Installation of the Transmission Output Speed Sensor{3175} Caterpillar

Articulated Truck:

740 (S/N: B1P1-UP; AXM1-UP)

740 EJECTOR (S/N: B1R1-UP; AZZ1-UP)

D250E Series II (S/N: 4PS1-UP)

D250E (S/N: 5TN1-UP)

D300E Series II (S/N: 5KS1-UP)

D300E (S/N: 7FN1-UP)

D350E Series II (S/N: 2XW1-UP)

D350E (S/N: 9LR1-UP)

D400E Series II (S/N: APF1-UP; 8PS1-UP)

D400E (S/N: 2YR1-UP)

Off-Highway Truck/Tractor:

69D (S/N: 9SS1-UP; 9XS1-UP)

73D (S/N: 1GW1-UP)

768C (S/N: 02X1-UP)

769C (S/N: 01X1-UP)

769D (S/N: 5TR1-UP; 5SS1-UP; BBB1-UP)

770 (S/N: BZZ1-UP)

772 (S/N: RLB1-UP)

772B (S/N: 64W1-UP)

773B (S/N: 5SC1-UP; 63W1-UP)

773D (S/N: 7ER1-UP; 7CS1-UP; NBJ1-UP)

773E (S/N: ASK1-UP; BDA1-UP)

776 (S/N: 14H1-UP)

776B (S/N: 6JC1-UP)

776C (S/N: 2TK1-UP)

776D (S/N: 5ER1-UP; AFS1-UP)

777 (S/N: 84A1-UP)

777B (S/N: 3NF1-UP; 4YC1-UP)

777C (S/N: 4XJ1-UP)

777D (S/N: 2YW1-UP; 3PR1-UP; AGC1-UP; AGY1-UP; FKR1-UP)

784B (S/N: 5RK1-UP)

784C (S/N: 2PZ1-UP)

785 (S/N: 8GB1-UP)

785B (S/N: 6HK1-UP)

785C (S/N: 1HW1-UP; 5AZ1-UP; APX1-UP)

789 (S/N: 9ZC1-UP)

789B (S/N: 7EK1-UP)

789C (S/N: 2BW1-UP)

793 (S/N: 3SJ1-UP)

793B (S/N: 1HL1-UP)

793C (S/N: 4AR1-UP; 4GZ1-UP; ATY1-UP; CBR1-UP)

793D (S/N: FDB1-UP)

Quarry Truck:

771C (S/N: 3BJ1-UP)

771D (S/N: 6JR1-UP; 6YS1-UP; BCA1-UP)

775B (S/N: 7XJ1-UP)

775D (S/N: 6KR1-UP; 8AS1-UP)

775E (S/N: BEC1-UP)

Underground Articulated Truck:

AD40 Series II (S/N: 1YZ1-UP)

AD45 (S/N: BKZ1-UP)

AE40 II (S/N: 1ZZ1-UP; BLW1-UP)

Wheel Tractor-Scraper:

621E (S/N: 6AB1-UP; 6BB1-UP; 2TF1-UP)

621F (S/N: 4SK1-UP; 5JK1-UP; 8PL1-UP; 9NL1-UP)

621G (S/N: ALP1-UP; CEN1-UP; CEP1-UP)

621S (S/N: 8KD1-UP)

623E (S/N: 5SG1-UP; 6CB1-UP; 6DB1-UP; 6YF1-UP)

623F (S/N: 3XW1-UP; 5SG1-UP; 5EW1-UP; 6BK1-UP)

623G (S/N: ARW1-UP; CES1-UP)

627B (S/N: 14S1-UP)

627E (S/N: 6EB1-UP; 6FB1-UP; 6GB1-UP; 6HB1-UP; 7CG1-UP)

627F (S/N: 1DL1-UP; 4YK1-UP)

627G (S/N: AXF1-UP; CEX1-UP; CEZ1-UP)

631C (S/N: 67M1-UP)

631E Series II (S/N: 1AB1-UP; 1BB1-UP; 1NB1-UP; 3ND1-UP; 6PC1-UP)

631E (S/N: 4LD1-UP)

631G (S/N: AWK1-UP; CLR1-UP)

633E Series II (S/N: 2PS1-UP)

637E Series II (S/N: 1FB1-UP; 1HB1-UP; 7CB1-UP)

637E (S/N: 1JB1-UP; 1LB1-UP)

637G (S/N: AXT1-UP; CEH1-UP)

651E (S/N: 4YR1-UP; 5XR1-UP; 88Z1-UP; 89Z1-UP)

657E (S/N: 5YR1-UP; 6MB1-UP; 6PR1-UP; 6TR1-UP; 7KR1-UP; 86Z1-UP; 87Z1-UP; 90Z1-UP; 91Z1-UP)

657G (S/N: W1B1-UP; W1C1-UP; W1E1-UP)

Introduction

The ""Remove The Old Sensor" " section of this Special Instruction applies to the transmissions with the 144-0178 Speed Sensor or the 3E-6955 Speed Sensor .

If the old sensor is a 109-7330 Speed Sensor , proceed to ""Install The New Sensor" ".

If the 258-4521 Speed Sensor is already installed, proceed to ""Install The New Sensor" ".

If replacement of the 144-0178 Speed Sensor Gp with the 258-4521 Speed Sensor Gp is to be performed, then the sensor housing may also need replaced. A transmission that contains a 6T-5631 Sensor Housing will need to be replaced with a 369-6693 Sensor Housing .

Important Safety Information

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Sudden movement or accidental starting of the machine can cause personal injury or death to persons on or near the machine. To prevent personal injury or death, perform the following: Park the machine on a smooth level surface. Lower the bucket and or attachments to the ground. Stop the engine and engage the parking brake. Block the wheels and install the steering frame lock. Turn the battery disconnect switch to the OFF position and remove the key. Place a Special Instruction, SEHS7332, "Do Not Operate" tag at the battery disconnect switch location to inform personnel that the machine is being worked on.

Do not perform any procedure in this Special Instruction until you have read this Special Instruction and you understand this information. Use only proper tools and observe all precautions that pertain to the use of those tools. Failure to follow these procedures can result in personal injury. The following procedures should also be observed.

Work safely. Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs.

A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools to perform these functions properly.

Safety precautions and warnings are provided in this instruction and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.

Therefore, the warnings in this publication and the warnings that are on the product are not all inclusive. Ensure that any tool, procedure, work method, or operating technique you use that is not recommended by Caterpillar is safe.

Ensure that the product will not be damaged or the product will not be made unsafe by the operation, lubrication, maintenance, or repair procedures used.

Remove The Old Sensor

Note: When you replace the old sensor, first disconnect the connector to the speed sensor in order to identify the wires that go to each pin. The wire connections may not be obvious since the wires are potted. In order to reduce the chance for error, cut one wire at a time. Perform a continuity check between the cut wire that is connected to the old connector and the pin on the old connector. Insert one wire at a time into the new connector before going on to the next wire.

1. On the mating harness connector, identify the wire that is connected to pin A on the old sensor. Identify the wire that is connected to pin B on the old sensor. Identify the wire that is connected to pin C on the old sensor. Refer to Illustration 1. Record each wire color and each wire number.

   1. Label each wire.

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Illustration 1	g01223536
Old 144-0178 Speed Sensor

2. Disconnect the connector and remove the existing 144-0178 Speed Sensor or the 3E-6955 Speed Sensor .

3. Cut off the existing circular mating harness connector.

4. Strip off 6 mm (0.250 inch) to 8 mm (0.312 inch) of insulation from each wire.

5. Crimp a 9X-3402 Socket onto each wire with the 1U-5804 Crimping Tool .

6. Install each harness wire into the DT connector that is included in the 155-2260 Kit . Refer to Table 1.

   Note: The orientation of the pins is different on the new DT connector. Refer to Illustration 2.

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   Table 1

   Wire	Connector
   A	Pin A (Power)
   B	Pin B (Return)
   C	Pin C (Signal)

Note: The orientation of the pins on the new DT connector is different.

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Illustration 2	g01240391
New 258-4521 Speed Sensor

7. Insert the green wedge from the 155-2260 Kit into the DT connector.

Install The New Sensor

1. Assemble the 8L-2786 O-Ring onto the new 258-4521 Sensor .

2. Install the 258-4521 Sensor on the transmission or the torque converter. Tighten the sensor to 25 ± 5 N·m (18 ± 4 lb ft).

3. Plug the mating harness connector into the connector for the 258-4521 Sensor . Ensure that the locking tab is secure.

   Secure the harness no more than 104 mm (4 inch) from the sensor. Use the 130-5300 Mounting Clip and the 3S-2093 Cable Straps in order to secure the connector and the harness.

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NOTICE
Do not stress the lead or have less than 10 mm (.4 inch) bend radius on the leads as the leads exit the sensor body.

Note: The 130-5300 Mounting Clip and the 3S-2093 Cable Straps are not included in the kit.

4. Calibrate the sensor per standard testing and adjustment procedures. Ensure that no fault or event codes were generated. If fault codes still occur, verify that the wiring of the connector is correct.