9026

S92J6D3001094

S92J7D3001119

26

Toronto Transit Commission - TTC - Ontario

L777

9027

9152

S92J7E3001123

S92J6E3001372

126

York Regional Transit - Ontario

L964

1770

1774

S92J6G3750420

S92J3G3750424

5

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WARNING

FOLLOW YOUR INTERNAL SAFETY PROCEDURES.

PROCEDURE

LEVEL 1 - BYPASS CABLE WIRE KIT INSTALLATION
NOTE

Level 1 involves the installation of a bypass cable wire kit in the engine compartment. If this solution fails,
level 2 involves the installation of a one-piece cable wire kit from the throttle pedal to the engine ECM.

Read and understand Appendix 1. 2 and 3 at the end of this document before beginning.
1.1.

Bypass cable wire kit N632000435 (see Figure 1).

Figure 1 - Bypass Cable Wire Kit

1.2.

Open the battery compartment access door, and 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
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1.3.

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Remove the two screws that secure the strain relief for the engine harness and disconnect the ECM connector
(see Figure 3).

Remove the two screws
of the strain relief

Figure 3 - Remove the Engine Harness Strain Relief and Disconnect

1.4.

Raise the bus, open the ECM connector back shell, remove the red lock and extract the terminals and wires
from the ECM connector for APS 1 and APS 2 using the Cummins 4918921 extraction tool. Avoid pulling on
the wires before pushing the lip locks with the Cummins extraction tool. Insert the Cummins extraction tool
avoiding a rotation movement. Pull on the wire once the wedge of the extraction tool has unlocked the pin
(see Figure 4).

ECM connector

Red lock
Use the Cummins
4918921 extraction
tool or equivalent

Figure 4 - Extract the Wires From the ECM Connector
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1.5.

Cut and tape back using N27548-18 all wires that were disconnected. For APS 1, use positions 9, 10 and
33. For APS 2, use positions 61 and 64. Install the five new wires of the bypass cable wire kit. Reassemble
the ECM connector and lower the vehicle (see Figure 5).

Tape back

White

Figure 5 - Extract the Wires From the ECM Connector

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1.6.

Reconnect the ECM connector, secure the strain relief, fasten the bypass cable wire kit with three tie wraps
(G5007995), and route the wire kit from the ECM connector (+MT-X95W) as shown below (see Figure 6).

ECM connector

Three tie wraps
G5007995
Bypass cable
wire kit

Figure 6 - Reconnect, Secure and Fasten the Bypass Cable Wire Kit

1.7.

From the ECM connector, route the wire kit upwards and install the first N56836 dual swivel spacer with two
G5007995 tie wraps (see Figure 7).
Install dual swivel spacer
N56838 and two tie
wraps G5007995

Bypass cable
wire kit

Figure 7 - Install the Dual Swivel Spacer with Two Tie Wraps

1.8.

Install the second N56836 dual swivel spacer with two G5007995 tie wraps (see Figure 8).
Install dual swivel spacer
N56838 and two tie
wraps G5007995

Bypass cable
wire kit

Figure 8 - Install the Dual Swivel Spacer with Two Tie Wraps

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1.9.

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Install dual clamp ties N37749 on both sides of the bypass cable wire kit maintenance connectors (see Figure 9).
Install dual clamp ties
N37749 on both sides
of the connectors

Bypass cable
wire kit

Figure 9 - Install Two Dual Clamp Ties

1.10.

Route the bypass cable wire kit upwards (see Figure 10).

Bypass cable wire kit

Figure 10 - Route the Bypass Cable Wire Kit Upwards

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1.11.

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Install the dual clamp tie (see Figure 11).

Figure 11 - Install the Dual Clamp Tie

1.12.

Install two N56836 dual spacer swivels and four G5007995 tie wraps (see Figure 12).

Figure 12 - Install Two Dual Spacer Swivels and Four Tie Wraps

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1.13.

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Remove the +IB-X6499A bulkhead connector and extract the seven specified terminals for the APS 1 and
APS 2 cables. Cut and tape back using N27548-18 all wires that were disconnected. For APS 1, use positions
88, 89, 90 and 91. For APS 2 use positions 84, 85 and 86. Install the seven wires from the bypass cable wire
kit. Reassemble the bulkhead connector (see Figure 13).

+IB-X6499A
bulkhead
connector

Use Deutsch DT-RT-1
extraction tool or equivalent

Tape back

Figure 13 - Install the Seven Wires From the Bypass Cable Wire Kit

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1.14.

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Secure the excess length of the bypass cable wire kit onto the existing wire harness with two G5007996 tie
wraps (see Figure 14).

Tie wrap G5007996

Figure 14 - Secure Excess Length of the Bypass Cable Wire Kit

1.15.

Activate the vehicle's power supply.

1.16.

Close the battery compartment access door.

1.17.

Make sure that the engine starts properly.

1.18.

Make sure that the throttle pedal operates properly.

1.19.

Make sure that no active fault codes are present. If the Cummins 1242 fault codes return go to level 2 step 2.1.

1.20.

Stop the engine.

1.21.

Return the bus to service.

LEVEL 2 - FRONT TO BACK CABLE WIRE KIT INSTALLATION
NOTE

Level 1 involves the installation of a bypass cable wire kit in the engine compartment, if this solution fails,
level 2 involves the installation of a one piece cable wire kit from the throttle pedal to the engine ECM.
2.1.

Prepare to install the 60-ft front-to-back cable wire kit (N632000652) by performing step 1.2.

2.2.

Remove the rear panel to access the Fire Suppression System (FSS) area (see Figure 15).

Remove the rear panel

Figure 15 - Remove the Rear Panel
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2.3.

Drill two 12 mm holes to the left of the +IB-X6499A bulkhead connector located in the lower part of the FSS
area. Align the first hole vertically with the center of the connector and 63 mm to the left. Align the second
hole vertically with the center of the connector and 133 mm to the left (see Figure 16).

133 mm

63mm

Figure 16 - Drill Two Holes for Later Installation of Cable Glands

2.4.

Remove the following panels for access prior to routing the front-to-back wire kit: lateral console panel, foot
guard panel, front console panel, driver partition panel, and all streetside baselight panels. Open the ITS
compartment (see Figure 17).

Remove the lateral conRemove the front
sole and foot guard panels console panel

Remove the driver
partition panel

Open the ITS
compartment

Remove all streetside
baselight panels
Figure 17 - Remove Panels

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2.5.

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Start the front to back cable routing at the throttle pedal connectors and route under the dash towards the
throttle pedal (see Figure 18).

Front-toback cable
routing

Throttle pedal
connectors

Figure 18 - Front-to-Back Cable Routing
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2.6.

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Cut the original throttle pedal connectors on the main harness side and tape back the original breakout wires.
Connect the throttle pedal connectors to the front to back cable connectors (+DH-X01D and +DH-X01E) and
secure with tie wraps from the throttle pedal connectors to the ITS compartment (see Figure 19).

Figure 19 - Front to Back Cable Connection

2.7.

Continue the front to back cable routing and tie wrapping through the lateral console and driver partition
(see Figure 20).

Lateral console
routing
Driver partition routing

Figure 20 - Front to Back Cable Routing in Driver Area

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2.8.

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Continue routing and tie wrapping the front to back cable through the ITS compartment (see Figure 21).

Routing through the
ITS compartment

Figure 21 - Front to Back Cable Routing in the ITS Panel Area

2.9.

Continue routing and tie wrapping the front to back cable through the streetside baselights (see Figure 22).

Front to back cable routing
through streetside baselights
Figure 22 - Front to Back Cable Routing in the Streetside Baselights

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2.10.

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Continue routing and tie wrapping the front to back cable through the front bulkhead towards the EGS (see
Figure 23).

Routing into the bulkhead

Routing inside the front bulkhead

Figure 23 - Front-to-Back Cable Routing in the Front Bulkhead Area

2.11.

Continue routing the front to back cable through the EGS, secure it to the existing cables with tie wraps and
continue routing through the rear bulkhead (see Figure 24).

EGS Routing