Installation Of The 194-5339 Speed Sensor Gp and The 194-5340 Speed Sensor Gp Kits{1900, 1907} Caterpillar

Engine:

C-10 (S/N: 3CS1-UP)

C-12 (S/N: 2KS1-UP; 9SM1-UP; 8YF1-UP)

C-15 (S/N: 6NZ1-UP)

C-16 (S/N: 7CZ1-UP)

3406E (S/N: 1MM1-UP; 2WS1-UP)

Introduction

The butt splice assembly must be used only on the replacement C-10/C-12 integral camshaft speed sensor or the replacement 3406E/C-15/C-16 integral crankshaft speed sensor.

When using the butt splice assembly, both the engine harness speed sensor socket terminals and the 2-pin male DT connector will be removed from the engine harness speed sensor leads.

Installation Instructions

1. Cut the leads of the engine wiring harness to the speed sensor between the back of the mating connector and the start of the braid on the harness.

2. Strip the wire insulation back 1/4 inch from the cut and crimp the butt splices with the 9S-9150 Terminal Crimp Tool or crimp with similar crimping pliers. DO NOT USE STANDARD PLIERS TO PERFORM THE CRIMP.

3. The butt splice assemblies in the repair kits are color coded in order to match the engine wiring harness. This will help eliminate the reversal of polarity.
   Show/hide table

   Table 1

   Engine Model Serial Prefix	Diagnostic Code Sensor	Part Number for the Repair Kit Consist.
   C-10/C-12 3CS, 2KS, 9SM	64-12 Camshaft	194-5340 ( 1 - 189-9801, Speed Sensor and 1 - 194-5321, Butt Splice Assembly)
   C-15/C-16/3406E 6NZ, 7CZ, 1MM, 2WS	190-12 Crankshaft	194-5339 (1 - 189-9266, Speed Sensor and 1 - 194-5322, Butt Splice Assembly)

4. Use a heat gun to shrink the insulation on the butt splice. This will properly seal the crimped connections. There should be a small bead of adhesive formed on each end of the shrink wrap that follow the heat shrink.

5. Install the new engine speed sensor that is contained in the repair kit. Refer to Table 1.

6. Connect the new engine harness connector to the new sensor.

7. REPLACE ANY TIE-WRAP CONNECTORS REMOVED DURING THE REPAIR. DO NOT TIE-WRAP THE BUTT SPLICE DIRECTLY TO THE ENGINE OR HARNESS CLIP.

Note: Start the engine to ensure that the polarity of the connections is correct. Check the ECM for active diagnostic codes with an electronic service tool. If an active speed sensor diagnostic code is generated, or the engine will not start, the polarity of the repair is suspect. Be sure to clear all logged diagnostic codes from the ECM when you are finished with this repair. When you enter a warranty claim for this repair, claim the repair kit part number in the part causing failure field.