NHTSA ID Number: 10144000
Manufacturer Communication Number: BS3626ER2
TSB/Document Date: 2018-08-20
Summary
Cummins
code 1242 for accelerator sensors circuit
L859
8400
8400
L82J5F3001405
L82J5F3001405
1
Toronto Transit Commission - TTC - Ontario
L860
8401
8504
L82J0F3001554
L82JXF3001805
104
Toronto Transit Commission - TTC - Ontario
L937
8510
8568
L82J9G3750001
L82J6G3750179
59
University of Alabama - Alabama
L787
—
—
L82J2E4500507
L82J4E4500508
2
University of Alabama - Alabama
L902
7030
7030
L82J2F4500993
L82J4F4500994
2
University of Alabama - Alabama
L961
7032
7033
L82J7G9775294
L82J9G9775295
2
Walt Disney World - Florida
L763
—
—
S92U0D3001019
S92U4D3001024
6
Welland Ontario
L866
L82J9F3001648
L82J9F3001648
1
Welland Ontario
L933
—
—
L82J1G3750011
L82J1G3750011
1
Whitehorse - Yukon
L784
43
43
L82U9D3001057
L82U9D3001057
1
Windsor - Ontario
L886
570
577
L82J8F3001818
L82J5F3001825
8
Woodstock - Ontario
L778
—
—
L82U2D3001014
L82U2D3001014
1
Woodstock - Ontario
L832
—
—
L82J9E3001342
L82J9E3001342
1
Woodstock - Ontario
L923
15-16
15-16
L82J9F3001746
L82J9F3001746
1
York Regional Transit - Ontario
L896
1501
1517
L82J2F3001619
L82JXF3001741
17
York Regional Transit - Ontario
L936
1518
1518
L82J3G3750012
L82J3G3750012
1
PAGE 4 OF 13
SERVICE BULLETIN
SAV.1E.2012MA
BS3626ER2
FOLLOW YOUR INTERNAL SAFETY PROCEDURES.
PROCEDURE
1.1.
Replacement wire kit N632000435 (see Figure 1).
Figure 1 - Replacement Wire Kit
1.2.
Open the battery compartment access door, ensure that the vehicle's power supply has been deactivated
by turning off the battery cut-off switch (see Figure 2).
Battery cut-off switch
Battery compartment
access door
Figure 2 - Deactivate the Vehicle's Power Supply
PAGE 5 OF 13
SERVICE BULLETIN
1.3.
SAV.1E.2012MA
BS3626ER2
Open the rear engine door to remove the engine control box. Disconnect both connectors on the rear of
the engine control box and remove the four screws that hold the engine control box in place (see Figure 3).
Engine
control box
Disconnect the two
connectors on the rear
of the engine control box
Remove the four screws that hold the
control box of the engine in place
Figure 3 - Remove Engine Control Box
1.4.
Remove the left engine control box support bracket for easier access to the engine harness. Remove the two
screws that secure the strain relief for the engine harness and disconnect the ECM (see Figure 4).
Remove the left side
support bracket for
easier access to the
engine harness
Remove the two screws of the
ECM harness strain relief
Figure 4 - Remove the Support Bracket and ECM Harness Strain Relief
PAGE 6 OF 13
SERVICE BULLETIN
1.5.
SAV.1E.2012MA
BS3626ER2
Raise the bus, open the ECM connector back shell, remove the red lock and extract the terminals and wires
from the ECM connector for the APS1 and APS2 using the Cummins 4918921 extraction tool (see details
provided next page on Figure 6). Avoid pulling on the wires prior to having pushed on the lip locks with the
Cummins extraction tool. Insert the Cummins extraction tool while avoiding a rotation movement, then pull
on the wire once the wedge of the extraction tool has unlocked the pin (see Figure 5).
ECM connector
Red lock
Use the Cummins
4918921 extraction
tool or equivalent
Figure 5 - Extract the Wires From the ECM Connector
PAGE 7 OF 13
SERVICE BULLETIN
1.6.
SAV.1E.2012MA
BS3626ER2
Tape back using heat shrink tubing (N27548-18) on all wires that were cut or disconnected. For APS1 use
positions 9, 10 and 33. For APS2 use positions 61 and 64. Install the five new wires of the wire kit. Reassemble
the ECM connector and lower the vehicle (see Figure 6).
Tape back
White
Figure 6 - Extract the Wires From the ECM Connector and Install Wire Kit Wires
PAGE 8 OF 13
SERVICE BULLETIN
1.7.
SAV.1E.2012MA
BS3626ER2
Reconnect the ECM connector, secure the strain relief and zip tie the harness and the wire kit with three zip
ties (G5007995). Route the wire kit from connector +MT-X95W as shown below (see Figure 7).
ECM connector
Three zip ties
G5007995
Figure 7 - Reconnect, Secure and Zip tie the Wire Kit
1.8.
Continue routing up along the blue hose using a dual clamp zip tie (N37749) as shown below (see Figure 8).
Dual clamp
N37749
Wire kit
Figure 8 - Routing of Wire Kit
PAGE 9 OF 13
SERVICE BULLETIN
1.9.
SAV.1E.2012MA
BS3626ER2
Continue routing the wire kit along the blue hose with a dual clamp (N37749). Note the position of the service
disconnect. The excess length of the wire kit will need to be attached later with zip ties (see Figure 9).
Service
disconnect
Dual clamp
N37749
Wire kit
Figure 9 - Routing of Wire Kit
PAGE 10 OF 13
SERVICE BULLETIN
1.10.
SAV.1E.2012MA
BS3626ER2
Continue along the blue air line and then along the CAC pipe until turning towards the +IB-X6499A bulkhead
connector. Remove the +IB-X6499A connector and extract the seven required terminals for the APS1 and
APS2. Tape back using heat shrink tubing (N27548-18) on all wires that were cut or disconnected. For APS1
use positions 88, 89, 90 and 91. For APS2 use positions 84, 85 and 86. Install the seven wires from the wire
kit. Reassemble the connector (see Figure 10).
+IB-X6499A
bulkhead
connector
Use Deutsch DT-RT-1
extraction tool or equivalent
Tape back
Figure 10 - Connecting Wire Kit
PAGE 11 OF 13
SERVICE BULLETIN
1.11.
SAV.1E.2012MA
BS3626ER2
Attach the wire kit to harness 64 with a zip tie (G5007996) (see Figure 11).
Zip tie G5007996
Figure 11 - Attach Wire Kit
1.12.
Attach the wire kit to the CAC pipe with four zip ties (G5007996) and two swivels (N56836) (see Figure 12).
Zip ties
G5007996
Swivels
N56836
Zip ties
G5007996
Figure 12 - Attach Wire Kit to the CAC Pipe
PAGE 12 OF 13
SAV.1E.2012MA
BS3626ER2
SERVICE BULLETIN
1.13.
Continue along the blue air line, install a dual clamp (N37749) and connect the service connectors. Secure the
excess length of the wire kit onto the wire kit already installed with two zip ties (G5007996) (see Figure 13).
Dual clamp N37749
Zip ties
G5007996
Connect service
connectors
Figure 13 - Secure the Excess Length of the Wire Kit
1.14.
Activate vehicle's power supply.
1.15.
Close battery compartment access door.
1.16.
Make sure that the engine starts properly.
1.17.
Make sure that no active engine fault code is present.
1.18.
Make sure that the accelerator pedal operates properly.
1.19.
Stop the engine.
PAGE 13 OF 13
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TSB/Document ID: BS3626ER2
Replacement Service Bulletin Number:
MFR Communication Date: 2018-07-18
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: VEHICLE SPEED CONTROL
MFR Component System:
MFR Component Subsystem:
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