Procedures To Install a 3406C Electronic Engine, And Reprogram The Electronic Control Module (ECM), In a Truck Chassis Formerly Equipped With a 3406B PEEC Engine{1000, 1900} Caterpillar

Introduction

To ensure proper operation of the 3406C Electronic Diesel Engine the 3406B PEEC engine's Customer Specified Parameters must be retrieved from the ECM and transferred to the 3406C ECM.

The procedures in this instruction MUST be performed in the sequence shown when installing a 3406C engine in a truck chassis previously wired for a 3406B PEEC 2.0 system.

Reference: SENR3472 ... 3406B Troubleshooting Guide

Reference: SENR5503 ... 3406C Electronic Troubleshooting Guide

Reference: SENR5509 ... Schematic 3406C (PEEC III) Diesel Truck Engine

Reference: SEHS8743-05 ... Using the NEXG4508 3406B Programmable Electronic Engine Control (PEEC) Service Program Module ... or

Reference: SEHS8834 ... Using the NEXG4512 Customer Parameter Configuration Aid Service Program Module

Reference: SEHS9349 ... Using the NEXG4522 Truck Engine Functions Dual Service Program Module

Retrieve and Record Customer Specified Parameters (CSP)

The 3406B PEEC engine's Customer Specified Parameters must be retrieved from the ECM and transferred to the 3406C ECM:

Engine Rating Selection

Engine RPM at Vehicle Speed Limit

High Cruise Control Speed Set Limit

High Gears Engine RPM Limit

High Gears Turn On Speed

Idle Shutdown Timer

Low Cruise Control Speed Set Limit

Low Gears #1 Engine RPM Limit

Low Gears #1 Turn Off Speed

Low Gears #2 Engine RPM Limit

Low Gears #2 Turn Off Speed

Password No. 1

Password No. 2

PTO Mode Engine RPM Limit

PTO Mode Vehicle Speed Limit

Top Engine Limit

Vehicle Id

Vehicle Speed Calibration

Vehicle Speed Limit

NOTE: The 3406B PEEC 2.0 engine's ECM Customer Specified Parameters can be DOWNLOADED/UPLOADED electronically (using the Electronic Control Analyzer Programmer), refer to the Write Parameters To ECM in:

SEHS8834 ... Using the NEXG4512 Customer Parameter Configuration Aid Service Program Module

Remove 3406B PEEC 2.0 Engine

Remove 3406B PEEC 2.0 Engine. If the engine or the block is to be used for a core credit, refer to:

PEGP7818-01 ... Core Acceptance Criteria (Engines) ... and/or

PEGP7825-01 ... Core Acceptance Criteria (Short Block)

Install 3406C Electronic Engine

1. Install the 3406C Electronic Engine.

Install Conversion Harness and OEM Connector

PEEC III System Component Diagram. Refer to SENR5509 ... Schematic 3406C (PEEC III) Diesel Truck Engine for electrical schematics.

2. Install the engine's 6I3168 Conversion Harness adapter into to the engine's harness OEM connector.

3. Rewire the cab clutch and brake switches as shown in SENR5509 ... Schematic 3406C (PEEC III) Diesel Truck Engine.

4. Run ground wire to ground stud on engine as shown in SENR5509 ... Schematic 3406C (PEEC III) Diesel Truck Engine.

Engine Monitoring

5. If the Engine Monitoring is to be used, a WARNING Lamp (red) must be installed in the vehicle cab's dash.

Refer to:

* The above PEEC III System Component Diagram ... and

* SENR5509 ... Schematic 3406C (PEEC III) Diesel Truck Engine

Coolant Level Sensor

If the Coolant Level Sensor¹ is NOT installed and wired² to the ECM than the Coolant Level Sensor input must be disabled, by the ECAP³, through the Engine Monitoring Parameters.

NOTE: To install a Coolant Level Sensor, contact the truck OEM for wiring harness information.

Monitoring Package

If the Monitoring Package is NOT going to be used then th e Engine Monitoring Parameter MUST be set to the OFF position.

Engine Retarder

If the Engine Retarder is to be controlled by the 3406C Electronic control then the Engine Retarder switches used presently will need to be rewired to a cab mounted engine brake relay and fuse:

* SENR5509 ... Schematic 3406C (PEEC III) Diesel Truck Engine.

Low Idle Validation Switch

The existing low idle validation switch on the throttle position sensor is not used.

Throttle Position Sensor and Vehicle Speed Buffer

Connect the NEG (-) battery (sensor common) wiring of the Throttle Position Sensor and Vehicle Speed Buffer:

* SENR5509 ... Schematic 3406C (PEEC III) Diesel Truck Engine

Service Brake and Clutch Switches

Connect the wiring of the service brake and clutch switches:

* SENR5509 ... Schematic 3406C (PEEC III) Diesel Truck Engine

NOTE: Use the SAME ground as the Throttle Position Sensor and Vehicle Speed Buffer. Do NOT use any other vehicle wiring or the vehicle cab as a ground.

Power Up ECM

6. Power up the engine's ECM, and using the Digital Diagnostic Tool (DDT) or Electronic Control Analyzer (ECAP):

* Enter the Customer Specified Parameters, retrieved from the 3406B PEEC 2.0 Engine's ECM, into the 3406C Electronic Engine's ECM.

* Calibrate the Boost Sensor.

* Calibrate the Throttle Position Sensor.

* Calibrate Rack Sensor (only to insure that Jake will come ON).

Vehicle Test Drive or Chassis Dynamometer Test

Preliminary Setup

The vehicle MUST be test driven with a loaded trailer or perform a chassis dynamometer test.

The test checklist charts are used to ensure that all necessary connections have been made and that the truck functions in an acceptable manner for the customer.

Record all logged faults which occur during the following tests in the appropriate chart location(s).

NOTE: Refer to SENR5503 ... 3406C Electronic Troubleshooting Guide for an explanation of the code(s) and the course of action to troubleshoot.

Testing Instructions:

Perform the following functional tests in the order shown.