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Service Bulletin No.2969C

1. Service Bulletin No 2969C DATE APR 13 2009 PAGE 23 DPF and HET Regen Tell tale Conditions Regeneration Tell tale High Exhaust Temp Tell tale Engine Response Operator Action DPF HET Engine responds normally OFF OFF No Driver action required Engine responds normally ON SOLID Regeneration required Increase vehicle speed above 5 mph for a minimum of twenty 20 minutes or perform a stationary regen within two 2 hours Engine responds normally ON SOLID Regeneration in process Temperature Dependant No driver action required Regen required FLASHING OFF or ON SOLID gt hiv Perform a stationary regen within one 1 hour Temperature Dependant Engine De rated FLASHING w CHECK ENG OFF or ON SOLID Tell tale Temperature Dependant Regen required Perform Stationary Regen within thirty 30 minutes Engine de rated or shutdown FLASHING w CHECK ENG OFF or ON SOLID engaged Tell tale and STOP ENG Temperature Dependant Tell tale Regeneration locked out Flashing SEL tell tale indicates thirty 30 seconds to shutdown Once shutdown coach may need to be towed Service required Printed in Canada Service Bulletin No 2969C DATE APR 13 2009 PAGE 24 The CHECK MESSAGE tell tale illumination indicates that a message regarding additional tell tale information is displayed on the alphanumeric display of speedometer Dependant of the message displayed a buzzer may accompa
2. 4 Shorted to Low Source run at all 647 Fan Control Circuit Voltage Above Normal or The fan may stay on continuously or not run at all 3 Shorted to High Source 651 Injector Solenoid Driver Cylinder 1 Circuit Current Current to injector is shut off Engine can possible 6 Above Normal or Grounded Circuit misfire or run rough 651 Injector Solenoid Driver Cylinder 1 Circuit Current Current to injector is shut off Engine can possibly 5 Below Normal or Open Circuit misfire or run rough 653 Injector Solenoid Driver Cylinder 3 Circuit Current Current to injector is shut off Engine can possible 6 Above Normal or Ground Circuit misfire or run rough 653 Injector Solenoid Driver Cylinder 3 Circuit Current Current to injector is shut off Engine can possibly 5 Below Normal or Open Circuit misfire or run rough 654 Injector Solenoid Cylinder Number 4 Circuit Cur Current to injector is shut off Engine can possibly 6 rent Above Normal or Grounded Circuit misfire or run rough 654 Injector Solenoid Driver Cylinder 4 Circuit Current Current to injector is shut off Engine can possibly 5 Below Normal or Open Circuit misfire or run rough 655 Injector S olenoid Driver Cylinder 5 Circuit Current Current to injector is shut off Engine can possible 6 Above Normal or Grounded Circuit misfire or run rough 655 Injector Solenoid Drive Cylinder 5 Circuit Current Current to injector is shut off Engine can po
3. The coolant temperature sensor is mounted in the engine thermostat housing Coolant Level Sensor CLS The coolant level sensor is a two piece assembly made up of a sensor probe and module The sensor is located near the bottom of the radiator s surge tank and monitors the coolant level Air Temperature Sensor ATS The air temperature sensor monitors intake manifold air temperature to use for charge air clutch fan control Printed in Canada Service Bulletin No 2969C DATE APR 13 2009 PAGE 5 PREVENTIVE MAINTENANCE SCHEDULE Engine Service Intervals Generally the service intervals given in the Cummins ISM Service Manual are minimum requirements to keep the engine warranty valid When determining maintenance schedules more frequent service intervals should be considered for operating conditions that are harsher than normal Lube oil sample analysis at regular drain intervals is recommended to detect internal engine malfunctions before a costly catastrophic failure and a coach down occurs Filter Service Intervals NOTE Local conditions severity of operation or duty cycle may require more frequent fluid change intervals that differ from the recommended Cummins ISM Operation and Maint Manual fluid change intervals Change fluid filters after recommended mileage months or hours have elapsed whichever occurs first Change lubricating oil and filter every 6000 miles 9600 km 500 hours or 3 months Change fuel filter e
4. Normal engine operation does not provide sufficient exhaust temperature for passive regent to occur Regeneration system raises the exhaust temp for regen to occur 3 Stationary Regen Normal operation of the engine will not allow for passive or active regeneration to occur The operator must initiate a regen with the remote switch located in the curbside rear side service compartment The regeneration toggle switch is located in the RH rear service compartment Figure 17 Figure 17 Regeneration switch located in the curbside rear service compartment WARNING To avoid serious personal injury or property damage ensure that no persons or objects are at or within two feet of the exhaust outlet at any time during a regeneration Ensure that exhaust and outlet are clear of any trash grasses or other vegetation or debris Use extreme caution during a stationary regeneration as exhaust gas tail pipe outlet temperatures can exceed 900 degrees F 482 degrees C Stationary regererations are to be performed outdoors only DO NOT leave the coach unattended during a stationary regeneration DO NOT perform inside a garage or maintenance facility DO NOT attach an exhaust extraction hose to the exhaust outlet NOTE If the coach will be idling for an expended period of time or overnight with the DPF tell tale lamp illuminated a stationary regen is required to avoid unnecessary engine derate or shutdown Printed in Canada
5. SPN 27 FMI 4 NOTE MCI has designated Source Code 0 for the engine codes FIGURE 3 Speedometer alphanumeric display Printed in Canada Service Bulletin No 2969C DATE APR 13 2009 PAGE 7 Engine Code Retrieval cont d To navigate to the FAULTS screen on the speedometer alphanumeric display press the MODE button LH side of the speedometer 5 times to display the DIAGNOSTIC screen Figure 4 FIGURE 4 Speedometer Diag screen press the SET button RH side of the speedometer 1 time to display the AUTO screen Figure 5 FIGURE 5 Speedometer press the MODE button LH side of the speedometer 2 times to display the FAULTS screen Figure 6 FIGURE 6 Speedometer Faults screen Printed in Canada Service Bulletin No 2969C DATE APR 13 2009 PAGE 8 Engine Code Retrieval cont d press the SET button 1 time to display the Parameter Group Number PGN code screen Figure 7 FIGURE 7 Speedometer PGN screen press the SET button 1 time to display the SPN Source screen FIGURE 8 Speedo Source code SRC NOTE MCI has designated Source Code 0 for the engine codes press the SET button 1 time to display the FMI screen Figure 9 FIGURE 10 Speedometer No codes present Printed in Canada Service Bulletin No 2969C DATE APR 13 2009 PAGE 9 CUMMINS ISM DIAGNOSTIC TROUBLE CODES Fault Code Information J 1939 P SPN
6. or Incor The fan will only be in the ON or OFF position 2 rect 2623 Accelerator Pedal or Lever Position Sensor 2 Cir Severe derate in power output of the engine Limp 3 cuit Voltage Above Normal or Shorted to High home power only Source 2623 Accelerator Pedal or Lever Position Sensor 2 Cir Severe derate in power output of the engine Limp 4 cuit Voltage Below Normal or Shorted to Low home power only Source 2789 Turbocharger Turbine Inlet Temperature Calcu Fuel is limited in an attempt to decrease the ex 15 lated Data Valid but Above Normal Operational haust gas temperature entering the turbocharger Range Least Severe Level Printed in Canada Service Bulletin No 2969C DATE APR 13 2009 PAGE 16 Fault Code Information Continued J 1939 SPN EFFECT FMI 2790 Turbocharger Compressor Outlet Temperature Fuel is limited in an attempt to decrease the ex 15 Calculated Data Valid but Above Normal Opera haust gas temperature entering the turbocharger tional Range Least Severe Level 2791 EGR Valve Controller Bad Intelligent Device or EGR valve operation will be disabled 12 Component 2791 EGR Valve Controller Out of Calibration EGR valve operation will be disabled 13 2791 EGR Actuator Driver Circuit Root Cause Not The EGR valve will hold the position of the last val 11 Known id J 1939 message 2791 EGR Valve Control Circuit Current Below Normal EGR valve actuation will be
7. 168 Battery 1 Voltage Data Valid but Above Normal Possible electrical damage to all electrical compo 16 Operational Range Moderately Severe Level nents 171 Ambient Air Temperature Sensor 1 Circuit Volt None on performance 3 age Above Normal or Shorted to High Source 171 Ambient Air Temperature Sensor 1 Circuit Volt None on Performance 4 age Below Normal or Shorted to Low Source Engine Oil Temperature High Data Valid but Progressive power derate increasing in severity Above Normal Operational Range Most Severe from time of alert If Engine Protection Shutdown Level feature is enabled engine will shut down 30 sec onds after red STOP lamp starts flashing 175 Engine Oil Temperature Sensor 1 Circuit Voltage No engine protection for engine oil temperature 3 Above Normal or Shorted to High Source 175 Engine Oil Temperature Sensor 1 Circuit Voltage No engine protection for engine oil temperature 4 Below Normal or Shorted to Low Source 190 Engine Crankshaft S peed P osition Data Valid but Fuel injection disabled until engine speed falls be 0 Above Normal Operational Range Most Severe _ low the overspeed limit Level 190 Engine Crankshaft Speed P osition Data Erratic Engine can run rough Possibly poor starting ca 2 Intermittent or Incorrect pability engine runs using backup speed sensor engine power is reduced 251 Real Time Clock Power Interrupt Data Erratic None on performance Data in the
8. EFFECT FMI 27 EGR Valve Position Circuit Voltage Below Nor EGR valve actuation will be disabled 4 mal or Shorted to Low Source a Exhaust Gas Circulation EGR System Condi EGR valve operation will be disabled tion Exists Engine Particulate Trap Inlet Pressure Data Valid None on performance 16 but Above Normal Operational Range Moderately Severe Level Wheel Based Vehicle Speed Data Erratic Inter Engine speed limited Maximum Engine Speed mittent or Incorrect without VSS parameter value Cruise control Geardown Protection and Road Speed Governor will not work Wheel Based Vehicle Speed Sensor Circuit Tam Engine speed limited Maximum Engine Speed pering has been Detected without VSS parameter value Cruise control Geardown Protection and Road Speed Governor will not work 91 Accelerator Pedal or Lever Position Sensor Cir Severe derate in power output of the engine Limp 3 cuit Voltage Below Normal or Shorted to High home power only Source 91 Accelerator Pedal or Lever Position Sensor 1 Cir Severe derate in power output of the engine Limp 4 cuit Voltage Above Normal or Shorted to Low home power only Source 91 Accelerator Pedal or Lever Position Sensor 1 and The engine will only idle 2 2 Data Erratic Intermittent or Incorrect 91 SAE J 1939 Multiplexed Accelerator Pedal or Lever Engine may only idle or engine will not accelerate 19 Sensor System Received Network Dat
9. Hold up the regen switch to the Initiate position for 5 seconds and release Do not move the switch to the Regen Inhibit position Stationary Regen Operation DPF lamp will illuminate for 1 sec and turn off for the duration of regen Engine RPM will rise to 1600 RPM HET lamp will illuminate after approx 3 minutes indicating high exhaust temperature during the regen and remain on until after the exhaust is below the predetermined temp Duration of the regen is 20 40 minutes depending on the level of soot in the DPF When the regen is completed all telltales will be OFF engine RPM will return to idle A Stationary Regen can be disabled by Disabling one or more of the Stationary Regen requirements or Toggle the Regen switch to Inhibit position for 5 seconds or Turn OFF the ignition switch An Active Regen can be disabled by Reducing vehicle speed to below 5 mph Procedure complete Printed in Canada
10. disabled 5 or Open Circuit 2791 EGR Valve Control Circuit Voltage Below Normal EGR valve actuation will be disabled 4 or Shorted to Low Source 2791 EGR Valve Control Circuit Mechanical System EGR valve actuation will be disabled 7 Not Responding Property or Out of Adjustment 2789 Turbocharger Turbine Inlet Temperature Calcu Fuel is limited in an attempt to decrease the calcu 16 lated Data Valid but Above Normal Operational lated exhaust gas temperature entering the turbo Range Moderately Severe Level charger 3050 Catalyst Missing Condition Exists Active aftertreatment diesel particulate filter regen 31 eration will be disabled 3050 Catalyst Efficiency Out of Calibration 13 3050 Catalyst Face Plugged Root Cause Not Known 11 3050 Catalyst Efficiency Out of Calibration 13 3241 Aftertreatment Exhaust Gas Temperature 1 Circuit Active aftertreatment diesel particulate filter regen 3 Voltage Above Normal or Shorted to High eration will be disabled Source 3241 Aftertreatment Exhaust Gas Temperature 1 Data Active aftertreatment diesel particulate filter regen 2 Erratic Intermittent or Incorrect eration will be disabled 3241 Aftertreatment Exhaust Gas Temperature 1 Circuit Active aftertreatment diesel particulate filter regen 4 Voltage Below Normal or Shorted to Low Source eration will be disabled 3241 Aftertreatment Exhaust Gas Temperature 1 Data Active aftertreatm
11. is a six cylinder four stroke right hand rotation high speed high torque diesel engine with exhaust gas recirculation EGR This engine is turbocharged intercooled and electronically controlled by the engine control module ECM COOLANT TEMPERATURE OPERATING RANGE NORMAL OPERATING RANGE 190 F 205 F 87 C 96 C AMBER CHECK ENGINE TELLTALE LAMP ILLUMINATES 216 F 102 C RED STOP ENGINE TELLTALE LAMP ILLUMINATES 226 F 108 C WATER TEMPERATURE GAUGE RED LED LIGHT ILLUMINATES 227 F 108 C ENGINE THERMOSTAT STARTS TO OPEN 180 F 82 C ENGINE THERMOSTAT FULLY OPEN 201 F 94 C DIESEL FUEL NOTE Effective with unit number 64455 as well as 63876 64301 64302 64342 64343 64371 64372 and 64402 engines must must comply with EPA mandated low emission guidelines by using ULSD ultra low sulfur diesel fuel Refer to MCI Service Bulletin 2947 located at www mcicoach com for more information regarding ULSD Failure to use ULSD fuel in 2007 EPA engines will result in component damage LUBRICATION Diesel Engine Lubricating Oils Cummins Diesel ISM engines have an oil capacity of 36 U S qts Diesel engines require heavy duty lubricating oils Basic requirements of such oils are lubricating quality high heat resistance and control of contaminants The only lubricating oil recommended for ISM diesel engines is the CES 20071 or CES 20076 and viscosity grade SAE 15W 40 Synthetic Oils Synthetic oils
12. may be used in Cummins engines provided they are API licensed and meet the performance and chemical requirements of non synthetic oils in the API Category lll and viscosity grade SAE 15W 40 The use of synthetic oil does not extend the oil drain interval recommended by Cummins Table 1 Lubricating Oil Recommended API Service Code SAE Classification Grade 15W 40 Summer 15W 40 Summer 5W 40 Winter 5W 40 Winter CAUTION Effective with unit number 64455 as well as 63876 64301 64302 64342 64343 64371 64372 and 64402 2007 EPA engines mustonly use CJ 4engineoil If the ambient temperature is above 15 F 9 5 C 15W40 oil must be used If the ambient temperature is below 15 F 9 5 C 5W40 must be used Failure to use CJ 4 engine oil in 2007 EPA engines will reduce component life Printed in Canada Service Bulletin No 2969C DATE APR 13 2009 PAGE 3 OO T 0 Figure 1 Cummins ISM engine oil fill and dipstick location COOLANT Power Cool or Power Cool Plus can be used in Cummins ISM engines Before changing or adding coolant to the coach system verify the type of coolant used in the coach Power Cool Plus can be identified by it s red color Power Cool can be identified by it s purple color CAUTION DO NOT mix Power Cool and Power Cool Plus coolant Each contains different inhibitors which are not compatible Mixing coolants will result in component failure SURGE TANK Coaches equip
13. 9 PAGE 20 Figure 12 DPF components Diesel Particulate Filter Pressure Sensor Line Temperature Sensor Electrical Connector Catalyst Module Band Clamps S Outlet Module Support Brace Printed in Canada Service Bulletin No 2969C DATE APR 13 2009 PAGE 21 REGENERATION MCI coaches with an EPA 2007 engine are equipped with three specific tell tales for the regeneration system CHEO MESSAGE ENGINE RIRDR ieri DE BRAKE APPLIED is a KA Figure 13 LH tell tale 1 Regeneration Tell tale Lamp DPF Tell tale illuminates when a regeneration is required Tell tale is OFF during regeneration Figure 14 Regeneration Tell tale Lamp 2 High Exhaust Temperature Tell tale Lamp HET This tell tale will illuminate when the coach is moving less than 5 mph approximately and the exhaust outlet temperature exceeds the predetermined level Figure 15 High Exhaust Temperature Tell tale Lamp 3 Malfunction Indicator Tell tale Lamp MIL on DDC engines ONLY This tell tale indicates a failure of a emission system component on DDC equipped coaches only Figure 16 Malfunction Indicator Tell tale Lamp MIL DDC ONLY Printed in Canada Service Bulletin No 2969C DATE APR 13 2009 PAGE 22 On MCI coaches there are three regeneration modes 1 Passive Regen Normal engine operation provides sufficient exhaust temperature for regen to occur with no noticeable effects to the driver 2 Active Regen
14. ECM will not 2 Intermittent or Incorrect have accurate time and date information 411 Exhaust Gas Recirculation Valve Delta Pressure EGR valve actuation will be disabled 2 Data erratic Intermittent or Incorrect 411 Exhaust Gas Recirculation Valve Delta Pressure EGR valve actuation will be disabled 3 Sensor Circuit Voltage Above Normal or Shorted to High Source 411 Exhaust Gas Recirculation Valve Delta Pressure EGR valve actuation will be disabled 4 Sensor Circuit Voltage Below Normal or Shorted to Low Source 411 Exhaust Gas Recirculation Valve Delta Pressure EGR valve actuation will be disabled 16 Data Valid but Above Normal Operational Range Moderately Severe Level 411 Exhaust Gas Recirculation Valve Delta Pressure EGR valve operation will be disabled 18 Data Valid but Above Normal Operational Range Moderately Severe Level 412 Exhaust Gas Recirculation Temperature Sensor EGR valve actuation will be disabled 3 Circuit Voltage Above Normal or Shorted to High Source 412 Exhaust Gas Recirculation Temperature Sensor EGR valve actuation will be disabled 4 Circuit Voltage Below Normal or Shorted to Low Source 412 Exhaust Gas Recirculation Temperature Data Slight fueling derate to bring EGR temperature un 15 Valid but Above Normal Operational Range Least der the maximum limit Severe Level Printed in Canada Service Bulletin No 2969C DATE APR 13 2009 PAGE 13 Fault Code Information Con
15. a a Gi Service Bulletin No 2969C TYPE SECTION GROUP DATE E J Series Coaches April 13 2009 SveHEGE CUMMINS ISM DIESEL EPA ENGINES CONDITIONS Service Information Only THIS BULLETIN SUPERCEDES FIELD SERVICE BULLETIN 2969 amp 2969B IN THEIR ENTIRETY FIELD SERVICE BULLETIN 2969B WAS REVISED TO REVISION C TO UPDATE THE REGENERATION INFORMATION ON PAGES 22 23 amp 25 Description This service information bulletin will provide customer support documentation for E J series coaches equipped with a Cummins ISM EPA engine Service information contained in this bulletin covers the following items CUMMINS ISM EPA ENGINE General Description Page 2 ULSD Fuel Page 2 Lubrication Page 2 Coolant Page 3 Electronic Engine Control System General Description Page 4 Electronic Engine Control System Components Page 4 Preventive Maintenance Schedule Page 5 Electronic Engine Control System Diagnostics Page 5 Diagnostic Trouble Codes Retrieval Page 6 Diagnostic Trouble Codes Page 9 Torque Chart Page 17 Engine Data Page 17 Specifications Page 18 DIESEL PARTICULATE FILTER General Description Page 19 Regeneration Page 21 Regeneration Tell tale Lamps Page 21 Regeneration Modes Page 22 Regeneration Switch Page 22 Regeneration Strategy Page 25 Check Message Tell tale Page 24 Printed in Canada Service Bulletin No 2969C DATE APR 13 2009 PAGE 2 CUMMINS DIESEL ISM ENGINE GENERAL DESCRIPTION The Cummins Diesel ISM engine
16. a in Error to full speed 97 Water In Fuel Indicator Data Valid but Below Nor Possible white smoke loss of power or hard start 15 mal Operational Range Least Severe Level ing 97 Water in Fuel Indicator Sensor Circuit Voltage None on performance No water in fuel warning 3 Above Normal or Shorted to High Source available 97 Water in Fuel Indicator Sensor Circuit Voltage None on performance No water in fuel warning 4 Below Normal or Shorted to Low Source available 100 Engine Oil Riffle Pressure 1 Sensor Circuit Volt None on performance No engine protection for oil 3 age Above Normal or Shorted to High Source pressure a Engine Oil Riffle Pressure 1 Sensor Circuit Volt None on performance No engine protection for oil age Below Normal or Shorted to Low Source pressure o Engine Oil Riffle Pressure Data Valid but Below Progressive power derate increasing in severity 18 Normal Operational Range Moderately Severe from time of alert Level D Engine Oil Riffle Pressure Data Valid but Below Progressive power derate increasing in severity Normal Operational Range Most Severe Level from time of alert If Engine P rotection Shutdown feature is enabled engine will shut down 30 sec onds after red STOP lamp starts flashing Printed in Canada Service Bulletin No 2969C DATE APR 13 2009 PAGE 10 Fault Code Information Continued J 1939 SPN EFFECT FMI 100 Engine Oil Riffle Pressure Data Err
17. aa each he Nook oh Combination Lubricating Filter LOCO salda dd ds a des Filter Head Mounted LH Side of Coach Fuel Filter Assembly Primary Di a o e dd O Spin On LOCAUON eden tr td id se he He lean Filter Head Mounted RH Side of Coach Fuel Filter Assembly Secondary DESIG ee deat 2 deis Lene anasto i tele ie ng Spin On LOCAHON A a ea ate GG att Filter Head Mounted RH Side of Coach Water Charge Filter Assembly DESIG 3 25 aa ee ante aes arenes Wieden ii Shee ea Spin On A E ages Filter Head Mounted LH Side of Coach Cooling System Capacitan 26 Gal U S 98 4 liters Printed in Canada 18 Service Bulletin No 2969C DATE APR 13 2009 PAGE 19 DIESEL PARTICULATE FILTER GENERAL DESCRIPTION For 2007 vehicles the Environmental Protection Agency EPA requires a 50 reduction in emissions of nitrogen oxides NOx and a 90 reduction in particulate matter PM Oxides of nitrogen are created by the high temperature and speed of combustion Once in the atmosphere NOx results in ground level ozone formation and smog Emission particulates include unburned fuel and lube oil liquid hydrocarbons carbon soot from incomplete combustion main contributor to smoke water from combustion and sulfate from the sulfur in the fuel To comply with these new regulations many changes were made including diesel fuel engine engine oil vehicle design and the exhaust system The new exhaust system treats the engine exhaust and is referred t
18. accumulated ash out of the DPF as needed This will require special tools to flush the ash out of the filter For heavy duty applications the average mileage service interval is estimated to be 150 000 miles The average time service interval is estimated to be from 1 to 1 1 2 years The time to perform this cleaning should be approximately equivalent to the time required for an oil change Diesel Particulate Filter DPF Removal 1 Position the main battery switch to OFF and block the wheels 2 Disconnect the coach wiring harness that connects to the DPF sensor box 3 Remove the clean gas induction pipe from the DPF 4 Remove clamps that secure the inlet and outlet sections to the DPF 5 Slide the outlet module towards the rear of the vehicle approx 2 to allow the diesel particulate filter to be removed NOTE Mark the outlet end of the diesel particulate filter prior to removal for reference during installation 6 Remove the DPF Diesel Particulate Filter Installation 1 Position the diesel particulate filter on the catalyst module making sure that the outlet end of the diesel particulate filter is facing in the right direction 2 Secure the band clamp at the diesel particulate filter and catalyst module Slide the outlet module into the diesel particulate filter and secure the band clamp Torque clamp to 100 in lb 4 Install the clean gas induction pipe w Printed in Canada Service Bulletin No 2969C DATE APR 13 200
19. and possible engine shutdown if en 15 Above Normal Operational Range Least Severe gine protection shutdown feature is enabled Level 111 Coolant Level Sensor 1 Circuit Voltage Above None on performance 3 Normal or Shorted to High Source 111 Coolant Level Sensor 1 Circuit Voltage Below None on performance 4 Normal or Shorted to Low Source 111 Coolant Level Data Valid but Below Normal Op None on performance 18 erational Range Moderately Sever Level 17 Coolant Level Data Valid but Below Normal Op None on PAU O erational Range Least Severe Level a Electrical Charging System Voltage Data Valid Amber warning A illuminated until high battery 16 but Above Normal Operational Range Moderately voltage condition is corrected Severe Level 167 Electrical Charging System Voltage Data Valid Amber lamp will light until low battery voltage con 18 but Below Normal Operational Range Moderate dition is corrected ly Severe Level 167 Electrical Charging System Voltage Data Valid Red lamp illuminated until very low battery voltage 1 but Below Normal Operational Range MostSe condition is corrected vere Level 168 Battery 1 Voltage Data Valid but Below Normal Engine may stop running or be difficult to start 18 Operational Range Moderately Severe Range Printed in Canada Service Bulletin No 2969C DATE APR 13 2009 PAGE 12 Fault Code Information Continued J 1939 SPN EFFECT FMI
20. atic Intermit None on performance No engine protection for oil 2 tent or Incorrect pressure 101 Crankcase Pressure Data Valid but Above Nor None on performance 16 mal Operational Range Moderately Severe Level 101 Crankcase Pressure Data Valid but Above Nor Engine power derate 0 mal Operation Range Most Severe Level 101 Crankcase Pressure Circuit Voltage Above Nor No engine protection for high crankcase pressure 3 mal or Shorted to High Source 101 Crankcase Pressure Circuit Voltage Below Nor No engine protection for high crankcase pressure 4 mal or Shorted to Low Source 101 Crankcase Pressure Data Erratic Intermittent or None on performance 2 Incorrect 101 Crankcase Pressure Data Valid but Above Nor None on performance 15 mal Operational Range Least Severe Level 102 Intake Manifold 1 Pressure Sensor Circuit Volt Derate in power output of the engine 3 age Above Normal or Shorted to High Source 102 Intake Manifold 1 Pressure Sensor Circuit Volt Derate in power output of the engine 4 age Below Normal or Shorted to Low Source 102 Intake Manifold 1 Pressure Data Erratic intermit Engine power derate 2 tent or Incorrect 103 Turbocharger 1 Speed Data Valid but Above Nor Engine power derate to lower the turbocharger 15 mal Operational Range Least Severe Level speed 103 Turbocharger 1 Speed Abnormal Rate of None on performance The ECM uses a
21. ent diesel particulate filter regen 2 Erratic Intermittent or Incorrect eration will be disabled 3241 Catalyst Inlet Temperature Sensor Swapped with _ Active aftertreatment diesel particulate filter regen 31 Outlet Condition Exists eration will be disabled 3245 Aftertreatment Exhaust Gas Temperature 3 Circuit None on performance 3 Voltage Above Normal or Shorted to High Source 3245 Aftertreatment Exhaust Gas Temperature 3 Circuit None on performance 4 Voltage Below Normal or Shorted to Low Source Printed in Canada Service Bulletin No 2969C DATE APR 13 2009 PAGE 17 TORQUE CHART For complete engine specifications refer to the Cummins Diesel Engine Service Manual Torque Value Range EIN EIN NI NES MEAN ass E 3 AE E EI 4 ernianaviratonDameereom E PS eanananrueyeom CR sfoanens AECI AECA 7 E AC ME E AE M E E E MEME AN o ENGINE DATA Tec No of Cylinders A ON Bore Inches Bore mm os O Se nT ICO er 102 Printed in Canada SPECIFICATIONS Cummins ISM 410 HP Engine A AAN 4 cycle Number of GylinGers hi o a Boece teed 6 BOMG ste Sheen vie tore antes e ed ieee es Suda 4 921 inches 125 mm STOKE iii ganesh A seas alate Shaper anced sshd Rat ade hess E A aad eee Auten ala Greeti ant 5 787 inches 147 mm cl A E padres 661 in 3 10 8 L Rated Full Load Sped iira e naa a A ea see ad Pee eae ie ane oe 2100 RPM Oil Filter Assembly E A epee eR ie ad eh he Ndi
22. er 30 seconds The operator can delay shutdown for 30 seconds by pressing the override switch The override can be activated as often as required If the fault was temporary the telltales go out and normal operation resumes A fault code is logged in memory until the memory is cleared The memory can be cleared with a diagnostic data reader Printed in Canada Service Bulletin No 2969C DATE APR 13 2009 PAGE 6 DIAGNOSTIC TROUBLE CODE RETRIEVAL NOTE Effective with unit number 64455 as well as 63876 64301 64302 64342 64343 64371 64372 and 64402 engine diagnostic trouble codes are indicated through the alphanumeric display located at the bottom of the speedometer The yellow Check Engine and red Stop Engine tell tale lights no longer indicate engine codes Engine Code Retrieval The alphanumeric display located at the bottom of the speedometer displays the diagnostic trouble codes Figure 3 The diagnostic trouble codes are displayed as J1939 SPN FMI codes A maximum of five codes can be listed at one time These codes are logged in the ECM with the most severe or recent code listed first The MODE switch allows the driver to scroll through active system messages when the coach is at a complete stop Pressing the SET switch will not clear the diagnostic trouble codes Record all codes Engine Code Example 27 4 EGR Valve Position Circuit Voltage Below Normal or Shorted to Low Source Source Code 0 Engine P
23. hen keyswitch is in OFF position 639 SAE J 1939 Multiplexing PGN Timeout Error Abnor One or more multiplexed devices will not operate 9 mal Update Rate properly One or more symptoms will occur 639 SAE J 1939 Multiplexing Configuration Error Out Atleast one multiplexed device will not operate 13 of Calibration properly MEN 1939 Datalink Abnormal Update Rate Engine speed will ramp down and remain at idle 9 641 VGT Actuator Driver Over Temperature Calcu None on performance 15 lated Data Valid but Above Normal Operational Range Least Severe Level 641 VGT Actuator Driver Circuit Root Cause Not VGT actuation will be disabled 11 Known 641 VGT Actuator Driver Circuit Motor Mechanical VGT travel may be limited 7 System Not Responding Properly or Out of Adjust ment 641 VGT Actuator Controller Bad Intelligent Device or VGT actuation will be disabled 12 Component VGT Actuator Driver Circuit Condition Exists VGT actuation will be disabled 31 641 VGT Actuator Driver Circuit Abnormal Update Active aftertreatment diesel particulate filter regen 9 Rate eration will be disabled VGT Actuator Controller Out of Calibration Low intake manifold pressure 13 Printed in Canada Service Bulletin No 2969C DATE APR 13 2009 PAGE 14 Fault Code Information Continued J 1939 SPN EFFECT FMI 647 Fan Control Circuit Voltage Below Normal or The fan can possibly stay on continuously or not
24. nd esti 10 Change mated turbocharger speed 103 Turbocharger 1 Speed Data Erratic Intermittent None on performance The ECM uses an esti 2 or Incorrect mated turbocharger speed 103 Turbocharger 1 Speed Data Valid but Below Nor Engine power derate The ECM uses an estimated 18 mal Operational Range Moderately Severe Level turbocharger speed 105 Intake Manifold 1 Temperature Sensor Circuit Possible white smoke Fan will stay ON if con 3 Voltage Above Normal or Shorted to High Source trolled by ECM No engine protection for engine coolant temperature 105 Intake Manifold 1 Temperature Sensor Circuit Possible white smoke Fan will stay ON if con 4 Voltage Below Normal or Shorted to Low Source trolled by ECM No engine protection for engine coolant temperature 105 Intake Manifold 1 Temperature Data Valid but Progressive power derate increasing in severity 15 Above Normal Operational Range Least Severe from time of alert Level 0 105 Intake Manifold 1 Temperature Data Valid but Progressive power derate increasing in severity Above Normal Operational Range MostSevere from time of alert If Engine Protection Shutdown Level feature is enabled engine will shut down 30 sec onds after red STOP lamp starts flashing Printed in Canada Service Bulletin No 2969C DATE APR 13 2009 PAGE 11 Fault Code Information Continued J 1939 SPN EFFECT FMI 108 Barometric Pressure Sensor Ci
25. ny the message m ey Lact FIGURE 18 LH Tell tale Cluster Move the coach to a safe parking area to view the message displayed on the alphanumeric display of speedometer After the message has been recorded the operator can press the SET button RH side of the speedometer to dismiss the message The CHECK MESSAGE tell tale will remain illuminated but the message will not appear until the system re broadcasts the signal FIGURE 19 Speedometer alphanumeric display The tell tale information displayed on the alphanumeric display of speedometer are Lavatory Emergency displayed as LAVTORY and Baggage Lights BAG LTS Printed in Canada Service Bulletin No 2969C DATE APR 13 2009 PAGE 25 ENGINE SPECIFIC REGENERATION STRATEGY CUMMINS ISM Before a parked or stationary regen can occur these required functions must occur The DPF tell tale lamp illuminated solid or flashing Locate the transmission push button shift selector While making a service brake application cycle the push button shift selector by pressing NEUTRAL DRIVE NEUTRAL NEUTRAL selected on the transmission push button shift selector Locate the park brake While making a service brake application cycle the Park Brake ON OFF ON Park brake is applied The HVAC system is OFF Vehicle speed is O MPH Engine running at idle speed Not fast idle Service brake released DOC inlet air temp gt 300 degrees F 149 degrees C
26. o as an aftertreatment system The main components of the Aftertreatment System consist of the turbo pipe Diesel Oxidation Catalyst DOC Diesel Particulate Filter DPF sensors and wiring The new exhaust system components in general are more fragile complex and larger A muffler is no longer needed because the DPF effectively replaces the muffler The DPF is a porous ceramic filter housed in stainless steel chamber Flow requirements force the inlet and outlet to be on opposite ends As the exhaust flows through this filter emission products are burned and converted to ash The aftertreatment system monitors the efficiency of the DPF A self cleaning function called regeneration is used to keep the DPF functioning properly between regular ash clean out maintenance intervals which must be performed by Service Technicians An optimal DPF size was chosen for low backpressure and to maximize ash storage capacity between periodic cleaning Regeneration MCI coaches with an EPA 2007 engine are equipped with a DPF system The ECM monitors engine and after treatment temperature and pressure sensors to determine when a regeneration of the DPF is required The DPF collects soot and the engine oil in the exhaust system The regeneration process converts soot into gas and engine oil into ash Residual ash from the engine oil remains in the DPF until the DPF is cleaned Cleaning A Service Technician must perform a cleaning procedure to clean the
27. ped with Cummins ISM engines have a new designed surge tank installation with an increased rad cap pressure of 15 psi CAUTION DO NOT interchange a radiator cap without verifying that the replacement cap is rated for 15 psi Service Cooling m Fan Fuel Primin Starter Pump Control Engine Printed in Canada Service Bulletin No 2969C DATE APR 13 2009 PAGE 4 ELECTRONIC ENGINE CONTROL SYSTEM GENERAL DESCRIPTION The electric engine control system receives processes and stores information from sensors located throughout the engine and related components The electronic engine control system has protection circuits that reduce power and shut the engine down under potentially damaging conditions such as low oil pressure low coolant level or high engine temperature The electronic engine control system is self diagnostic and warns the operator of fault conditions and potential problems by lighting telltales Fault codes that identify failed components are logged into the system s ECM memory for readout by maintenance personnel COMPONENTS Electronic Control Module ECM The electronic control module is the microprocessor controlled electronic monitoring and storage unit for the engine control system The ECM can identify problem conditions within the engine by comparing input from the various sensors to a set of parameters calibration and design data stored within the ECM After processing the input the ECM sends high c
28. rcuit Voltage Engine power derate 3 Above Normal or Shorted to High Source 108 Barometric Pressure Sensor Circuit Voltage Be Engine power derate 4 low Normal or Shorted to Low Source 108 Barometric Pressure Data Erratic Intermittent or Engine power derate 2 Incorrect 110 Engine Coolant Temperature 1 Sensor Circuit Possible white smoke Fan will stay ON if con 3 Voltage Above Normal or Shorted to High Source trolled by ECM No engine protection for engine coolant temperature 110 Engine Coolant Temperature 1 Sensor Circuit Possible white smoke Fan will stay ON if con 4 Voltage Below Normal or Shorted to Low Source trolled by ECM No engine protection for engine coolant temperature 110 Engine Oil Riffle Pressure Data Valid but Above _ Power derate and possible engine shutdown If 16 Normal Operational Range Moderately Severe Engine Protection Shutdown feature is enabled Level Engine Coolant Temperature Data Valid but Progressive power derate increasing in severity Above Normal Operational Range Mose Severe from time of alert If Engine Protection Shutdown Level feature is enabled engine will shut down 30 sec onds after red STOP lamp starts flashing Engine Coolant Temperature Conditions Exists EGR valve actuation will be disabled 31 Engine Coolant Temperature Condition Exists EGR valve actuation will be disabled 31 110 Engine Coolant Temperature Data Valid but Power derate
29. ssibly 5 Below Normal or Open Circuit misfire or run rough 656 Injector S olenoid Driver Cylinder 6 Circuit Current Current to injector is shut off Engine can possibly 5 Below Normal or Open Circuit misfire or run rough 656 Injector Solenoid Driver Cylinder 6 Circuit Current Current to injector is shut off Engine can possible 6 Above Normal or Grounded Circuit misfire or run rough 662 Injector S olenoid Driver Cylinder 2 Circuit Current Current to injector is shut off Engine can possible 6 Above Normal or Grounded Circuit misfire or run rough 677 Starter Relay Driver Circuit Voltage Above Nor Either the engine will not start or the engine will not 3 mal or Shorted to High Source have starter lockout protection 677 Starter Relay Driver Circuit Voltage Below Nor The engine will not have starter lockout protection 4 mal or Shorted to Low Source 723 Engine Camshaft S peed P osition Sensor Data Engine can run rough Possible poor starting ca 2 Erratic Intermittent or Incorrect pability Engine runs using primary engine position sensor 974 Remote Accelerator Pedal or Lever Position Sen Remote accelerator will not operate Remote ac 3 sor 1 Circuit Voltage Above Normal or Shorted to celerator position will be set to zero percent High Source 974 Remote Accelerator Pedal or Lever Position Sen Remote accelerator will not operate Remote ac 4 sorl Circuit Voltage Below Normal or Shorted
30. tinued J 1939 SPN EFFECT FMI 412 Exhaust Gas Recirculation Temperature Data Severe fueling derate to bring EGR temperature 16 Valid but Above Normal Operational Range Mod under the maximum limit erately Severe Level on Engine Magnetic Speed P osition Lost Both of Two None on A Data Erratic Intermittent or Incorrect aa Start Enable Device 1 Circuit Ether Injection Ether start ii a will be disabled 3 Voltage Above Normal or Pa to High Source 626 Start Enable Device 1 Circuit Ether Injection Ether start functionality will be disabled 4 Voltage Below Normal or Shorted to Low Source 627 Injector Power Supply Bad Intelligent Device or Possible low power engine misfire and or engine 12 Component will not start 627 Power Supply Lost With Ignition On Data Erratic Possible no noticeable performance effects or en 2 Intermittent or Incorrect gine dying or hard starting Fault information trip information and maintenance monitor data can be inaccurate 629 Electronic Control Module Critical Internal Failure Engine may not start 12 Bad Intelligent Device or Component 632 Engine Fuel Shutoff Valve Driver Circuit Voltage Fuel shutoff valve will close Engine will shutdown 4 Below Normal or Shorted to Low Source 632 Engine Fuel Shutoff Valve Driver Circuit Voltage Fuel shutoff valve may not open when keyswitch is 3 Above Normal or Shorted to High Source in ON position or may not close w
31. to celerator position will be set at zero percent Low Source 974 SAE J 1939 Multiplexing Remote Accelerator Ped The engine will not respond to the remote throttle 19 al or Lever Position Sensor System Received Engine may only idle The primary or cab acceler Network Data in Error ator may be able to be used 1072 Engine Brakes Actuator Driver 1 Circuit Voltage Engine brake on cylinders 1 2 and 3 can be on all 3 Above Normal or Shorted to High Source the time or can not be activated Printed in Canada Service Bulletin No 2969C DATE APR 13 2009 PAGE 15 Fault Code Information Continued J 1939 SPN EFFECT FMI 1072 Engine Brakes Actuator Driver 1 Circuit Voltage Engine brake on cylinders 1 2 and 3 can not be 4 Above Below or Shorted to Low Source activated 1073 Engine Brake Actuator Driver Output 2 Circuit Engine brakes on cylinders Number 4 5 and 6 4 Voltage Below Normal or Shorted to Low Source can not be activated 1073 Engine Brake Actuator Driver Output 2 Circuit Engine brakes on cylinders Number 4 5 and 6 3 Voltage Above Normal or Shorted to High Source can not be deactivated or can not be activated 1136 ECM Internal Temperature Sensor Circuit Volt None on performance 3 age Above Normal or Shorted to High Source 1136 ECM Internal Temperature Sensor Circuit Volt None on performance 4 age Below Normal or Shorted to Low Source 1172 Turbocharger 1 Compressor Inlet Tempera
32. ture Engine power derate 3 Sensor Circuit Voltage Above Normal 1172 Turbocharger 1 Compressor Inlet Temperature Engine power derate 4 Sensor Circuit Voltage Below Normal or Shorted to Low Source 1209 Exhaust Gas Pressure Sensor Circuit Voltage None on performance 3 Above Normal or Shorted to Low Source 1209 Exhaust Gas Pressure Sensor Circuit Voltage None on performance 4 Below Normal or Shorted to Low Source 1209 Exhaust Gas Pressure Data Erratic Intermittent The ECM will estimate the exhaust gas pressure 2 or Incorrect 1209 Exhaust Gas Pressure Data Valid but Above Nor Fueling derate to bring exhaust gas pressure below 16 mal Operational Range Moderately Severe Level the maximum operating limits 1267 Idle Shutdown Vehicle Accessories Relay Driver Vehicle accessories or ignition bus loads controlled 3 Circuit Voltage Above Normal or Shorted to High by the idle shutdown relay will not power up Source 1267 Idle Shutdown Vehicle Accessories Relay Driver Vehicle accessories or ignition bus loads controlled 4 Circuit Voltage Below Normal or Shorted to Low by the idle shutdown relay will not power up Source 1378 Engine Oil Change Interval Condition Exists Maintenance reminder only 31 1590 Adaptive Cruise Control Mode Data Erratic Inter Adaptive cruise control will not operate Standard 2 mittent or Incorrect cruise control may not operate 1639 Fan Speed Data Erratic Intermittent
33. urrent command pulses to the injector solenoids to initiate fuel injection The ECM also receives feedback regarding the start and end of injection for a given cylinder NOTE There are no user serviceable parts within the ECM The ECM is factory programmed for a specific engine transmission tire size and axle ratio combination Electronic Unit Injectors EUI Electronic unit injectors are electronically controlled fuel injectors They are mounted into the cylinder heads above each cylinder The solenoid operated poppet valve on each EUI performs injection timing and fuel metering functions Throttle Position Sensor TPS The throttle position sensor is located in the electronic foot pedal assembly The TPS converts the throttle position into a signal for the ECM Turbocharged Boost Sensor TBS The turbocharged boost sensor is located between the turbocharger discharge waste gate and the blower The TBS monitors turbocharger compressor discharge pressure Oil Pressure Sensor OPS The oil pressure sensor is located at the rear RH side of the engine block The OPS monitors oil pressure in the engine If engine oil pressure falls below the specified minimum the ECM lights the CHECK ENGINE and or STOP ENGINE telltales The ECM initiates the engine protection shutdown sequence Oil Temperature Sensor OTS The oil temperature sensor is located in the engine oil gallery at rear RH side of the engine block Coolant Temperature Sensor CTS
34. very 6000 miles 9600 km 500 hours or 3 months Change coolant filter every 150 000 miles 240 000 km 4000 hours or 1 year DIAGNOSTICS The ISM electronic engine control system s diagnostics feature can be separated into three areas engine performance diagnostics self diagnostics and engine protection Engine Performance Diagnostics The system continuously monitors sensors and makes adjustments to the injector timing and fuel quantity input This provides optimum performance and minimal acceleration smoke under all operating conditions Cold weather starting is improved by matching the fuel input and timing to the ambient air temperature System Self Diagnostics The system continually monitors itself and all related wiring for faults If a fault is detected the CHECK ENGINE and or STOP ENGINE telltales light If the fault is in the main microprocessor a backup microprocessor takes control When the system is under the control of the backup microprocessor the engine continues to work normally A generic set of calibration data is substituted which may degrade engine performance Auxiliary features that remain operational during backup mode are the engine protection feature and accessory equipment pulse width modulation Engine Protection When the engine protection feature is initiated the check engine and stop engine telltales light A fault code is logged into the ECM s memory and the engine is rapidly derated until it shuts down aft

Service Bulletin No.2969C

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