Workhorse Motorhome & Commercial Chassis Workshop Service Repair Manual 1999-2005 PDF with Wiring Diagrams - MWHMISC9905OPES.zip

A complete factory workshop repair and service manual, featuring full electrical wiring diagrams, covering Workhorse Motorhome and Commercial Chassis models from 1999 through 2005. This is the identical manual dealerships rely on, guaranteed complete and fully working with every page included.

The Workhorse Custom Chassis service and repair manual (containing upkeep, overhaul, teardown and reassembly, adjustments, tune-ups, operation, inspections, diagnostics and troubleshooting, and more) is organized into separate sections. Each one focuses on an individual component or system and comes with detailed illustrations, plus its own table of contents at the front. Locating pages is simple thanks to the category layout, and every page can be zoomed for close-up detail. These print-ready PDF files run smoothly on virtually any device.

“’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