Copyright 1991, 2006 Caterpillar Inc. All Rights Reserved.

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6HK 785B TRUCK Testing & Adjusting

Media Number SENR9122-02 Publication Date 1998/12/01 Update Date 2001/09/25

TOS Sensor Or COS Sensor Replacement

Transmission Output Speed (TOS) Sensor

Or Torque Converter Output Speed (COS) Sensor

(1) Nose piece.

The transmission output speed (TOS) sensor and the torque converter output speed (COS) sensor are
the same. The TOS sensor (used on all machines) is located on the sensor gear housing at the front or
rear of the transmission. The COS speed sensor (only used on machines with VIMS) is located on
the torque converter housing.

NOTE: For the 785B with VIMS, the TCO speed sensor is a passive, magnetic pickup type of
sensor. For replacement, adapt the procedures for engine output speed (EOS) sensor.

NOTE: The air gap between the gear and the sensor automatically adjusts itself when properly
installed.

Prior to replacement of the sensor, ensure that replacement is necessary. Always check that power is
available to the sensor; approximately +10 DCV is required between contacts A and B of the
machine harness connector for the sensor. Check the harness connectors for damage.

Procedure

1. Turn the disconnect switch to the OFF position. Disconnect the machine harness connector from
the desired sensor. Remove the sensor.

2. Fully extend nose piece (1) of the new sensor. At the slots in nose piece (1), use a small
screwdriver to pry nose piece (1) out until it no longer moves; approximately 6.5 mm (.25 in).

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3. Install the new sensor into the sensor gear housing and tighten to 23 ± 4 N·m (17 ± 3 lb ft).

As the sensor is tightened, the nose piece contacts the gear face and slides back into the sensor body.
After the sensor is fully tightened, the nose piece is at the correct air gap and no adjustments are
required.

4. Inspect the sensor connector of the machine harness. Connect the machine harness to the TOS
sensor.

5. Check the sensor:

TOS Sensor - It is easily noticed if the sensor is not working; the sensor can be checked by
monitoring the TOS indicator of the display. With the machine stopped, the TOS indicator is OFF.
With the machine moving, the TOS indicator is ON.

COS Sensor - Clear any previous CID 672 faults from the diagnostics of EPTC II. Operate the
machine in second gear or higher for a brief period of time. Stop the machine. Check the diagnostics
to see if a CID 672 fault has occurred.

Copyright 1991, 2006 Caterpillar Inc.

All Rights Reserved.

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