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 Service Manual.pdf”
Workhorse Custom Chassis (Motorhome and Commercial Chassis) Electronic Service Manual ’99-'03 + Wiring; 8,512 pages

“'04-'05 Service Manual Supplement.pdf”
Workhorse Custom Chassis (Motorhome and Commercial Chassis) Electronic Service Manual Supplement '04-'05; 1,625 pages

“'04 Electrical Schematics”

“'05 Electrical Schematics”

EXCERPT:
Engine
Engine Mechanical - 4.8L and 6.0L
Camshaft Bearing Installation
Tools Required
J 33049 Camshaft Bearing Service Set
Important: The engine block camshaft bearing bores are machined for 3 different outside diameter (OD) size bearings. Positions 1 and 5 are the largest diameter bores. Position 3 is the smallest diameter bore. Positions 2 and 4 are the intermediate size bores. The inside diameter (ID) for all camshaft bearings is the same size.
1. Measure the engine block camshaft bearing bores (1–5) to identify the correct OD size bearing for each position. Refer to Engine Mechanical Specifications (LR4 VIN V) or Engine Mechanical Specifications (LQ4 VIN U).
2. Select the expanding driver (4–8) and washer (2 or 3) from the J 33049. Refer to Camshaft Bearing Removal.
3. Assemble the tool.
4. Insert the tool through the front of the engine block and into the bearing.
5. Tighten the expander assembly nut until snug.
6. Push the guide cone into the front camshaft bearing to align the tool.
7. Drive the bearing into the block bore.
8. Repeat the above procedures to install the remaining bearings.
Timing Chain and Sprockets Cleaning and Inspection
1. Clean the components with cleaning solvent.
Caution: Refer to Safety Glasses Caution in Cautions and Notices.
2. Dry the components with compressed air. 3. Inspect the timing chain for binding or wear.
…

'04 Electrical Schematics................2
  FE20-L18................3
  P32-L18................64
  P32-L31................122
  P42-L31................148
  P42-L35................200
  P42-L4B................247
  P42-L57................304
  P42-LQ4-LR4................356
  P42-LU3................411
  W22-L18................458
  W24-L18................513
  W52-L18................576
'04-'05 Service Manual Supplement................631
  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................902
          Untitled................902
      Cummins ISB4 Electronic Tech Package.pdf................0
        Cummins Inc. 1460 National Road Columbus, Indiana 47201................1756
          This document, and the information herein, is CONFIDENTIAL and PROPRIETARY, and shall not be disc...................1756
            1.1 TECHNICAL PACKAGE INTRODUCTION................1762
            1.2 About the ISB4/ISBE engines................1762
            1.3 AUTOMOTIVE FEATURES................1762
            2.1 ACCELERATOR INTERLOCK................1764
            2.2 AUXILIARY PROTECTION SYSTEM................1764
            2.3 BATTERY VOLTAGE MONITOR................1764
            2.4 CAB SWITCHABLE GOVERNOR................1764
            2.5 CRUISE CONTROL................1764
            2.6 CRUISE CONTROL GOVERNOR TAILORING................1765
            2.7 DIAGNOSTICS................1765
              2.7.1 ON BOARD DIAGNOSTICS................1765
              2.7.2 Offboard Diagnostics................1765
            2.8 ENGINE PROTECTION SYSTEM................1766
              2.8.1 Torque Derate................1766
              2.8.2 Speed Derate................1766
              2.8.3 Engine Protection Shutdown................1766
            2.9 ENGINE WARM-UP PROTECTION................1766
            2.10 EXHAUST BRAKE................1766
              2.10.1 Exhaust Brake/Cruise Control Interaction................1767
              2.10.2 Exhaust Brake / Automatic Transmission Interaction................1767
              2.10.3 Exhaust Brake / Driveline Retarder................1767
            2.11 FAN CLUTCH CONTROL................1767
            2.12 GEAR DOWN PROTECTION................1768
            2.13 FUEL HEATER CONTROL................1768
            2.14 GRID HEATER CONTROLS................1768
            2.15 IDLE SHUTDOWN................1769
            2.16 INFORMATION LOG................1769
            2.17 KEY SWITCH ON................1770
            2.18 Limp Home Throttle Operation................1770
            2.19 LOW IDLE SPEED ADJUSTABILITY................1771
            2.20 MAINTENANCE MONITOR................1771
            2.21 MULTILEVEL SECURITY................1771
            2.22 POWER TAKEOFF (PTO) GOVERNOR................1772
            2.23 POWER TRAIN PROTECTION................1775
            2.24 REMOTE THROTTLE................1776
            2.25 ROAD SPEED GOVERNOR................1777
              2.25.1 Smart RSG................1777
              2.25.2 RSG Increment / Decrement Values................1777
              2.25.3 Switched RSG................1777
              2.25.4 RSG ‘Set’................1777
              2.25.5 Kick-down Throttle................1777
              2.25.6 Switched RSG Low Speed Application................1778
            2.26 STARTER LOCKOUT................1778
            2.27 SWITCHED MAX OPERATING SPEEDS................1778
              2.27.1 Two Position Switch................1778
            2.28 TACHOGRAPH (ISBe)................1778
            2.29 TACHOMETER OUTPUTS................1778
            2.30 TRANSMISSION SHIFT MODULATION (Analog Torque) LOAD SIGNAL................1778
            2.31 TWO SPEED AXLE (Rear Axle Ratio)................1778
            2.32 VEHICLE ACCELERATION RATE LIMITER (Rate Management)................1779
            2.33 VEHICLE ANTI-THEFT PROTECTION................1779
            2.34 VEHICLE SPEED SENSOR (VSS) ANTI - TAMPERING................1779
            2.35 WATER-IN-FUEL WARNING................1779
            3.1 ELECTRIC CONTROL MODULE................1781
              Figure 3-1: Electronic Control Module................1782
            3.2 HARNESSES................1782
            3.3 ENGINE POSITION SENSOR................1782
            3.4 ENGINE SPEED SENSOR................1782
            3.5 INTAKE MANIFOLD pressure/AIR TEMPERATURE SENSOR................1782
            3.6 COOLANT TEMPERATURE SENSOR................1783
            3.7 OIL PRESSURE/TEMPERATURE SENSOR (OPTIONAL)................1783
            3.8 Oil Pressure switch................1783
            3.9 RAIL PRESSURE SENSOR................1783
            3.10 AMBIENT AIR PRESSURE SENSOR................1783
            3.11 FUEL TEMPERATURE SENSOR (pre MY04 engines)................1783
            3.12 OEM COMPONENTS................1783
            3.13 CONTACTS and CONNECTORS................1783
            3.14 OEM HARNESS and HARNESS ROUTING................1784
            3.15 VEHICLE KEY SWITCH................1784
            3.16 VEHICLE SPEED SENSOR................1785
            3.17 TACHOGRAPH INPUT (ISBe)................1785
            3.18 OEM TEMPERATURE SENSOR................1785
            3.19 OEM PRESSURE SENSOR................1785
            3.20 STARTER LOCKOUT RELAY................1786
            3.21 TACHOMETER INTERFACE................1786
              3.21.1 High Side................1786
              3.21.2 Low Side................1786
            3.22 ACCELERATOR PEDAL ASSEMBLY................1786
              3.22.1 Throttle Pedal with Idle Validation switches................1786
              3.22.2 Dual Potentiometer Throttle Pedal (MY04 and beyond)................1786
            3.23 EXHAUST BRAKE Control................1787
              3.23.1 Exhaust Brake Wiring with Manual Transmissions................1787
                Figure 3-2: Exhaust Brake Wiring with Manual Transmission................1787
              3.23.2 Exhaust Brake Wiring with Allison AT, MT Transmissions................1787
                Figure 3-3: Exhaust Brake Wiring w/Allison AT & MT Transmission or other Non-Electronic Transmiss...................1787
              3.23.3 Exhaust Brake Wiring with Allison MD Transmission................1788
                Figure 3-4: Exhaust Brake Wiring w/Allison MD Transmission................1788
              3.23.4 Typical rewire Installation of Vehicle Exhaust Brake Systems connecting to the Allison MD ...................1788
            3.24 DRIVELINE RETARDER CONTROL................1789
            3.25 REMOTE THROTTLE ASSEMBLY................1789
            3.26 TRANSMISSION SHIFT MODULATION SIGNAL................1790
              Table 3-1: Transmission Shift Modulation Signals................1790
            3.27 COOLANT LEVEL SENSOR................1790
            3.28 WATER IN FUEL SENSOR................1791
              Table 3-2: WIF Sensor Performance Requirements................1791
            3.29 FUEL HEATER INTERFACE................1791
              Figure 3-5: Fuel Heater Electrical Connections................1791
              Table 3-3: 12 and 24 Volt Fuel Heater Details................1791
            3.30 GRID - INTAKE AIR HEATER RELAYS................1791
              Table 3-4: Grid Heater Electrical Connection Table................1792
                Figure 3-6: Grid Heater Electrical Connections................1793
                Figure 3-7: Grid Heater Systems Layout................1793
            3.31 SERVICE BRAKE SWITCH................1794
            3.32 Parking Brake Switch................1794
            3.33 CLUTCH PEDAL SWITCH................1794
            3.34 CRUISE CONTROL / PTO SWITCHES................1794
              3.34.1 Cruise / PTO - On/Off Switch................1794
              3.34.2 Cruise / PTO - Set-Resume Switches................1794
        3.34.2.1 Vehicle in Cruise................1794
        3.34.2.2 Vehicle in PTO................1795
        3.34.2.3 Cruise Control Switch Reconfiguration................1795
          3.35 DIAGNOSTIC TEST SWITCH................1795
          3.36 Idle/Diagnostic Increment/Decrement Switch................1795
          3.37 Fan Clutch Interface................1795
            3.37.1 Manual Override Fan Clutch Switch................1796
            3.37.2 Air Conditioner Pressure Switch................1796
          3.38 accelerator Interlock Switch................1796
          3.39 Two Speed Axle Switch................1796
          3.40 Cab Switchable Governor Switch................1796
          3.41 Powertrain Protection Torque Limit Switch................1796
          3.42 SWITCHED MAX OPERATING SPEEDS................1796
            Table 3-5: Voltages at B89.................1797
          3.43 Switched RSG................1797
          3.44 Engine Protection Override Switch................1797
          3.45 INDICATOR LAMPS................1797
          3.46 Data Links................1797
            3.46.1 J1939 Data Links................1797
            3.46.2 J1939 Data-link Backbone................1797
              Figure 3-8: OEM supplied J1939 backbone harness................1798
            3.46.3 J1587 Data-link................1798
          3.48 OTHER RECOMMENDATIONS................1799
            3.48.1 ECM to Vehicle Connection Procedure................1799
            3.48.2 Data Link Device Power Connections................1799
            3.48.3 Vehicle Welding Recommendations................1799
            3.48.4 Engine Painting Recommendations................1799
            3.48.5 Engine Jump Start Recommendations................1799
            3.48.6 Vehicle Battery Disconnection Recommendations................1800
              Table 3-6: CM800 Output Current Capabilities................1800
          4.1 ELECTRICAL WIRING................1801
            4.1.1 OEM & Engine Wiring Harnesses................1801
              Figure 4-1: Legend for Wiring Diagram................1801
              Figure 4-2: ISB4/ISBE Wiring Diagram (OEM Connector B)................1802
              Figure 4-3: ISB4/ISBe Wiring Diagram (Connectors C and A)................1803
              Figure 4-4: 4 Cylinder Engine Harness................1804
              Figure 4-5: 4 Cylinder Engine Harness Schematic................1805
              Table 4-1: 4 Cylinder Engine Harness Connection List................1806
                Figure 4-6: 6 Cylinder Engine Harness................1808
                Figure 4-7: 6 Cylinder Wiring Schematic................1809
                Figure 4-8: Sample ISB4/ISBE OEM DATALINK Harness Section................1812
              Table 4-3: Current Usage................1812
          4.2 PARTS LIST FOR OEM HARNESS INTERFACES TO ENGINE CONTROLLER................1813
          4.3 ISB4/ISBe Engine Pins................1814
            Table 4-4: ISB4/ISBE Engine A Connector................1814
            Table 4-5: ISB4/ISBE Engine B Connector................1815
            Table 4-6: ISB4/ISBe Engine C Connector................1818
          5.1 CONNECTORS................1819
            5.1.1 OEM Connector................1819
              Figure 5-1: OEM Connector................1819
            5.1.2 Fan Clutch Connector................1821
              Figure 5-2: Fan Clutch Connector................1821
            5.1.3 Fuel Heater Connector................1823
              Figure 5-3: Fuel Heater Connector................1823
            5.1.4 Coolant Level Connector................1825
              Figure 2-4 Coolant Level Connector................1825
            5.1.5 J1939 Tool Connector................1827
              Figure 5-5: J1939 Tool Connector................1827
              Table 5-1: J1939 Tool Connector Part List................1828
            5.1.6 9 PIN Datalink Tool Connector................1829
              Figure 5-6: 9 PIN Datalink Tool Connector................1829
              Table 5-2: 9-Pin J1939 Datalink Connector Parts List................1829
          5.2 SENSORS................1831
            5.2.1 Vehicle Speed Sensor (Variable Reluctance Magnetic Pickup)................1831
              Figure 5-7: Vehicle Speed Sensor................1831
          5.3 PRESSURE SWITCHES................1833
            5.3.1 Brake Switch................1833
              Figure 5-8: Pressure Switch................1833
          5.4 SWITCHES AND SWITCH ASSEMBLIES................1835
            5.4.1 Rotary Clutch Switch Assembly................1835
              Figure 5-9: Rotary Clutch Assembly................1835
            5.4.2 Optional Levered Clutch or Brake Switch................1837
              Figure 5-10: Optional Levered Clutch or Brake Switch................1837
            5.4.3 Optional Clutch or Brake Switch................1839
              Figure 5-11: Optional Clutch or Brake Switch................1839
            5.4.4 Toggle Switches................1841
              Figure 5-12: Toggle Switches................1841
            5.4.5 Radiator Coolant Level Switch................1843
              Figure 5-13: Radiator Coolant Level Switch................1843
            5.4.6 Remote Throttle/Remote PTO Switch................1845
          5.5 LAMPS................1847
            5.5.1 Fault Lamps................1847
          5.6 Relays and Relay Assemblies................1848
            5.6.1 Grid Heater Power Relays................1848
              Figure 5-14: High Power Relay (Note: Drawing shown for form features only.)................1848
            5.6.2 Fuel Heater Relay................1849
              Figure 5-15: Fuel Heater Relay................1849
          5.7 COMPONENT SOURCES................1850
          5.8 ELECTRONIC THROTTLE INTERFACE, CES 14118................1851
          5.9 MIDRANGE ACCELERATOR PEDAL ASSEMBLY INSTALLATION RECOMMENDATIONS................1851
            5.9.1 Introduction................1851
          6.1 ONBOARD DIAGNOSTICS................1852
            6.1.1 Fault Detection................1852
            6.1.2 Flash Out of Fault Codes................1852
          6.2 OFFBOARD DIAGNOSTICS................1852
            6.2.1 Fault Information Management................1852
        6.2.1.1 Display Fault Codes and Fault Information................1852
        6.2.1.2 Erase Fault Codes................1853
        6.2.1.3 Save Fault Codes and Data................1853
          6.2.2 Monitor Mode................1853
          6.2.3 ECM Data Plate Information................1854
            Table 6-1: Minimum Required Data Plate Layout................1854
          6.2.4 Performance Tests................1856
          6.2.5 Special Functions................1856
          6.2.6 INSITE and ECM Security................1857
        6.2.6.1 Password Security................1857
        6.2.6.2 Multi-Level Security................1857
          6.2.7 Fault Information System (FIS)................1858
            Figure 6-1. Service Tools for ISB4/ISBE Engines................1858
          7.1 Introduction................1859
            7.1.1 Hardware Implementation................1860
          7.2 J1587 SERIAL COMMUNICATIONS................1860
            7.2.1 Introduction................1860
            7.2.2 Message Priority................1860
            7.2.3 Communications Requests................1860
        7.2.3.1 Data Requests................1860
        7.2.3.2 Broadcasts................1860
        7.2.3.3 Data Writes................1860
          7.2.4 Integrity................1861
        7.2.4.1 Error Detection................1861
        7.2.4.2 Collision Avoidance................1861
          7.2.5 Operational Notes................1861
        7.2.5.1 Packing PIDs and Data................1861
        7.2.5.2 Normal Data Transfer................1861
        7.2.5.3 Bus Utilization................1861
        7.2.5.4 Message Identifier Usage................1863
          7.2.6 More Detail on PIDs................1863
        7.2.6.1 PID 2 - Status Word 1................1863
        7.2.6.2 PID 3 - Diagnostic Status................1863
        7.2.6.3 PID 193 - Diagnostic Table................1863
        7.2.6.4 PID 194 - Transmitter System Diagnostic Code and Occurrence Count Table................1864
        7.2.6.5 PID 243 - Component Identification................1867
        7.2.7 Bus Utilization for J1587 Standard Broadcast Data................1867
        7.2.8 Assumptions and Definitions For FMIs................1868
          Table 7-1: PIDs Supported on J1587................1869
          Table 7-2: J1587 Parameter Specifications................1870
          Table 7-3: Available Authorized Data Writes................1871
        7.3.1 Introduction................1872
          7.3.2 Hardware Implementation................1872
          7.3.3 Messages Supported on J1939................1872
            Table 7-4: Messages Supported on J1939................1873
          7.4 Fault Codes................1883
            Table 7-5: FAULT CODES FOR ISB4/ISBe ENGINES................1883
          8.1 Temperature Resistance................1894
            8.1.1 Operating - High Temperature................1894
            8.1.2 Non-operational Storage Temperature................1894
            8.1.3 Operating - Low Temperature................1894
          8.2 Climate and Chemical Resistance................1894
            8.2.1 Humidity................1894
            8.2.2 Industrial Climates................1894
            8.2.3 Salt Mist................1894
            8.2.4 Chemical Resistance................1894
          8.3 Mechanical Resistance................1895
            8.3.1 Vibration................1895
              Figure 8-1: Summary of Vibration................1896
            8.3.2 Mechanical Shock................1896
          8.4 Protection against Water / Dust Ingress................1896
          8.5 Harness Length / Impedance................1896
          8.6 Harness attachment................1896
          9.1 Electronic Components Environment................1897
            Table 9:1 Environmental, Mechanical, Electrical Ranges................1897
              Figure 9-1: Electronic Control Module................1898
              Figure 9-2: Close up of ECM Label................1899
            Table 9:2 Vibration Break Points - All Axes................1900
              Figure 9-3: Inductive Load Switching #1................1900
            Table 9:3 Inductive Load Switching #1................1901
              Figure 9-4: Inductive Load Switching #2................1901
            Table 9:4 Inductive Load Switching #2................1901
            Table 9:5 Inductive Key Off Switching #1................1902
              Figure 9-5: Inductive Key Off Switching #1................1902
              Figure 9-6: Inductive Key Off Switching #2................1903
            Table 9:6 Inductive Key Off Switching #2................1903
              Figure 9-7: Switching Spikes #1................1904
            Table 9:7 Switching Spikes #1................1904
              Figure 9-8: Switching Spikes #2................1905
            Table 9:8 Switching Spikes #2................1905
              Figure 9-9: Mutual Coupling................1906
            Table 9:9 Mutual Coupling................1906
              Figure 9-10: Starter Motor Engagement................1907
            Table 9:10 Starter Motor Engagement................1907
              Figure 9-11: Field Decay Transient................1908
            Table 9:11 Alternator Field Decay................1908
            Table 9:12 Waveform Parameters................1908
              Figure 9-12: Load Dump................1909
              Figure 9-13: Radiated Emissions................1910
        ACRONYMS and ABBREVIATIONS................1913
    Section 7 - Transmission.pdf................0
      Transmission.pdf................0
        Transmission.pdf................0
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    Section 8 - Electrical.pdf................0
      Actia.pdf................0
        Actia.pdf................0
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          Page #24................2236
          Page #25................2237
          Page #26................2238
          Page #27................2239
          Page #28................2240
          Page #29................2241
          Page #30................2242
          Page #31................2243
          Page #32................2244
          Page #33................2245
          Page #34................2246
          Page #35................2247
          Page #36................2248
          Page #37................2249
          Page #38................2250
'05 Electrical Schematics................2256
  FE20................2257
  P32-L18................2320
  P42-L4B................2377
  P42-LQ4-LR4................2434
  P42-LU3................2488
  W22-L18-web................2535
  W24-L18................2587
  W52-L18................2650
'99-'03 Service Manual................2704