Procedure to Install the Advanced Productivity Wiring Kit on Certain 773G, 775G and 777G Off Highway Truck {1408, 7301, 7606} Caterpillar

Off-Highway Truck/Tractor

777G (S/N: T5A1-UP; TNM1-UP; RDR1-UP; T4Y1-UP)

Quarry Truck

773G (S/N: MWH1-UP; JWS1-UP; T5S1-UP; T5T1-UP)

775G (S/N: T5F1-UP; RFM1-UP; MJS1-UP; T5W1-UP)

Introduction

This Special Instruction contains information to install the advanced productivity wiring kit on the machines listed above.

Do not perform any procedure in this Special Instruction until you have read the information and you understand the information.

Reference

Reference: Special Instruction, M0072768, "Installation Procedure for the Pro Product Link ^® PL641 On Certain 773G, 775G, and 777G Off Highway Trucks."

Reference: Special Instruction, REHS8836, "Procedure For Enhancing the Ethernet Adapter For VIMS^™ on Certain Cat^® Products."

Safety

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Do not operate or work on this product unless you have read and understood the instruction and warnings in the relevant Operation and Maintenance Manuals and relevant service literature. Failure to follow the instructions or heed the warnings could result in injury or death. Proper care is your responsibility.

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Failure to follow all safety guidelines prescribed in this document and by governing authorities and regulatory agencies may result in severe injury or death of personnel or machine damage.

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Before servicing/performing maintenance on the machine, electrical power must be physically disconnected; battery plugs must be disconnected from the batteries, or the trailing cable must be unplugged, and warning tags and padlocks shall be applied by a certified electrician. Certified electricians shall perform or direct any electrical work, including any energized testing, repair work in controllers, motors, or other approved compartments, and shall insure that all compartments are properly closed and inspected prior to re-energization. All applicable lock out and tag out procedures must be followed.

Required Parts

Removal Procedure

Note: If the machine is already equipped with a PL641 system, then proceed to Step 1 of Section "Removal Procedure".

Note: If the machine is not equipped with a PL641, follow Steps 1 through 9, Steps 19 through 20, and Steps 23 through 30 in the Section of "Installation Procedure" of Special Instruction , M0072768 , "Installation Procedure for the Pro Product Link^® PL641 on Certain 773G, 775G, and 777G Off Highway Trucks."

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Illustration 1	g06332966
Rear side of the cab (A) Rear access panel

1. Remove and retain rear access panel (A) from the cab arrangement. Refer to Illustration 1.
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   Illustration 2	g06333568
   (B) Operator Seat (C) Plastic Panel

2. Slide operator seat (B) forwards then remove and retain the plastic panels (C) above the ECM which is above the fuse panel.
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   Illustration 3	g06332449
   (D) 493-2549 Wiring Harness

3. Remove wiring harness (D) from the machine (if equipped with existing PL641 system).

   Note: PL641 wiring harness (D) connects at the service port location near the fuse panel in the cab.

   Note: Wiring harness (D) routes out through the cab rear bulk head in the right rear corner and connects to the VIMS main ECM and associated connectors. This would only be present if the machine is already equipped with a PL641 system

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   Illustration 4	g06332635
   (E) ECM mounting panel.

4. Remove and retain ECM mounting panel (E) from its base and rotate to gain access to the bottom. Refer to Illustration 4.

Installation Procedure

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Illustration 5	g06331222
(1) 362-0169 Electronic Control Module

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Illustration 6	g06334250
(1) 362-0169 Electronic Control Module (2) 8T-0275 Bolt (3) 8C-5608 Spacer (4) 9X-6165 Washer (5) 8C-5607 Isolation Mount (6) 7K-1181 Cable Strap (7) 550-5047 Wiring Harness

1. Install Electronic Control Module (1) on the bottom of ECM mounting plate near the Right-hand side of the cab. Refer Illustration 5.

   Secure ECM mounting by using Isolation mount (5), Washer (4), Spacer (3) and Bolt (2). Refer to Illustration 6.

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   Illustration 7	g06332095
   (7) 550-5047 Wiring Harness

2. Locate wiring harness (7) and connect to 40-pin connector which is labelled as 'Ethernet switch' to the Ethernet Switch in Electronic Control Module (1). Reinstall the ECM mounting panel (E) that was removed in Step 1 of Section "Removal Procedure".

   Note: Route harness (7) from Ethernet switch module towards the front panel through the same routing as the former harness.

   Note: Use Cable Strap (6) for harness material as needed. Refer to Illustration 6.

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   Illustration 8	g06334579
   (8) 270-2679 Lockwasher (9) 203-9007 Nut (10) 455-9568 Cap As (11) 9P-6573 Plug

3. Route the "Service port cab" connector from wiring harness (7) through the hole near the fuse panel where 9-pin "MC-C95" was disconnected, and then secure the "service port cab" connection by using lock washer (8), nut (9), cap assembly (10), and plug (11).
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   Illustration 9	g06331638
   (F) Service Connector

4. Attach the removed 9-pin MC-C95 to the mating service connector (F) MC-C80 on the wiring harness (7). Refer to Illustration 9.
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   Illustration 10	g06332642
   (G) 50.8 mm (2.00 inch) Hole (H) Cab harness (7) 550-5047 Wiring Harness

5. Route wiring harness (7) along with existing cab harness (H) into hole (G). Refer to Illustration 10.

   Note: Use Cable Strap (6) as needed. Refer to Illustration 6.

6. Route the 5 connectors as follows, through the hole and into the right side area of the cab.

   • PL641Radio

   • Ethernet Adapter MC-C97

   • Term Resistor MC-C78 - (1 Male and 1 Female 3-pin connectors)

   • PL641 Satellite Radio MC-C21

   Note: Use Cable Strap (6) as needed. Refer to Illustration 6.

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   Illustration 11	g06331741
   (12) 2G-1133 Grommet

7. Insert grommet (12) into hole (G). Refer to Illustration 11.
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   Illustration 12	g06332213
   (I) (12-pin) PL641 Radio Connector (7) 550-5047 Wiring Harness

8. Secure Radio connector (I) from wiring harness (7) to communication radio group PL641.
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   Illustration 13	g06331812

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   Illustration 14	g06331860

9. Remove and save the terminating resistor MC-C53 from the existing machine cab harness (or from the original PL641 harness) and connect the (female 3 pin) Term Resistor MC-C78 connector from new wiring harness (7) to the existing connector on the cab harness. Refer to Illustration 13 and Illustration 14.
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   Illustration 15	g06331875

10. Connect terminating resistor MC-C53 that is saved in Step 9 of Section "Installation Procedure" with the (male 3 pin) Term Resistor MC-C78 Connector from wiring harness (7). Refer to Illustration 15.
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    Illustration 16	g06331888

11. Secure the connector labeled PL641 Satellite Radio MC-C21 (12 pin) from wiring harness (7) with MC-C21 PL321 (12pin) satellite connector of the existing cab harness. Refer to Illustration 16.
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    Illustration 17	g06332066

12. Secure the connector labelled 'Ethernet Adapter MC-C97' (8 pin) to the connector located on harness (7) below the VIMS Main ECM labelled 'VIMS Adapter or Jumper'.

    Note: If the machine has this 8-pin VIMS Adapter or Jumper harness present it will have a cap attached. Remove the cap from the connector and discard. If the connector is not present, refer to Special Instruction, REHS8836, "Procedure For Enhancing the Ethernet Adapter For VIMS^™ on Certain Cat^® Products" to install adapter harness.

13. Once the installation is finished, then follow Steps 30 through Steps 44 in the Section of "Installation Procedure" of Special Instruction, M0072768, "Installation Procedure for the Pro Product Link^® on Certain 773G, 775G, and 77G Off- Highway Trucks" to complete the installation and flashing of the PL641 radio.