Installation Guide for the Tire Monitoring System on Cat<SUP>&reg;</SUP> and Non-Cat Equipment {4203, 7490} Caterpillar


Installation Guide for the Tire Monitoring System on Cat® and Non-Cat Equipment {4203, 7490}

Usage:

MT700 018


Caterpillar Products
All Machines

Introduction

This Special Instruction contains information for installing and configuring the Tire Monitoring System on all Caterpillar and non-Caterpillar wheeled machines. There are two systems in which the band mount is intended for tubeless tires sizes less than or equal to R29.5 and the magnetic mount is intended for tubeless tire size greater than R29.5. Individual tire pressures are displayed to the operator through a Messenger display. The Messenger also displays warnings for low pressure, high pressure, and various Tire Monitoring System system diagnostics. The system consists of one dash-mounted Messenger display, one receiver, one antenna, and harnessing to connect the system components and connections to the main communication data bus on the machine. Cat® Electronic Technician (Cat ET) provides configuration and management support. When tires are rotated or replaced, Cat ET can be used to program the new sensor identification numbers into the system.

Important Safety Information

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 not be made unsafe by the operation, lubrication, maintenance, or repair procedures used.

------ WARNING! ------

Accidental engine starting can cause injury or death to personnel.

To prevent accidental engine starting, turn the ignition switch to the OFF position and place a do not operate tag at the ignition switch location.


------ WARNING! ------

Improper operation of an access platform could result in injury or death. Operators must carry out their duties properly and follow all instructions and guidelines given for the machine and access platform.


------ WARNING! ------

Be sure all personnel are clear of the equipment while the equipment is being lowered.

Failure to stay clear of the equipment while the equipment is being lowered may result in personal injury.


------ WARNING! ------

Do not operate or work on this machine unless you have read and understand the instructions and warnings in the Operation and Maintenance Manual. Failure to follow the instructions or heed the warnings could result in injury or death. Contact any Caterpillar dealer for replacement manuals. Proper care is your responsibility.


------ WARNING! ------

Personal injury or death can result from fumes, gases and ultraviolet rays from the weld arc.

Welding can cause fumes, burn skin and produce ultraviolet rays.

Keep your head out of the fumes. Use ventilation, exhaust at the arc, or both, to keep fumes and gases from your breathing area. Wear eye, ear and body protection before working.

Protect yourself and others; read and understand this warning. Fumes and gases can be dangerous to your health. Ultraviolet rays from the weld arc can injure eyes and burn skin. Electric shock can cause death.

Read and understand the manufacturer's instructions and your employer's safety practices. Do not touch live electrical parts.

See "American National Standard Z49.1, Safety in Welding and Cutting" published by the American Welding Society.

American Welding Society
2501 N.W. 7th Street
Miami, Florida 33125

See "OSHA Safety and Health Standards, 29 CFR 1910", available from U.S. Department of Labor.

U.S. Department of Labor
Washington, D.C. 20210

------ WARNING! ------

A wireless communication device is installed on the machine. Attempting to operate a machine equipped with a wireless communication device could result in an explosion hazard causing serious injury or death. Do not operate the machine less than the recommended distance from a blast zone.



NOTICE

This kit isnot intendedto be used on machines utilizing fluids inside the tires. This includes all additives, rust inhibitors, and ballast. The use of such fluids will have adverse effects on sensor life.


FCC Notice

This device complies with part 15 of the FCC rules. Operation is subject to the following two conditions:

1. This device may not cause harmful interference, and 2. This device must accept any interference received, including interference that may cause undesired operation. This equipment has been tested and found to comply with the limits for a class B digital device, pursuant to part 15 of the FCC rules. These limits are designed to provide reasonable protection against harmful interference in a residential installation. This equipment generates, uses, and can radiate radio frequency energy and, if not installed and used in accordance with the instructions, may cause harmful interference to radio communications. However, there is no guarantee that interference will not occur in a particular installation. If this equipment does cause harmful interference to radio or television reception, which can be determined by turning the equipment off and on, the user is encouraged to try to correct the interference by one or more of the following measures:

  • Reorient or relocate the receiving antenna

  • Increase the separation between the equipment and receiver

  • Connect the equipment into an outlet on a circuit different from that to which the receiver is connected

  • Consult the dealer or an experienced radio/tv technician for help

Changes or modifications to this device without the express approval may void the users authority to use this device.

Industry Canada Notice to Users

Operation is subject to the following two conditions:

  • This device may not cause interference

  • This device must accept any interference, including interference that may cause undesired operation of the device. Refer to RSS-GEN 7.1.5.

Operation Information and Requirements

The Tire Monitoring System control is designed to operate either a 12 VDC or a 24 VDC system. The current draw of the control package is less than two amps. External solenoids, loads driven by the controls relays and connection of the Cat ET communications adapter will add to the current draw.

The TMS harness is fitted with a 5A fuse to protect the receiver, Messenger, communication adapter, and any additional components added to this power system.

The sensor is in a dormant state, a minimum pressure of 206.84 kPa (30 psi) activates the sensor, or is activated by the optional service tool. Premature activation can reduce the life of the sensor by draining the battery.

The tire sensor may not be compatible with rust inhibiting additives. No tire sealants should be used.

Preparation Prior to Installation

Unpack shipping cartons and visually inspect the contents for any signs of damage. Make sure that all the required parts are available.

Machine Preparation

------ WARNING! ------

Do not attempt to disassemble or assemble this machine until you read and understand the disassembly and assembly instructions. Improper disassembly and assembly procedures could result in injury or death.


------ WARNING! ------

Improper operation of an access platform could result in injury or death. Operators must carry out their duties properly and follow all instructions and guidelines given for the machine and access platform.


------ WARNING! ------

Sudden movement or accidental starting of the machine can cause personal injury or death to persons on or near the machine.

To prevent personal injury or death, perform the following:

Park the machine on a smooth level surface.

Lower the blade and or attachments to the ground.

Stop the engine and engage the parking brake.

Block the wheels and install the steering frame lock.

Turn the battery disconnect switch to the OFF position and remove the key.

Place a Special Instruction, SEHS7332, "Do Not Operate" tag at the battery disconnect switch location to inform personnel that the machine is being worked on.


------ WARNING! ------

Be sure all personnel are clear of the equipment while the equipment is being lowered.

Failure to stay clear of the equipment while the equipment is being lowered may result in personal injury.


------ WARNING! ------

Structural damage, an overturn, modification, alteration, or improper repair can impair this structure's protection capability thereby voiding this certification. Do not weld on or drill holes in the structure. Consult a Caterpillar dealer to determine this structure's limitations without voiding its certification.


------ WARNING! ------

Do not operate or work on this machine unless you have read and understand the instructions and warnings in the Operation and Maintenance Manual. Failure to follow the instructions or heed the warnings could result in injury or death. Contact any Caterpillar dealer for replacement manuals. Proper care is your responsibility.


------ WARNING! ------

Before service work is begun, park the machine on a hard level surface. Block the wheels of the machine so unexpected movement will not occur. Unexpected movement of the machine can cause personal injury or death.


Required Parts

Tire Monitoring System Main Kit

The main kit of the Tire Monitoring System consists of a Messenger display, receiver, antenna, harnesses, and mounting hardware. The main kit does not contain any sensors. The Tire Monitoring System is a software enabled attachment. The kit comes with the premium configuration of the software enabled attachment activated. The part number for the Tire Monitoring System Main Kit is 434-4542.

Available Extension Harnesses

Extension harnesses is serviceable parts, if additional harness is required, and are included in the 434-4542 Tire Monitor Gp. Table 1 identifies the extension harnesses that is available.

Table 1
Extension Harnesses 
Harness Function  Part Number  Description 
1 m (3.28 ft) Receiver Extension Harness  456-4310 Monitor Harness As  This harness is used to extend the connection from the Receiver to the 454-3067 Monitor Harness As. 
1 m (3.28 ft) Messenger Extension Harness  456-4311 Monitor Harness As  This harness is used to extend the connection from the Messenger to the 454-3068 Monitor Harness As. 
3.05m (10 ft) Extension Harness  449-0883 Wiring Harness  This harness is used to extend the connection between the 456-4311 Monitor Harness As or the 454-3067 Monitor Harness As and the 456-4311 Monitor Harness As or the 454-3068 Monitor Harness As. 

Tire Monitoring System Sensor Kit

There are two distinct mounting configurations that can be used to mount the pressure sensors into the tires on the machine. One kit is for Band Mount and the alternate kit is for Magnetic Mount. It is important to read this entire special instruction before determining which method will be used.

The sensor kit consists of a sensor, sensor holder, and straps for attachment to the tire rim. One sensor kit must be ordered for each tire on the machine.

It is necessary to order the correct number of tire pressure sensors . One sensor kit will be required for each tire.

The part number for the band mount sensor kit is 457-5705.

The part number for the magnetic mount sensor kit is 477-3960. If using the magnetic mount sensor kit, it will be necessary to order one mounting arm for the magnetic mount.

Installation of the Tire Monitoring System Receiver

Upon installation, the Tire Monitoring System receiver is connected to the Messenger ECM and any recording and monitoring ECM, such as Product Link or VIMS. The Tire Monitoring System receiver is configured by the Messenger.

The preferred mounting location of the Tire Monitoring System receiver is inside the cab. When mounting the receiver inside the machine, choose the mounting location wisely. Do not mount the receiver where the receiver inhibits the operation of the machine. Do not mount the receiver where the receiver inhibits the operator's visibility around the machine. Do not mount the receiver where the receiver inhibits the egress of the operator.

Outside cab mounting although not preferred, is possible but the following guidelines should be followed:

Note: Only mount the receiver outside the cab if all possible inside cab locations have been eliminated.

  • Mounted to the machines chassis or frame rail near the front of the machine and positioned as close to the machines center line as possible.

  • Mount the receiver connectors facing away from the forward driving direction.

  • If possible, have an object between the receiver and open road surface such as a cross member.

  • The receiver can be mounted with the connectors facing downward (to shed water) or upward (to protect cables from ground effects damage).

Mounting the receiver may require the use of a bolt on face plate, heavy-duty straps, or a custom mount. The hardware has been supplied to aid in the installation of the receiver. Torque the receiver mounting hardware to 13 N·m (9.59 lb ft).

Given the wide range of machines to which the Tire Monitoring System can be applied, a standardized mounting method is not possible. Some of the considerations to be made when selecting the receiver mounting location include:

  • Access of less than 1 m (3.28 ft) to connect the receiver to the service port.

  • Access of less than 1 m (3.28 ft) to connect to the Messenger.

  • Access to a fused source of battery power.

  • Access to "Keyswitch" as supplied by the key switch circuit.

  • Access to ground.

  • Access to the main data link or links on the machine.

Note: Additional extension harnesses are available to allow installation distance extension of up to 9.14 m (30 ft).

Installation of the Messenger Display

Mount the Messenger display in the cab in a location where the display can be clearly seen by the operator. Plug in the 8-pin connector and verify that the Messenger powers up. The Messenger display will come from the factory with the application flashed and the TMS software enabled attachment feature activated. The display comes programmed with a special machine serial number as the TMS product ID. The special machine serial number is separate from the product ID for the machine on which the TMS is being installed.

For more information on installing the Messenger display, refer to Special Instruction, REHS1413, "Installation and Operation of the Caterpillar Messenger Driver Information Display".

Installation of the Tire Monitoring System Harnesses

The kit for the Tire Monitoring System can be used on Caterpillar and competitor's machines. The harnesses used during an installation will depend on the machine on which the system is being installed.

Wire Harness Routing Guidelines

Use the following guidelines when routing the Tire Monitoring System receiver harness:

  • Protect the harness from heat and sharp edges. Keep an adequate distance from exhaust pipes and avoid potential chafing on sharp metal.

  • Route the harness along existing harnesses when possible.

  • Provide some slack in the harness to allow for slight repositioning if needed.

  • Apply cable ties every 60.96 cm (24 inch) to ensure secure attachment. Do not over tighten cable ties.

  • Do not secure the harness to any hydraulic hose.

  • Secure antenna cable with cable ties on both sides of connectors for extensions, splitters, and mounts.

  • Verify that all connections are properly locked and secured.

  • Do not strain the harness and harness connectors if length barely reaches. Chassis flex during driving may break an already tight cable.

  • Do not subject the harness to sharp bends.

  • Do not route over or under moving parts such as steering linkages and shock mounts.

Tire Monitoring System Schematics



Illustration 1g06039367
Schematic of the 454-3067 Monitor Harness As.


Illustration 2g06039373
Schematic of the 454-3068 Monitor Harness As.

Harness Connection Options

After the 449-0884 Wiring Harness has been wired into the machine, review the following harness connection options. Various harness combinations can be used. Choose the option that best fits the topology of the machines.

Connection Option One



Illustration 3g06038322

  1. Connect the 449-0884 Wiring Harness to the main machine harness. Refer to "Harness Connections for the 449-0884 Wiring Harness".

  2. Connect the 454-3068 Monitor Harness As to the 449-0884 Wiring Harness and the TMS Receiver.

  3. Connect the 454-3067 Monitor Harness As to the 454-3068 Monitor Harness As and the Messenger Electronic Control Module.

    Note: The 449-0883 Wiring Harness can be used as an extension harness between the 454-3067 Monitor Harness As and the 454-3068 Monitor Harness As.

Connection Option Two



Illustration 4g06038324

  1. Connect the 449-0884 Wiring Harness to the main machine harness. Refer to "Harness Connections for the 449-0884 Wiring Harness".

  2. Connect the 454-3068 Monitor Harness As to the 449-0884 Wiring Harness and the 456-4311 Monitor Harness As.

    Note: The 449-0883 Wiring Harness can be used as an extension harness between the 454-3068 Monitor Harness As and the 456-4311 Monitor Harness As.

  3. Connect the TMS Receiver to the 454-3068 Monitor Harness As.

  4. Connect the 456-4311 Monitor Harness As to the Messenger Electronic Control Module.

Connection Option Three



Illustration 5g06038327

  1. Connect the 449-0884 Wiring Harness to the main machine harness. Refer to "Harness Connections for the 449-0884 Wiring Harness".

  2. Connect the 454-3067 Monitor Harness As to the 449-0884 Wiring Harness and the 456-4310 Monitor Harness As.

    Note: The 449-0883 Wiring Harness can be used as an extension harness between the 454-3067 Monitor Harness As and the 456-4310 Monitor Harness As.

  3. Connect the Messenger Electronic Control Module to the 454-3067 Monitor Harness As.

  4. Connect the TMS Receiver to the 454-3067 Monitor Harness As.

Connection Option Four



Illustration 6g06038329

  1. Connect the 449-0884 Wiring Harness to the main machine harness. Refer to "Harness Connections for the 449-0884 Wiring Harness".

  2. Connect the 456-4311 Monitor Harness As to the 449-0884 Wiring Harness and to the Messenger Electronic Control Module.

    Note: The 449-0883 Wiring Harness can be used as an extension harness between the 449-0884 Wiring Harness and the 456-4311 Monitor Harness As.

  3. Connect the 456-4310 Monitor Harness As to the 449-0884 Wiring Harness and to the TMS Receiver.

    Note: The 449-0883 Wiring Harness can be used as an extension harness between the 449-0884 Wiring Harness and the 456-4310 Monitor Harness As.

    Note: After installation of the harness and all connections are made measure the resistance with an ohm meter between CAN HI and CAN LO. The resistance must be approximately 60 ohms. If the resistance is not approximately 60 ohm, one or more of the CAN termination resistors must be removed. Refer to the Table 2.

    Table 2
    Removal of Extra CAN Termination Resistors 
    CAN Resistance  CAN Termination Resistors to Remove 
    40 Ohms 
    30 Ohms 
    20 Ohms 

Harness Connections for the 449-0884 Wiring Harness

The following 449-0884 Wiring Harness connections must be made to the main machine harness:

  1. Connect wire 101-C14-RD(Red)to unswitched battery power.

  2. Connect wire 200-C15-BK(Black)to battery ground.

  3. Connect wire 306-C16-YL(Yellow)to key switch.

  4. Connect wire K900-C4-YL(Yellow)to the machines service port CAN positive.

  5. Connect wire K900-C5-GN(Green)to the machines service port CAN negative.

    Note: Connecting to the service port CAN allows Tire Monitoring communication via Cat ET.

Installation of the Tire Monitoring System Antenna

Antenna Placement Guidelines

The antenna can be mounted in various places depending on the machine. Use the following guidelines when choosing a mounting location for the antenna:

  • Choose a location for the antenna that is within 12.19 m (40 ft) of the receiver

  • Choose a location where the antenna does not contact the machine. The antenna should only contact the machine at the mounting base.

  • Orient the antenna so that there is a clear line of sight to the tires. A horizontal antenna orientation along the center line of the machine will yield the best results.

  • A minimum of 46 cm (18.11 inch) is required between the tip of the antenna and the ground.

  • If the tip of the antenna is pointed upward, the antenna cannot be shielded by any metal on the underside of the vehicle.

  • When placing the antenna near the front axle, choose a location that offers protection in the driving direction. If placed on a front cross member, face the antenna rearward on the rear most vertical side of the cross member.

  • If placing the antenna near or on suspension supports, make sure that there is enough room to allow for full suspension travel.

  • Do not place the antenna near large concentrations of metal such as a steel I-beam support and axle differentials.

  • Do not place the antenna near large concentrations of electrical wiring, generators, amplifiers, or pre-existing transceiver assemblies such as GPS/Telematics systems and CB radios.

  • Do not place the antenna on or near moving parts such as steering linkages, drive shafts, or suspension assemblies.

Antenna Cable Routing Guidelines

The antenna cable routing can be achieved in a variety different paths depending on the machine. Use the following guidelines when routing cables for the antenna:

  • Choose an adequate cable length for the antenna location.

  • Protect the cable from heat and sharp edges. Keep an adequate distance from exhaust pipes and avoid potential chafing on sharp metal.

  • Route the cable along existing cables on the underside of the machine.

  • Provide some slack in the cable at each endpoint of cable to allow for slight repositioning if needed.

  • Route the small cable end first for hole-through and magnetic mount antennas when passing cable through frame holes and tight access points.

  • Apply cable ties every 60.96 cm (24 inch) to ensure secure attachment. Do not over tighten cable ties.

  • Do not secure the antenna to any hydraulic hose.

  • Secure antenna cable with cable ties on both sides of the connectors for extensions, splitters, and antenna mounts.

  • Verify that all connections are properly locked and secured.

  • Apply 1.92 N·m (17 lb in) to 2.60 N·m (23 lb in) of torque for TNC Hex heads fasteners.

  • Do not strain the cable and cable connectors if length barely reaches. Choose a longer cable. Chassis flex during driving may break an already tight cable.

  • Do not subject the cable to bends of 90 degrees or less.

  • Do not route over or under moving parts such as steering linkages and shock mounts.

  • If signal strength is not adequate, some sensor pressures and temperatures may not be seen in the Messenger display. In this event, it is recommended to install an additional antenna with a splitter and coaxial cable to increase signal strength.

Tire Monitoring System Sensor Installation Procedure

The Tire Monitoring System sensors may be installed with the tire and wheel assembly on or off the truck. This Special Instruction will focus on installing the sensors with the tire and wheel assembly on the truck. There are two types of mechanisms that can be used to mount the sensors inside the tires:

  • Band Mount - The part number for the Band Mount Sensor Kit is 457-5705.

  • Magnetic Mount - The part number for the Magnetic Mount Sensor Kit is 477-3960. An additional mounting tool is required for the Magnetic Mount installation. The part number for the mounting tool is 492-4434.

Only a qualified Technician should service the tires and rims.

Before installing the Pressure Sensor, it is important to make note of the sensors ID number and the tire in which the sensor will be installed. Use the Tire Sensor Record to record the sensor ID numbers. After the sensor has been successfully installed in the tire, use the additional sensor ID sticker that was provided in the kit to mark the position of the sensor on the outside of the tire.

Table 3
Tire Designation  Sensor ID Number 
Axle 1 Tire 1   
Axle 1 Tire 2   
Axle 2 Tire 1   
Axle 2 Tire 2   
Axle 2 Tire 3   
Axle 2 Tire 4   

------ WARNING! ------

Personal injury can result from improper tire inflation.

A tire blowout or rim failure can result from improper or misused equipment.

Use a self-inflating chuck and stand behind the tread when inflating a tire.

Proper inflating equipment, and training in using the equipment, are necessary to avoid overinflating.

Before inflating tire, put the tire in a restraining device.


------ WARNING! ------

Follow the recommended procedure for removal and installation of tires and or wheel assemblies.

Ensure that the machine and tire and or wheel assembly are properly supported at all times.

Improper procedures that are used to remove and install tires and or wheel assemblies can result in personal injury or death.


------ WARNING! ------

Improper blocking of the rear axle housing can cause personal injury.

The rear axle housing is made to oscillate. During removal and installation of the rear tires and rims, the rear axle housing must be prevented from oscillating.

Place wood blocks between the rear axle housing and the rear main frame to prevent oscillation of the rear axle housing.



NOTICE

This kit isnot intendedto be used on machines utilizing fluids inside the tires. This includes all additives, rust inhibitors, and ballast. The use of such fluids will have adverse effects on sensor life.


Note: Do not use spacer rings when you are replacing the tires with Michelin tires.

Note: When installing the sensors, locate the sensors on the non-locking ring side of the tire.

Note: Refer to Disassembly and Assembly Manual for procedures tire and rim removal and installation.

Note: The sensor kit is shipped with a film that is loose in the box. Place the loose sticker on the outside of the tire in line with the sensor after the sensor has been installed on the tire rim.



Illustration 7g03696708

Note: Before installing the Pressure Sensor, make note of the sensor ID number and the tire in which the sensor will be installed.

Note: The sensor ID number will be the number after the SN: MARK

Band Mount Installation Procedure for Tubeless Tires Sized Less Than or Equal to R29.5



    Illustration 8g03692155

  1. Thread a 6V-7555 Cable Strap through the slots on the 421-1154 Holder with the serrated side of the band facing away from the cradle. Refer to Illustration 8.


    Illustration 9g03692156

  2. Attach the three 6V-7555 Cable Straps together to form a loose circle. Ensure that the 6V-7555 Cable Straps do not twist. Refer to Illustration 9.

    ------ WARNING! ------

    Servicing and changing tires and rims can be dangerous. This work must be done only by trained personnel with correct tools and procedures. If correct procedures are not followed while servicing tires and rims, the assemblies can burst with explosive force and cause serious physical injury or death. Follow carefully the specification information provided by your tire servicing person or dealer.


    ------ WARNING! ------

    Follow the recommended procedure for removal and installation of tires and or wheel assemblies.

    Ensure that the machine and tire and or wheel assembly are properly supported at all times.

    Improper procedures that are used to remove and install tires and or wheel assemblies can result in personal injury or death.


  3. With the wheel and tire assembly still on the machine, separate the outer side of the tire from the rim.

  4. Place the 6V-7555 Cable Strap and 421-1154 Holder assembly and size the assembly on the rim. Do not fully tighten the straps.


    Illustration 10g03693923

  5. Place the 6V-7555 Cable Strap and 421-1154 Holder assembly on the non-lock ring side of the rim just past the o-ring seal. Refer to Illustration 10.

    Note: Align up the tire monitoring sensor with the valve stem.



    Illustration 11g03714146

  6. Hand tighten the band assembly as much as possible. Cut off the excess length of band if necessary.

  7. Mark the location of the 351-7567 Pressure Sensor on the outside of the tire with a piece of tape or tire crayon.

    The tape or tire crayon mark will be used as the location for the sensor on the outside of the tire later in this instruction.

  8. Finish installing the tire.

    Note: Refer to Disassembly and Assembly Manual for the machine you are working on for tire and rim removal and installation.

Label Installation Procedure



Illustration 12g03700268

Place the 458-6617 Film shown in Illustration 12 on the rim near the valve stem. The location of the film should be visible to the operator and any technician who would maintain the machine.

Magnetic Mount Installation Procedure for Tubeless Tires Sized Greater than R29.5 or for Medium Wheel Loaders Tubeless Tires Greater than R25

Magnet Safety Overview

Read this document carefully to understand all the precautions required when handling neodymium magnets. The magnets should be handled only by trained personnel. Neodymium magnets are strong and require special care to avoid personal injury and damage to the magnets.

  • The magnets must be stored in safe location until they are installed.

  • Neodymium magnets should never be burned, as burning will create toxic fumes.

  • The magnetic mounts exert strong attractive forces on other magnets and ferromagnetic objects. They can cause small ferromagnetic objects to become projectiles and can cause personal injury and equipment damage.

Handling of Magnets

Fingers can get pinched between the magnet and attracting material. It is recommended to wear gloves to reduce the pinching hazard. Neodymium magnets are brittle, and can crack or shatter if allowed to slam to a surface. Eye protection should be worn when handling these magnets, because shattering magnets can launch pieces at great speed, potentially causing damage to eyes and skin by sharp fragments of broken magnets.

The strong magnetic field of these magnets can damage magnetic media such as computer discs, credit cards, magnetic ID cards, cassette, or video tapes and similar items. They can damage televisions, computers, computer displays, cell phones, pagers, and other electronics. Never place magnets near any electronic object.

Magnets generate magnetic fields that can cause damage to, or impair the operation of magnetically sensitive equipment. Internal medical devices can move or dislodge in the presence of strong magnets, causing injury to the user. Other medical devices can be disabled by magnetic fields. Do not allow the magnets near a person with a pacemaker, defibrillator, insulin pump, or similar medical device. The strong magnetic fields can affect the operation of such devices.

Installation Tool for Magnetic Mounts

The magnetic mounts must be installed in tires using the specially designed tool. A picture of the mounting tool is shown in 14. This tool does not come with the basic kit. The part number to order the mounting arm assembly can be found in table Magnetic-Mount Installation Tool (481-2116) . Included in the 481-2116 Magnetic-Mount Installation Tool will be a Head As and a Tool-Arm. Remove the Head As that comes attached to the Tool-Arm and replace it with the Head As 477-3965.

Table 4
Magnetic-Mount Installation Tool(481-2116
Quantity  Part Number  Description 
477-3965  Head As 
477-3969  Tool-Arm 

Magnetic Sensor Assembly

The sensor will come in the kit previously inserted into the holder and attached to the mounting plate.



Illustration 13g06038786

Engaging the Magnetic Sensor Assembly and Disengaging the Magnetic Sensor Assembly Installation Tool

  1. With the wheel and tire assembly still on the machine, separate the outer side of the tire from the rim.

  2. Position the Magnetic Sensor Assembly onto the end piece of the Installation Tool.

  3. Slide the Installation Tool into position resting against plastic heel.

  4. Engage the Magnetic Sensor Assembly by tilting the Installation Tool.

  5. Disengage from the Magnetic Sensor Assembly by pulling back on tool.


    Illustration 14g06038794

  6. Using appropriate tools, Move it to the center of the rim, on the non-lock ring side of the rim just past the o-ring seal.

  7. Align up the tire monitoring sensor with the valve stem.


    Illustration 15g06038795

  8. Hand tighten the screws on the mount as much as possible.

  9. Mark the location of the Pressure Sensor on the outside of the tire with a piece of tape or tire crayon. The tape or tire crayon mark will be used as the location for the sensor on the outside of the tire later in this instruction.

  10. Finish installing the tire.

TMS Sensor Programming

Axle Designations and Tire Designations

There are potentially two axle designations. The system can be configured for four or six tires.

The naming convention will be axle X and tire Y. Axle naming is always numbered starting with number one from the front axle to the rear axle. Tire naming is always numbered starting with number one from the left when facing in the direction of forward vehicle travel.

Two Axles, Four Tires



Illustration 16g03693476

Table 5
Two Axles with Four Tires Naming Convention 
Tire Location  Axle  Tire  Parameter 
Left Front  Axle 1, Tire 1 
Right Front  Axle 1, Tire 2 
Left Rear Outer  Axle 2, Tire 1 
Right Rear Outer  Axle 2, Tire 2 

Two Axles, Six Tires



Illustration 17g03693481

Table 6
Two Axles with Six Tires Naming Convention 
Tire Location  Axle  Tire  Parameter 
Left Front  Axle 1, Tire 1 
Right Front  Axle 1, Tire 2 
Left Rear Outer  Axle 2, Tire 1 
Left Rear Inner  Axle 2, Tire 2 
Right Rear Inner  Axle 2, Tire 3 
Right Rear Outer  Axle 2, Tire 4 

Configuration and Navigation of the Messenger Display

The main menu of the Messenger display contains information on:

  • Settings

  • Parameters

  • Service: System Information

  • Diagnostics/Events

  • Configuration


Illustration 18g06038813
Messenger Display Menu Structure

Illustration 18 is a quick guide to the menu structure of the tire monitoring system on the Messenger display.



Illustration 19g03710111
(1) Return key. Used to return to the previous menu.
(2) Up arrow. Used to scroll the menu up.
(3) Down arrow. Used to scroll the menu down.
(4) OK. Used to get into the detailed page of the highlighted menu option.

Illustration 19 illustrates the navigation keys of the Messenger display.

"Settings" Menu



Illustration 20g03696400

The "Settings" menu will allow the user to adjust the display settings. The "Settings" menu is the first screen that you will see. "Brightness Adjust" allows the user to adjust the brightness of the display. "Contrast Adjust" allows the user to set the display contrast. Additional system settings include "Language" preference and "Unit" preferences.

"Service Parameters" Menu

The "Service Parameters" menu will allow the Messenger display to show all tire pressures and all tire temperatures.



    Illustration 21g03696403

  1. Navigate to "Service Parameters" from the "Main Menu".


    Illustration 22g03709152

  2. Inside the "Service: Parameters" menu selects "Parameters".


    Illustration 23g03709195

  3. Inside the "Parameters" select "Pressure".


    Illustration 24g03709200

  4. Inside the "Pressure" menu, the tire location and tire pressure information is displayed.


    Illustration 25g03696403

  1. Navigate to "Service Parameters" from the "Main Menu".


    Illustration 26g03709152

  2. Inside the "Service: Parameters" menu selects "Parameters".


    Illustration 27g03709204

  3. Inside the "Parameters" select "Temperature".


    Illustration 28g03709205

  4. Inside the "Temperature" menu, the tire location and tire pressure information is displayed.

"Service: System Info" "Monitoring System" Menu



Illustration 29g03696407


Illustration 30g03696408


Illustration 31g03696409

The "Service: System Info" "Monitoring System" menu will give the following information:

  • Hardware Part Number

  • Software Part Number

  • Software Release Date

  • Software Description

"Diagnostic/Events" Menu



Illustration 32g03696421


Illustration 33g03696423


Illustration 34g03696425


Illustration 35g03696426

The "Diagnostic/Events" menu allows Messenger to show all active and logged diagnostic trouble codes (DTC) related to tire pressure and sensor status.

"Configuration" Menu

The Messenger "Configuration" menu will allow the user to do the initial configurations for the Messenger.



    Illustration 36g03696623

  1. Navigate to the "Configuration" menu.


    Illustration 37g03696624

  2. Select the "Config Axle and Tire Info" option.


    Illustration 38g03696626

  3. Input the number of axles.


    Illustration 39g03696627

  4. Input the number of tires in Axle one.


    Illustration 40g03696628

  5. Input the number of tires in Axle two.

    Note: Illustration 40 shown above is for a machine with four tires on the rear axle. If the machine has two tires on the rear axle, change the default value of"No of Tires in Axle2", to two (2).



    Illustration 41g03696630

  6. The "Sensor Installation Status" status screen can be used to configure (install/unstall) specific sensors to tailor specific diagnostic reports.

Configuration of the Axle and Tire Information Using Messenger



    Illustration 42g03773057

  1. From the "Main Menu" of the Messenger, navigate to the "Configuration" screen. Refer to Illustration 42.


    Illustration 43g03773074

  2. From the "Configuration" screen, select the "OK" button to configure the number of axles and tires. Refer to Illustration 43.


    Illustration 44g03773316

  3. Select the number of axles on the machine. Refer to Illustration 44.


    Illustration 45g03773348

  4. Select the number of tires in axle one. Refer to Illustration 45.


    Illustration 46g03773351

  5. Select the number of tires in axle two. Refer to Illustration 46.

  6. After configuring the Messenger for the required combination of axles and tires, cycle the key switch OFF then ON.

Configuration of the Tire Sensor Installation Status Using Messenger



    Illustration 47g03773057

  1. From the "Main Menu" of the Messenger, navigate to the "Configuration" screen. Refer to Illustration 47.


    Illustration 48g03773417

  2. From the "Configuration" screen, select the "OK" button to configure the "Sensor Installation Status". Refer to Illustration 48.


    Illustration 49g03773433

  3. Select the down arrow to display the screen for each of the tires in which the tire pressure sensors have been installed. Refer to Illustration 49.


    Illustration 50g03773434

  4. Go to the screen that says Axle 1 Tire 1 and toggle to the "Installed" status. Continue for each tire on axle one. Refer to Illustration 50.


    Illustration 51g03773436

  5. Continue to the screen for axle two. Set the Installed status for each tire on axle two. Refer to Illustration 51.

  6. After indicating to the Messenger all the installed sensor locations, cycle the key switch OFF then ON.

Verifying the Installed Tire Sensors Using Cat ET

  1. Connect to the TMS Messenger ECM with Caterpillar Electronic Technician (Cat(R) ET).

  2. Navigate to the "Tire Monitoring System Configuration" screen.


    Illustration 52g03773805

  3. Verify that the configuration of the tire sensors indicates that the correct sensors are programmed as "Installed". Refer to Illustration 52 for an example that shows a machine with sensors installed in two front tires and four rear tires.

  4. If the "Tire Monitoring System Configuration" screen is correct, cycle the key switch OFF then ON.

Mapping the Tire Sensors Using Cat ET



    Illustration 53g03773910

  1. Navigate to the "Tire Monitoring System Sensor Identifiers" heading of the ET "Configuration" screen.

  2. Using the tire sensor serial number that was recorded at the time the pressure sensor was installed in the tire, enter the sensor identification number next to the appropriate tire location for the tire sensor.

  3. After the sensor serial number have been configured into Cat ET, verify that the sensor identification numbers display correctly. The numbers may take two to four minutes to update in Cat ET.

  4. If the sensor identification numbers do not display correctly, repeat Step 2 until all sensor identification numbers are correct.

  5. If the sensor identification numbers are correct, cycle the key switch OFF then ON.

Configuration of the Tire Pressure Parameters Using Cat ET

The Tire Monitoring System will come pre-configured with default settings listed below:

  • Cold Inflation Pressure (CIP): 689.476 kPa (100 psi).

  • Pressure Deviation Alert (FAL): Is set to plus or minus 15 percent of CIP.

  • Critical Low Pressure Alert (SAL): Is set to minus 20 percent of CIP.


    Illustration 54g03696265

  1. Set the Default Cold Inflation Pressures.

    Default Cold Inflation Pressures should be customized to the machine tires using Cat ET. The Cat ET interface will allow the customizing of Cold Inflation Pressure per axle. Consult and follow the tire manufacturers recommendation for Cold Inflation Pressure, Pressure Deviation, and Critical Low Pressure for each tire.

    It is recommended that the following three parameters are all set to 'Disabled' under Tire Monitoring System Event Configurations

    • Tire Monitoring System Barometric Pressure Compensation Enable Status

    • Tire Monitoring System First Alert Temperature Compensation Enable Status

    • Tire Monitoring System Second Alert Temperature Compensation Enable Status

    Note: Never inflate a tire to less than the tire's recommended cold inflation pressure. A tire is considered to be "cold" when the tires temperature is 18.33° C (65° F) or less. The tire temperature can be estimated using the outside temperature.



    Illustration 55g03696378

  2. If desired, change the settings for the "Tire Monitoring System First Alert Pressure Percentage Threshold", and the "Tire Monitoring System Second Alert Pressure Percentage Threshold".

    Once all TMS installation and configuration has been completed, it is necessary to save the system data to an ECM Replacement file using Cat ET. In the event of a Messenger ECM failure, this ECM replacement file can be used to restore the installation and configuration settings, including the system sensor configuration data.

Tire Monitoring System Lamps, Warnings, and Alarms Displayed Through the Messenger Display

Lamps and Warnings



Illustration 56g06044773
Tire Pressure Lamp


Illustration 57g06044782
Tire Failure/Malfunction Lamp


Illustration 58g06044779
Tire Temperature Lamp

Alarms



Illustration 59g03731198

When an alarm activates, Messenger will indicate which tire is producing the event and the reason through a pop-up message. Refer to Illustration 59.

If a sensor battery has low voltage, then the low voltage diagnostic for that sensor will be active.

If the pressure is not being updated, the display will show **** due to an abnormal update rate.

There are two types of alarms. Level one alarms have the ability to be snoozed. To snooze a level one alarm, press the "OK" button. Level two alarms cannot be snoozed and should be addressed as soon as possible.

Refer to Table 7for a list of the Tire Monitoring System alarms on the Messenger.

Table 7
Tire Monitoring System Alarms 
Alarm / Annunciation  Snooze Time 
Over Pressure  2 minutes 
Under Pressure  20 minutes 
Extreme Under Pressure  2 minutes 
High Temperature  2 minutes 
Tire Sensor Low Battery  1 hour 

Tire Monitoring System Final Checks and Validation

Perform the following checks before placing the Tire Monitoring System into service.

Cat ET

  • Verify that the ET summary screen lists the correct software version.

  • Verify that the configuration screen allows values to be edited.

  • Verify that all sensor ID numbers are recorded correctly, tire locations are correct, and the sensor identifiers are in the correct locations.

  • Confirm that the Cold Inflation Pressure configuration values are correct on each axle.

  • Confirm that the Pressure Threshold Percentages configuration value is correct on each axle.

Messenger Display

  • Verify the Messenger display powers up and the display is visible.

  • Verify that the configuration can be set/reset as required.

  • All active diagnostic codes should be clear at start-up.

  • Verify that all tire values are reading correctly.

Product Status Report



Illustration 60g06101378

The system will not report on a Cat Data Link (CDL) only machine. If a Product Status Report (PSR) is needed, the service tool (Cat ET) must be connected on J1939.

ECM File Replacement

Upon the initial installation and configuration of the Tire Monitoring System, it is important to save configured data to an off-board ECM replacement file using Cat ET.

In the event of a loss of data, this ECM replacement file can be used to restore the installation and configuration settings and data.

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