Installation of Cat® Detect Object Detection for the 777D Off-Highway Truck/Tractor {1408, 7348} Caterpillar

Machine Control and Guidance Products

CAT DETECT (S/N: DTK1-UP)

Off-Highway Truck/Tractor

777D (S/N: AGC1-UP; FKR1-UP; 3PR1-UP; 2YW1-UP; AGY1-UP)

Introduction

The information that is contained in this Special Instruction guides the user in the installation of the object detection system.

Do not perform any of the procedures until you have read the information in this publication.

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 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.

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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.

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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.

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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.

Weld Specifications and Qualifications

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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

Note: Personal breathing protection should be worn by the personnel that are welding. Personal breathing protection will prevent fumes from entering the lungs of the person that is welding. Use a 1U-8088 Type H Respirator Gp for breathing protection.

Welders must be qualified for fillet welding and groove welding. The welder must be qualified in different welding angles. The angles are vertical, horizontal, exedra. The welders should be qualified in the use of the welding processes that follow: Shielded Metal Arc Welding (SMAW), Flux Cored Arc Welding (FCAW) and Gas Metal Arc Welding (GMAW). Refer to ISO 9606 or "American National Standards Institute (ANSI)/American Welding Society (AWS) Specification D1.1, or Specification D14.3" for information that regards the qualifications for the processes that follow: SMAW process, FCAW process, and GMAW process. The welders must have used the process at some time within the last 6 months. The welders must complete the process of certification if the welders have not used the welding processes for 6 months.

The power source should be able to supply 500 A or more with DC current for the welding operation. The power source should be able to gouge metal with 500 A.

Use the direct current electrode positive (DC reverse polarity).

The welding wire must be shielded with CO₂ gas or Argon/CO₂ 80/20 gas.

All repair welds should be done in a controlled environment. Controlled environments prevent the rapid cooldown after the repair. Controlled environments would be inside a repair shop.

All welds should be done in the horizontal position to make a smooth surface finish.

If the vertical position must be used in the welding procedure, the operation should be performed in the "vertical up" direction, instead of the "vertical down" direction.

Table 1

Allowed Filler Material
AWS A5.18 ER70S-6
DIN 8559 SG3
EN 440 G4Si1

Recommended European weld consumables: SAF Oerlikon Carbofil SG3, ESAB OK Autrod 12.64, Pittini Pitarc G9, or Thyssen® Union k56

If only manual welding is possible, use ESAB OK 48.00 with a rod diameter of 3.25 mm (0.128 inch) or the equivalent AWS A5.1 E7018 or EN ISO 2560-A E 42 4 B 42 H5.

If welding quenched steel or tempered steel, use specific filler metal with higher mechanical properties and lower hydrogen levels. A flux cored wire with AWS A5.20 Class E70T-5 specification works well. If something other than an AWS A5.20 Class E70T-5 Electrode is used, preheat to 200° C (392° F) and maintain an interpass temperature at 150° C (302° F).

Mask all parts prior to gouging.

Proper Welding Procedure on Machines and Engines with Electronic Controls

Proper precautions are necessary to prevent damage to electronic controls. When you weld on a machine with electronic controls, use the steps that follow:

1. Turn off the engine. Put the key start switch in the OFF position.

2. If the machine has a battery disconnect switch, open the switch. If the machine does not have a battery disconnect switch, disconnect the negative battery cable at the battery.

3. Connect the ground cable for the welder directly to the actual machine component that will be welded. Attach the clamp for the ground cable as close as possible to the area that is being welded. Attach the clamp closer will reduce the chance of damage from welding current to the components that follow: bearings, hydraulic components, and electrical components.

   Note: Do NOT use electrical components as a ground point for the welder. Do NOT use ground points for electronic components as a ground point for the welder.

4. Protect the wiring harnesses from the weld splatter.

Preparing the Metal for Welding

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Personal injury can result from flame cutting or welding on painted areas. The effect of gasses from burned paint is a hazard to the person doing the cutting or welding. Do not flame cut or weld on painted areas.

All grease, water, paint, rust, dirt, and scale must be removed before welding. Any of these materials will discharge gas which will cause porosity in the weld deposit. Water and rust will cause hydrogen embrittlement. Hydrogen embrittlement causes cracks in the weld deposit.

Required Parts

777D Full (4 Radars / 4 Cameras)

Table 2

Required Parts for the 777D 4 Radars / 4 Cameras
Object Detection System
Quantity	Part Number	Description
1	462-5010	Monitor Kit
1	462-2940	Display Mounting Kit
1	462-2924	Object Detector Gp
1	380-4459(1)	Object Detector Gp
1	516-5944	Object Detection Kit
1	516-9081	Object Detection Kit

(1)	The 393-6270 Object Detection Kit (Vision Front/Rear) will be required if installing the 380-4459 Object Detector Gp(Vision Sides), instead of the 462-2924 Object Detector Gp (Vision Front/Rear).

Contents of the 462-2940 Display Mounting Kit, 462-2924 Object Detector Gp, 380-4459 Object Detector Gp, 516-5944 Object Detection Kit, and the 516-9081 Object Detection Kit

Table 3

Contents of the 462-2940 Display Mounting Kit
Quantity	Part Number	Description
2	6V-4248	Bolt
4	6V-5683	Bolt
2	7K-1181	Cable Strap
2	8T-4121	Hard Washer
4	114-6658	Washer
2	132-5789	Clip
1	360-0191	Bracket As
1	398-1744	Bracket As

Table 4

Contents of the 462-2924 Object Detector Gp
Quantity	Part Number	Description
1	368-2992	Camera Mounting Gp
1	368-2994	Camera Mounting Gp
1	382-1562	Object Detection Wiring Gp
1	433-0581	Object Detector Gp
1	476-8708	Camera Wiring Gp

Table 5

Contents of the 380-4459 Object Detector Gp
Quantity	Part Number	Description
1	362-8527	Object Detection Wiring Gp
1	368-2995	Camera Wiring Gp

Table 6

Contents of the 516-5944 Object Detection Kit
Quantity	Part Number	Description
1	362-8526	Object Detection Wiring Gp
1	513-7090	Sensor and Mounting Gp
1	513-7092	Object Detection Box and Mounting Gp
1	433-0584	Object Detector Gp

Table 7

Contents of the 516-9081 Object Detection Kit
Quantity	Part Number	Description
1	513-7091	Object Detection Box and Mounting Gp
1	516-5940	Object Detection Box and Mounting Gp

Contents of the 462-2924 Object Detector Gp

Table 8

Contents of the 368-2992 Camera Mounting Gp
Quantity	Part Number	Description
2	8T-4121	Hard Washers
2	8T-4136	Bolts
1	271-6768	Plate
1	360-3917	Bracket
1	361-4970	Bracket As

Table 9

Contents of the 368-2994 Camera Mounting Gp
Quantity	Part Number	Description
6	8T-4121	Hard Washers
3	8T-4133	Nuts
3	8T-5005	Bolts
1	067-2551	Clip
3	198-4777	Hard Washers
1	305-3748	Plate As

Table 10

Contents of the 382-1562 Object Detection Wiring Gp
Quantity	Part Number	Description
1	3E-5239	Relay As
6	3S-2093	Cable Straps
2	4P-8134	Clips
1	5S-7349	Bolt
1	6T-3644	Circuit Breaker As
25	7K-1181	Cable Straps
2	7U-4892	Screws
15	7X-7877	Edging Strips
1	8T-4205	Hard Washer
2	9X-2043	Screws
4	9X-2044	Screws
1	134-5245	Bolt
1	361-5211	Cab Harness As

Table 11

Contents of the 433-0581 Object Detector Gp
Quantity	Part Number	Description
1	345-7489	Monitor Harness As
1	422-7022	Monitor Software Gp

Table 12

Contents of the 476-8708 Camera Wiring Gp
Quantity	Part Number	Description
2	8T-4142	Bolt
4	261-3233	Bracket As
2	274-4477	Cable As
2	283-0658	Cable As
1	315-5391	Nut
2	336-6684	Camera Gp
1	340-7161	Power Converter
1	348-9226	Grommet Assembly
1	448-6963	Cable As

Contents of 380-4459 Object Detector Gp

Table 13

Contents of 362-8527 Object Detection Wiring Gp
Quantity	Part Number	Description
1	3E-6753	Grommet
6	3S-2093	Cable Straps
1	4P-7428	Clip
8	4P-7581	Clips
20	7K-1181	Cable Straps
1	7M-3361	Grommet
1	8T-4137	Bolt
1	8T-4896	Hard Washer
1	294-3313	Clip
1	352-3968	Clip
1	361-1264	Wiring Harness
1	361-1267	Wiring Harness
1	373-1344	Wiring Harness

Table 14

Contents of 368-2995 Camera Wiring Gp
Quantity	Part Number	Description
6	4L-6459	Bolts
12	5P-1075	Hard Washers
6	6V-8801	Nuts
8	7X-7729	Washers
8	8T-4195	Bolts
2	219-6485	Flood Lamps Gp
2	251-8248	Communication Cables As
2	283-0658	Cables As
2	305-3747	Plates As
2	305-3748	Plates As
2	336-6684	Cameras Gp
2	348-8789	Blocks

Contents of the 516-5944 Object Detection Kit

Table 15

Contents of the 362-8526 Object Detection Wiring Gp
Quantity	Part Number	Description
45	7K-1181	Cable Straps
1	130-5300	Clip
1	361-0851	Rear Harness As
1	361-1262	Front Harness As
1	363-8847	Chassis Harness As
3	132-5789	Clips
9	4P-7581	Clips
6	5M-3062	Bolts
6	8T-4896	Hard Washers

Table 16

Contents of the 513-7090 Sensor and Mounting Gp
Quantity	Part Number	Description
4	5P-1076	Hard Washers
4	5P-4115	Hard Washers
4	7X-0818	Bolts
2	7X-7729	Washers
4	8T-4138	Bolts
4	8T-4139	Bolts
2	8T-4195	Bolts
8	8T-9655	Isolation Mounts
4	8T-9658	Spacers
4	9N-0869	Hard Washers
1	430-8391	Object Detection Box Gp
1	359-7444	Bracket As
1	360-3915	Bracket As
1	364-5871	Bracket As
2	364-5878	Blocks

Table 17

Contents of the 513-7092 Object Detection Box and Mounting Gp
Quantity	Part Number	Description
4	5P-4115	Hard Washer
4	7X-0818	Bolt
4	7X-3185	Bolt
2	7X-7729	Washer
4	8T-4138	Bolt
2	8T-4195	Bolt
8	8T-9655	Isolation Mount
4	8T-9658	Spacer
4	9N-0869	Hard Washer
1	430-8391	Object Detection Box Gp
1	359-7444	Bracket As
1	360-3915	Bracket As

Contents of the 516-9081 Object Detection Kit

Table 18

Contents of the 513-7091 Object Detection Box and Mounting Gp
Quantity	Part Number	Description
4	5C-7261	Nuts
8	5P-4116	Hard Washers
8	7X-0613	Hard Washers
4	7X-0818	Bolts
2	7X-7729	Washers
2	8T-4195	Bolts
4	8T-4971	Bolts
4	8T-7547	Bolts
8	8T-9655	Isolation Mounts
4	8T-9658	Spacers
4	9N-0869	Hard Washers
1	430-8391	Object Detection Box Gp
1	359-7850	Bracket As
1	360-3919	Bracket As
1	364-5738	Bracket As

Table 19

Contents of the 516-5940 Object Detection Box and Mounting Gp
Quantity	Part Number	Description
1	359-7850	Bracket As
1	364-5738	Bracket As
1	430-8391	Object Detection Box Gp
8	8T-9655	Isolation Mount
4	8T-9658	Spacer
4	9N-0869	Hard Washer
4	7X-0818	Bolt
8	7X-0613	Hard Washer
4	8T-4971	Bolt
1	360-3920	Bracket As
2	7X-7729	Washer
2	8T-4195	Bolt
8	5P-4116	Hard Washer
1	369-9384	Plate
4	8T-7547	Bolt
4	344-5674	Nut
1	360-3919	Bracket As

777D Full (4 Radars / 4 Cameras)

Table 20

Required Parts for the 777D 2 Radars / 4 Cameras Object Detection System
Quantity	Part Number	Description
1	372-1304	Object Detector Gp
1	516-5944	Object Detection Kit

Contents of the 372-1304 Object Detector Gp and the 516-5944 Object Detection Kit

Table 21

Contents of the 372-1304 Object Detector Gp
Quantity	Part Number	Description
1	368-0883	Object Detection Kit
1	368-2992	Object Detection Kit
1	368-2994	Object Detection Kit
1	368-2995	Object Detection Kit
1	361-5212	Object Detection Wiring Gp
1	362-8526	Object Detection Wiring Gp

Table 22

Contents of the 516-5944 Object Detection Kit
Quantity	Part Number	Description
1	362-8526	Object Detection Wiring Gp
1	513-7090	Sensor and Mounting Gp
1	513-7092	Object Detection Box and Mounting Gp
1	433-0584	Object Detector Gp

Contents of the 372-1304 Object Detector Gp

Table 23

Contents of the 368-0883 Object Detection Kit
Quantity	Part Number	Description
2	8T-4142	Bolt
4	261-3223	Coaxial Cable As
2	274-4477	Cable As
2	283-0658	Cable As
1	315-5391	Nut
1	319-6830	Sensor Harness As
2	336-6684	Camera Gp
1	340-7161	Power Converter
1	348-9226	Grommet Assembly
1	355-9048	Monitor Display Gp

Table 24

Contents of the 368-2992 Object Detection Kit
Quantity	Part Number	Description
2	8T-4121	Hard Washers
2	8T-4136	Bolts
1	271-6768	Plate
1	360-3917	Bracket
1	361-4970	Bracket As

Table 25

Contents of the 368-2994 Object Detection Kit
Quantity	Part Number	Description
6	8T-4121	Hard Washers
1	305-3748	Plate As
3	8T-5005	Bolts
3	198-4777	Hard Washers
3	8T-4133	Nuts
1	067-2551	Pipe

Table 26

Contents of the 368-2995 Object Detection Kit
Quantity	Part Number	Description
2	336-6684	Camera Gp
2	283-0658	Cable As
2	251-8248	Communication Cable As
2	305-3748	Plate As
2	305-3747	Plate As
6	4L-6459	Bolt
6	6V-8801	Nut
12	5P-1075	Hard Washer
2	348-8789	Block
8	7X-7729	Washer
8	8T-4195	Bolt
2	219-6485	Flood Lamp Gp

Table 27

Contents of the 361-5212 Object Detection Wiring Gp
Quantity	Part Number	Description
1	360-0191	Bracket As
1	362-2231	Bracket As
2	7X-7729	Washer
2	6V-4248	Bolt
1	361-5211	Cab Harness As
2	9X-2044	Screw
1	3E-5239	Relay As
1	6T-3644	Circuit Breaker As
2	7U-4892	Screw
1	134-5245	Bolt
25	7K-1181	Cable Strap
150 mm (5.90 inch)	7X-7877	Edging Strip
2	4P-8134	Clip
1	5S-7349	Bolt
6	3S-2093	Cable Strap
1	8T-4205	Hard Washer

Table 28

Contents of the 362-8527 Object Detection Wiring Gp
Quantity	Part Number	Description
6	3S-2093	Cable Straps
20	7K-1181	Cable Straps
1	361-1264	Wiring Harness
1	361-1267	Wiring Harness
1	373-1344	Wiring Harness
1	294-3313	Clip
1	352-3968	Clip
1	3E-6753	Grommet
1	4P-7428	Clip
8	4P-7581	Clips
1	7M-3361	Grommet
1	8T-4137	Bolt
1	8T-4896	Hard Washer

Contents of the 516-5944 Object Detection Kit

Table 29

Contents of the 362-8526 Object Detection Wiring Gp
Quantity	Part Number	Description
45	7K-1181	Cable Straps
1	130-5300	Clip
1	361-0851	Rear Harness As
1	361-1262	Front Harness As
1	363-8847	Chassis Harness As
3	132-5789	Clips
9	4P-7581	Clips
6	5M-3062	Bolts
6	8T-4896	Hard Washers

Table 30

Contents of the 513-7090 Sensor and Mounting Gp
Quantity	Part Number	Description
4	5P-1076	Hard Washers
4	5P-4115	Hard Washers
4	7X-0818	Bolts
2	7X-7729	Washers
4	8T-4138	Bolts
4	8T-4139	Bolts
2	8T-4195	Bolts
8	8T-9655	Isolation Mounts
4	8T-9658	Spacers
4	9N-0869	Hard Washers
1	430-8391	Object Detection Box Gp
1	359-7444	Bracket As
1	360-3915	Bracket As
1	364-5871	Bracket As
2	364-5878	Blocks

Table 31

Contents of the 513-7092 Object Detection Box and Mounting Gp
Quantity	Part Number	Description
4	5P-4115	Hard Washer
4	7X-0818	Bolt
4	7X-3185	Bolt
2	7X-7729	Washer
4	8T-4138	Bolt
2	8T-4195	Bolt
8	8T-9655	Isolation Mount
4	8T-9658	Spacer
4	9N-0869	Hard Washer
1	430-8391	Object Detection Box Gp
1	359-7444	Bracket As
1	360-3915	Bracket As

777D Vision Only (4 Cameras)

Table 32

Required Parts for the 777D Vision Only Object Detection System
Quantity	Part Number	Description
1	372-1304	Object Detector Gp

Contents of the 372-1304 Object Detector Gp

Table 33

Contents of the 368-0883 Object Detection Kit
Quantity	Part Number	Description
2	8T-4142	Bolt
4	261-3223	Coaxial Cable As
2	274-4477	Cable As
2	283-0658	Cable As
1	315-5391	Nut
1	319-6830	Sensor Harness As
2	336-6684	Camera Gp
1	340-7161	Power Converter
1	348-9226	Grommet Assembly
1	355-9048	Monitor Display Gp

Table 34

Contents of the 368-2992 Object Detection Kit
Quantity	Part Number	Description
2	8T-4121	Hard Washers
2	8T-4136	Bolts
1	271-6768	Plate
1	360-3917	Bracket
1	361-4970	Bracket As

Table 35

Contents of the 368-2994 Object Detection Kit
Quantity	Part Number	Description
6	8T-4121	Hard Washers
1	305-3748	Plate As
3	8T-5005	Bolts
3	198-4777	Hard Washers
3	8T-4133	Nuts
1	067-2551	Pipe

Table 36

Contents of the 368-2995 Object Detection Kit
Quantity	Part Number	Description
2	336-6684	Camera Gp
2	283-0658	Cable As
2	251-8248	Communication Cable As
2	305-3748	Plate As
2	305-3747	Plate As
6	4L-6459	Bolt
6	6V-8801	Nut
12	5P-1075	Hard Washer
2	348-8789	Block
8	7X-7729	Washer
8	8T-4195	Bolt
2	219-6485	Flood Lamp Gp

Table 37

Contents of the 361-5212 Object Detection Wiring Gp
Quantity	Part Number	Description
1	360-0191	Bracket As
1	362-2231	Bracket As
2	7X-7729	Washer
2	6V-4248	Bolt
1	361-5211	Cab Harness As
2	9X-2044	Screw
1	3E-5239	Relay As
1	6T-3644	Circuit Breaker As
2	7U-4892	Screw
1	134-5245	Bolt
25	7K-1181	Cable Strap
150 mm (5.90 inch)	7X-7877	Edging Strip
2	4P-8134	Clip
1	5S-7349	Bolt
6	3S-2093	Cable Strap
1	8T-4205	Hard Washer

Table 38

Contents of the 362-8527 Object Detection Wiring Gp
Quantity	Part Number	Description
6	3S-2093	Cable Straps
20	7K-1181	Cable Straps
1	361-1264	Wiring Harness
1	361-1267	Wiring Harness
1	373-1344	Wiring Harness
1	294-3313	Clip
1	352-3968	Clip
1	3E-6753	Grommet
1	4P-7428	Clip
8	4P-7581	Clips
1	7M-3361	Grommet
1	8T-4137	Bolt
1	8T-4896	Hard Washer

Prepare the Machine

1. Raise the truck body and install the body retaining pin for the truck body.

2. Set the parking brake.

3. Turn the key start switch and the disconnect switch to the OFF position.
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   Illustration 1	g02163053
   (1) Cover

4. Remove the cover (1) behind the seat.

5. Remove the headliner.

Drill the Holes for the Harness

Drill a hole in the following locations:

• Left Fender Wall (Harness Routing)

• Right Rear Corner of Cab (Harness Routing)

• Right Platform (Harness Routing)

• Right Platform (Radar Bracket)

Left Fender Wall (Harness Routing)

Illustration 2	g02172675
Location of Hole (2) on finder wall.

Illustration 3	g02486028
Dimensions of Hole (2).

Table 39

Point	Dimension
A	40 mm (1.57 inch)
B	60 mm (2.36 inch)
C	40 mm (1.57 inch)

1. Lay out the dimensions for the hole (2) on the fender wall. Refer to the dimensions that are provided in Illustration 2 and Table 39.

2. Drill a 40 mm (1.57 inch) hole in the fender wall.

Right Rear Corner of Cab

Illustration 4	g02486029
(3) Hole for camera cables (4) Hole for interface harness

Illustration 5	g02486035
Dimensions of Hole (3).

Table 40

Point	Dimension
D	50 mm (1.97 inch)
E	63 mm (2.48 inch)
F	250 mm (9.84 inch)

1. Lay out the dimensions for hole (3).

   Refer to the dimensions that are provided in Illustration 5 and Table 40.

2. Drill a 50 mm (1.97 inch) in the plate.

Illustration 6	g02486056
Dimensions of Hole (4).

Table 41

Point	Dimension
G	43 mm (1.69 inch)
H	70 mm (2.76 inch)
J	180 mm (7.09 inch)

1. Lay out the dimensions for hole (4).

   Refer to the dimensions that are provided in Illustration 6 and Table 41.

2. Drill a 43 mm (1.69 inch) in the plate.

Right Platform

Illustration 7	g02486076
Dimensions of Hole (5).

Table 42

Point	Dimension
K	200 mm (7.87 inch)
L	63 mm (2.48 inch)
M	50 mm (1.97 inch)
N	44 mm (1.73 inch)

1. Lay out the dimensions for the four holes (5) on the right platform. Refer to the dimensions that are provided in Illustration 7 and Table 42.

2. Drill four 11 mm (0.43 inch) holes (5).

Illustration 8	g02486116
Dimensions of Hole (6).

Table 43

Point	Dimension
P	150 mm (5.91 inch)
Q	175 mm (6.89 inch)
R	30 mm (1.18 inch)

1. Lay out the dimensions for the single hole (6) on the right platform. Refer to the dimensions that are provided in Illustration 8 and Table 43.

Component Assembly

Assemble the Cameras

Note: An arrow is at the top of the camera lens which indicates the up direction of the camera.

Illustration 9	g02174089
(1) Camera shell (2) Bolts (3) Camera (4) Bolts (5) Nuts (6) Nuts

1. Assemble the four cameras (if applicable) with the parts that are supplied with the cameras.

   Refer to Illustration 9.

   Note: Do not tighten the nuts (6). The nuts will be used in the following procedure to attach the camera to the brackets for the camera.

Assemble the Front and Side Cameras to the 305-3748 Plate As

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Illustration 10	g02476642
(6) Nuts (7) Camera cable

1. Route the harness for the camera (7) and the connector for the camera through the hole that is provided in the 305-3748 Plate As. Place the grommet that is provided on the harness for the camera through the hole. Repeat this procedure for all the cameras.

2. Install the 336-6684 Camera Gp to the 305-3748 Plate As. Use the nuts (6) that were left loose in Step 1 to secure the camera to the plate.

Assemble the Rear Camera to the 360-3917 Bracket

Illustration 11	g02476721
(6) Nuts (7) 360-3917 Bracket

1. Mount the assembled camera to the 360-3917 Bracket (7). Use the nuts (6) that were left loose in Step 1 to secure the camera to the plate.

Assemble the Side Cameras to the 305-3747 Plate As

Illustration 12	g02486159
(8) Camera (9) 305-3748 Plate As (10) 8T-6466 Bolt (11) 8T-4133 Nut (12) 8T-4121 Hard Washer (14) 305-3747 Plate As

1. Mount the assembled camera and 305-3748 Plate As (9) to the 305-3747 Plate As (14). Tighten the mounting bolts.

   Refer to Illustration 12.

Assemble the Radar Boxes to the Brackets

The sensors for the object detection are assembled before shipping. The sensors have functionally tested in the radar boxes. Use the following procedure to assemble the mounting brackets to the radar boxes.

Note: Inspect the vent and the grommet on the bottom of the radar box. Ensure that the sealant has not been disturbed during shipment. If the seal is not intact, use silicone sealant to seal the grommet and the vent.

Note: Ensure that the shipping film is removed from the lens of the radar box.

Mount the Front 340-0575 Object Detection Sensor Gp to the 359-7444 Bracket As

Illustration 13	g02486162
(15) 359-7850 Bracket As (16) 359-7444 Bracket As (17) 7X-0818 Bolt (18) 9N-0869 Hard Washer (19) 8T-9655 Isolation Mount (20) 8T-9658 Spacer

1. Install the 359-7444 Bracket As (16) to the 359-7850 Bracket As (15). Use the 7X-0818 Bolts (17), 9N-0869 Hard Washers (18), 8T-9655 Isolation Mounts (19), and 8T-9658 Spacers (20).

   Refer to Illustration 13.

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   Illustration 14	g02486176
   (21) 8T-4138 Bolts (22) 5P-4115 Hard Washers (23) 340-0575 Object Detection Sensor Gp

2. Mount the 340-0575 Object Detection Sensor Gp (23) to the 359-7444 Bracket As (16). Use the 8T-4138 Bolts (21) and 5P-4115 Hard Washers (22).

Mount the Side 340-0575 Object Detection Sensor Gp to the 364-5738 Bracket As

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Illustration 15	g02486197
(15) 359-7850 Bracket As (17) 7X-0818 Bolt (18) 9N-0869 Hard Washer (19) 8T-9655 Isolation Mount (20) 8T-9658 Spacer (24) 364-5738 Bracket As

1. Install the 364-5738 Bracket As (24) to the 359-7850 Bracket As (15). Use the 7X-0818 Bolts (17), 9N-0869 Hard Washers (18), 8T-9655 Isolation Mounts (19), and 8T-9658 Spacer (20).

   Refer to Illustration 15.

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   Illustration 16	g02486201
   (23) 340-0575 Object Detection Sensor Gp (24) 364-5738 Bracket As (25) 8T-4971 Bolt (26) 6V-3964 Hard Washer

2. Mount the 340-0575 Object Detection Sensor Gp (23) to the 364-5738 Bracket As (24). Use the 8T-4971 Bolts (25) and 6V-3964 Hard Washer (26).

   Refer to Illustration 16.

Mount the Rear 340-0575 Object Detection Sensor Gp to the 359-7444 Bracket As

Illustration 17	g02486242
(16) 359-7444 Bracket As (17) 7X-0818 Bolt (18) 9N-0869 Hard Washer (19) 8T-9655 Isolation Mount (20) 8T-9658 Spacer (27) 360-3915 Bracket As

1. Install the 359-7444 Bracket As (16) to the 360-3915 Bracket As (27). Use the 7X-0818 Bolts (17), 9N-0869 Hard Washers (18), 8T-9655 Isolation Mounts (19), and 8T-9658 Spacer (20).

   Refer to Illustration 17.

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   Illustration 18	g02486256
   (21) 8T-4138 Bolts (22) 5P-4115 Hard Washers (23) 340-0575 Object Detection Sensor Gp

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   Illustration 19	g02476739
   (7) 360-3917 Bracket (22) 5P-4115 Hard Washers (25) 8T-4971 Bolts

2. Mount the 340-0575 Object Detection Sensor Gp (23) to the 359-7444 Bracket As. Use the 8T-4138 Bolts (21) and 5P-4115 Hard Washers (22) on the left side. Install the 360-3917 Bracket (7) and camera assembly on the right side. Use the 8T-4971 Bolts (25) and 5P-4115 Hard Washers (22).

Cab Hardware and Harness Installation

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Illustration 20	g02350611

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Illustration 21	g02350613

1. Lay out the dimensions for the 360-0191 Bracket As. Refer to Illustration 20, Illustration 21, and Table 44 for the location of the 360-0191 Bracket As.
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   Table 44

   Point	Dimension
   A	74 mm (2.91 inch)
   B	290 mm (11.42 inch)

2. Weld the 360-0191 Bracket As to the ceiling with a 2 mm (0.08 inch) fillet weld around each corner.

   Note: The material of the cab is thin.

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   Illustration 22	g02400216
   Example of Cable Labels (1) Camera 1 Front (2) Camera 2 Right (3) Camera 3 Rear (4) Camera 4 Left

3. Label the 251-8248 Communication Cable As. Use the numbers one through four at both ends of the cable.
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   Illustration 23	g02486280
   (1) 319-6830 Sensor Harness As (2) 340-7161 Power Converter (3) 355-9048 Monitor Display Gp (4) 361-5211 Cab Harness As (5) 360-0191 Bracket As (6) 274-4477 Cable As (7) 7K-1181 Cable Strap (8) 8T-4121 Hard Washer (9) 8T-4136 Bolt

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   Illustration 24	g02164941
   Example of harness routing inside cab

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   Illustration 25	g02164535
   View (C)

4. Route the 361-5211 Cab Harness As (4) per Illustration 23.

5. Route the four 274-4477 Cable As to the four video connectors of the 319-6830 Sensor Harness As (1). Connect the cables. Refer to Table 45.
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   Table 45

   274-4477 Cable As Cable Label	319-6830 Sensor Harness As Connector Label	Camera
   1	Cam 1	Front
   2	Cam 2	Right
   3	Cam 3	Rear
   4	Cam 4	Left

6. Enlarge the slot for the cables in the headliner to allow the following connectors to pass through:

   • Two 12-pin connectors

   • Light Switch connector of 361-5211 Cab Harness As

   • 12-pin connector of 319-6830 Sensor Harness As

7. Secure the 361-5211 Cab Harness As (4), 274-4477 Cable As and 319-6830 Sensor Harness As (1) to the tie links around the ceiling of the cab. Allow enough slack for the 12-pin connectors and switch to connect to the system display and light switch without placing stress on the wiring. Allow enough slack in the harness to allow for adjustment of the display. The remaining slack of the harnesses should be pulled back into the electronics bay.

8. Reinstall the headliner and components.

   Note: The headliner must be cut for proper reinstallation.

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   Illustration 26	g02486317
   (5) 360-0191 Bracket As (8) 8T-4121 Hard Washer (9) 8T-4136 Bolt (10) 362-2231 Bracket As

9. Assemble the 362-2231 Bracket As (10) to the 360-0191 Bracket As (5) with two 8T-4136 Bolt and two 8T-4121 Hard Washer.

   Refer to Illustration 26.

10. Install the 355-9048 Monitor Display Gp (3) onto the 362-2231 Bracket As (10) using the screws that are provided with the display.

11. Connect the three 12-pin connectors to the corresponding connectors on the back of the display. The video harness connects to the green connector. The 12-pin connector with two wires connects to the black connector and the 12-pin connector with five wires connects to the gray connector.

12. Locate the 19-pin bulkhead connector of the 361-5211 Cab Harness As (4). Insert the connector through the 43 mm (1.69 inch) hole that was drilled in the plate at the right rear corner of the cab. Refer to Illustration 24. Secure the connector with the nut and washers that are provided with the connector.

13. Locate a suitable location in the electronics bay to install the 340-7161 Power Converter (2). Use the 6V-8931 Washer Head Screws to install the converter.

    Note: Ensure that the harness connections will reach the power converter before you install the power converter.

Cab Harness Connections

1. Make the electrical connections of the 361-5211 Cab Harness As that are listed below:

   1. Connect wire C234-BK(Black)and the ground wires 200-BK(Black)to the ground post of the cab.

   2. Connect wire 130-RD(Red)to one side of the 6T-3644 Circuit Breaker As.

   3. Connect wire 109-RD(Red)to the other side of the 6T-3644 Circuit Breaker As.

   4. Locate an empty mounting location for the circuit breaker. Secure the circuit breaker with the screws that are provided.
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      Illustration 27	g02076196

   5. Connect wire 109-RD(Red) (R) to the unswitched power side of the main power relay.

      Refer to Illustration 27.

   6. Connect the wires 308-YL(Yellow) (Y) to the coil of the main power relay.

      Refer to Illustration 27.

   7. Locate connector "A-C52" on the plate on the lower right-hand side of the cab.

   8. Extract pin 5, wire 892-BR(Brown), and pin 6, wire 893-GN(Green)from connector "A-C52"

      Note: The wires in this step are the wires that were removed from connector "A-C52".

   9. Insert wire 892-BR(Brown)into contact 1 and wire 893-GN(Green)into contact 2 of connector "CM-C8" (2-pin connector).

      Note: The wires in this step are from 361-5211 Cab Harness As.

   10. Insert wire 892-BR(Brown)into pin 5 and wire 893-GN(Green)into pin 6 of connector "A-C52".

   11. Connect connector "CM-C4" to the 340-7161 Power Converter.

2. Label the four video cables "front", "right", "left", and "rear" for the corresponding camera that is connected to the cable.

3. Insert the four video cables into the 348-9226 Grommet Assembly. Secure the grommet into the second hole that was drilled in the plate at the right rear corner of the cab. Torque the nut of the 348-9226 Grommet Assembly. Pass the excess video cable into the electronics bay.
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   Table 46

   Video Cables to Display	Video Cables to Camera
   1	Front
   2	Right
   3	Rear
   4	Left

4. Connect the four video cables from the cameras to the four video cables from the display. Refer to Table 46.

5. Secure the harnesses in the electronics bay with the 3S-2093 Cable Straps.

Radar and Camera Installation Procedure

Bracket Installation Procedure

Left Side Radar Bracket

Illustration 28	g02399877
View of 369-9384 Plate location

Illustration 29	g02351685
(1) 369-9384 Plate

Table 47

Point	Dimension
A	13.5 mm (0.53 inch)
B	285 mm (11.22 inch)

1. Lay out the dimensions for the 369-9384 Plate (1).

   Refer to Illustration 29 and Table 47.

2. Weld the 369-9384 Plate (1) to the ROPS using a 3 mm (0.12 inch) fillet weld.

Left Side Camera Bracket

Illustration 30	g02463079
(2) 255-8274 Plate

Note: Measurements are from the edges of the 255-8274 Plate (2).

Table 48

Point	Dimension
C	10 mm (0.39 inch)
D	140 mm (5.51 inch)

1. Lay out the dimensions for the 255-8274 Plate (2).

   Refer to Illustration 30 and Table 48.

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   Illustration 31	g02165055
   Orientation of the 255-8274 Plate

2. Weld the 255-8274 Plate to the left fender with a 3 mm (0.12 inch) fillet weld.

   Refer to Illustration 31 for the proper orientation of the 255-8274 Plate.

Right Side Radar Bracket

Illustration 32	g02486336
(3) 360-3919 Bracket As (4) 8T-7547 Bolts (5) 5P-4116 Hard Washers (6) 5C-7261 Nuts

1. Install the 360-3919 Bracket As (3) to the platform. Use the 8T-7547 Bolts (4), 5P-4116 Hard Washers (5), and 5C-7261 Nuts (6) to secure the bracket.

Right Side Camera Bracket

Illustration 33	g02486338
(7) 255-8274 Plate

Table 49

Point	Dimension
E	14 mm (0.55 inch)
F	261 mm (10.28 inch)

1. Lay out the dimensions for the 255-8274 Plate (7).

   Refer to Illustration 33 and Table 49.

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   Illustration 34	g02165055
   Orientation of the 255-8274 Plate

2. Weld the 255-8274 Plate (7) to the right fender with a 3 mm (0.12 inch) fillet weld.

   Refer to Illustration 33 for the proper orientation of the 255-8274 Plate (7).

Front Radar Bracket

Illustration 35	g02485961
(8) 364-5871 Bracket As (9) 364-5878 Blocks (10) 8T-4139 Bolts (11) 5P-1076 Hard Washers

Illustration 36	g02476876
(8) 364-5871 Bracket As

Table 50

Point	Dimension
G	1571 mm (61.85 inch)
H	78 mm (3.07 inch)

1. Install the 364-5871 Bracket As (8) on two 364-5878 Blocks (9) with four 8T-4139 Bolts (10) and four 5P-1076 Hard Washers (11).

2. Place the 364-5871 Bracket As (8) with the 364-5878 Blocks (9) on the front bumper. Use Illustration 36 and Table 50 for the bracket location and orientation.

3. Weld the 364-5878 Blocks (9) to the front bumper with a 3 mm (0.12 inch) fillet weld.

Rear Radar Bracket

Illustration 37	g02484305
(12) 361-4971 Bracket (13) 9D-0968 Plate

Table 51

Point	Dimension
J	19 mm (0.75 inch)
K	485 mm (19.09 inch)

1. Place the 361-4971 Bracket (12) on the 9D-0968 Plate (13) at the rear of the machine using Illustration 37 and the dimensions from Table 51.

2. Weld the 361-4971 Bracket (12) to the 9D-0968 Plate (13) with a 6 mm (0.24 inch) fillet weld on each side of the bracket.

Camera and Radar Installation

Left Side (Radar)

Illustration 38	g02486479
(14) 8T-4137 Bolt (15) 7X-7729 Washer (16) 369-9384 Plate

1. Install the assembled 340-0575 Object Detection Sensor Gp to the 369-9384 Plate (16) with the 8T-4137 Bolts (14) and the 7X-7729 Washers (15).

Left Side (Camera)

Illustration 39	g02486498
(14) 8T-4137 Bolts (17) 305-3747 Plate As (18) 8T-4121 Hard Washers (19) 219-6485 Flood Lamp Gp Mounting Location

1. Install the 305-3747 Plate As (17) to the block on the machine with four 8T-4137 Bolts (14) and four 8T-4121 Hard Washers (18).

   Refer to Illustration 39.

2. Install the 219-6485 Flood Lamp Gp to the 305-3747 Plate As (17) in the location shown (19).

   Refer to Illustration 39.

Right Side (Radar)

1. Install the assembled 340-0575 Object Detection Sensor Gp to the 360-3920 Bracket As (20) with the 8T-4195 Bolts and 7X-7729 Washers.

Right Side (Camera)

Illustration 40	g02486542
(14) 8T-4137 Bolts (15) 8T-4121 Hard Washers (21) 305-3747 Plate As

1. Install the 305-3747 Plate As (21) to the block on the machine with four 8T-4137 Bolts (14) and four 8T-4121 Hard Washers (15).

   Refer to Illustration 40.

2. Install the 219-6485 Flood Lamp Gp to the 305-3747 Plate As (21).

Front Radar

Illustration 41	g02477219
(8) 364-5871 Bracket As

1. Installed the assembled 340-0575 Object Detection Box Gp to the 364-5871 Bracket As (8) with two 8T-4195 Bolts and two 7X-7729 Washers.

Front Camera

Illustration 42	g02476281

Table 52

Point	Dimension
L	450 mm (17.72 inch)
M	400 mm (15.75 inch)
N	24 mm (0.945inch)

1. Use Illustration 42 and the measurements in Table 52 to find the location of the front camera.

2. Install the camera through the grill. Use three 8T-4121 Hard Washers and three 8T-4133 Nuts on the back side to secure the camera.

Rear Radar and Camera

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Illustration 43	g02484225
(12) 361-4971

1. Attach the rear radar and camera assembly to the 361-4971 (12). Use two 8T-4195 Bolts and two 7X-7729 Washers.

Harness Installation Procedure

Note: Route all camera cables at the same time as the radar harnesses. Use Illustration 44, Table 53, and Table 54 as a guide for all harness and cable routing.

Illustration 44	g02490896

Table 53

Routing Index for the Radar Harnesses
Callout	Part Number	Description
1	363-8847	Chassis Harness As
2	361-1267	Wiring Harness
3	373-1344	Wiring Harness
4	361-1264	Wiring Harness
5	361-1262	Front Harness As
6	361-0851	Rear Harness As

Table 54

Routing Index for the Camera Cables
Callout	Part Number	Description	Routing
F	274-4477	Cable As	From Cab Bulkhead to Front Camera.
R	283-0658	Cable As	From Cab Bulkhead to Rear Camera.
LT	274-4477	Cable As	From Cab Bulkhead to Left Camera Cable.
RT	283-0658	Cable As	From Cab Bulkhead to Right Camera Cable.

Main Harness

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Illustration 45	g02482176
(1) 363-8847 Chassis Harness As

1. Route the 363-8847 Chassis Harness As (1) from the right rear of the cab towards the front of the machine. Use the existing hardware and install a 4P-7581 Clip (8) in the location shown in Illustration 45. Secure the 363-8847 Chassis Harness As (1) to the existing harness and the 4P-7581 Clip (8) with 7K-1181 Cable Straps.

   Refer to Illustration 45.

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   Illustration 46	g02482256
   (1) 363-8847 Chassis Harness As (7) 132-5789 Clip (8) 4P-7581 Clip (9) 4P-7428 Clip

2. Continue routing the 363-8847 Chassis Harness As (1) around the bottom of the 5T-3530 Pipe. Install the following clips:

   • One 132-5789 Clip (7)

   • One 4P-7581 Clip (8)

   • One 4P-7428 Clip (9)

   Use one 5M-3062 Bolt and one 8T-4896 Hard Washer to secure the 132-5789 Clip (7) and the 4P-7581 Clip (8) to the machine. Use the existing hardware to secure the 4P-7428 Clip (9) to the machine.

   Refer to Illustration 46.

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   Illustration 47	g02482417
   (1) 363-8847 Chassis Harness As

3. Attach the short section of 363-8847 Chassis Harness As (1) shown in Illustration 47 to the existing harness. The front harness will connect to the main harness at this connection point. The front harness routing will take place later in this instruction.
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   Illustration 48	g02482420
   (1) 363-8847 Chassis Harness As (8) 4P-7581 Clips

4. Continue routing the short section of 363-8847 Chassis Harness As (1) as shown in Illustration 48. Attach the 363-8847 Chassis Harness As (1) to the 4P-7581 Clips (8) that are shown in Illustration 48. The left harness will connect to the main harness at this connection point. The left harness routing will take place later in this instruction.
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   Illustration 49	g02482280
   (1) 363-8847 Chassis Harness As

5. Continue routing the 363-8847 Chassis Harness As (1). Secure the 363-8847 Chassis Harness As (1) to the lighting harness with 7K-1181 Cable Straps across the front of the machine to the right side. The right harness will connect to the main harness at the connection point where the main harness ends here.

   Refer to Illustration 49.

Right Side

Illustration 50	g02482822
(1) 363-8847 Chassis Harness As (2) 361-1267 Wiring Harness

1. Connect the 361-1267 Wiring Harness (2) to the 363-8847 Chassis Harness As (1). Route the 361-1267 Wiring Harness (2) as shown in Illustration 50. Use 7K-1181 Cable Straps to secure the 361-1267 Wiring Harness (2).

2. Feed the 373-1344 Wiring Harness (3) and the 283-0658 Cable As (RT) through the hole that was made in the 242-0428 Plate earlier in this instruction. Install the 3E-6753 Grommet in the hole on the 242-0428 Plate.
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   Illustration 51	g02482897
   (2) 361-1267 Wiring Harness (3) 373-1344 Wiring Harness

3. Route the 373-1344 Wiring Harness (3) along the existing harness from the connection to the 361-1267 Wiring Harness (2) to the hole in the 242-0428 Plate. Use 7K-1181 Cable Straps to secure the harness.

   Refer to Illustration 51.

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   Illustration 52	g02482958
   (3) 373-1344 Wiring Harness (10) 352-3968 Clip (11) 4P-7581 Clips

4. Route the 373-1344 Wiring Harness (3) along the outside of the right side platform.

   1. Install one 352-3968 Clip (10) using the existing hardware from the hand rail.

   2. Install two 4P-7581 Clips (11) on the 8W-6062 Deflector using the existing hardware.

   3. Secure the 373-1344 Wiring Harness (3) to the clips with 7K-1181 Cable Straps.

   4. Connect the 373-1344 Wiring Harness (3) to the radar and the 283-0658 Cable As (RT) to the camera.

Left Side

1. Feed the 361-1264 Wiring Harness (4) and the 274-4477 Cable As (LT) through the hole that was made in the 245-7748 Fender earlier in this instruction. Install the 7M-3361 Grommet in the hole on the 245-7748 Fender.
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   Illustration 53	g02491917
   Left Harness Connection (1) 363-8847 (4) 361-1264 Wiring Harness (8) 4P-7581 Clip

2. Connect the 361-1264 Wiring Harness (4) to the 363-8847 Chassis Harness As (1). Use the 4P-7581 Clip (8) and 7K-1181 Cable Straps to secure the harness.

   Refer to Illustration 53.

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   Illustration 54	g02491937
   (4) 361-1264 Wiring Harness

3. Route the 361-1264 Wiring Harness (1) along the front of the machine.

   Refer to Illustration 54.

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   Illustration 55	g02491957
   (12) 4P-7428 Clip (13) 8T-4137 Bolt (14) 8T-4896 Hard Washer (15) 4P-7581 Clip

4. Install the 4P-7428 Clip (12), use the existing hardware. Install the 4P-7581 Clip (15), use the 8T-4137 Bolt (13) and 8T-4896 Hard Washer (14).

   Route the harnesses as shown in Illustration 55.

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   Illustration 56	g02491962
   Left Side Harness (4) 361-1264 Wiring Harness (8) 4P-7581 Clips

5. Route the 361-1264 Wiring Harness (4) along the left side of the machine. Use the 4P-7581 Clips (8) and existing bolts to secure the harness.

   Refer to Illustration 56.

6. Connect the 361-1264 Wiring Harness (4) to the left radar and the 274-4477 Cable As (LT) to the left camera.

Front Harness, Radar, and Camera

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Illustration 57	g02482998
(1) 363-8847 Chassis Harness As (5) 361-1262 Front Harness As (7) 132-5789 Clips (16) 130-5300 Clip

1. Install the following clips:

   • Three 132-5789 Clips (7)

   • One 130-5300 Clip (16)

   Use one 5M-3062 Bolt and one 8T-4896 Hard Washer to install each clip.

   Note: The 274-4477 Cable As (F) will follow Step 1 through Step 4.

2. Connect the 361-1262 Front Harness As (5) to the 363-8847 Chassis Harness As (1).

3. Secure the 361-1262 Front Harness As (5) to the clips with 7K-1181 Cable Straps.

   Refer to Illustration 57.

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   Illustration 58	g02483056
   (5) 361-1262 Front Harness As

4. From the last clip route the 361-1262 Front Harness As (5) along the disconnect switch harness and below the baffle. Refer to Illustration 58.
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   Illustration 59	g02483082
   (11) 4P-7581 Clips

5. Install three 4P-7581 Clips (11) below the grill as shown in Illustration 59. Secure the 361-1262 Front Harness As (5) to the 4P-7581 Clips (11) with 7K-1181 Cable Straps.

6. Finish routing the 361-1262 Front Harness As (5) to the front radar.
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   Illustration 60	g02483116

7. Finish routing the 274-4477 Cable As (F) from Step 4. Continue routing the 274-4477 Cable As (F) under the grill and out to the front. Route the harness up the grill and attach with 7K-1181 Cable Straps. Refer to Illustration 60.

Rear Harness

Illustration 61	g02492198
(6) 361-0851 Rear Harness As

1. Connect the 361-0851 Rear Harness As (6) to the 363-8847 Chassis Harness As (1).

2. Route the 361-0851 Rear Harness As (6) and the 283-0658 Cable As (R) on the left side of the frame. Use 7K-1181 Cable Straps to secure the 361-0851 Rear Harness As (6) and the 283-0658 Cable As (R) to the existing harness.

   Refer to Illustration 61.

3. Connect the 361-0851 Rear Harness As (6) to the rear radar and the 283-0658 Cable As (R) to the rear camera.

Adjust the Object Detection Sensors

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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.

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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.

There are two angle adjustments for the object detection sensors. The adjustments are the Azimuth or horizontal adjustment and the Elevation or the vertical adjustment. The angles that are provided in Table 55 are the angles that were found to work best.

These angles are guidelines and may require an adjustment of a few degrees to bring the detection area of the system into an acceptable limit. This adjustment is necessary because of differences in machines that are not controlled by Caterpillar.

The type of tires that are used on a machine may affect the height of the machine. This procedure must be used with the "Calibrate the Object Detection Sensors" procedure that is contained in the manual.

Table 55

Radar Angles
Front Radar		Rear Radar		Side Radar
Azimuth (deg)	Elevation (deg)	Azimuth (deg)	Elevation (deg)	Azimuth (deg)	Elevation (deg)
0	0 down	0	12 down	0	50 down

Azimuth Adjustment Procedure

Illustration 62	g02203958
(1) Azimuth adjustment for medium range radar brackets

Table 56

Required Tools
13 mm Wrench	1
Protractor	1

1. Loosen the four azimuth adjustment bolts on the brackets for the radars.

2. Use a protractor to set the proper azimuth angle or adjust the angle to fine-tune the system. Refer to the angles listed in Table 55.

3. Carefully tighten the four azimuth adjustment bolts on the brackets for the radars.

4. Check the angle again to verify that the bracket is set to the proper angle.

5. Tighten the bolts.

6. Check the angle again to verify that the bracket is set to the proper angle.

7. Proceed to the "Elevation Adjustment Procedure".

Elevation Adjustment Procedure

Illustration 63	g01944710
Elevation Adjustment bolts for Medium Range Radar

Table 57

Required Tools
10 mm Wrench	1
Inclinometer or Digital Level	1

1. Loosen the four adjustment bolts on the bracket for the radar.

2. Use an inclinometer or a digital level to set the proper elevation angle or adjust the angle to fine- tune the system. Refer to the angles that is listed in Table 57.

3. Carefully tighten the four azimuth adjustment bolts on the brackets for the radars.

4. Check the angle again to verify that the bracket is set to the proper angle.

5. Tighten the bolts.

6. Check the angle again to verify that the bracket is set to the proper angle.

Camera Adjustment Procedure

Prior to operating the machine, ensure the proper orientation of the image on the monitor. Adjust the camera to provide the following view from the machine:

• Optimum view of blind spots on machine

Consult your Cat dealer before any adjustments are made to the camera.

Prior to operating the machine, ensure that the features of the display are properly adjusted. Ensure that the brightness and the contrast are adjusted prior to operating the machine. Ensure that the brightness and the contrast are adjusted after changes in the conditions for ambient light.

Prior to operating the machine, ensure that the display is positioned to provide clear visibility of the display from the operator seat. Do not position the display in a way that will cause the following conditions:

• Cover any safety messages or other important information.

• Impede the entry to the cab or impede the exit from the cab.

• Obstruct the visibility of the operator.

• Obstruct the view of any indicators, gauges, or monitoring system.

• Impair access to any operator controls or impair movement of any operator controls.

Prior to operating the machine, ensure that the camera lens and the display are clean.

Flash the Software onto the Display

The display is shipped blank and will need the software installed. Refer to REHS7353, "Procedure for Installing Object Detection Software on Monitor Display Group of Certain Off-Highway Trucks", for software installation instructions.

For most up-to-date software please refer to the most recent Object Detection Service Magazine.

System Information

The system is designed to enhance operator awareness of surroundings. Use of this system does not replace basic safety precautions and procedures for operating the machine.

The object detection system uses radar and video to provide the operator with additional information about the work area around the machine. The display interfaces with the radar sensors that are mounted around the machine. The radar sensors provide detection of objects that are normally in areas of restricted visibility around the machine. The system may detect objects as small as a standing adult person.

Recognition of an object is dependent upon the material composition and the geometry of the object. The system may detect an object that is the size of a standing adult human. However, due to the limited number mounting areas for the object detection sensors on the machine, there are gaps in the radar coverage that would allow the system to miss a person.

Objects are most likely to enter the areas of restricted radar detection when the machine has been stopped. The system operation can be configured for "Distance" based operation or "Speed" based operation. This is selectable via the configuration menu. This option is not operator configurable. The service tool must be connected to the machine and communicating to change this option.

The "Distance" based option activates when the key switch is turned to the ON position and remains in the active state until the machine transitions from a stopped state and has traveled for a minimum of 12 m (40 ft) in the forward direction. The system remains in the active state anytime the machine is traveling in reverse. The system will return to the active state automatically after the machine is brought to a complete stop and has remained stopped for the delay time that has been configured. The reactivation delay is used to stop the system from transitioning from the standby state to the active state while making short stops.

The "Speed" based option allows the system to remain active when the machine is traveling in the forward direction at speeds less than 8 km/h (5 mph). The system will transition to the standby mode when the machine is traveling in the forward direction at speeds less than 8 km/h (5 mph). The system will become active whenever the machine speed falls below 4.8 km/h (3 mph) for the configured delay activation time. The system will always be active when the machine is traveling in reverse.

Effects on System Operation

The operation of the system can be affected by any of the following factors.

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Personal injury or death could result without observing the following information. Environmental conditions, installation, and topographical factors can effect the proper operation of the Cat Integrated Object Detection System. The following information must be taken into consideration.

Environmental - Weather conditions such as rain, snow, and sleet can create road conditions that may cause mud to build up on the face of the object detection sensor. The moisture in the mud can reduce the effectiveness of the coverage of the radar. The mud absorbs the RF energy that is emitted by the object detection sensors. If an accumulation of mud is observed on the object detection sensors, then clean the surface of the sensor. Refer to the Operation and Maintenance Manual, "Object Detection Sensor - Clean/Inspect" section of this manual for addition information on how to clean the sensors.

Note: The object detection sensors have blockage detection diagnostics that display a message on the display when mud or other substances block the object detection sensors. The event will remain active until the sensor has been cleaned or the blockage is removed.

Installation - Incorrect sensor bracket installation and or alignment may also cause the object detection sensors to give nuisance warnings to the operator. The system may sense false objects because the object detection sensors are not set to the correct angle.

Note: The brackets may become misaligned over time because of shock and vibration the machine is subjected to during normal operations. The condition of the radar brackets should be inspected daily.

Topographical - The system may sense objects even though no objects are present. These detections may occur if the grade of a haul road, a loading area, or a ready line are significant enough to reflect RF energy in the same way as a vehicle or berm would. One or more false targets are possible when a V-ditch is utilized when parking the machine. The V-ditch can cause a false indication at the front or sides of the machine.

If an object is in the critical zone, the display will provide an audible and visual warning.

Any critical zone warning that has not been acknowledged will trigger an audible alarm if either of the following conditions are true.

1. If the operator has placed the machine in gear, and attempts to move in the direction that an object is detected. This situation applies to the rear of the machine only.

2. If the operator has placed the machine in gear, and attempts to move in the direction that an object is detected. This situation applies to the rear of the machine only.

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NOTICE
Radar information will not be used to determine the exact position of the object. Only the general area of the object relative to the machine will be displayed. The operator must use the camera for the designated machine quadrant to determine if the object is in the path of the machine and evasive action is required.

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Identify the object and the location of the object before you move the machine. Failure to identify the object and the location of the object prior to moving the machine can result in product damage, personal injury, or death.

Power ON/OFF

Illustration 64	g03798907
The system feature set is "Object Detection".

Power is supplied to the system when the operator turns the machine key switch to the ON position. A screen similar to Illustration 64 appears. The screen contains the CAT logo and the system feature set available with the software installed. The system feature set will read either "Vision" or "Object Detection".

If the feature set reads "Vision", the system is a vision system. Vision systems use only the camera component to provide visual information to the operator. The proximity detection bar is not active with the Vision system and the software does not provide detection-based information to the operator.

If the feature set reads "Object Detection", the system is a vision and detection system. Object Detection system uses Object Detection sensors and the camera components to provide visual information to the operator. The proximity detection bar is active with the Object Detection system and the software will provide detection information to the operator.

Illustration 65	g03406276

After the splash screen containing the logo and feature set has appeared, the disclaimer screen will be shown. After the disclaimer has been read and understood, press the "OK" button to advance to the self-test.

Illustration 66	g06015084
System Status Indicator

During the power-up process, the display will perform a self-test. During the self-test the display will ensure that all components are communicating and the alarm on the display will sound momentarily. When the self-test is complete, the following occurs:

• The system status indicator will turn green.

• The cameras will be active

• The proximity bar will be active.

Note: Ensure that the model of machine listed to the right of the "Zone Directional Radar Indicator" matches the machine that is being operated. If the correct machine does not appear, contact your Cat dealer. If the self-test fails, the system status indicator will turn red, the camera screens will be active, and the object detection sensor screen will be disabled. If the self-test fails, contact your Cat dealer.

Configuration Screen

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Do not attempt to configure the display while operating the machine. Configuration activities can distract the operator from the critical task of maintaining control of the machine which could result in personal injury or death. Please restrict configuration activities to times when the machine is appropriately parked and in a safe state.

Press the main menu button to access the following sub menus:

• Display

• System Information

• Settings

• Diagnostics

To edit the settings, the operator must first press the "OK" button. After entering the edit mode, the first parameter in the list that can be configured will be highlighted. The parameter must be highlighted to allow the parameter to be changed. Press the left arrow or the right arrow on the arrows button to change the highlighted parameter.

Navigation between parameters is accomplished by pressing the top and bottom parts of the arrows button. Any changes that are made to parameters will not become active until the operator has pressed the "OK" button to exit the edit mode. An example of the configuration screen is shown in Illustration 67.

Illustration 67	g03408448

Illustration 67 shows the view that appears on the display when the configure screen is accessed for the first time. The "Change Settings" box will be located opposite the "OK" button to indicate the purpose of the button. The "Change Screens" box will be located opposite the tab button to indicate the purpose of the button.

Configure Parameters

The following list of parameters can be configured when the "Change View" screen is accessed.

Illustration 68	g03408477

Display consists of language selection and brightness selection. Refer to Illustration 68

Illustration 69	g03408526
System Information Screen

System Information provides the following information:

• Machine Model

• Product ID

• Software Version

• OS Version

• SW Release Date

• Unit Serial Number

• Hardware P/N

• System Hardware Description

Illustration 70	g03408536
Settings Selection Screen

The settings selection screen has two selections that can be selected:

• Auto Dim

• Alarm Mode

The "Auto Dim" can be Enabled or Disabled. The "Alarm Mode" can be set to be continuous or discrete.

Illustration 71	g03408552
Diagnostics Selection Screen

Illustration 72	g03408558
Diagnostics Signal Page

Illustration 73	g03408581
Diagnostics Detail Screen

In the display screen, language is an option. To change the language, select "Language". Refer to illustration 68.

Illustration 74	g03408478
Language Screen

The display supports the following list of languages:

• English

• French

• Indonesian

• Portuguese

• Spanish

Refer to Illustration 74.

Illustration 75	g03408468
Setting Selection Screen

Under the setting screen, select "Auto Dim". Refer to Illustration 75. The auto dim feature will reduce the display and video brightness by one third of the current brightness setting. When night mode is selected, the system will stop providing video and the entire screen will be dimmed.

Illustration 76	g03408480

Auto dimming can be either "Enabled" or "Disabled". Refer to Illustration 76.

Illustration 77	g03408469

Under the setting screen, select "Alarm Mode". Refer to Illustration 75 The "Object Detection Alarm Mode" parameter configures the audible alarm mode. The alarm mode will be "Continuous" by default. "Discrete" alarming can be selected to reduce the length of audible alarming.

Note: This parameter is only adjustable when the Cat ^® Electronic Technician (Cat ET) is connected and communicating with the system.

Table 58

Component	Event	Description	Possible Cause
Battery Supply Voltage	E875	Voltage Below Normal	System voltage is below normal. There is a possible issue with the charging system. Object detection system and warnings are disabled until the system voltage is above the threshold level. Call your Caterpillar dealer.
Battery Supply Voltage	E876	Voltage Above Normal	System voltage is above normal. There is a possible issue with the charging system. The object detection system and warnings are disabled until system voltage is below the threshold level. Call your Caterpillar dealer.
Left Front Object Detection Sensor	E1143	Radar Blockage Detected	The object detection sensor has detected a blockage. Check for debris in the box that houses the object detection sensor detector. If debris is present, remove the debris. Clean the plastic cover that is on the object detection sensor housing to remove mud or debris. An object that is too close to the object detection sensor can also cause this event.
Right Front Object Detection Sensor	E1144	Radar Blockage Detected
Left Side Object Detection Sensor	E1145	Radar Blockage Detected
Left Rear Upper Object Detection Sensor	E1146	Radar Blockage Detected
Left Rear Lower Object Detection Sensor	E1147	Radar Blockage Detected
Rear Right Lower Object Detection Sensor	E1148	Radar Blockage Detected
Right Side Object Detection Sensor	E1149	Radar Blockage Detected
Right Rear Upper Object Detection Sensor	E1150	Radar Blockage Detected

Illustration 78	g02400796
Typical example of the proper orientation of the image from front camera on the monitor

Adjust the front camera to provide the following view from the machine front:

• Partial view of the radiator grill

• Partial view of the stairs

• View of an object on the ground in front of the stairs

Illustration 79	g02351896
Typical example of the proper orientation of the image from rear camera on the monitor The dump body is shown in the lowered position.

Adjust the rear camera to provide the following view from the machine rear:

• Partial view of the rear of the dump body

• Partial view of the rear frame

• Partial view of the tires

• View of an object on the ground 15 m (50 ft) behind the rear tires

Illustration 80	g02351899
Typical example of the proper orientation of the image from left or right side camera on the monitor

Adjust the left or right side camera to provide the following view from the machine side:

• Partial view of the front left or right corner of the dump body

• Partial view of the front left or right fender

• Partial view of the front left or right tire

• View of an object on the ground to the right of the front left or right corner of the machine

This procedure is used to calibrate the object detection sensors. The object detection sensors must be calibrated if any of the conditions that are listed below have occurred:

• Initial installation of the object detection system.

• Any of the object detection sensors were replaced.

• Any of the object detection sensors have been adjusted or the brackets replaced.

This procedure is used to validate that the radars for the system have been installed and adjusted correctly. The procedure will utilize an object. The object will be used to explore the limits of radar coverage.

This procedure will define the radar mapping coverage for objects. The angles at which the radar brackets are oriented determine the proper coverage area of the radars and avoid ground reflections. Ground reflections caused by improperly positioned radar brackets may cause false detections. Record any instances where the alarm system failed to perform properly, including any nuisance alarms. A case where there might be holes in coverage, such that the object might disappear, should be avoided.

Table 59

Test Equipment	Quantity
Digital Level	1
Survey Paint	1
Person	1
Two-way Radios	2

Note: Prior to performing this procedure ensure that all components are installed in the appropriate positions as described in the "Adjust the Object Detection Sensors" section of this manual and adjust the camera angles to obtain the best view of coverage areas.

1. Park the machine in a wide open area that is large and level. This area should have 30 m (98.5 ft) of clearance to rear of the machine.

2. Set the parking brake.

3. Turn the disconnect switch to the ON position

4. Start the machine.

5. Verify that the system is powered up and the system status indicator and the system fault indicators are illuminated green on the display.

6. While the machine is parked in the large wide open area check for any surrounding obstacles like bumps, by observing the display for any flashing areas in the radar detection area. The situations that are listed in Table 60 can cause false targets to be detected and are listed in order of precedence:
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   Table 60

   Description of Cause	Resolution
   Test area is not level, area in front or rear of machine has an uphill slope.	Find a test area that is more level or reposition the area of the machine being validated to face the area with the down hill slope to calibrate the system. Do not use an area with too great of slope (2 to 3 percent max) to validate the system.
   The object detection sensor angle is too low and is detecting ground reflections.	The object detection sensor angles provided in the installation information were determined to be the optimum angles for installation. However due to installation variations and differences in machines the actual angle may require adjustment. Refer to "Adjust the Object Detection Sensors" section of this manual for additional information
   There is mud or some other type of debris blocking the sensor.	This is unlikely to occur unless there is an active event displayed on the display. Clean the object detection sensors to eliminate the issue.

The calibration process consists of a person referred to as the object being moved into and out of the object detection sensors coverage area. The person moving the object will be told to stop via radio whenever the object appears or disappears on the display. This procedure is performed to determine the limits of the coverage area and any identify holes that may exist in the coverage area. In the case that the limits of the coverage area are inadequate, adjustments will need to be made. Adjust the angles of the object detection sensors and the brackets of the object detection sensors. This procedure will be performed for the following areas of the machine:

• Front

• Rear

• Sides

Lay out a line perpendicular to the centerline of the radar. Extend the line 15 m (50 ft). Lay out extra lines parallel to the centerline of the radar. Lay out lines at the following intervals:

• 1 m (3 ft)

• 1.5 m (5 ft)

• 3 m (10 ft)

• 6 m (20 ft)

• 9 m (30 ft)

• 12 m (40 ft)

• 15 m (50 ft)

The object will be moved close to the machine and parallel to the front of the machine and the display is checked for the object detection. The object will then be moved perpendicular to the front of the machine as shown in Illustration 81. The object should start close to the machine for the first pass and work away from the machine with each successive pass. Stop the passes once the object is no longer detected.

Illustration 81	g02401176
Testing the object detection coverage area at the front of the machine

The person in the cab of the machine will inform the person moving the object when to mark the coverage start/stop point. The start/stop points must be marked when the object first appears or first disappears from radar coverage on the display. The designated reference point for the rear radar will be the center of the machine. The distance from the initial perpendicular detection must be measured and should be approximately 2 m (6.6 ft) from the front of the machine. Refer to Illustration 82.

Illustration 82	g02401217
Sample of object detection coverage area at the front of the machine

If the detection area is not approximately 10 m (32 ft) long by 7 m (23 ft) wide, or the coverage area contains holes, adjust the angles of the brackets for the object detection sensors. Refer to the "Adjust the Object Detection Sensors" section of this manual for additional information regarding the adjustment of the brackets.

Note: If the detection area is larger than the dimensions listed above, adjustment of the object detection sensors is not required.

Operate the machine to determine if more adjustment is required.

Lay out a line perpendicular to the centerline of the radar. Extend the line 15 m (50 ft). Lay out extra lines parallel to the centerline of the radar. Lay out lines at the following intervals:

• 1 m (3 ft)

• 1.5 m (5 ft)

• 3 m (10 ft)

• 6 m (20 ft)

• 9 m (30 ft)

• 12 m (40 ft)

• 15 m (50 ft)

The object will be moved close to the machine and parallel to the rear of the machine and the display is checked for the object detection. The object will then be moved perpendicular to the rear of the machine as shown in Illustration 83. The object should start close to the machine for the first pass and work away from the machine with each successive pass. Stop the passes once the object is no longer detected.

Illustration 83	g02401299
Target moving behind the rear of the machine

The person in the cab of the machine will inform the person moving the object when to mark the coverage start/stop point. The start/stop points must be marked when the object first appears or first disappears from radar coverage on the display. The designated reference point for the rear radar will be the center of the machine. The distance from the initial perpendicular detection must be measured and should be approximately 2 m (6.6 ft) from the rear of the machine. Refer to Illustration 84.

Illustration 84	g02401357
Sample of object detection coverage area at the rear of the machine

If the detection area is to narrow or contains holes in the coverage area the angles of the brackets of the object detection sensors. Refer to the "Adjust the Object Detection Sensors" section of this manual for additional information regarding the adjustment of the brackets.

Note: If the detection area is larger than the dimensions listed above, adjustment of the object detection sensors is not required.

Operate the machine to determine if more adjustment is required.

Lay out a line perpendicular to the centerline of the radar. Extend the line 6 m (20 ft). Lay out extra lines parallel to the centerline of the radar. Lay out lines at the following intervals:

• 0.5 m (1.5 ft)

• 1 m (3 ft)

• 1.5 m (5 ft)

• 3 m (10 ft)

The object will be moved close to the machine and parallel to the side of the machine and the display is checked for the object detection. The object will then be moved perpendicular to the rear of the machine as shown in Illustration 85. The object should start close to the machine for the first pass and work away from the machine with each successive pass. Stop the passes once the object is no longer detected.

This pattern will be completed on both sides of the machine. The target should start outside of the detection range of the radar. The target will walk parallel to the machine and stop whenever the target appears in the radar detection area.

Illustration 85	g02402152
Target moving on side of machine

The person in the cab of the machine will inform the person moving the object when to mark the coverage start/stop point. The start/stop points must be marked when the object first appears or first disappears from radar coverage on the display. The designated reference point for the rear radar will be the center of the machine. The distance from the initial perpendicular detection must be measured and should be approximately 0.3 m (1.0 ft) from the rear of the machine. Refer to Illustration 86.

Illustration 86	g02401377
A sample of right side and left side machine target detection

If the detection area is to narrow or contains holes in the coverage area the angles of the brackets of the object detection sensors. Refer to the "Adjust the Object Detection Sensors" section of this manual for additional information regarding the adjustment of the brackets.

Note: If the detection area is larger than the dimensions listed above, adjustment of the object detection sensors is not required.

Operate the machine to determine if more adjustment is required.