil Pressure switch....1154
3.9 RAIL PRESSURE SENSOR....1154
3.10 AMBIENT AIR PRESSURE SENSOR....1154
3.11 FUEL TEMPERATURE SENSOR (pre MY04 engines)....1154
3.12 OEM COMPONENTS....1154
3.13 CONTACTS and CONNECTORS....1154
3.14 OEM HARNESS and HARNESS ROUTING....1155
3.15 VEHICLE KEY SWITCH....1155
3.16 VEHICLE SPEED SENSOR....1156
3.17 TACHOGRAPH INPUT (ISBe)....1156
3.18 OEM TEMPERATURE SENSOR....1156
3.19 OEM PRESSURE SENSOR....1156
3.20 STARTER LOCKOUT RELAY....1157
3.21 TACHOMETER INTERFACE....1157
3.21.1 High Side....1157
3.21.2 Low Side....1157
3.22 ACCELERATOR PEDAL ASSEMBLY....1157
3.22.1 Throttle Pedal with Idle Validation switches....1157
3.22.2 Dual Potentiometer Throttle Pedal (MY04 and beyond)....1157
3.23 EXHAUST BRAKE Control....1158
3.23.1 Exhaust Brake Wiring with Manual Transmissions....1158
Figure 3-2: Exhaust Brake Wiring with Manual Transmission....1158
3.23.2 Exhaust Brake Wiring with Allison AT, MT Transmissions....1158
Figure 3-3: Exhaust Brake Wiring w/Allison AT & MT Transmission or other Non-Electronic Transmiss....1158
3.23.3 Exhaust Brake Wiring with Allison MD Transmission....1159
Figure 3-4: Exhaust Brake Wiring w/Allison MD Transmission....1159
3.23.4 Typical rewire Installation of Vehicle Exhaust Brake Systems connecting to the Allison MD ....1159
3.24 DRIVELINE RETARDER CONTROL....1160
3.25 REMOTE THROTTLE ASSEMBLY....1160
3.26 TRANSMISSION SHIFT MODULATION SIGNAL....1161
Table 3-1: Transmission Shift Modulation Signals....1161
3.27 COOLANT LEVEL SENSOR....1161
3.28 WATER IN FUEL SENSOR....1162
Table 3-2: WIF Sensor Performance Requirements....1162
3.29 FUEL HEATER INTERFACE....1162
Figure 3-5: Fuel Heater Electrical Connections....1162
Table 3-3: 12 and 24 Volt Fuel Heater Details....1162
3.30 GRID - INTAKE AIR HEATER RELAYS....1162
Table 3-4: Grid Heater Electrical Connection Table....1163
Figure 3-6: Grid Heater Electrical Connections....1164
Figure 3-7: Grid Heater Systems Layout....1164
3.31 SERVICE BRAKE SWITCH....1165
3.32 Parking Brake Switch....1165
3.33 CLUTCH PEDAL SWITCH....1165
3.34 CRUISE CONTROL / PTO SWITCHES....1165
3.34.1 Cruise / PTO - On/Off Switch....1165
3.34.2 Cruise / PTO - Set-Resume Switches....1165
3.34.2.1 Vehicle in Cruise....1165
3.34.2.2 Vehicle in PTO....1166
3.34.2.3 Cruise Control Switch Reconfiguration....1166
3.35 DIAGNOSTIC TEST SWITCH....1166
3.36 Idle/Diagnostic Increment/Decrement Switch....1166
3.37 Fan Clutch Interface....1166
3.37.1 Manual Override Fan Clutch Switch....1167
3.37.2 Air Conditioner Pressure Switch....1167
3.38 accelerator Interlock Switch....1167
3.39 Two Speed Axle Switch....1167
3.40 Cab Switchable Governor Switch....1167
3.41 Powertrain Protection Torque Limit Switch....1167
3.42 SWITCHED MAX OPERATING SPEEDS....1167
Table 3-5: Voltages at B89.....1168
3.43 Switched RSG....1168
3.44 Engine Protection Override Switch....1168
3.45 INDICATOR LAMPS....1168
3.46 Data Links....1168
3.46.1 J1939 Data Links....1168
3.46.2 J1939 Data-link Backbone....1168
Figure 3-8: OEM supplied J1939 backbone harness....1169
3.46.3 J1587 Data-link....1169
3.48 OTHER RECOMMENDATIONS....1170
3.48.1 ECM to Vehicle Connection Procedure....1170
3.48.2 Data Link Device Power Connections....1170
3.48.3 Vehicle Welding Recommendations....1170
3.48.4 Engine Painting Recommendations....1170
3.48.5 Engine Jump Start Recommendations....1170
3.48.6 Vehicle Battery Disconnection Recommendations....1171
Table 3-6: CM800 Output Current Capabilities....1171
4.1 ELECTRICAL WIRING....1172
4.1.1 OEM & Engine Wiring Harnesses....1172
Figure 4-1: Legend for Wiring Diagram....1172
Figure 4-2: ISB4/ISBE Wiring Diagram (OEM Connector B)....1173
Figure 4-3: ISB4/ISBe Wiring Diagram (Connectors C and A)....1174
Figure 4-4: 4 Cylinder Engine Harness....1175
Figure 4-5: 4 Cylinder Engine Harness Schematic....1176
Table 4-1: 4 Cylinder Engine Harness Connection List....1177
Figure 4-6: 6 Cylinder Engine Harness....1179
Figure 4-7: 6 Cylinder Wiring Schematic....1180
Figure 4-8: Sample ISB4/ISBE OEM DATALINK Harness Section....1183
Table 4-3: Current Usage....1183
4.2 PARTS LIST FOR OEM HARNESS INTERFACES TO ENGINE CONTROLLER....1184
4.3 ISB4/ISBe Engine Pins....1185
Table 4-4: ISB4/ISBE Engine A Connector....1185
Table 4-5: ISB4/ISBE Engine B Connector....1186
Table 4-6: ISB4/ISBe Engine C Connector....1189
5.1 CONNECTORS....1190
5.1.1 OEM Connector....1190
Figure 5-1: OEM Connector....1190
5.1.2 Fan Clutch Connector....1192
Figure 5-2: Fan Clutch Connector....1192
5.1.3 Fuel Heater Connector....1194
Figure 5-3: Fuel Heater Connector....1194
5.1.4 Coolant Level Connector....1196
Figure 2-4 Coolant Level Connector....1196
5.1.5 J1939 Tool Connector....1198
Figure 5-5: J1939 Tool Connector....1198
Table 5-1: J1939 Tool Connector Part List....1199
5.1.6 9 PIN Datalink Tool Connector....1200
Figure 5-6: 9 PIN Datalink Tool Connector....1200
Table 5-2: 9-Pin J1939 Datalink Connector Parts List....1200
5.2 SENSORS....1202
5.2.1 Vehicle Speed Sensor (Variable Reluctance Magnetic Pickup)....1202
Figure 5-7: Vehicle Speed Sensor....1202
5.3 PRESSURE SWITCHES....1204
5.3.1 Brake Switch....1204
Figure 5-8: Pressure Switch....1204
5.4 SWITCHES AND SWITCH ASSEMBLIES....1206
5.4.1 Rotary Clutch Switch Assembly....1206
Figure 5-9: Rotary Clutch Assembly....1206
5.4.2 Optional Levered Clutch or Brake Switch....1208
Figure 5-10: Optional Levered Clutch or Brake Switch....1208
5.4.3 Optional Clutch or Brake Switch....1210
Figure 5-11: Optional Clutch or Brake Switch....1210
5.4.4 Toggle Switches....1212
Figure 5-12: Toggle Switches....1212
5.4.5 Radiator Coolant Level Switch....1214
Figure 5-13: Radiator Coolant Level Switch....1214
5.4.6 Remote Throttle/Remote PTO Switch....1216
5.5 LAMPS....1218
5.5.1 Fault Lamps....1218
5.6 Relays and Relay Assemblies....1219
5.6.1 Grid Heater Power Relays....1219
Figure 5-14: High Power Relay (Note: Drawing shown for form features only.)....1219
5.6.2 Fuel Heater Relay....1220
Figure 5-15: Fuel Heater Relay....1220
5.7 COMPONENT SOURCES....1221
5.8 ELECTRONIC THROTTLE INTERFACE, CES 14118....1222
5.9 MIDRANGE ACCELERATOR PEDAL ASSEMBLY INSTALLATION RECOMMENDATIONS....1222
5.9.1 Introduction....1222
6.1 ONBOARD DIAGNOSTICS....1223
6.1.1 Fault Detection....1223
6.1.2 Flash Out of Fault Codes....1223
6.2 OFFBOARD DIAGNOSTICS....1223
6.2.1 Fault Information Management....1223
6.2.1.1 Display Fault Codes and Fault Information....1223
6.2.1.2 Erase Fault Codes....1224
6.2.1.3 Save Fault Codes and Data....1224
6.2.2 Monitor Mode....1224
6.2.3 ECM Data Plate Information....1225
Table 6-1: Minimum Required Data Plate Layout....1225
6.2.4 Performance Tests....1227
6.2.5 Special Functions....1227
6.2.6 INSITE and ECM Security....1228
6.2.6.1 Password Security....1228
6.2.6.2 Multi-Level Security....1228
6.2.7 Fault Information System (FIS)....1229
Figure 6-1. Service Tools for ISB4/ISBE Engines....1229
7.1 Introduction....1230
7.1.1 Hardware Implementation....1231
7.2 J1587 SERIAL COMMUNICATIONS....1231
7.2.1 Introduction....1231
7.2.2 Message Priority....1231
7.2.3 Communications Requests....1231
7.2.3.1 Data Requests....1231
7.2.3.2 Broadcasts....1231
7.2.3.3 Data Writes....1231
7.2.4 Integrity....1232
7.2.4.1 Error Detection....1232
7.2.4.2 Collision Avoidance....1232
7.2.5 Operational Notes....1232
7.2.5.1 Packing PIDs and Data....1232
7.2.5.2 Normal Data Transfer....1232
7.2.5.3 Bus Utilization....1232
7.2.5.4 Message Identifier Usage....1234
7.2.6 More Detail on PIDs....1234
7.2.6.1 PID 2 - Status Word 1....1234
7.2.6.2 PID 3 - Diagnostic Status....1234
7.2.6.3 PID 193 - Diagnostic Table....1234
7.2.6.4 PID 194 - Transmitter System Diagnostic Code and Occurrence Count Table....1235
7.2.6.5 PID 243 - Component Identification....1238
7.2.7 Bus Utilization for J1587 Standard Broadcast Data....1238
7.2.8 Assumptions and Definitions For FMIs....1239
Table 7-1: PIDs Supported on J1587....1240
Table 7-2: J1587 Parameter Specifications....1241
Table 7-3: Available Authorized Data Writes....1242
7.3.1 Introduction....1243
7.3.2 Hardware Implementation....1243
7.3.3 Messages Supported on J1939....1243
Table 7-4: Messages Supported on J1939....1244
7.4 Fault Codes....1254
Table 7-5: FAULT CODES FOR ISB4/ISBe ENGINES....1254
8.1 Temperature Resistance....1265
8.1.1 Operating - High Temperature....1265
8.1.2 Non-operational Storage Temperature....1265
8.1.3 Operating - Low Temperature....1265
8.2 Climate and Chemical Resistance....1265
8.2.1 Humidity....1265
8.2.2 Industrial Climates....1265
8.2.3 Salt Mist....1265
8.2.4 Chemical Resistance....1265
8.3 Mechanical Resistance....1266
8.3.1 Vibration....1266
Figure 8-1: Summary of Vibration....1267
8.3.2 Mechanical Shock....1267
8.4 Protection against Water / Dust Ingress....1267
8.5 Harness Length / Impedance....1267
8.6 Harness attachment....1267
9.1 Electronic Components Environment....1268
Table 9:1 Environmental, Mechanical, Electrical Ranges....1268
Figure 9-1: Electronic Control Module....1269
Figure 9-2: Close up of ECM Label....1270
Table 9:2 Vibration Break Points - All Axes....1271
Figure 9-3: Inductive Load Switching #1....1271
Table 9:3 Inductive Load Switching #1....1272
Figure 9-4: Inductive Load Switching #2....1272
Table 9:4 Inductive Load Switching #2....1272
Table 9:5 Inductive Key Off Switching #1....1273
Figure 9-5: Inductive Key Off Switching #1....1273
Figure 9-6: Inductive Key Off Switching #2....1274
Table 9:6 Inductive Key Off Switching #2....1274
Figure 9-7: Switching Spikes #1....1275
Table 9:7 Switching Spikes #1....1275
Figure 9-8: Switching Spikes #2....1276
Table 9:8 Switching Spikes #2....1276
Figure 9-9: Mutual Coupling....1277
Table 9:9 Mutual Coupling....1277
Figure 9-10: Starter Motor Engagement....1278
Table 9:10 Starter Motor Engagement....1278
Figure 9-11: Field Decay Transient....1279
Table 9:11 Alternator Field Decay....1279
Table 9:12 Waveform Parameters....1279
Figure 9-12: Load Dump....1280
Figure 9-13: Radiated Emissions....1281
ACRONYMS and ABBREVIATIONS....1284
Section 7 - Transmission.pdf....0
Section 8 - Electrical.pdf....0
'99-'03 Service Manual....1627
Workhorse Motorhome & Commercial Chassis Service Repair Manual 1999-2005
