ADEM2000 Heavy Duty Truck Engine Speed Sensor Service Caterpillar

ADEM2000 Heavy Duty Truck Engine Speed Sensor Service

Usage:

ENGINESC-10 (3CS),
C-12 (2KS, 9SM),
3406E (1MM, 2WS),
C-15 (6NZ),
C-16 (7CZ) TRUCK ENGINES

THIS TIB REPLACES THE AUGUST 04, 1999 ENGINES TIB, COMPONENT CODE 1408, 1900. DESTROY THE AUGUST 04, 1999 TIB. IT WILL NOT APPEAR IN THE QUARTERLY INDEX.

Problem:

There has been an engine speed sensor issue identified that may cause the ECM to detect an intermittent engine speed signal. This issue may effect the above engines operating in on-highway trucks. If the intermittent condition occurs, the ECM will log a 190-12 (Loss of Engine Crank Sensor RPM Signal) and/or a 64-12 (Loss of Engine Cam Sensor RPM Signal) diagnostic code. The occurrence of these diagnostics generally has no effect on engine performance, although the diagnostics are occasionally accompanied by a noticeable engine speed burp.

Solution:

If a CAT-powered truck has an active or logged 190-12 or 64-12 diagnostic code present in the ECM, then

1. Follow troubleshooting procedures as per Troubleshooting Guide RENR2238, Engine Speed/Timing Circuits Test, Steps 2 and 3.

2. If Steps 2 and 3 check out OK, the next step will be to order the proper repair kit as shown in Table 1 below. If the engine being repaired is a C-10 or C-12 Engine with no active camshaft speed sensor diagnostics, repair the engine crankshaft speed sensor only. If the engine being repaired is a 3406E, C-15, or C-16 Engine with no active crankshaft speed sensor diagnostics, repair only the engine camshaft speed sensor.

194-5338 and 194-5341 Service Kits (C-10/C-12 with 190-12 faults or 3406E/C-15/C-16 with 64-12 faults)

1. The 9X-3402 gold machined sockets must be used only when mating to the pigtailed C-10/C-12 crankshaft speed sensor or the pigtailed 3406E/C-15/C-16 camshaft speed sensor.

2. When using the 9X-3402 Sockets (machined gold), only the existing speed sensor sockets will be replaced on the engine harness, not the 2-pin male DT connector. Before removing the wires from the connector, note the relationship between the color of the wire and the socket cavity number at the back of the connector. Cut off the engine wiring harness speed sensor leads flush with the speed sensor sockets. The existing integral engine speed sensor will be replaced with the proper pigtailed engine speed sensor. The 9X-3402 Sockets will be installed using the 1U-5804 Deutsch Crimping Tool. The existing 2-pin DT connector shall be reused. Install the wires with the new sockets into the same connector cavities from which they were removed.

3. Install the new engine speed sensor contained in the repair kit. Connect the 2-pin male DT connector to the new sensor. DO NOT TIE-WRAP THE CONNECTOR DIRECTLY TO THE ENGINE OR HARNESS CLIP. TIE-WRAP TO THE BRAIDED PORTION ON THE ENGINE HARNESS.

NOTE: To ensure that the polarity of the connections is correct, start the engine and check the ECM for active diagnostic codes with an electronic service tool. If an active speed sensor diagnostic is generated, or the engine will not start, the polarity of the repair is suspect. See Table 2 for sensor wiring information.

194-5339 and 194-5340 Service Kits (C-10/C-12 with 64-12 faults or 3406E/C-15/C-16 with 190-12 faults)

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

2. When using the butt-splice assembly, both the harness speed sensor connector sockets and the 2-pin male DT connector will be removed from the engine harness speed sensor leads. Cut the engine wiring harness speed sensor leads back from the sensor end, but not shorter than the wiring harness braid. When performing the butt splices, use the 9S-9150 or similar crimping pliers. DO NOT USE STANDARD PLIERS TO PERFORM THE CRIMP. The butt splice assemblies in the repair kits are color-coded to match the engine wiring harness to help eliminate polarity reversal (See Table 2). Once the butt splice is properly crimped to the engine speed sensor harness, use a heat gun to shrink the insulation to properly seal the crimped connections. There should be a small bead of adhesive formed on each end of the shrink-wrap following the heat shrink. (See the Illustration).

Properly Installed Butt Splice Assembly

3. Install the new engine speed sensor contained in the repair kit. Connect the new engine harness connector to the new sensor. DO NOT TIE-WRAP THE BUTT SPLICE ASSEMBLY DIRECTLY TO THE ENGINE OR HARNESS CLIP. TIE-WRAP TO THE BRAIDED PORTION OF THE ENGINE WIRING HARNESS.