TPMS

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Product: TRUCK
Model: 777D TRUCK AGY
Configuration: 777D Truck AGY00001-UP (MACHINE) POWERED BY 3512B Engine
Special Instruction
Installation Procedure to Install New & Upgrading Existing Kit for Retrofit Truck Payload Monitoring System on Caterpillar 777D, 773E, and 773D {1408, 7490, 7494, 7610}
Media Number -M0069272-03 Publication Date -16/08/2018 Date Updated -16/08/2018
i07483541
Installation Procedure to Install New & Upgrading Existing Kit for Retrofit Truck Payload Monitoring System on Caterpillar 777D, 773E,
and 773D {1408, 7490, 7494, 7610}
SMCS - 1408; 7490; 7494; 7610
Off-Highway Truck/Tractor
773D (S/N: NBJ1-UP)
773E (S/N: BDA1-UP; KEG1-UP; ASK1-UP)
777D (S/N: AGC1-UP; FKR1-UP; 3PR1-UP; 2YW1-UP; AGY1-UP)
Introduction
This Special Instruction contains information for upgrading existing kits and for installing new kits for Truck Payload Monitoring System on Caterpillar 777D & 773E. This will measure the active payload present in the
truck. It consists of sensors and Electronic Control Module (ECM). The system will transmit this data, along with diagnostic information, and the main CDL data link to be received by a recording ECM such as Product
Link .
Safety Section
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 be made unsafe by the operation, lubrication, maintenance, or the repair
procedures that are used.
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Personal injury or death can result from improper assembly

procedures.
Do not attempt any assembly until you have read and understand the
assembly instructions.
Accidental engine starting can cause injury or death to personnel

working on the equipment.
To avoid accidental engine starting, disconnect the battery cable from

the negative (−) battery terminal. Completely tape all metal surfaces of
the disconnected battery cable end in order to prevent contact with
other metal surfaces which could activate the engine electrical system.
Place a Do Not Operate tag at the Start/Stop switch location to inform

personnel that the equipment is being worked on.
Overview
Applicability
Truck Payload Monitoring System (TPMS) is proposedto be usedon 777D and 773E machines of Caterpillar. This can either be a new fitment or an upgrade. This kit can be retrofitted to all 777D and 773E machines and is
offered as an after market attachment.
Required Documents
The reference documents are available on the Caterpillar Service Information System web site. The reference documents should be reviewed and required portions should be potentially printed for reference prior to
installation. The reference documents should be reviewed and required portions potentially printed for reference prior to installation.
Software Enabled Attachments (SEA) Instructions
TPMS requires purchase of an activation code from Caterpillar Feature Protection System (FPS). Use the link below to access Caterpillar FPS.
https://fps.cat.com
Note: CWS account is required to access Caterpillar FPS. Refer to Special Instruction, REHS1238, "Obtaining Factory Passwords and Software Enabled Attachments" for instructions.
For field installation, permanent software can be purchased through the Caterpillar FPS and enabled by a dealer technician with Cat® Electronic Technician (Cat ET) and a SEA activation code.
The SEA part number is 277-0589 Premium Configuration. Consult Antares parts distribution system for current SEA price.
Electrical Requirements
This control is designed to operate on 12 volts DC or 24 volts DC, negative ground. Current draw of the control package is less than 2.0 amps. External solenoids or other loads driven by the control and connection of a
Cat® Electronic Technician (Cat ET) communications adapter will add to the current draw.
Features
The Truck Payload Monitoring Sensor is a precision device. All the components are calibrated to work as a single unit. The system supports both Cat Data Link protocols. Retrofit TPMS is PL ready and will respond to data
request messages from recording ECMs, such as Product Link. When connected, Cat ET will display current flow volumes, supply and return fuel temperatures, and diagnostic information.
Parts List
Table 1
Qty Part Number Part Name Description
1 488-0981 Sensor and Mounting Kit New TPMS Kit for 777D
1 488-0982 Payload Installation Ar TPMS Upgrade Kit for 777D
1 488-0983 Sensor and Mounting Kit New TPMS Kit for 773E / 773D
1 488-0984 Payload Installation Ar TPMS Upgrade Kit for 773E / 773D
Note: It is not necessary to buy all the above kits, customer can buy the kit that suits their respective machine.
Installation of New Retrofit Kit ( 488-0981) in 777D

Table 2
Contents of the 488-0981 Sensor and Mounting Kit
Qty Part Number Description
1 125-9274 Sensor Wiring Gp
1 391-2646 Wiring Harness
1 478-1472 Monitor Wiring Gp
1 478-3252 Monitor Electronic Control Module
1 488-0988 Payload Sensor and Mounting
Machine preparation
1. Drive the machine onto a smooth level surface that can support the weight of the machine.
2. Turn off the machine with engine switch to the OFF position.
Illustration 1 g00104545
3. Use proper Lock out and Tag out procedures. Attach a "Do Not Operate" warning tag to the machine start switch or the controls before you perform any service to the machine. These warning tags are available from
your Caterpillar Dealer.
Installation Procedure
The process for installing this retrofit kit is described briefly here and in detail below. The steps to be followed include:
4. TPMS Mounting and Routing
5. Front Side Electrical Connection
6. Rear Side Electrical Connection
7. Mounting in LH Front Side Suspension
8. Mounting in RH Front Side Suspension
9. Mounting in LH Rear Side Suspension
10. Mounting in RH Rear Side Suspension
11. Sensor Harness Connection Front Suspension
12. Sensor Harness Connection Rear Suspension
Mounting and Routing in Cab
(1) 308-3869 Control Gp.
(2) 162-4056 Panel
(3) 3T-3046 Clip
(4) 9x-2045 Screw
(5) 461-6795 Harness
13. Mount and route harness (5) in the cab rear side using nylon strap. If power is not available, use 391-2646 and tap power from chassis harness.
14. Clip the TPMS harness (5) in the cab front top side. Fit the Panel (2) in the cab. Fit the Control group (1), using four clips (3) and four Screws (4).
15. Connect the TPMS harness (5) in the main harness.
16. Fix the control group (1) in the cab front top side and using screws in proper position.
17. Connect the TPMS harness (5) in the TPMS lamp assembly.
(6) 322-6549 TPMS Lamp
(7) 5M-3062 Bolt
(8) 8T-4896 Washer
18. Mount TPMS lamp (6) as in the cab rear LH outer side and fix the clip cab inner side in proper place using four bolts (7) and four washers (8).
19. Clipping the harness in the clip using strap .
20. Fix the download port with cap in the cab rear diagnostic panel and connect TPMS harness wire in the rear side and using screw , washer , and nut .
21. Mount the TPMS Control Module (285-1142) on the control mounting plate in the cab rear side and using bolts in proper position.
22. Procedure to drill additional holes in bracket assembly: remove existing TPMS Control Module. Align new TPMS Control Module to existing holes. Punch and mark for new holes. Use 3.0 mm (0.12 inch) drill bit
drill a fine hole in the intended position. Gradually increase the drill bit size in order of 3.0 mm (0.12 inch), 5.0 mm (0.20 inch), 8 mm (0.31 inch), and 16 mm (0.630 inch). Use High Speed Steel (HSS) drill bits.
23. Connect the TPMS harness to the TPMS Control Module .
24. Clipping the TPMS Control Module harness in the control mounting plate and using clip , bolt , and washer .
25. Mount the TPMS Control Module harness one end in the cab RH side manifold in proper port.
26. Tight all the bolts
27. Connect c9 of 461-6795 to "FH-C4 VIMS_POWER" in 391-2646.
28. If Product link is present, Disconnect the product link (PA-C3) and machine harness (A-C52). Connect C7 of 461-6795 to machine harness 6-pin connector (A-C52 for harness 396-8630, A-C48 for harness
297-1309). Connect C8 connector of 461-6795 to 6-pin connector, PA-C3, of Product link, that was disconnected from A-C52.
29. If Product link is not present, Connect C7 of 461-6795 to machine harness 6-pin connector (A-C52 for harness 396-8630, A-C48 for harness 297-1309).
Front Side Electrical Connection
(7) 5M-3062 Bolt
(8) 8T-4896 Washer
(9) 4P-7581 Clip
(10) 180-1497 Harness
(11) 7K-1181 Strap
30. Connect the one end of harness (10) to the TPMS cab port .
31. Route harness (10) in the front of the torsion bar using clip (9), bolts (7), and washer (8).
32. Add the clip loop and strap (11) in harness (10) in the front of the torsion bar.
(7) 5M-3062 Bolt
(8) 8T-4896 Washer
(9) 4P-7581 Clip
(10) 180-1497 Harness
(11) 7K-1181 Strap
(12) 9M-8406 Clip
33. Secure the harness in the top of the RH frame rail with the clip loop and the clip (9).
34. Add strap (11) in the harness (10) by side of the hood mount in the RH side.
35. Secure harness (10) using Clip (12), bolt (7), and washer (8) in the bottom of the RH platform.
(7) 5M-3062 Bolt
(10) 180-1497 Harness
(13) 4D-7794 Clip
(14) 130-5300 Clip
36. Route harness (10) to TPMS in RH front suspension mounting using bolt (7) and clip (13)
37. Route harness (10) to TPMS in RH front suspension mounting using bolt (7) and clip (14).
(6) 322-6549 TPMS Lamp
(7) 5M-3062 Bolt
(8) 8T-4896 Washer
(15) 3P-3839 Grommet
38. Install TPMS lamp assembly (6) in RH platform using bolts (7), washer (8), and by adding grommet (15) in the bottom for harness connection.
(7) 5M-3062 Bolt
(8) 8T-4896 Washer
(10) 180-1497 Harness
(16) 033-8248 Clip
39. Connect other end of harness (10) to TPMS RH lamp using clip (16), bolt (7), and washer (8) at the bottom of RH platform.
40. Tighten all bolts (7).
Rear Side Electrical Connection
(7) 5M-3062 Bolt
(8) 8T-4896 Washer
(10) 180-1497 Harness
(13) 4D-7794 Clip
(14) 130-5300 Clip
41. Connect the end of harness assembly (10) to the RH TPMS in the RH rear suspension.
42. Install harness assembly (10) using clip (14), bolt (7), and washer (8).
43. Secure harness assembly (10) using two clips (13), two bolts (7), and two washers (8) on the top of TPMS frame.
(10) 180-1497 Harness
(13) 4D-7794 Clip
44. Secure harness assembly (10) at the top of rear frame using clip (13).
(7) 5M-3062 Bolt
(8) 8T-4896 Washer
(10) 180-1497 Harness
(13) 4D-7794 Clip
(14) 130-5300 Clip
45. Connect the end of harness assembly (10) to the LH TPMS in the LH rear suspension.
(10) 180-1497 Harness
(11) 7K-1181 Strap
48. Secure the harness (10) using twelve straps (11).
(7) 5M-3062 Bolt
(9) 4P-7581 ladder Clip
(10) 180-1497 Harness
(11) 7K-1181 Strap
(13) 4D-7794 Clip
(14) 130-5300 Clip
49. Install the harness (10) to the LH TPMS in the top of the front suspension using clip (14) and bolt (7).
50. Secure the harness (10) to the LH TPMS in the top of the front suspension using clip (13) and bolt (7).
51. Secure the harness (10) to the LH side top part of the frame using ladder clip and three straps (11).
Sensor Installation Parts
Parts required to install Sensors in Front and Rear sides
Table 3
Required Parts
Item Part Number Description
7 5M-3062 Bolt
8 8T-4896 Washer
17 243-1779 Cover As-LH
17A 243-1783 Cover As
18 129-1029 Value Gp-Check
19 228-4929 Block As
20 4L-7124 Bolt
21 5P-0537 Hard Washer
22 8M-4435 O-ring Seal
23 030-0167 Back up Ring
24 114-3361 Fuel system -Seal

25 033-6039 O-Ring Seal
26 3J-1907 O-ring Seal
27 221-3417 Sensor Gp-Pressure
28 372-1181 Charging Valve
29 3E--2385 Decal
30 242-2427 Plate
31 8T-9378 Bolt
32 5P-8167 Bolt
33 4L-6454 Bolt
34 8M-9124 Hard Washer
36 1C-2551 Bolt
37 5M-2894 Washer
38 243-3413 Manifold
39 8M-4447 O-ring seal
40 2K-6073 Bolt
41 240-4665 Cover As
42 4L-9337 Bolt
43 238-9928 Charging Valve
Sensor Installation in LH Front Suspension
(17) 243-1779 Cover As-LH
(18) 129-1029 Valve Gp- Check
52. Discharge nitrogen from suspension, refer to Special Instruction, REHS4445, "Servicing the Suspension Cylinders for Off-Highway Trucks" and Special Instruction, SEHS9411, "Servicing the Suspension Cylinders
for Large Off-Highway Trucks" for proper discharge procedure.
53. Remove cover assembly - LH (17) from valve group (18).
(18) 129-1029 Value Gp-Check
(19) 228-4929 Block As
(20) 4L-7124 Bolt
(21) 5P-0537 Hard Washer
(22) 8M-4435 O-ring Seal
(23) 030-0167 Back-up Ring
(24) 114-3361 Fuel system -Seal
(25) 033-6039 O-Ring Seal
54. Install support block (19) using two screws (20), two washers (21) with O-ring seal (22).
55. Install back up ring (23) and seal fuel system (24) onto the valve group (18). Install O-ring seal (25) on the other side of valve group (18).
(26) 3J-1907 O-ring Seal
(27) 221-3417 Sensor Gp-Pressure
(28) 372-1181 Charging Valve
56. Install pressure sensor (27) using o-ring seal (26) onto the valve group (27).
57. Install charging valve (28) onto the valve group (18).
(8) 8T-4896 Washer
(17) 243-1779 Cover As-LH
(29) 3E--2385 Decal
(30) 242-2427 Plate
(31) 8T-9378 Bolts
(32) 5P-8167 Bolt
(33) 4L-6454 Bolt
(34) 8M-9124 Washer
58. Place decal (29) in plate (30).
59. Mount cover assembly (17) in the LH front suspension rear side using two bolts (31).
60. Install plate (30) using bolt (32), two bolts (33), three washers (8) and inner washer (34) in cover assembly (17).
(36) 1C-2551 Bolts
(37) 5M-2894 Bolts
61. Mount front plate using two bolts (36) and washer (37) in the front suspension side . Install charging valve (28).
62. Mark and torque charging valve (28) to torque of 14 Nm (123 lb in).
63. Charge nitrogen for suspension, refer to Special Instruction, REHS4445, "Servicing the Suspension Cylinders for Off-Highway Trucks" and Special Instruction, SEHS9411, "Servicing the Suspension Cylinders for
Large Off-Highway Trucks" for proper charge procedure.
Sensor Installation in RH Front Suspension
(17A) 243-1783 Cover As
65. Remove cover assembly (17A) from valve group (18).
66. Install support block using two screws , two washers with O-ring seal .
67. Install back up ring and seal fuel system onto the valve group . Install O-ring seal on the other side of valve group .
68. Install pressure sensor using o-ring seal onto the valve group .
69. Install charging valve onto the valve group .
(8) 8T-4896 Washer
(17A) 243-1783 Cover As
(29) 3E--2385 Decal
(30) 242-2427 Plate
(31) 8T-9378 Bolts
(32) 5P-8167 Bolt
(33) 4L-6454 Bolt
(34) 8M-9124 Washer
70. Place decal (29) in plate (30).
71. Mount cover assembly (17A) in the LH front suspension rear side using two bolts (31).
72. Install plate (30) using bolt (32), two bolts (33), three washers (8) and inner washer (34) in cover assembly (17A).
(36) 1C-2551 Bolts
(37) 5M-2894 Bolts
73. Mount front plate using two bolts (36) and washer (37) in the front suspension side . Install charging valve (28).
74. Mark and torque charging valve (28) to torque of 14 Nm (123 lb in.).
Sensor Installation on LH Rear Suspension
Parts Required to Mount Manifold and block
(7) 5M-3062 Bolt
(8) 8T-4896 Washer
(19) 228-4929 Block As
(20) 4L-7124 Bolt
(23) 030-0167 Back-up ring
(24) 114-3361 Back-up ring
(25) 033-6039 O-ring Seal
(38) 243-3413 Manifold
(40) 2K-6073 Bolt
(41) 240-4665 Cover As
(42) 4L-9337 Bolt
77. Install two O-ring seals (39) to manifold (38).
78. Install four bolts (40) to manifold (38). Tighten bolts (40) to a torque of 47 ± 9 Nm (415 ± 79 lb in).
79. Install back up ring (23), (24), and O-ring seals (25) to valve group-check (18) as shown in illustration 24.
80. Apply the sealant in O-ring seal (25).
81. Install valve (18) to manifold (38).
82. Install two bolts (20) and two washers (21) to block assembly (19). Install block assembly to manifold (38).
83. Install O-ring seal (26) to sensor group-pressure (27) and install to valve (18).
84. Install bolts (42), (7), and washer (8) to cover assembly (41). Install cover assembly to manifold (38).
85. Install manifold (38) with bolts (40), blocks assembly (19), sensor group pressure (27), cover assembly (41) to the LH side rear suspension . Tighten bolts (40) to a torque of 47 ± 9 Nm (415 ± 79 lb in.).
86. Install charging valve (43) to two ends of manifold (38).
Sensor Installation on RH Rear Suspension
(7) 5M-3062 Bolt
(8) 8T-4896 Washer
(19) 228-4929 Block As
(20) 4L-7124 Bolt
(23) 030-0167 Back-up ring
(24) 114-3361 Back-up ring
(25) 033-6039 O-ring Seal
(38) 243-3413 Manifold
(40) 2K-6073 Bolt
(41) 240-4665 Cover As
(42) 4L-9337 Bolt
89. Install two O-ring seals (39) to manifold (38).
90. Install four bolts (40) to manifold (38). Tighten bolts (40) to a torque of 47 ± 9 Nm (415 ± 79 lb in).
91. Install back up ring (23), (24), and O-ring seals (25) to valve group-check (18) as shown in illustration 26.
92. Apply the sealant in O-ring seal (25).
93. Install valve (18) to manifold (38).
94. Install two bolts (20) and two washers (21) to block assembly (19). Install block assembly to manifold (38).
95. Install O-ring seal (26) to sensor group-pressure (27) and install to valve (18).
96. Install bolts (42), (7), and washer (8) to cover assembly (41). Install cover assembly to manifold (38).
97. Install manifold (38) with bolts (40), blocks assembly (19), sensor group pressure (27), cover assembly (41) to the RH side rear suspension . Tighten bolts (40) to a torque of 47 ± 9 Nm (415 ± 79 lb in.).
98. Install charging valve (43) to two ends of manifold (38).
Upgrading existing TPMS kit ( 488-0982) in 777D

Note: Applicable Machines : 777D machines with FKR Prefix.
Table 4
Contents of the 488-0982 Payload Installation Ar
4 5C-9553 Bolt
40 7K-1181 Cable Strap
8 8C-5607 Isolation Mount
8 8C-5608 Spacer
8 8K-1433 Grommet
8 8T-4121 Hard Washer
4 8T-4136 Bolt
8 8T-4137 Bolt
4 9X-2042 Screw
8 9X-8256 Washer
4 121-9870 Screw
8 198-4775 Hard Washer
1 285-1142 Electronic Control Module
2 322-6549 Payload Signal Lamp Gp
2 352-3964 Clip
1 461-2077 Sensor Harness As
1 461-6795 Control Harness As
1 464-0679 Plate
1 464-0681 Plate
1 475-2593 Monitor Software Gp
1 478-1471 Film
Machine preparation
Mounting in Cab
(44) 107-8266 Bracket
(45) 464-0679 Plate
4. Remove display group-payload monitor with its existing bracket (44) and Install new plate (45) in the cab as per shown in illustration 29.
5. Insert messenger supportive plate to the rear of messenger and screw it tightly as shown in illustration 30.
(A) 49 mm (1.9 inch)
(B) 47 mm (1.8 inch)
(46) 9x-6847 Display Gp-Payload Monitor
(47) 308-3869 Control Gp-Messenger
6. Remove display group-payload monitor (46) assembled with screws and Install control group-Messenger (47) assembled by press fit as per shown in illustration 31.
7. Procedure to drill additional holes in bracket assembly: remove existing ECM. Align new ECM to existing holes. Punch and mark for new holes. Use 3 mm drill bit drill a fine hole in the intended position. Gradually
increase the drill bit size in order of 3 mm, 5 mm, 8 mm, and 16 mm. Use High Speed Steel (HSS) drill bits.
(48) 9x-6846 Control Gp-Monitor

(49) 285-1142 Control Gp
(50) 167-4414 Bracket As
(50A) 167-4414 Bracket As
8. Remove existing control group-monitor (48) with bracket assembly (50) and install new control group (49) with updated four holes in bracket assembly (50A) to the wiring group-cab as shown in illustration 32.
(51) 9x-6846 Receptacle As-Connecter
(52) 210-8950 Receptacle-Connector
(53) 163-0842 Plate
(54) 464-0781 Plate
9. Remove existing receptacle assembly-connecter (51) with plate (53) and install new receptacle-connector (52) with updated holes in plate (54) for mounting receptacle-connector (61) to the wiring group-cab as shown
in illustration 33.
10. Remove fuse harness 391-2646 from existing TPMS. Connect the same into new TPMS harness.
11. Connect the 12-pin mate connector into service port connector.
297-1309). Connect C8 connector of 461-6795 to 6-pin connector, PA-C3, of Product Link, that was disconnected from A-C52.
14. If Product Link is not present, connect C7 of 461-6795 to machine harness 6-pin connector (A-C52 for harness 396-8630, A-C48 for harness 297-1309).
Cab Wiring Harness Connection
(C) Service connector
(D) ECM connector
(E) TPMS Board Connector
(F) A-C69 Connector
(G) Product link
(H) A-C52 Connector
(55) 461-6795 Harness As
15. Connect harness assembly (55) to service connector (C), ECM connector (D), TPMS board connector (E), A-C69 (F), product link (G), and A-C52 (H) as shown in illustration 34.
(J) TPMS Lamp
(K) Chassis Interface Connector
(55) 461-6795 Harness As
16. Connect harness assembly (55) to TPMS lamp (J) and chassis interface connection (K) as per shown in illustration 35.
(55) 461-6795 Harness As
(56) 161-9845 Harness As
17. Remove existing harness assembly (56) and install new harness assembly (55) as per shown in illustration 36.
Pay Load Lamp Upgrade for 777D
(57) 322-6549 Lamp Gp (Existing)
(58) 322-6549 Lamp Gp (New)
18. Remove existing lamp group (57) and install new lamp group (58) to the cab as shown in illustration 37.
(58) 322-6549 Lamp Gp
(59) 461-2077 Harness As
19. Install Harness assembly (59) to lamp group (58) to accommodate harness routing changes.
Installation of New Retrofit Kit ( 488-0983) in 773E and 773D

Table 5
Contents of the 488-0983 Sensor and Mounting Kit

1 137-6813 Sensor Wiring Gp
1 478-1472 Monitor Wiring Gp
Machine preparation
Installation Procedure
The process for installing this retrofit kit is described briefly here and in detail below. The steps to be followed include:
4. TPMS Mounting and Routing
5. Front Side Electrical Connection
6. Rear Side Electrical Connection
7. Mounting in LH Front Side Suspension
8. Mounting in RH Front Side Suspension
9. Mounting in LH Rear Side Suspension
10. Mounting in RH Rear Side Suspension
11. Sensor Harness Connection Front Suspension
12. Sensor Harness Connection Rear Suspension
Mounting and Routing in Cab
(1) 308-3869 Control Gp.
(2) 162-4056 Panel
(3) 3T-3046 Clip
(4) 9x-2045 Screw
(60) 161-9845 TPMS Harness
13. Mount and routing the TPMS harness (60) in the cab rear side using nylon strap.
14. If power line is not available, use (391-2646) and tap power from chassis harness.
15. Clip the TPMS harness (60) in the cab front top side. Fit the Panel (2) in the cab. Fit the Control group (1), using four clips (3) and four Screws (4).
16. Connect the TPMS harness (60) in the main harness.
17. Fix the control group (1) in the cab front top side and using screws in proper position.
18. Connect the TPMS harness (60) in the TPMS lamp assembly.
(6) 322-6549 TPMS Lamp
(7) 5M-3062 Bolt
(8) 8T-4896 Washer
19. Mount TPMS lamp (6) as in the cab rear LH outer side and fix the clip cab inner side in proper place using four bolts (7) and four washers (8).
20. Clipping the harness in the clip using strap .
21. Fix the download port with cap in the cab rear diagnostic panel and connect TPMS harness wire in the rear side and using screw , washer , and nut .
22. Mount the TPMS control (285-1142) on the control mounting plate in the cab rear side and using bolts in proper position.
24. Connect the TPMS harness to the TPMS control .
25. Clipping the TPMS control module harness in the control mounting plate and using clip , bolt , and washer .
26. Mount the TPMS harness one end in the cab RH side manifold in proper port.
27. Tighten all the bolts.
Front Side Electrical Connection
(7) 5M-3062 Bolt
(8) 8T-4896 Washer
(9) 4P-7581 Clip
(10) 180-1497 Harness
(11) 7K-1181 Strap
31. Connect the one end of the harness to the TPMS cab port.
32. Route the harness (10) in the front of the torsion bar using clip (9), bolts (7), and washer (8).
33. Add the clip loop and strap (11) in the harness (10) in the front of the torsion bar.
(7) 5M-3062 Bolt
(8) 8T-4896 Washer
(9) 4P-7581 Clip
(10) 180-1497 Harness
(11) 7K-1181 Strap
(12) 9M-8406 Clip
34. Secure harness (10) in the top of the RH frame rail with the clip loop and the clip (9).
35. Add strap (11) in the harness (10) by side of the hood mount in the RH side.
36. Secure harness (10) using Clip (12), bolt (7), and washer (8) in the bottom of the RH platform.
(7) 5M-3062 Bolt
(10) 180-1497 Harness
(13) 4D-7794 Clip
(14) 130-5300 Clip
(6) 322-6549 TPMS Lamp
(7) 5M-3062 Bolt
(8) 8T-4896 Washer
39. Install TPMS lamp assembly (6) in RH platform using bolts (7), washer (8), and by adding grommet (15) in the bottom for harness connection.
(7) 5M-3062 Bolt
(8) 8T-4896 Washer
(10) 180-1497 Harness
(16) 033-8248 Clip
40. Connect other end of harness (10) to TPMS RH lamp using clip (16), bolt (7), and washer (8) at the bottom of RH platform.
41. Tighten all bolts (7).
Rear Side Electrical Connection
(7) 5M-3062 Bolt
(8) 8T-4896 Washer
(13) 4D-7794 Clip
(14) 130-5300 Clip
(61) 180-1403 Harness
42. Connect the end of harness assembly (61) to the RH TPMS in the RH rear suspension.
(13) 4D-7794 Clip
(61) 180-1403 Harness
45. Secure harness assembly (61) at the top of rear frame using clip (21).
(7) 5M-3062 Bolt
(8) 8T-4896 Washer
(13) 4D-7794 Clip
(14) 130-5300 Clip
(61) 180-1403 Harness
46. Connect the end of harness assembly (61) to the LH TPMS in the LH rear suspension.
(11) 7K-1181 Strap
(61) 180-1403 Harness
49. Secure the harness (61) using twelve straps (11).
(7) 5M-3062 Bolt
(11) 7K-1181 Strap
(13) 4D-7794 Clip
(14) 130-5300 Clip
(61) 180-1403 Harness
50. Install the harness (61) to the LH TPMS in the top of the front suspension using clip (14) and bolt (7).
51. Secure the harness (61) to the LH TPMS in the top of the front suspension using clip (13) and bolt (7).
52. Secure the harness (61) to the LH side top part of the frame using ladder clip (9) and three straps (11).
Sensor Installation Parts
Parts required to install Sensors in Front
Table 6
Required Parts
Item Part Description

Number
8 8T-4896 Washer
18 129-1029 Value Gp-Check
19 228-4929 Block As
20 4L-7124 Bolt
21 5P-0537 Hard Washer
22 8M-4435 O-ring Seal
23 030-0167 Back up Ring
24 114-3361 Fuel system -Seal
25 033-6039 O-Ring Seal
26 3J-1907 O-ring Seal
27 221-3417 Sensor Gp-Pressure
62 243-1768 Block
63 5S-7383 Bolt
Mounting in LH Front Suspension
Parts Required for Mount Manifold and Block
(8) 8T-4896 Washer
(19) 228-4929 Block As
(20) 4L-7124 Bolt

(23) 030-0167 Back-up ring
(24) 114-3361 Back-up ring
(25) 033-6039 O-ring Seal
(62) 243-1768 Block
(63) 5S-7383 Bolt
54. Remove the charging valve from the rear of the LH front suspension cylinder.
55. Install seal o-ring (24) in the large end of valve (18)
56. Install backup ring (23) inside valve (18) and then add o-ring seal (25).
57. Install valve (18) to block (62) and tighten it.
58. Install block (19) using two bolts (20) and two washers (21) onto block (62).
59. Insert seal o-ring (24) in the sensor press (27)
60. Install sensor press (27) in the block (19) and tighten it.
61. Install block (62) with block (19), sensor (27), two washers (8), and two bolts (63) onto the LH front suspension cylinder.
Mounting in RH Front Suspension
(8) 8T-4896 Washer
(19) 228-4929 Block As
(20) 4L-7124 Bolt

(23) 030-0167 Back-up ring
(24) 114-3361 Back-up ring
(25) 033-6039 O-ring Seal
(62) 243-1768 Block
(63) 5S-7383 Bolt
64. Remove the charging valve from the rear of the RH front suspension cylinder.
65. Install seal o-ring (24) in the large end of valve (18)
66. Install backup ring (23) inside valve (18) and then add O-ring seal (25).
69. Insert seal o-ring (24) in the sensor press (27)
71. Install block (62) with block (19), sensor (27), two washers (8), and two bolts (63) onto the RH front suspension cylinder.
Mounting in LH Rear Suspension
Part Required to Mount Manifold and Block
(8) 8T-4896 Washer
(19) 228-4929 Block As
(20) 4L-7124 Bolt
(23) 030-0167 Back-up ring
(24) 114-3361 Back-up ring
(25) 033-6039 O-ring Seal

(62) 243-1768 Block
(63) 5S-7383 Bolt
74. Remove the charging valve from the LH rear suspension system.
75. Install seal O-ring (24) in the large end of valve (18).
79. Insert seal o-ring (26) in the sensor press (27).
81. Install block (62) with block (19), sensor (27), two washers (8), and two bolts (63) onto the LH Rear suspension cylinder.
82. Install block (62) in the left side of LH rear suspension cylinder using two bolts (63) and two washers (8).
Mounting in RH Rear Suspension
(8) 8T-4896 Washer
(19) 228-4929 Block As
(20) 4L-7124 Bolt

(23) 030-0167 Back-up ring
(24) 114-3361 Back-up ring
(25) 033-6039 O-ring Seal
(62) 243-1768 Block
(63) 5S-7383 Bolt
85. Remove the charging valve from the RH rear suspension system.
86. Install seal O-ring (24) in the large end of valve (18).
90. Insert seal o-ring (26) in the sensor press (27).
92. Install block (62) with block (19), sensor (27), two washers (8), and two bolts (63) onto the RH Rear suspension cylinder.
93. Install block (62) in the left side of RH rear suspension cylinder using two bolts (63) and two washers (8).
Location of Harness Routing
Harness Routing in Front Side
View of Area M
(8) 8T-4896 Washer
(11) 7K-1181 Strap
(13) 4D-7794 Clip
(14) 130-5300 Clip
(61) 180-1403 Harness
(64) 4P-8134 Clip
(65) 5S-7379 Bolt
(66) 3S-2093 Strap
95. Install the end of harness (61) to the LH TPMS front sensor using clip (14), bolt (65), and washer (8).
96. Connect one end of harness assembly (61) to the cab port and add strap (11).
97. Secure harness (61) in the LH side beam using three straps (11).
98. Secure harness (61) in the front side of tie bar using four straps (11).
99. Secure the harness (61) at the RH fore after beam using clip (65) and strap (11).
100. Install the one end of harness (61) in the bottom side of the platform using three straps (11).
101. Secure harness (61) RH TPMS front sensor using clip (14), bolt (65), and washer (8).
102. Add the grommet (15) in the RH platform.
103. Install TPMS lamp as in the RH platform using four bolts (68), four washers (8).
104. Route the other end of harness (61) in the side of the battery box in the bottom of the RH Platform using clips (64) and strap (65).
105. Secure harness (61) using clip (64) and strap (66).
106. Secure harness (61) using clip (9) and strap (66).
107. Secure harness (61) using clip (13).
108. Connect the end of RH TPMS light.
Harness Routing in Rear Side
View of Area L
(8) 8T-4896 Washer
(11) 7K-1181 Strap
(13) 4D-7794 Clip
(14) 130-5300 Clip
(61) 180-1403 Harness
(65) 5S-7379 Bolt
109. Mount harness (61) in the frame.
110. Secure harness (61) using clip (14), bolt (65), and washer (8) another end using two clips (13), two bolts (65), and two washers (8).
111. Secure harness (61) at the RH side at the top of rear frame using clip (13), bolt (65), and (8).
112. Secure harness (61) in the top of rear frame beam using (13).
113. secure harness (61) in the back of alarm point using strap (11).
114. Add clip (9) and strap (11) in the body up sensor bracket.
115. Secure harness (61) using clip (14), bolt (65), and washer (8) another end using two clips (13), two bolts (65), two washers (8) at the LH rear frame.
116. Secure harness (61) in the top of rear frame beam using (13).
117. Route harness in the LH side of the frame rail by using five straps (11).
118. Add four straps (11) in harness (61) from the right of the center of beam frame.
119. Mark and torque all bolts.
Upgrading existing TPMS kit ( 488-0984) in 773E and 773D

Note: Applicable Machines : 773E machines with ASK Prefix.
Table 7
Contents of the 488-0984 Payload Installation Ar
4 5C-9553 Bolt
40 7K-1181 Cable Strap
8 8C-5607 Isolation Mount
8 8C-5608 Spacer
8 8T-4121 Hard Washer
4 8T-4136 Bolt
8 8T-4137 Bolt
4 9X-2042 Screw
8 9X-8256 Washer
4 121-9870 Screw
8 198-4775 Hard Washer
2 322-6549 Payload Signal Lamp Gp
2 352-3964 Clip
1 461-2077 Sensor Harness As
1 461-6795 Control Harness As

1 464-0679 Plate
1 464-0681 Plate
1 478-1471 Film
Machine preparation
Mounting in Cab
(44) 107-8266 Bracket
(45) 464-0679 Plate
4. Remove display group-payload monitor with its existing bracket (44) and Install new plate (45) in the cab as per shown in illustration 29.
5. Insert messenger supportive plate to the rear of messenger and screw it tightly as shown in illustration 30.
(A) 49 mm (1.9 inch)
(B) 47 mm (1.8 inch)
(46) 9x-6847 Display Gp-Payload Monitor
(47) 308-3869 Control Gp-Messenger
6. Remove display group-payload monitor (46) assembled with screws and Install control group-Messenger (47) assembled by press fit as per shown in illustration 31.
(48) 9x-6846 Control Gp-Monitor

(49) 285-1142 Control Gp
(50) 167-4414 Bracket As
(50A) 167-4414 Bracket As
8. Remove existing control group-monitor (48) with bracket assembly (50) and install new control group (49) with updated four holes in bracket assembly (50A) to the wiring group-cab as shown in illustration 32.
(51) 9x-6846 Receptacle As-Connecter
(52) 210-8950 Receptacle-Connector
(53) 163-0842 Plate
(54) 464-0781 Plate
9. Remove existing receptacle assembly-connecter (51) with plate (53) and install new receptacle-connector (52) with updated holes in plate (54) for mounting receptacle-connector (61) to the wiring group-cab as shown
in illustration 33.
10. Connect the 12-pin mate connector into service port connector.
11. Remove fuse harness 391-2646 from existing TPMS. Connect the same into new TPMS harness.
Cab Wiring Harness Connection
(C) Service connector
(D) ECM connector
(E) TPMS Board Connector
(F) A-C69 Connector
(G) Product link
(H) A-C52 Connector
(55) 461-6795 Harness As
15. Connect harness assembly (55) to service connector (C), ECM connector (D), TPMS board connector (E), A-C69 (F), product link (G), and A-C52 (H) as shown in illustration 34.
(J) TPMS Lamp
(K) Chassis Interface Connector
(55) 461-6795 Harness As
16. Connect harness assembly (55) to TPMS lamp (J) and chassis interface connection (K) as per shown in illustration 35.
(55) 461-6795 Harness As
(56) 161-9845 Harness As
17. Remove existing harness assembly (56) and install new harness assembly (55) as per shown in illustration 36.
Pay Load Lamp Upgrade for 773E
(57) 322-6549 Lamp Gp (Existing)
(58) 322-6549 Lamp Gp (New)
18. Remove existing lamp group (57) and install new lamp group (58) to the cab as shown in illustration 37.
(58) 322-6549 Lamp Gp
(59) 461-2077 Harness As
19. Install Harness assembly (62) to lamp group (61) to accommodate harness routing changes.
Configuration of Installed System

Software Set-Up
• Flash TPMS ECM through ET.
• Upload Config File to TPMS, using VIMSpc.
• Flashing Messenger through ET.
• Open config in ET screen for Messenger and TPMS write product ID (machine serial number).
• Verify if overload is set at 110%.
• Verify if Target Payload is set at 95 tonnes (for 777D), 54 tonnes (for 773E).
• Set config of Green & Red TPMS lamps as LED.
• Set Truck Payload Last Pass indicator to Enabled.
• Perform key cycle.
TPMS Calibration
This step is to calibrate the system to the "Zero Load" value.
• Ensure that the machine is stationary, engine is running, truck body is empty, service brake and park brakes should be disengaged.
• Drive the machine onto a smooth level surface that can support the weight of the machine.
• Connect to the machine using ET via the Comm Adapter 3.
• Navigate to the calibration menu and select "Payload Calibration".
• Click "Start Calibration".
• Engage a gear and move the machine forward at a minimum speed of 10KMpH.
• Once the machine has reached 10KMpH, engage ‘Neutral’ gear and let the machine coast to a stop without applying the service or parking brakes.
• Make sure that machine speed is ZERO.
• Click "Complete" on the calibration page in ET.
• Once this is complete, a "Calibration Successful" message will appear on the screen.
• The machine is now calibrated to the "Zero Load".
• For every change in strut pressure sensor, including change and service, TPMS should be calibrated again.
Validation of the Installed System

Electrical Validation
Initial Check
• After installation of the TPMS system, turn on both master key and ignition key.
• The Messenger should turn on and display the Cat logo.
• After this, the screen will change to display the strut pressure sensor values.
• If all the strut pressure values are showing on the display, the system is connected and working properly.
Functional Validation
Payload Test
The following steps will help in running a payload cycle and run the checks for all the messages on the display and payload lights:
• Stop the truck in the loading area – the Messenger should display "Stopped Empty".
• Once the loader has emptied the first load into the truck body, the Messenger display will change to "Loading" and the current payload weight will be displayed. Also the GREEN LED will ILLUMINATE.
• Continue loading the machine.
• Once the payload detects the next pass of the loader at 95% of the target weight ( 95 tonne in the 777D and 57 tonne in 773E), the Messenger will display "Last Pass". Also the RED LED will START FLASHING.
• Once the target weight has been reached the Messenger will display "Fully Loaded". Also the RED LED light will CONTINUOUSLY ILLUMINATE.
Second Gear Reweigh
Second gear reweigh feature is used to improve the accuracy of the measured payload by measuring the payload once the truck has moved for a certain distance and has reached a particular speed and the second gear has
been engaged.
• Once the truck has moved from the loading area for a minimum distance of 160.0 m (524.93 ft) and second gear is engaged, the TPMS system reweighs the payload.
• Once the reweigh is completed, the "Fully Loaded" message and the Payload weight will disappear from the Messenger and the "Traveling Loaded" message will be displayed.
• Also, the RED LED light will go off.
Copyright 1993 - 2020 Caterpillar Inc. Thu Aug 6 12:32:30 UTC+0430 2020
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777D Truck AGY00001-UP (MACHINE) POWERED BY 3512B Engine(SEBP3017 - 123)/Basic Search Page 1 of 60

Personal injury or death can result from improper assembly

Accidental engine starting can cause injury or death to personnel

To avoid accidental engine starting, disconnect the battery cable from

Place a Do Not Operate tag at the Start/Stop switch location to inform

Software Enabled Attachments (SEA) Instructions

Installation of New Retrofit Kit ( 488-0981) in 777D

4. TPMS Mounting and Routing

5. Front Side Electrical Connection

6. Rear Side Electrical Connection

7. Mounting in LH Front Side Suspension

8. Mounting in RH Front Side Suspension

9. Mounting in LH Rear Side Suspension

10. Mounting in RH Rear Side Suspension

11. Sensor Harness Connection Front Suspension

12. Sensor Harness Connection Rear Suspension

Mounting and Routing in Cab

15. Connect the TPMS harness (5) in the main harness.

19. Clipping the harness in the clip using strap .

23. Connect the TPMS harness to the TPMS Control Module .

26. Tight all the bolts

27. Connect c9 of 461-6795 to "FH-C4 VIMS_POWER" in 391-2646.

Front Side Electrical Connection

40. Tighten all bolts (7).

Rear Side Electrical Connection

48. Secure the harness (10) using twelve straps (11).

Sensor Installation Parts

Parts required to install Sensors in Front and Rear sides

24 114-3361 Fuel system -Seal

Sensor Installation in LH Front Suspension

53. Remove cover assembly - LH (17) from valve group (18).

58. Place decal (29) in plate (30).

Sensor Installation in RH Front Suspension

65. Remove cover assembly (17A) from valve group (18).

69. Install charging valve onto the valve group .

70. Place decal (29) in plate (30).

Sensor Installation on LH Rear Suspension

77. Install two O-ring seals (39) to manifold (38).

80. Apply the sealant in O-ring seal (25).

81. Install valve (18) to manifold (38).

86. Install charging valve (43) to two ends of manifold (38).

Sensor Installation on RH Rear Suspension

89. Install two O-ring seals (39) to manifold (38).

92. Apply the sealant in O-ring seal (25).

93. Install valve (18) to manifold (38).

98. Install charging valve (43) to two ends of manifold (38).

Upgrading existing TPMS kit ( 488-0982) in 777D

(48) 9x-6846 Control Gp-Monitor

12. Connect c9 of 461-6795 to "FH-C4 VIMS_POWER" in 391-2646.

Cab Wiring Harness Connection

Pay Load Lamp Upgrade for 777D

Installation of New Retrofit Kit ( 488-0983) in 773E and 773D

Qty Part Number Description

4. TPMS Mounting and Routing

5. Front Side Electrical Connection

6. Rear Side Electrical Connection

7. Mounting in LH Front Side Suspension

8. Mounting in RH Front Side Suspension

9. Mounting in LH Rear Side Suspension

10. Mounting in RH Rear Side Suspension

11. Sensor Harness Connection Front Suspension

12. Sensor Harness Connection Rear Suspension

Mounting and Routing in Cab

16. Connect the TPMS harness (60) in the main harness.