Installation of Cat® Detect Object Detection for the 24H Motor Grader {1408, 7348} Caterpillar

Machine Control and Guidance Products

CAT DETECT (S/N: DTK1-UP)

Motor Grader

24H (S/N: 7KK1-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.

Note: Some components are not shown in the illustrations in this Special Instruction for clarity.

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 in order 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.

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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.

Required Parts

Table 1

Required Parts for the 24H
Quantity	Part Number	Description
1	462-5010	Monitor Kit
1	462-2965	Display Mounting Kit
1	462-2927	Object Detector Gp
1	489-6033	Object Detection Box and Mounting Gp

Contents of the 462-5010 Monitor Kit

Table 2

Contents of the 462-5010 Monitor Kit
Quantity	Part Number	Description
1	459-2220	Electronic Control Gp
1	517-1039	Monitor Software Gp

Contents of the 462-2965 Display Mounting Kit

Table 3

Contents of the 462-2965 Display Mounting Kit
Quantity	Part Number	Description
1	462-5001	Bracket
4	114-6658	Washers
4	6V-5683	Bolts
2	9X-2045	Screws

Contents of the 462-2927 Object Detector Gp

Table 4

Contents of the 462-2927 Object Detector Gp
Quantity	Part Number	Description
1	382-1575	Wiring Kit
1	433-0585	Object Detector Gp
1	476-8709	Camera Wiring Gp

Contents of the 382-1575 Wiring Kit

Table 5

Contents of the 382-1575 Wiring Kit
Quantity	Part Number	Description
1	6T-3644	Circuit Breaker As
1	274-4477	Cable As
1	274-4478	Cable As
1	283-1626	Cover
1	365-6203	Cab Harness As
1	365-8153	Cab Harness As
1	390-2722	Switch Harness As
1	391-3761	Plate As
2	096-6166	Hard Washers
1	130-5300	Clip
5	132-5789	Clips
2	232-1473	Washers
2	352-3968	Clips
1	2M-3433	Grommet
1	2Y-5429	Grommet
4	3S-2093	Cable Straps
2	4B-4863	Washers
6	4P-7581	Clips
2	5M-3062	Bolts
1	6V-8225	Nut
4	6V-9632	Weld Nuts
55	7K-1181	Cable Straps
2	7U-4892	Screws
4	8T-4138	Bolts
2	8T-4647	Screws
2	8T-4896	Hard Washers
2	9D-5659	Bosses
1	9X-2045	Screw
4	9X-8256	Washers

Contents of the 489-6033 Object Detection Box and Mounting Gp

Table 6

Contents of the 489-6033 Object Detection Box and Mounting Gp
Quantity	Part Number	Description
7	3S-2093	Cable Strap
23	7K-1181	Cable Strap
16	8T-9655	Isolation Mount
8	8T-9658	Spacer
1	352-3968	Clip
1	359-7442	Bracket As
1	359-7443	Bracket As
2	359-7444	Bracket As
2	359-7850	Bracket As
1	365-7226	Chassis Harness As
2	430-8391	Object Detection Box Gp
1	130-5300	Clip
2	2M-3433	Grommet
20	344-5675	Nut
7	4P-7581	Clip
2	4P-7582	Clip
8	5P-4115	Hard Washer
2	5P-9297	Clip
8	7X-0818	Bolt
36	7X-7729	Washer
8	8T-4138	Bolt
16	8T-4186	Bolt
8	8T-4195	Bolt
8	9N-0869	Hard Washer

Contents of the 476-8709 Camera Wiring Gp

Table 7

Contents of the 476-8709 Camera Wiring Gp
Quantity	Part Number	Description
1	251-8248	Communication Cable As
1	333-8153	Connection Assembly
1	336-6684	Camera Gp
1	340-7161	Power Converter
1	448-6963	Cable As
2	8T-4180	Screws

Secure the Machine

1. Set the parking brake.

2. Turn the key start switch and the disconnect switch to the OFF position.

3. Install the frame lock link into the LOCKED position.

4. Secure the frame lock link in the LOCKED position with the locking pin.

Prepare the Cab for Harness Installation

1. Remove the WAVS display (1) and mounting bracket (if equipped).
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   Illustration 1	g02520656
   (1) 206-9651 Plate (2) 2A-7184 Plate (3) 2A-6798 Plate

2. Remove the 206-9651 Plate (1) and the 2A-7184 Plate (2) from the left side of the operator console and the 2A-6798 Plate (3) from the front of the operator console.

3. Remove the headliner.

   Note: The radio, switches, and other components in the headliner may require removal to facilitate routing of the cab harness.

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   Illustration 2	g02495159

4. Remove the operator console, seat, right rear c-pillar cover, and any other covers on the right side of the seat. Refer to Illustration 2.
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   Illustration 3	g02494581
   (4) 145-7321 Plate

5. Remove the floor mat from the cab. Remove the 145-7321 Plate (4) from the left-hand side of the cab.
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   Illustration 4	g02495279
   View looking down of the cab floor with the 145-7321 Plate (4) removed. (5) 29 mm (1.14 inch) Hole (6) 2Y-5429 Grommet

6. With the 145-7321 Plate (4) removed, drill a 29 mm (1.14 inch) hole (5) in the location shown in Illustration 4. Install one 2Y-5429 Grommet (6) in the hole (5) that was drilled.

   Note: Ensure that nothing will be damaged on the bottom side of the cab before drilling the hole (5).

Install the Display

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Illustration 5	g02495338
(7) 148-0141 Channel

1. Locate the 148-0141 Channel (7).
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   Illustration 6	g02495398
   (7) 148-0141 Channel (8) Holes

2. Use Illustration 6 and Table 8 to locate and drill two 7 mm (0.28 inch) holes (8) in the 148-0141 Channel (7).
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   Table 8

   Point	Dimension
   A	291.5 mm (11.48 inch)
   B	90 mm (3.54 inch)
   C	17.5 mm (0.69 inch)
   8	7 mm (0.28 inch)

3. Attach the 365-9610 Bracket to the 148-0141 Channel (7) with two 9X-2045 Screws and two 6V-8225 Nuts.

4. Install the 355-9048 Monitor Display Gp to the 365-9610 Bracket with four 096-6166 Hard Washers and the existing screws located in the back of the monitor.

Install the Power Supply

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Illustration 7	g02498556
(9) 340-7161 Power Converter

1. Under the left side of the cab mount the 340-7161 Power Converter (9) using two 8T-4180 Screws in the approximate location shown in Illustration 7.

Headliner Cutout

Illustration 8	g02496137
(10) Hole

Table 9

Point	Dimension
D	255.4 mm (10.05 inch)
E	152 mm (5.99 inch)
F	50 mm (1.97 inch)

1. Remove a section of the headliner. Use Illustration 8 and Table 9 to locate the section of the headliner that needs removed.

2. A 30.16 ± 0.50 mm (1.19 ± 0.02 inch) hole (10) in the headliner will also be necessary for the harness to pass through. The actual location may vary slightly but keep the hole (10) within 150 mm (5.91 inch) of the 365-9610 Bracket. Install one 2M-3433 Grommet in hole (10). Refer to Illustration 8 for approximate hole (10) location.

   Note: Waiting to install the 365-8153 Chassis Harness As later on in this instruction may be best before locating hole (10). This will allow you to see the exact location of the 365-8153 Chassis Harness As routed in the cab.

Note: Do not reinstall the headliner now.

Prepare the Chassis for Harness Installation

Note: Removal of the belly pans may be necessary to route the harness to the back of the machine.

1. Remove any panels on the left side of the machine that may aid in the installation of the 365-7226 Chassis Harness As and the 274-4478 Cable As along the 260-6904 Chassis Harness As.

2. If needed, remove any belly pans that you find necessary to route the harness to the back of the machine.

Prepare the Radiator Guard

Locate and Drill Holes on the Left Side of the Radiator Guard

Illustration 9	g02516896
(1) Holes

Table 10

Point	Dimension
A	196 mm (7.72 inch)
B	103 mm (4.06 inch)
C	125 mm (4.92 inch)
D	48.85 mm (1.92 inch)
E	222.16 mm (8.75 inch)
F	80 mm (3.15 inch)

1. Lay out the dimensions for the four holes (1) on the left side of the radiator guard. Refer to Illustration 9 and the dimensions that are provided in Table 10.

2. Ensure that nothing will be damaged before drilling the four holes (1).

3. Drill four 11 mm (0.43 inch) holes (1).

Illustration 10	g02516798
(2) Hole

Table 11

Point	Dimension
G	510 mm (20.08 inch)
H	340 mm (13.39 inch)

1. Lay out the dimensions for hole (2) on the left side of the radiator guard. Refer to Illustration 10 and the dimensions that are provided in Table 11.

2. Ensure that nothing will be damaged before drilling hole (2).

3. Drill one 33 mm (1.30 inch) hole (2).

Locate and Drill Holes on the Right Side of the Radiator Guard

Illustration 11	g02517276
(3) Holes

Table 12

Point	Dimension
J	196 mm (7.72 inch)
K	103 mm (4.06 inch)
L	125 mm (4.92 inch)
M	48.85 mm (1.92 inch)
N	222.16 mm (8.75 inch)
P	80 mm (3.15 inch)

1. Lay out the dimensions for the four holes (3) on the right side of the radiator guard. Refer to Illustration 11 and the dimensions that are provided in Table 12.

2. Ensure that nothing will be damaged before drilling the four holes (3).

3. Drill four 11 mm (0.43 inch) holes (3).

Illustration 12	g02517217
(4) Hole

Table 13

Point	Dimension
Q	510 mm (20.08 inch)
R	340 mm (13.39 inch)

1. Lay out the dimensions for hole (4) on the left side of the radiator guard. Refer to Illustration 12 and the dimensions that are provided in Table 13.

2. Ensure that nothing will be damaged before drilling hole (4).

3. Drill one 33 mm (1.30 inch) hole (4).

Locate and Drill Holes on the Top of the Radiator Guard

Illustration 13	g02517545
(5) Hole (6) Holes

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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.

Table 14

Point	Dimension
S	Centerline of the 125-0175 Cover As on the top of the radiator guard.
T	62.50 mm (2.46 inch)
U	2.50 mm (0.098 inch)
V	65.00 mm (2.56 inch)
W	15.00 mm (0.59 inch)
X	125 mm (4.92 inch)

1. Remove the 125-0175 Cover As on the top of the radiator guard.

2. Lay out the dimensions for hole (5) and holes (6) on the top the radiator guard. Refer to Illustration 13 and the dimensions that are provided in Table 14.

3. Drill one 25.40 mm (1.00 inch) hole (5).

4. Drill four 9.50 mm (0.37 inch) holes (6).

5. Weld four 6V-9632 Weld Nuts on the bottom of the 125-0175 Cover As in the locations of holes (6).

6. Install one 9G-1307 Grommet in hole (5).

7. Reinstall the 125-0175 Cover As on the top of the radiator guard.

Assemble the Components

Assemble the Radar Boxes to the Brackets

The sensors for the object detection system are assembled before shipping. The sensors have been functionally tested in the radar boxes.

Note: Inspect the vent and the grommet on the bottom of the radar box to 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 340-0575 Object Detection Sensor Gp to the 359-7444 Bracket As

Illustration 14	g02236713
(1) 359-7850 Bracket As (2) 359-7444 Bracket As (3) 7X-0818 Bolt (4) 9N-0869 Hard Washer (5) 8T-9655 Isolation Mount (6) 8T-9658 Spacer

1. Install the 359-7444 Bracket As (2) to the 359-7850 Bracket As (1). Use the 7X-0818 Bolts (3), 9N-0869 Hard Washers (4), 8T-9655 Isolation Mounts (5), and 8T-9658 Spacer (6).

   Refer to Illustration 14.

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   Illustration 15	g02236793
   (7) 8T-4138 Bolts (8) 5P-4115 Hard Washers (9) 340-0575 Object Detection Sensor Gp

2. Mount the 340-0575 Object Detection Sensor Gp (9) to the 359-7444 Bracket As (2). Use the 8T-4138 Bolts (7) and 5P-4115 Hard Washers (8).

Assemble the Camera

Assemble the Camera to the Bracket

Illustration 16	g02174089
(1) Camera shell (2) Bolts (3) Camera (4) Bolts (5) Nuts (6) Nuts

1. Assemble the camera with the parts that are supplied with the cameras.

   Refer to Illustration 16.

   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.

Mount the 336-6684 Camera Gp to the 283-1626 Cover

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Illustration 17	g02238155
(1) 336-6684 Camera Gp (2) 283-1626 Cover

1. Install the 336-6684 Camera Gp (1) to the 283-1626 Cover (2).

   Refer to Illustration 17.

Component Installation

Install the Camera

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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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Illustration 18	g02523097
Location of the camera on the machine

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Illustration 19	g02523100
(1) Camera assembly (2) 8T-4138 Bolt (3) 9X-8256 Washer

1. Mount the rear camera assembly (1) on the 125-0175 Cover As on the top of the radiator guard. Use four 8T-4138 Bolts (2) and four 9X-8256 Washers (3).

   Refer to Illustration 19.

Note: Once the entire system is installed, the camera will need adjusted. For camera adjustment, refer to the "Camera Adjustment Procedure" section within this manual.

Install 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.

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Illustration 20	g02523076
Right-hand rear (4) Object Detection Sensor Assembly (5) 8T-4186 Bolt (6) 7X-7729 Washer (7) 359-7443 Bracket As (8) 8T-4195 Bolt

1. Mount the 359-7443 Bracket As (7) to the rear right-hand side of the machine. Use four 8T-4186 Bolts (5), eight 7X-7729 Washers (6), and four 256-0466 Nuts to secure the bracket to the machine.

2. Mount the 359-7442 Bracket As to the rear left-hand side of the machine. Use four 8T-4186 Bolts (5), eight 7X-7729 Washers (6), and four 256-0466 Nuts to secure the bracket to the machine.

3. Mount the object detection sensor assemblies (4) to the 359-7443 Bracket As and the 359-7442 Bracket As. Use two 8T-4195 Bolts (8) and two 7X-7729 Washers (6).

Note: Once the entire system is installed, the object detection sensors will need adjusted. For object detection sensor adjustment, refer to the "Adjust the Object Detection Sensors" section within this manual.

Harness Installation Procedure

Note: If the machine is not equipped with WAVS or the system is inoperative, then attach the camera harnesses to chassis harness. Attaching the harness will ease the installation of system.

Note: Some components are not shown in the Illustrations below for clarity.

Cab Harness Installation

Harness Routing Under the Cab

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Illustration 21	g02502018
(1) 132-5789 Clip

1. Install the 132-5789 Clip (1) with one 8T-4121 Hard Washer and one 8T-4137 Bolt. Refer to Illustration 21.
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   Illustration 22	g02501398
   Enlarged graphic of the bottom of the cab with the 365-8153 Chassis Harness As (3) and the 274-4477 Cable As (4) installed.

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   Illustration 23	g02512961
   (1) 132-5789 Clip (2) 122-1163 Platform Harness As (3) 365-8153 Chassis Harness As (5) 340-7161 Power Converter (6) Ground stud

2. Begin routing the 365-8153 Chassis Harness As (3) and the 274-4477 Cable As (4) along the 122-1163 Platform Harness As (2) on the bottom side of the cab.

3. Attach the connector near the center of the 365-8153 Chassis Harness As (3) to the 132-5789 Clip (1) with one 7K-1181 Cable Strap. The connector is shown in Illustration 23 with a plain arrow.

4. Begin to run one branch of the 365-8153 Chassis Harness As (3) under the left side of the cab along the 122-1163 Platform Harness As (2). Attach the 365-8153 (3) to the 122-1163 Platform Harness As (2) with 7K-1181 Cable Straps.

5. Plug the 365-8153 Chassis Harness As (3) into the 340-7161 Power Converter (5) that was installed earlier in this instruction.

6. Install both ground wires of the 365-8153 Chassis Harness As (3) to the ground stud (6). Refer to Illustration 23.

7. Route the remainder of the harness through the hole that was made earlier in this instruction.
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   Illustration 24	g02513037
   (1) 132-5789 Clip (3) 365-8153 Chassis Harness As (4) 274-4477 Cable As

8. Begin to run the other branch of the 365-8153 Chassis Harness As (3) and the 274-4477 Cable As (4) under the right side of the cab along the 122-1163 Platform Harness As (2).

9. The 274-4477 Cable As (4) will begin at the center connector of the 365-8153 Chassis Harness As (3) and routed along the right side of the cab. The center connector is shown in Illustration 24 with a plain arrow.

10. Route the 365-8153 Chassis Harness As (3) and the 274-4477 Cable As (4) along the 122-1163 Platform Harness As (2). Refer to Illustration 24.

11. Feed both the 365-8153 Chassis Harness As (3) and the 274-4477 Cable As (4) into the cab using the same opening that the 122-1163 Platform Harness As (2) uses to get inside the cab. Refer to Illustration 24.

12. Attach the 365-8153 Chassis Harness As (3) to the 122-1163 Platform Harness As (2) with 7K-1181 Cable Straps.

Continued Harness Routing Inside the Cab

Routing the 365-8153 Chassis Harness As (3) and the 274-4477 Cable As (4) From the Right Rear of the Cab

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Illustration 25	g02514922
(3) 365-8153 Chassis Harness As (4) 274-4477 Cable As (7) 365-6203 Control Harness As

1. Inside the right rear of the cab continue to route the 365-8153 Chassis Harness As (3) and the 274-4477 Cable As (4) up the right rear c-pillar. Route and attach both harnesses along the 197-4927 Cab Harness As. Use 7K-1181 Cable Straps to secure both harnesses to the 197-4927 Cab Harness As. Refer to Illustration 25.

2. The 365-8153 Chassis Harness As (3) will only travel a short distance up the right rear c-pillar. At that point connect the 365-6203 Control Harness As (7) to the 365-8153 Chassis Harness As (3) and continue to route up the c-pillar and along the 197-4927 Cab Harness As. Refer to Illustration 25.
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   Illustration 26	g02514998
   (4) 274-4477 Cable As (7) 365-6203 Control Harness As

3. Continue to route the 274-4477 Cable As (4) and the 365-6203 Control Harness As (7) along the 197-4927 Cab Harness As to the front of the cab.

4. Reinstall the headliner. Route the 274-4477 Cable As (4) and the 365-6203 Control Harness As (7) through the hole in the headliner that was made earlier in this instruction.

5. Connect the 274-4477 Cable As (4) and the 365-6203 Control Harness As (7) to the display.

Routing the 365-8153 Chassis Harness As (3) From Inside the Cab to the Operator Console

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Illustration 27	g02520817
(3) 365-8153 Chassis Harness As

1. Beginning in the left front of the cab where the 365-8153 Chassis Harness As (3) was routed from the bottom through the hole that was drilled previously in this instruction route the 365-8153 Chassis Harness As (3) as shown in Illustration 27.
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   Illustration 28	g02520856
   (3) 365-8153 Chassis Harness As (8) 8X-1920 Plate

2. Continue to route the 365-8153 Chassis Harness As (3) under and into the operator console.

   1. Once inside the operator console route the 365-8153 Chassis Harness As (3) up the inside and attaching it to links on the 8X-1920 Plate (8) with 3S-2093 Cable Straps. Refer to Illustration 28.

   2. Pass the 365-8153 Chassis Harness As (3) through a hole on the left side of the 8X-1920 Plate (8) located inside the operator console. This allows the 365-8153 Chassis Harness As (3) to be accessed from the front of the console for harness connections.
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   Illustration 29	g02520939

3. Find a suitable location for the 6T-3644 Circuit Breaker As (9) to be installed in the side of the 206-9651 Plate (10). Ensure that the wires from the 365-8153 Chassis Harness As (3) will be able to reach the 6T-3644 Circuit Breaker As (9) for connection.

   1. With the location found in the 206-9651 Plate (10) for the 6T-3644 Circuit Breaker As (9) drill the holes in the 206-9651 Plate (10).

   2. Mount the 6T-3644 Circuit Breaker As (9) to the 206-9651 Plate (10) with two 7U-4892 Screws and two 4B-4863 Washers.

Harness Connections

1. Make the following electrical connections for the 365-8153 Chassis Harness As.
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   Illustration 30	g02520960
   (11) Connection for wire (112-PU(Purple)) (12) Connection for wire (115-RD(Red))

   1. Connect wire (308-YL(Yellow)) to wire (112-PU(Purple)) (11).

      Refer to Illustration 30.

   2. Connect wire (109-RD(Red)) to wire (115-RD(Red)) (12).

      Refer to Illustration 30.

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      Illustration 31	g02520982
      (9) 6T-3644 Circuit Breaker As

   3. Connect wire (109-RD(Red)) to one side of the 6T-3644 Circuit Breaker As (9). Refer to Illustration 31.

   4. Connect wire (130-RD(Red)) to the other side of the 6T-3644 Circuit Breaker As (9). Refer to Illustration 31.
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      Illustration 32	g02520997

   5. Extract pin "D" wire (893-GN(Green)) and pin "E" wire (892-BR(Brown)) from connector "P-C21".

   6. Insert wire (893-GN(Green)) from the 360-4082 Cab Harness As into pin "D" of connector "P-C21".

   7. Insert wire (892-BR(Brown)) from the 365-8153 Chassis Harness As into pin "E" of connector "P-C21".

   8. Insert wire (892-BR(Brown)) into contact "1" of connector "CM-C8" of the 360-4082 Cab Harness As.

   9. Insert wire (893-GN(Green)) into contact "2" of connector "CM-C8" of the 365-8153 Chassis Harness As.

2. Reinstall all removed components from the cab.

Chassis Harness Installation

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Illustration 33	g02519096
(3) 365-8153 (4) 274-4477 Cable As (13) 365-7226 Chassis Harness As (14) 274-4478 Cable As

1. Connect the 365-7226 Chassis Harness As (13) to the 365-8153 (3) under the rear of the cab. The 365-8153 Chassis Harness As (3) was routed previously in this instruction. Refer to Illustration 33.

2. Connect the 274-4478 Cable As (14) to the 274-4477 Cable As (4). The 274-4477 Cable As (4) was routed previously in this instruction. Refer to Illustration 33.
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   Illustration 34	g02519222
   (13) 365-7226 Chassis Harness As (14) 274-4478 Cable As (15) 260-6904 Chassis Harness As

3. Route the 365-7226 Chassis Harness As (13) and the 274-4478 Cable As (14) from the bottom of the cab along the 260-6904 Chassis Harness As (15) and left frame rail. Use 7K-1181 Cable Straps to attach the 365-7226 Chassis Harness As (13) and the 274-4478 Cable As (14) to the 260-6904 Chassis Harness As (15). Refer to Illustration 34.
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   Illustration 35	g02519244
   (13) 365-7226 Chassis Harness As (14) 274-4478 Cable As (15) 260-6904 Chassis Harness As (16) 4P-7581 Clip

4. At the back of the chassis near the radiator guard the 260-6904 Chassis Harness As (15) will split. Follow the section that routs up on the frame rail and along the radiator. Refer to Illustration 35.

5. The 260-6904 Chassis Harness As (15) only travels up a small portion of the radiator. After the 260-6904 Chassis Harness As (15) stops following the radiator install one 4P-7581 Clip (16) in each of the three positions shown in Illustration 35. Attach the 365-7226 Chassis Harness As (13) and the 274-4478 Cable As (14) to the 4P-7581 Clips (16) with 7K-1181 Cable Straps.
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   Illustration 36	g02519569
   (16) 4P-7581 Clips (17) 5P-9297 Clips

6. Install two 4P-7581 Clips (16) and two 5P-9297 Clips (17) in the locations shown in Illustration 36.
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   Illustration 37	g02519538
   (13) 365-7226 Chassis Harness As (14) 274-4478 Cable As (16) 4P-7581 Clips (17) 5P-9297 Clip

7. Continue to route the 365-7226 Chassis Harness As (13) and the 274-4478 Cable As (14). The 365-7226 Chassis Harness As (13) will split into two branches. Refer to Illustration 37.

   1. The shorter branch of the 365-7226 Chassis Harness As (13) will attach to the 5P-9297 Clip (17) and route to the outside of the radiator guard via the hole that was drilled into the side of the radiator guard earlier in this instruction.

   2. The longer branch of the 365-7226 Chassis Harness As (13) and the 274-4478 Cable As (14) will route across the radiator towards the right side.

8. Attach the longer branch of the 365-7226 Chassis Harness As (13) and the 274-4478 Cable As (14) to both 4P-7581 Clips (16) with 7K-1181 Cable Straps. Refer to Illustration 37

9. After the second 4P-7581 Clip (16) located near the center of the radiator plug the 274-4478 Cable As (14) in to the camera. Refer to Illustration 37

10. Continue to route the remainder of the 365-7226 Chassis Harness As (13) harness across the radiator. Attach to the 5P-9297 Clip (17) on the right side of the radiator and then continue routing to the outside of the radiator guard via the hole that was drilled into the side of the radiator guard earlier in this instruction.
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    Illustration 38	g02519878
    (13) 365-7226 Chassis Harness As (16) 4P-7581 Clip

11. With the 365-7226 Chassis Harness As (13) on the outside of the radiator guard on the left and the right side install one 4P-7581 Clip (16) with the 359-7449 Plate hardware. Connect the 365-7226 Chassis Harness As (13) to the object detection sensor. Attach the 365-7226 Chassis Harness As (13) to the 4P-7581 Clip (16) and to the link on bottom of the object detection sensor with 7K-1181 Cable Straps. Refer to Illustration 38.

Adjust the Object Detection Sensors

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 15 are the angles that were found to work best.

These angles are a guideline 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 15

24H Radar Angles
Rear Radar
Azimuth (deg)		Elevation (deg)
20 degrees out left and right		12 down

Azimuth Adjustment Procedure

Illustration 39	g02203958
(1) Azimuth Adjustment for Medium Range Radar Brackets

Table 16

Required Tools
13 mm Wrench	1
Protractor	1

1. Loosen the two 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 15.

3. Carefully tighten the two 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. Proceed to the "Elevation Adjustment Procedure".

Elevation Adjustment Procedure

Illustration 40	g01944710
Elevation Adjustment bolts for Medium Range Radar

Table 17

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 17.

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.

Camera Adjustment Procedure

Prior to operating the machine, ensure the proper orientation of the image on the monitor.

Illustration 41	g01960631
Bolts

Aim the camera downward to show a portion of the rear of the machine.

To adjust the camera, loosen bolts (1) and move the camera for your desired view.

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 Special Instruction, REHS7353 for software installation instructions

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

Calibrate the Object Detection Sensors

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 18

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

Machine Preparation

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 19 can cause false objects to be detected and are listed in order of precedence:
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   Table 19

   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.

Calibration Procedure

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 to 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:

• Rear

Rear of the Machine

Lay out a line perpendicular to the centerline of the radar. Extend the line 15 m (50 ft). Lay out additional 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 42. 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 42	g02353039
Testing the object detection coverage area at 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 43.

Illustration 43	g02353063

If the detection area is not approximately 12 m (40 ft) long by 8 m (26 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.

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 after the machine 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 objects 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 if 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 44	g03798907
Object Detection as the system feature set.

Power is supplied to the system when the operator turns the machine keyswitch to the ON position. A screen similar to Illustration 44 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 45	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 46	g03406367
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 the 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 or refer to the Special Instruction or System Operations manual. Refer to Illustration 46.

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 or refer to the Special Instruction or System Operations manual.

Display Navigation

Illustration 47	g03406762
(1) Camera View (2) Alarm Acknowledge Button (3) Reference Line Button (4) System Menu Button (5) Alarm Acknowledged Indicator (6) Indicator for the System (7) Proximity Indicator Bar (8) Product ID (9) Zone Directional Indicator

Display Buttons

System Menu button - Used to access the main menu for the system.

Back - Used to return to the previous menu.

Home - Used to return to the main screen.

Scroll Up - Used to scroll up through choices

OK - Used to lock choice of selection

Scroll Down - Used to scroll down through choices

Reference Line Button - Toggles the reference line on and off

Day Mode - Used to activate display brightness for day use

Night Mode - Used to activate display brightness for night use

Note: The night mode will adjust the display to the minimum brightness setting to reduce the amount of light emitted during night time operation. The night mode brightness can be adjusted up or down and will be remembered the next time the night mode feature is enabled. When the display returns to the day mode the brightness setting will automatically adjust the 75 percent brightness. If necessary, adjust the brightness manually for personal view preferences.

Manual Brightness Increase - Used to adjust brightness up manually

Manual Brightness Decrease - Used to adjust brightness down manually

Illustration 48	g03408324

The system menu button will be pressed to access this menu, then the "UP", "DOWN". and "OK" buttons will be used to access the sub menus. The back button will go back to the previous menu. The home button will return the operator to the main menu.

To navigate to the brightness adjustment screen, press "System Menu", "Display", and "Brightness"

Illustration 49	g03408355
Day Mode Screen Selected

Illustration 50	g03408357
Manual Brightness Screen (10) Manual Decrease Adjustment Button (11) Manual Increase Adjustment Button

Illustration 51	g03408361
Night Mode Screen Selected

System Configuration

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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 52.

Illustration 52	g03408448

Illustration 52 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 53	g03408477

Display consists of language selection and brightness selection. Refer to Illustration 53

Illustration 54	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 55	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 56	g03408552
Diagnostics Selection Screen

Illustration 57	g03408558
Diagnostics Signal Page

Illustration 58	g03408581
Diagnostics Detail Screen

In the display screen, language is an option. To change the language, select "Language". Refer to illustration 53.

Illustration 59	g03408478
Language Screen

The display supports the following list of languages:

• English

• French

• Indonesian

• Portuguese

• Spanish

Refer to Illustration 59.

Illustration 60	g03408468
Setting Selection Screen

Under the setting screen, select "Auto Dim". Refer to Illustration 60. 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 61	g03408480

Auto dimming can be either "Enabled" or "Disabled". Refer to Illustration 61.

Illustration 62	g03408469

Under the setting screen, select "Alarm Mode". Refer to Illustration 60 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.

Troubleshooting

Diagnostic Summary Screen

The diagnostic summary screen is separate from the main screen. To access the Diagnostic Summary, select the "System Menu" button, then the "Diagnostics" menu, and finally the "Event List" menu. The screen that will appear when the diagnostic summary screen is accessed will be similar to Illustration 64.

Illustration 63	g03408603
Diagnostics Selection Screen

Illustration 64	g03408601
Diagnostics Signal Page

Illustration 65	g03408605
Diagnostics Detail Screen

Additional information of each code is available by highlighting the desired code and pressing the "OK" button. Press the up or down arrows to highlight the desired code. After pressing the "OK" button, the screen will change to a more detailed view of the selected code. Refer Illustration 65.

Active codes will have a "X" whereas logged currently inactive codes have a "-".