Caterpillar to Cummins swap pt.4

well I got back from vacation now a couple days off anyway I went up to see my son up in monument oregon and cut back and we've been hustling on this all day long and takes a long time to do this stuff you know I got the this air tank was originally mounted originally mounted up here or the DPF ser is right up under here and I relocated it back here was about the only place I could go with it really and I was what I was trying to do and I wanted it at first I was wanting to hide it behind the fuel tank then I was what I was trying to do is utilize every bolt hole that's already in here these bolts are these it already had holes here you know so I just I don't want to drill any more holes than I have to in the frame so my whole object is sometimes not really making it I want to make it look nice too I don't want to look like some hack job but I don't want to drill I don't want the whole you know the whole frame looked like a cheese grater and and holes in it everywhere so the less holes you can drill the better off you're gonna be I had to remove this step here to get in there but anyways we got that mounted and I plumbed all the air line to it that's all done now I was gonna go in here and tell you what I've been finding on the wiring okay so this is P 103 I thought you know I got a Peterbilt Lauren harness diagram I downloaded it from EPC catalogs or did it go right here this is P 103 okay so what I need there is I need the six wires for the throttle I need the idle validation three wires and the throttle wires there's six wires on your throttle position sensor I'll show you right here what did I do with it yeah and that's what we're gonna do here now we're gonna tear the four all back out of the sang and see if we can see if we can mount our electronic throttle position Williams controls throttle pedal in it anyway you're gonna have six on these newer trucks you're gonna have three for idle validation and 3/4 throttle so I don't have the the cab harness for this truck so what we're gonna do is I've been looking at the wiring diagram and just kind of trying to verify what I do need and what I don't need so what I'm gonna have to do here is I'll basically figure out what wires are what and I've got the pin out on them and everything and what color the wire is and all that good stuff so basically I'm basically gonna cut it off right here and we're gonna have to eliminate the wires that were not using and run the rest of them through the firewall and I ordered a I spent like six hundred bucks on two kits I ordered a weather pack terminal kit and a Deutsch connector terminal kit this is a Deutsch connector right here and then I ordered a 9-pin Deutsch data link connector that we've got a wire in so and then I've got to figure out like an amber light and a red LED light that I've got to put in the dash somewhere and why are the stop lamp and the so I'm gonna need those I'm gonna need the the amber lamps wire for that the stop lamp wire the six wires for the throttle I'm gonna need the ECU wake up wire which is gonna be an old wire and I don't kind of know what pin it's on and then I got a look in there there's like some other like a there's a couple ignition wires I'm gonna have to look a little more in-depth on to see if I need those but other than that the DPF SC are all that stuff back there is wired van clutch solenoid I've had my head up my ass today and I ordered it and I drove right by the place I told him I was gonna stop in and my mind's going a million miles an hour I got a bunch of service calls this morning I was anticipating coming down here and working on this thing first thing this morning then my plans changed we had a bunch of welding to do this one and a bunch of broken hay equipment I want a chisel passo got to go back and weld up a disk the frames broke on it anyway I got a I got a fan clutch solenoid the newer style you know that's this is this is a spring-loaded fan clutch it's locked up it takes air to release it so I have to get the the newer style which would be like a normally I think a normally open bank cut solenoid and then normally closed or normally open yeah because it closes the contacts it opened it opens air to go to it to release it these are a normally these are normally closed I think I'm saying that right I get that all screwed up sometimes anyways so right now I the that's another thing I did I mounted the parser and reservoir and that's another thing I'm trying to figure out what I'm gonna do with is the power steering cooler this truck didn't come with one on it I'm thinking do we need it call my buddy at a truck shop up there only for a big fuel hauling outfit and he said that they've got one of these trucks and that boils the it boils the power steering fluid in it all the time and he said you got to have a cooler on there and I said well this old truck it never did have a cooler on it so I was thinking about just taking the drain line or the return line here off the reservoir got the pump in it and just doing away with the cooler and taking this line right here and chopping it off and sticking it on the nipple right here in calling or good enough I don't know if he's make me nervous now I'm thinking that I might have a problem I wonder if I ought to try to fabricate something to mount that parser and cooler in there and make that work somehow and then I've got the fuel filter this newer style fill filter head that we've got to get mounted and run the lines to it so there's just so there's a lot of work to do a lot of work to do but we're gonna keep plugging along and try to knock out one thing at a time it's just it's kind of all you can do you know now we've got the air tank all mounted relocated plumbed the DEF tank is plumb the SCR DPF is plumbed mounted we've got a handle on what we need to do on our wiring once you get it all figured out it ain't too bad we're moving along I really anticipate you know we got this holiday weekend coming up I really anticipate next week by the end of the week when I get my parts and other stuff in we're gonna have it running so anyways oh that's another thing we've got to put this talk to Tom and we discussed this we've got to get this put on there okay that has to go on the truck so I don't figure out what I'm gonna do there on the shroud I stuck this shroud off the old one on there and I mean it's not even covering the blades or anything but we got to do something different there I don't know I don't think this I'm like trying mountain that all I'm here on the front of the engine to see if it'll seal up against here I don't know if that's going to or not but if that's not gonna do it then I'm gonna have to make what I'll have to do is take like a I'll have to take like a piece of sheet metal and some angles some small angle iron and spaced this off and then take a piece of sheet metal cut a hole in it you know with the plasma cutter and clean it up the same diameters this hole or you know measure this off or this you can tell whether this seals up against it here and you know I'll have to make it come out to where it'll seal up against that I'll have to make something because everybody's telling me that you've got to have the airflow ride on these newer engines or they've got hot on you you know because they're putting so much heat with a submission system they got to run them they got to run them hot I mean they're putting higher degree thermostats in them now to make them burn clean and I mean they're right on the line all the time of you know boiling over because everyone I'm so hot for the emissions crap you hardly ever see anything with a 180 thermostat on them anymore you know they're running around 200 200 205 1005 degrees my chevy pickup at home I got a tow for Chevy Silverado that runs right around 200 205 all the time you know ok guys well that's the skinny on this let's after let's put a military hospital for part of this truck and mount this total position sensor in here ok let me get some tools so I'm gonna replace this broken plug on here and I've figured out how to I think I know it's hard to see how I'm having a hell of a time to you okay there's one I'm out this little plastic retainer pry in here wonder if I should stick this over here in the vise and hold the stupid plug still while I'm wrestling with the retainer method a little maybe that'll help me out a little bit here I took a picture I just took a picture with my camera real close up and I got the numbers and everything on the backside of the plug so I know which ones go where so I'm cheating much better much better way of doing that okay come on get over there there we go well I don't have to replace those II ends basically just need to put another plug on the end of it and I'll probably save this too there's nothing wrong with that rubber all right we want to get another female plug now I seen that they had the rubbers in here already so we're not gonna use those just just pull it out of there we only need one of these what I grabbed two subtle tools kind of handy here now let's look at my picture so white was number four red is number five black was number six I'll start out with number one number one is Green number two is blue number three is orange okay so the number one is green must be twisted or something here huh trying to orientate this the right way in my head yeah number one all right I should clip in there just like that to this blue whenever three is orange okay what was the other one fourth white thighs red six is black fourth light red and then black those are all in there and then put your little wedge in which I'm gonna need a pair of burner see any a pair of these are gonna be and then you put your little plastic wedge in there that keeps all your pins in alignment obviously our red wire is not in there good enough or something because it's trying to come out something's not quite right the red wires not right okay I just pulled it up with that it wasn't all the way in what the needlenose so all right okay we have a new plug cool all right that's cool I'm proud of that it's the first one of those I've ever done in my life this kid is pretty cool it comes with all the different size this is obviously water size it says here in little stamp part 16 18 gauge it's got to be the wire size over here is 14 to 16 gauge some bigger wire but some of these will take different sized ends on it see these are bigger ends bigger eyes or whatever you call them so it comes with all those and you get a break those off that tab individually and then put them on your terminals and push them into your connectors so when we wire the other side the male side we'll have to build our own male plug and then everything will have to score spawned with the wires that go in here that's where we have to get a wiring schematic out but now we can bolt our total position I'm trying to figure out what this how does this work here I'm not really sure how that works here's a dummy plugs you can put in the back side for wires or not lose using so if you got like a nut old pan like this and you're not using two wires you can put these plugs in the back of them to seal them up but I got to figure out how these these two tools here are utilized I'm not really certain about that to be honest with you I wonder if you take those down here somehow and that collapses I'm not sure how that works guys might have to look that up so I'm doing this correctly when I build my male plug and put my ends on I might to go out and look it up okay so there's our male plug on our total position I'm gonna take you guys over here and show you the debacle that I've got going on here so that throttle pedal part was held down right here and of course there's nuts on the bottom size of the screws so I couldn't get to him from underneath to hold them or anything so then my other idea was to take these screws out and pull this whole plate to host a foot valve and/or treadle valve I better call it the right thing foot valve there anyway I was gonna pull that play it up just enough where I could get a wrench on it you know I thought just these screws out here bought them for probably a good hour to getting them vise grips penetrating oil back and forth these two here with my wherever it is Oh impact driver turning to plate had the impact driver couldn't even get these two loose back here it wouldn't even come loose as the impact driver so I finally got a dumb wedge stuff in there far enough to where I could get an inner inch on the nuts through the gap here and got the damn thing out of there so now I've got to figure out what I'm gonna do I'm gonna have to silicone this up where the plate goes down and then mount the other ones these two holes line up here and mount this thing down and then that total position wire will be routed up here you know back up and here somewhere all right guys we got the total pedal assembly mounted in the cab nice to look on everything around that to kind of seal that up we've gotta create try prevent any water intrusion into the cab ah yeah he keeps a pretty clean little truck but look how that gravel and dirt works its way underneath the formats and stuff on this thing amazing huh how you're out in the woods and that stuff I mean it's everywhere and he's pretty meticulous this guy is about keeping struggling clean the dirt out we're gonna blow it out as best we can vacuum it out before we completely put it back together but I'm gonna leave most of this one apart just for Matt pull back and when I get my other harness routed through the firewall where I want it and get my wires down in here I'm gonna have to do something about a data link connector to mount it somewhere here on it ah but I wanted to get that done so that that's that's completed and that was quite a chore in itself I mean I've a couple hours at least probably three hours trying to get that that's just me know them none of them screws that come out of there just fight it just I fight every step of the way so anyways there's a 95 Peterbilt with a modern subtle pedal position sensor in it he had that other pedal way up here so I got a feeling Tom apply strap some blocks or something to where he's seen he had a block on the old pedal strapped up there he he wanted his total pedal at a certain angle that's all I can do for him there besides jerry-rigged some blocks or something on it or his pedal feels right to him and we're probably gonna have to cut the mat I mean there's no way around it I'm probably gonna have to cut this mat and slide it over the top of it I think I'm gonna have to notch it back maybe in here even a little bit my lights in the way of everything but I might have to notch it back here a little further to to get it to slide around this because everything on this part of it's longer so that's gonna create an issue all the stuff is it's kind of come figured out as you go because it's not made for it you know it's just the way it is my buddy gave me a hat either day like my new hat buddy mine I went to high school with him and his brother good guys do some work for him from time to time they try to do as much as they can because they're kind of like neither owner-operators and just trying to make it and so they got to save money wherever they can so but when they get something they can't quite figure out or need help on or whatever they they give me a holler and I go over there and I you know what they always pay their bills real quick cuz they're one of the little guys you know the seam bucks a little small guys always pay their bills fast okay so there's a harness I'm trying to remember what was what that runs over here to you that they've taken off of this thing and I want to come over here and it's got to be the one that goes to the alternator and all that good stuff okay and AC compressor and that doesn't look so healthy it's definitely not gonna be very healthy when they leave it uncapped and I'm sure it's completely seized up how about the idler will it in my turn but let's figure out that I don't want to start routing this harness and trying to get it organized all right let me shine the light somewhere maybe where you can see AC compressor clutch wire I figured that one out this is obviously gonna be a pressure flip wire there's three wire pin goes to the coolant level sensor which we're gonna have to see if we can unconsidered cuz we're not gonna have one and let's see here let's go see if we can figure some more things out now that we've got that part of the strand figured out which it loops up over here where all these eyes are right here which this I should not be bent like that I'll get tied there closer I gotta know what FL 110 Freightliner out there any day put a front wheel salon today sometime there's a can terminator right here okay this gaggle of crap what we have here okay J 144 charge and start there's something here I can't read something spare looks that like a signal water harder I'm not real sure they're on that there's got to be another cornice it runs over to the I am NOT certain what goes there but there's ways we can figure these things out pretty easily once we get the data like wired and get the ECM powered up some of these things we don't know what they are what's this here clutch solenoid what clutch Oh fan clutch solenoid valve okay did I get the right fan clutch let's check that out I'm pretty certain that I did hmm well I've got a different connector here darn it this has a weather pack on it Oh so again well see what kind of connector is on this one it's just hard word vomiter we might have to do just like we did here down one side and just cut the plug off of it and wired like that I guess is what it is darn it I thought that was on huh I ordered a fan clutch solenoid for a Peterbilt and that's what they give me so well that's not too big of a deal we can figure that out very easily and wire that and it'd be nice if I just plugged in and all good under the warrant schematic and figure out what my ground is and what my feed is and I'll just cut it and all I might just I might just slaughter them together so I don't know we'll see but I do know I need to get that mounted metal mount right there where that one is sees this one this one say whether it's normally closed or psi 150 food Control Division and Parker known almond clicks on here as to whether it's a normally closed or normally open so hopefully it's the right one I guess you'll find out if you [Music] build air up and the clutch never will release and you've got power to it then you know it's the wrong one okay so let's figure this wiring out that's really really want to get done is get the wiring lined out today and identify most of it get it routed [Music] we're gonna go to loop all that stuff back under this big plug in here we'll go into that there's a few there's a refuse relay pill has the grid that the line here relates and stuff like that for for the Deaf system that are associated there so okay this is one I don't really know wait as far as a label transmission temp sensor I don't even think we're just gonna use the original one so I'll probably end up cutting that off but I don't before I cut anything off I want to get the insight plugged into it you know and make sure that I can can unconfessed ufff before I start cutting wires that is okay that's the old harness so we're grabbing the wrong wire here and this is clutch switch and we're not gonna have that we're definitely not going to have that in there and I think is this one here this is the one I think it's not labeled so I don't really know once I get inside up I can unplug it or jumper wire and make it through a code and figure out what it is there are numbers that are legible on this thing the pillars are pretty easy to read but the wire colors or that numbers aren't okay so there's got to be once this is routed this actually goes over I think over in here across the firewall there and gets hooked in there somewhere so there's another part of the harness it goes to the alternator over there that we need to find well there's a whole other part of the harness that's missing it's not here I think the other guy put it on his or something it's not here yeah I'm gonna do a back flip when I tell him that there's something else that the guy kept yeah whatever so I can wire the fan clutch solenoid I'll get it mounted I'm gonna get all this stuff tied in here kind of where it goes and get all this stuff I look at some other trucks and I thought man it's a heck of a mess of wire lumps and they do there they're all just clustered and tied together right down here above the starter so that's what we'll wind up doing and that's kind of curious right but there's our starter relay let's climb under this truck real quick juice yeah there's a pigtail right here says charged our harness looked up on the wiring schematic and there's another one up J 144 that goes over to the well I think he goes over let's see here maybe it goes to the starter I don't know let's see oh okay that charge start wires gonna go right there but we are still missing we're still missing what does that go to I remember seeing something like that that that got cut over here God would have none that this guy it made my job he made my job so difficult on this thing because he's just a numb nut you know cutting wires and like that on a on a on a project that you shouldn't cut waters on because you're you're trying to save the parts this is going to the fuel filter how is this tying into the ECML that's what I want to know it must be through this wire right here okay yeah that guy really screwed me Mom this thing he really did so that other one there's a one pin whine it's obviously gonna plug into that so we get a red wire down there on the start relay to telephone in for what is this no I thought this was going down to that start really and I was wrong it's going back in that's going into the harness I already got lose water in fuel sensor okay so let's go up to the fuel filter okay start really where shitbird cutoff let me tell you what that guy did he he got what he needed off the truck he took two of them and got one the were you know he took two trucks and made basically one out of it and he got what he needed and so on and so forth so that's got to be the signal wire right there that's got to be the signal wire going to the start relay right there and I don't see so you got one battery power feeding the relay and then the signal trying to see what the other one's going to hear it's going over okay so they ask the main signal wire going to this starter solenoid so this is that this is the one that'll put power to the starter to make everything happen okay so we got that figured out where what is this so now that I know what that wire is that he cut off what a mess water fuel sensor okay this is our actual signal our going north start relay that's gonna make a everything happen which I mean do we have to have that run through this ECM and all that so if it can we just use those already in the truck you know and wired into that I don't know what the hell is this here solenoid for something here I'll figure that out something else to figure out but I didn't take apart or anything okay then this little groundwater here it's another ground is what it is so I'm thinking either put it on is it numbered anywhere well that would be too easy wouldn't it it's too small of an eye to go over the starter I think the starter ground so I'm thinking probably yeah it's too small for that I got a feeling it's gonna be going over here to the block this other ground is right here that has a smaller worid fits on that one okay so that one's kind of accounted for it's a ground make sure that ground I'll rub on something in ground okay so those are identified at least did we do know that we are missing an entire harness that goes over to the alternator I do remember seeing the black junction box so somewhere I don't know what I did with it okay guys we're figuring this out P 102 is going to be part of the letterings going on it it's only got one wire I did identify the out wire I'm pretty certain that's gonna be P 102 engine harness okay then that's gonna come through the wound here well see it's cut I know what's going on now it's okay so what this thing does is it comes to P 102 comes along here goes through the neutral start they've got it jumpered for neutral start a little start in gear basically because it didn't have a neutral start switch of any kind so there's your neutral start it makes that loop right there it comes back around through or in 39 11-2 which should be if we could read it that's it right there oh are in three nine eleven - - and this should be three nine eleven - 1 1 1 - 0 that's what this one here's supposed to be and that's what this one is okay so we've identified what we need to do in general okay guys I'll get my fan clutch solenoid mounted I'm probably gonna have to mount a crack valve it's nice to put like a hundred psi crack valve on these because sometimes it'll bleed through and it'll make your bank let's drag and it'll burn your clutches up it's good to put a crack valve and I'm I didn't know that much about him till I was talking to my buddy on the phone it works on these all the time and he was telling me to do it so sounds like a good idea we might have to scab one of those in there so here's her where the hell's of that I just was looking at it wait a second I just was looking at the fan clutch solenoid ether short scent fan in Vann solenoid green and yellow so common return number that's gonna be the ground and the engine fan clutch that's gonna be the signal so the yellow signal and the green is the ground I've got some john deere harnesses over here I guess that's what I should have ordered to was a weather pack kid like I did the noise kid and I could have made my own end for that what style within does that tell me guys what do they call that one I got some John here harness over here I might I'd rather cut this one than the OEM harness all right so we took the Dillinger harness and I had the female side of the plug and we wired her in there so that turned out good and took it I cut it there and then soldered it and he shrunk it and turned out good so the fan clutch solenoid is wired I gotta find the hose I don't know what he did with that that's the next problem that I'm gonna have to figure out all right guys so we are wiring soldering we made her plug see here I mean our deutsch plugs the mill and the wires into the firewall on these federal positions on most harness you'll see I actually had a whole harness out of a 900 national and oh nine that had the three there's do it you'll have to twisted pairs of violet blue and green wires they're all the same color but they'll have on the factory side on this side they're gonna be different wire numbers so once you look at your worn diagram and you figure out your first one which I did what's the first one I did was the violent water I did the green violet 3140 2-0 I found that number on this wire I traced it down here to pin 1 let's look at this make sure we're going to write one here the violent wire so it'd be this strand which I got hooked up there violet pin one okay that's the one I've got soldered up here so the next thing it's easy then I mean once you get the first one identified then you know the these are all gonna be on the same strand you know that's what the three twisted ones or stay together so just do that I just do the twisted ones here on one strand and then do the next one so my green ones the next one I'm doing that's going to pin to and my plug in and pin three is my blue one so okay let's go to soldering and I've been practicing my solder from all the one video I did get that laid up there and shoot one thing you gotta be careful with this otter and her and it's got a little outlet right here you can do your heat shrink with and make sure that heat point until it's your heat shrink down there because you'll heat shrink will shrink up on you before you slide it and then you have to resort to taping it up or cut it back loose and do it again so I've made that mistake a couple times so I'm doing what I was I do I read all of those comments on that one Peterbilt video of all the soldering him and I've practiced since then and trying to hold the wire and get it hot and then touch the wire on top it takes a little bit work to get hot enough to start pulling it in definitely got to be patient come on there we go look at that it's a nice smooth seamless joint looks good fine but I listen to those people as I am definitely doing a better job of it now so way more comfortable with that holding up together that'll get that whole wire hot so you got to be careful and it'll come down here and build the heat in that wire and shrink that heat shrink up on you and that is not no good that is no good someone let the wire cool down before I decided to slide that heat shrink up there yeah that's a pretty good solid connection I'm pulling pretty damn hard it's probably stronger than what it was maybe I should I don't know maybe I'm full of blue wire to blue wire this wires a little bit smaller than the original wire oh you know what I forgot to do damn heat shrink on the tube there forgot all about it I might just go ahead and slide this one on up there and get it shrunk up that's what I'm gonna do I put a black one on the first one and I had a hell of a time getting it on it's a little bit too small and by the time I got this order on there it didn't want to slide on there so then I just point this little opening here in the tip looks pretty damn good all right now let's try this again and toss these two together this is very time-consuming doing this stuff here but it's gonna be done right and soldered together I'd have a bunch of butt connector I know I was younger I did I you know when you're younger year sometimes you sacrifice quality hang a lot I did a lot when I was younger I sacrificed a lot of quality for just getting it done you know and then two months later the guy called you your goddamn butt connectors came undone under the - now you get to redo it again so these aren't gonna come undone come on sometimes this thing don't gonna light okay let's hold her on there and get the wire hot takes a little time to do it I'll tell you that I want us you can take that little heat part of it in this well if that would get hot quicker I don't know I got a buddy that that Sauter's he does that's he was a lot like Martin on trailers and stuff for the truck shop and I was talking to him you know I said you'd use all the flux and all that stuff he goes no it's what you got rosin core solder for he said you don't need the flux so I'm going by what he said and he does it all the time heat shrink this on that all right so that strand of wires is done now it's pretty self-explanatory this match your colors up and you'll be good to go so yeah so remember three you're gonna be froth throttle three are gonna be for Auto validation you guys remember the old power strokes the old 7-3 he's had a switch on their idle validation switch the same thing yeah we're gonna need this orange wire or ECM wake up wire I got a fine there should be another wire for ignition power there's a few other wires we're gonna need in here but we don't need them all so there's our can hind can't alone but I have to work an Terminator in between there and the datalink the the Kaline wire is gonna be in there the can 1587 bus wires should be in there they're not twisted like the can high in can low are I'm kind of surprised that Peterbilt doesn't do like John Deere and doesn't put a screening wire on there you know and if you don't know what a screen wire is John Deere I'll use a they'll have their twisted pair like this yellow and green and then they'll have another set of wire wound around them or shielding around them a power and a ground 12-volt power and a ground for it is supposed to keep magnetic interference off the wire from another controller or another wire that's sitting alongside it is the purpose of that if you ever wondered what that was all about

Channel: western truck and tractor repair

Views: 32,877

Rating: 4.9665399 out of 5

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Id: DiSGEc7khN4

Length: 54min 46sec (3286 seconds)

Published: Mon Sep 02 2019