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All subjects related to maintenance and repairs to the diesel
engines are covered in the engine manual furnished by the
engine manufacturer. The instructions issued by the engine
manufacturer should be followed at all times. The local Cummins
dealer is capable and dedicated to performing warranty repairs
and any other services required. Contact your local Cummins
dealer on any questions related to engine performance or
problems.
It is advisable to obtain the necessary electronic test equipment
and trim the technicians that will be involved in servicing this
engine.
Special attention should be given to operating and servicing the
engine if operating in an environment involving severe cold
weather or extreme dusty conditions.
The electronically controlled ISC engine is a major step in
extended engine service life, reduced maintenance and
operating costs, and reduces problems created by driver error orabuse. The brain of the engine is the Electronic Control Module
(ECM) located on the left side of the engine.
Engine Data Plates
Three data plates are located on the engine. The information
listed on these plates are critical when ordering replacement
TL960 SERVICE MANUAL
Page 12-1
Cummins ISC
Engines
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parts or discussing service related problems with your area
Cummins service facility.
1. Engine Data Plate
This data plate, located on top of the engine front cover,contains the engine serial number (ESN) and a Control
Parts List (CPL) number. The ESN and CPL are required
when ordering parts. The engine serial number is
stamped in the engine block above the oil cooler housing.
2. Fuel Injection Pump Data Plate
The Fuel Injection Pump Data Plate is located on the side
of the fuel injection pump and contains the pump serial
number, part number, and factory code.
3. ECM Data Plate
This plate contains the ECM part number and serialnumber, engine serial number date code, and a code that
identifies the software number that tells how the ECM is
programmed.
Electronic Control Module
The command center for the operation of the engine is the ECM.
The ECM assimilates signals from various sensors on the
engine and transmission. Based on these signals, the ECM
modifies fuel flow to the injectors as necessary to control thevarious functions under its control. Some of these are:
Low Idle Speed •Engine Timing •Diagnostics
•Fast Idle Speed •Accelerator Interlock •Start-up & Emissions
•Top Engine RPM •Cruise Control •Top Road Speed
•Engine Protection System •Fuel Economy •Fault Detection
These are discussed briefly herein, however, they may be more
in-depth in the Operation and Maintenance Manual 3666242.
Some of the functions of the ECM are programmed into the ECM
by Cummins and cannot be changed. Others are programmed in
accord with the customer's requirements. In all cases, special
software and electronic service tools are required to make any
changes.
TL960 SERVICE MANUAL
Page 12-2
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Top Engine RPM
The ISC 215 and 250 hp, low torque engines are governed at
2400 rpm. All other high horsepower engines are governed at
2200 rpm.
One of the functions of the engine protection system is to reduce
rpm and torque in the event of a problem with engine oil
pressure, engine overheat, or high intake air temperature. Then
such a problem occurs the ECM reduces fuel to the injectors,
causing a power loss that is obvious to the driver and at the
same time causes a warning light to come "ON" on one of the
four warning lamps on the dash.
Vehicle Top Speed Limit
Maximum road speed is preset at the factory, based on tire size,
rear axle ratio, and the customer's request. This cannot be
altered in the field without special software and electronic
service tools.
As the bus approaches the top speed limit fuel to the injectors
will be be limited, causing a drop off of power within three (3)
mph of the limit. Full power will be restored when road speed
drops three (3) mph. The driver will notice the power drop offgradually as top speed is approached.
Engine Protection System
The ECM receives signals sent from sensors monitoring oil
pressure, coolant temperature, and intake air temperature.
The sensor monitoring intake air temperature is located in the
pipe between the CAC and the turbocharger. The coolant sensor
is just below it, in the top radiator pipe. The oil pressure sensoris located in the block, just below the fuel/water filter.
If any one of these systems fall below, or rises above its normal
operating range, the ECM will cause the YELLOW warning light
to flash. This alerts the driver of a potential problem. If the RED
stop lights comes on the driver should pull off the road as soon
as possible to prevent damage to the engine.
TL960 SERVICE MANUAL
Page 12-3
Caution : If the RED
warning light comes onwhile the bus is moving, thedriver should pull the bus offthe road as soon as possibleto avoid damage to theengine.
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When the YELLOW light begins flashing, engine power may
drop off depending on the severity of the problem. At the same
time, the ECM will file a diagnostic fault code in its memory. This
can be retrieved by using the diagnostic switch or by using
Cummins "INSITE" electronic service tool.
Engine Low Idle and Fast Idle RPM
Low idle of 700 rpm is set at the factory. Fast idle is set at 1000
rpm, both controlled by the ECM.
The ECM will cause the engine to shut down after a period of
idling and there has been no movement of the bus or of the
accelerator pedal. This period can be anywhere between five
minutes or 30 minutes, depending on the period determinedwhen the ECM was programmed. Thirty seconds before the
engine shuts down, the yellow light on the dash will flash. If the
operator wants the engine to continue idling, simply touch the
accelerator pedal or the brake pedal. Once this is done, the
automatic shutdown is no longer functional until the bus has
been moved.
The idle shut down system will not function if the coolant
temperature is below 1000 F (380 C).
Start-up and Emission Control
The ECM controls the operation of the two (2) grids heaters in
the intake manifold. The grid heaters heat the intake air to aid in
cold weather starting, and at the same time reduce white smoke
after starting.
The ECM controls the preheat operation by sensing signals sent
from the sensor in the radiator top pipe and from the sensor
installed in the pipe between the CAC and the turbocharger. Formore information on this refer to the Air Intake section of this
manual.
The Wait-to-Start light comes on at the same time the heater
grids are energized. No attempt to start the engine while this
light is on should be made. Remember as soon as the starter is
engaged the intake heater grids are deenergized by the ECM.
TL960 SERVICE MANUAL
Page 12-4
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After the engine starts, the heaters operate on and alternating
basis until the bus reaches a road speed of 19 mph, or for three
(3) minutes.
Cruise Control
Refer to the Cruise Control comments in the Electrical section of
this manual.
Your area Cummins dealer can provide the needed literature,
test equipment, and training for the technicians. The dealer is
well qualified to handle warranty repairs as well as any other
engine service.
ECM Diagnostic System
The ECM controls a built-in diagnostic system that alerts the
driver of a system problem by illuminating one of the warning
lamps on the dash. It also records the fault code(s) that may
appear.
Ignition Switch On, Diagnostic Switch Off, Engine Not
Running
With the ignition switch on and Diagnostic switch off, the ECMperforms diagnostic and status operations. The dash indicator
lamps (RED-stop, YELLOW-warning, Water-in-Fuel, and Wait-
to-Start) will illuminate for two (2) seconds, one after the other, to
verify they are in working order. This is a normal part of the
power-up sequence. If an active fault is present, one of the
lamps will remain lighted for a short period of time and then
begin flashing.
Ignition Switch On, Diagnostic Switch On, Outboard
Diagnostic Mode
In addition to alerting the driver of a problem while the bus is
moving, the four (4) lamps are also used in the diagnostic
operation.
With ignition on and diagnostic switch on, the YELLOW lamp will
flash at the beginning of a fault code sequence, then the RED
TL960 SERVICE MANUAL
Page 12-5
Note : If no active fault isrecorded, both the RED andYELLOW lamps will comeon and stay on.
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lamp will flash a 3-digit code for the active fault.
If a fault code is recorded, the following sequence will occur:
1. The YELLOW warning lamp will flash.
2. A short 1-2 second pause.3. The 3-digit fault code will flash on the RED lamp, with a
short 1-2 second pause in between each number.
4. When the number has finished flashing in RED, the
YELLOW lamp will appear again and the 3-digit code will
repeat in the same sequence.
The lights will flash each code two (2) times before advancing to
the next code, if one exists.
If only one code is recorded, the system will continuously showthe same code.
When not using the diagnostic system make sure the diagnostic
switch is OFF. If left ON during normal operation, the ECM will
not record some fault codes.
Throttle Control
Fuel flow to the cylinders is controlled by the Electronic Control
Module (ECM), which receives a signal from a Throttle PositionSensor (TPS) mounted on the back side of the accelerator
pedal. The ECM supplies 5 volts as input voltage to the pedal
sensor. This voltage will vary in output back to the ECM,
depending on the position of the accelerator pedal.
An Idle Validation Switch (IVS) is a part of the TPS assembly. It's
purpose is to advise the ECM when the accelerator pedal is, or
is not, at the idle position. The function of the IVS is to provide a
fail-safe in the event of a stuck-open throttle or a failure in the
throttle wiring or circuits. In the event such a failure occurs, theECM will cause the engine to idle only-it will not accelerate. At
the same time one of the fault codes relating to the IVS system
will appear on the dash instrument. Codes 431, 432, and 551
relate to the IVS system.
At this point, enough emphasis cannot be placed on the
procurement of the necessary test tools, which are available
TL960 SERVICE MANUAL
Page 12-6
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from your area Cummins dealer, Cummins Troubleshooting
Manual #3666194-00, and proper training for the technicians
that will be involved in servicing the electronic systems on all
current and future bus purchases.
To eliminate unnecessary and costly repairs it is important to
procure the test equipment mentioned in the first paragraph in
the part covering the testing of the throttle position sensor. Your
Cummins dealer will be anxious to help you obtain what you
need for the Cummins engines.
Calibrating the Throttle Position Sensor
Calibrating the throttle sensor is a simple event, and will have to
be done anytime the sensor is replaced, or the sensor leadshave been disconnected with the ignition switch ON, or if the
ECM has been replaced.
This is accomplished by turning the ignition switch ON, and
slowly depressing the pedal to FULL throttle, from complete
IDLE, three times. Release the pedal completely after each
pedal movement.
Replacement of the sensor assembly is simple, also. Remove
the two screws from the side of the sensor, disconnect thesensor harness at the connectors found in the compartment
behind the left windshield wiper door.
Throttle Position Sensor Test Procedure
The most efficient way to test the TPS is to use the Cummins
INSITE program, which makes use of an IBM PC (or 100%
compatible) and the Inline Adapter Kit. These are a part of the
service tools required to properly service/diagnose fault codes
that will occasionally appear. Instructions for checking thevarious sensors and circuits are included in the INSITE package,
which is available for your area Cummins dealer.
If this equipment is not available, you can use a multimeter and
service harness #3823255, which is available from your local
Cummins dealer.
TL960 SERVICE MANUAL
Page 12-7
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Testing the Idle Validation Switch
If using the multimeter instead of the Cummins INSITE program
to test the Idle Validation Switch (IVS), procure test leads
#3823995 and #3823996 from your area Cummins dealer.
Test Procedure (See Figure 1.)
1. Disconnect IVS connector from chassis harness located
in the compartment behind the left windshield wiper door.
Install test harness into IVS connector (from accelerator
pedal).
2. With pedal in IDLE (closed) position, measure the
resistance between pins 'A' and 'B'. Meter should register
125 ohms or less.3. Depress pedal to FULL throttle position, this value should
read infinite ohms (100K ohms or more).
4. With pedal in IDLE position, check resistance between
pins 'B' and 'C'. Should read infinite ohms.
5. Depress pedal to FULL throttle position, value should be
between 20 and 125 ohms.
If the above resistance values are not within the specifications
outlined, the IVS is defective and the complete sensor assembly
should be replaced.
If the IVS passes the above tests, it may still be necessary to test
for a short to ground.
1. Connect negative (-) lead of multimeter to a metal part of
the pedal assembly.
2. Connect the positive (+) meter lead to pin 'C' and then to
pin 'B'. Meter should show an open circuit, or 100K ohms
or more. If not within these specifications, replace the
IVS/TPS assembly.
Pages 19-64 through 19-69 in the Cummins Troubleshooting
Manual #3666194-00 go into much more detailed instructions in
troubleshooting the IVS system.
TL960 SERVICE MANUAL
Page 12-9
Figure 1
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Engine Removal Procedure
1. Observe all steps mentioned above.
2. Remove engine compartment door, if a fork lift is to be
used to remove the engine.3. Remove body rear bumper.
4. Remove chassis rear bumper.
5. Remove chassis upper support crossmember
6. Remove radiator module assembly. See the Cooling
section for removal instructions.
7. Remove hoses and pipes between charge air cooler and
engine. Tag the intake air temperature sensor connector.
8. Remove exhaust pipe from turbocharger.
9. Remove the metal elbow (turbo inlet air) from the turbo (to
avoid damage during engine removal.)10. Remove upper and lower radiator pipes. Tag the coolant
temperature sensor connector to insure it goes back onto
the coolant sensor.
11. If bus is equipped with air conditioning, remove A/C drive
belt.
12. Remove heater hoses from shut-off valves.
13. Disconnect oil pressure hose at oil filters.
14. Disconnect cables and wiring from 200 or 270-amp
alternators.
15. Disconnect fuel lines at rear of engine. Tag them to besure they go back onto the correct fitting.
16. Disconnect hydraulic supply hose at hydraulic pump.
17. Disconnect power steering pressure hose at union at rear
of engine.
18. Disconnect compressor main discharge hose from copper
tubing, same area.
19. Remove transmission dipstick support clamp at hydraulic
reservoir.
20. Disconnect D-1 governor air line.
21. If bus is equipped with a retarder, remove the retarder
cooler and hoses from the chassis. If no retarder,
disconnect the oil cooler hoses at the transmission.
22. Disconnect transmission temperature sensor lead.
23. Disconnect transmission wiring harness:
a. Disconnect speedometer sensor at rear of
transmission.
b. Disconnect speed sensor lead at lower front corner of
transmission.
TL960 SERVICE MANUAL
Page 12-11
Note : We recommendpulling the radiator for 2reasons: 1) It will probablybe sent out for cleaning if anew engine is to beinstalled. 2) Removal
provides greater access tothe wiring, connectors,hoses, etc. on the left side ofthe engine.
Note : If smaller alternators(120-160 amp) are on the
engine, consider removingthe alternator mounting boltsand pull the alternatorforward for easier access tothe wiring.
Caution : Carefully
observe to see that all
connections, hoses, wiring,etc. have beendisconnected.
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c. Separate transmission main harness at the
connector.
d. Remove transmission main harness support clip, top
of transmission.
24. Disconnect drive line from transmission, tie it up out of theway.
25. Disconnecting the various cables, harnesses, connectors
on the left side of the engine requires some study since
they are bundled together. The following suggestions are
offered in an effort to simplify this task as much as
possible.
a. Remove all cables and wiring from the starter. Tag
each as to which post it is to be reinstalled.
b. Cut all tie wraps that bind the harnesses, etc.
together.c. Disconnect the chassis harness connector to the
ECM.
d. Remove harness support clip at front of engine.
e. Disconnect intake heater grid cables at the grids.
f. After the tie wraps have been removed, separate the
cables, hose, etc. that will stay with the chassis from
those that go to the electrical modular compartment.
When separated, move the entire harness over the
top of the engine to the opposite side of the chassis.
Tie up out of the way.
26. Remove rear motor support bolts.
27. Remove front motor support bolts.
28. Place transmission jack beneath transmission, making
sure the oil pan is not damaged and the transmission sit
firmly on the jack.
29. The engine has a lifting eye at front and rear of the
cylinder head. Place engine lift bar or chain in place,
connect it to a floor hoist or fork lift. Take weight off the
motor supports.
30. Remove engine front support crossmember from the
chassis.
31. With adequate assistance, gently pull the
engine/transmission from the chassis. Carefully observe
to see that all wiring, air lines, hoses, etc. have been
disconnected.
32. After removal place assembly on a stable, secure
platform or mount to the perform removal of accessories,
fittings, etc.
TL960 SERVICE MANUAL
Page 12-12
Caution : Do NOT
disconnect any of theCummins suppliedconnectors. They arepainted the color of theengine.
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Once the assembly has been removed and safely mounted on
supports, everything connected to and with the package is now
easily accessed. Depending on the repairs to be made, it may
not be necessary to remove many of the accessories. If a
replacement engine is to be installed, it is a simple matter totransfer these items to the new engine as they are removed. All
components should be installed in the same position as
removed.
If this engine has over 250,000 miles, consider replacing or
rebuilding the alternator, starter, power steering pump, and air
compressor at this time, if they have not been replaced before.
If the radiator has not been cleaned, consider flushing it at this
time.
Engine Installation
If a new or exchange engine is to be installed, place it alongside
the engine removed to facilitate transferring components, hoses,
and harnesses. Make sure these items are positioned exactly as
removed. This will aid in installing the new engine, as well as
minimizing changes once the engine is in place.
Bind the hoses and harnesses together on the left side of theengine and secure them to minimize interference as the engine
assembly is moved into the chassis.
1. With the engine and transmission secure on the jack and
lift, move the assembly into position to go back into the
chassis.
2. With adequate assistance move the assembly back into
place in the chassis.
3. Install the engine front support crossmember. Torque
Grade 8 mounting bolts in accord with the torque chartshown.
4. Inspect engine mount isolators for condition, (replace if in
doubt).
5. At this point the most critical area of installation is the
correct routing of hoses and harnesses to prevent chafing
and fretting. Pull the main harness back into place and
make the electrical connections in accord with the tags
TL960 SERVICE MANUAL
Page 12-13
Bolt Size Torque Value
3/4-103/4-165/8-11
5/8-181/2-131/2-20
280 ft/lbs.320 ft/lbs.170 ft/lbs.
180 ft/lbs.80 ft/lbs.90 ft/lbs.
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