- Landfill Compactor
- All
- Machine Control and Guidance Products
- CAES ULTRA (S/N: 2TZ1-UP)
- Motor Grader
- All
- Wheel Dozer
- All
- Wheel Loader
- All
Introduction
This Special Instruction provides information for the installation of the 285-6661 CAESultra Electronic Kit and the Radio Kit.
The procedures describe the installation process for the Computer Aided Earthmoving System on Wheel Loaders, Wheel Dozers, Landfill Compactors, and Motor Graders. The installation will require welding, cutting holes, using electrical tools, and using mechanical tools. After a technician has completed the first installation process, future installations should require 6 to8 hours for completion.
The installation process can be separated into the following procedures:
- GNSS Receiver, GNSS Receiver Harness, and Chassis Harness Installation
- Machine Radio Installation
- Rear Harness Assembly Installation
- Operator Display Installation
- Front Harness Assembly Installation
- Battery Backup Installation
- Power Harness and Fuse Installation
- Initial Power Checks
- Machine ID Worksheet Entries
- Dimension Measurements and Measure Up
Operation and Maintenance Manual
Locate the Operation and Maintenance Manual, SMRU8277, "Multi-language CD". Print the Operation and Maintenance Manual of the desired language and secure the manual in the cab of the machine.
The operation of the CAESultra is covered in the Operation and Maintenance Manual, SEBU8277, "CAESultra". Refer to this manual for more information.
Important Safety Information
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.
When a tool, procedure, work method, or operating technique that Caterpillar does not recommend is used, ensure that you and others are safe during use. Also, ensure that the product will not be damaged or made unsafe by the operation, lubrication, maintenance, or repair procedures that are used.
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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 Manuals. Failure to follow the instructions or heed the warnings could result in injury or death. Contact your Cat dealer for replacement manuals. Proper care is your responsibility. |
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Electrocution Hazard! Keep the machine and attachments a safe distance from electrical power. Stay clear 3 m (10 ft) plus twice the line insulator length. Read and understand the instructions and warnings in the Operation and Maintenance Manual. Failure to follow the instructions and warnings will cause serious injury or death |
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Machine swings. Stay back. Crushing hazard could cause serious injury or death. |
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Accidental engine starting can cause injury or death to personnel working on the equipment. To avoid accidental engine starting, disconnect the battery cable from the negative (−) battery terminal. Completely tape all metal surfaces of the disconnected battery cable end in order to prevent contact with other metal surfaces which could activate the engine electrical system. Place a Do Not Operate tag at the Start/Stop switch location to inform personnel that the equipment is being worked on. |
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Personal injury or death can result from sudden machine movement. Sudden movement of the machine can cause injury to persons on or near the machine. Prevent possible injury by performing the procedure that follows before working on the machine. Move the machine to a smooth horizontal location. Move away from working machines and personnel and lower the implement to the ground. Permit only one operator on the machine. Keep all other personnel away from machine or in view of the operator. Engage the parking brake. Stop the engine. Move the hydraulic control levers to all positions to release the pressure in the hydraulic system. |
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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 Society2501 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 LaborWashington, D.C. 20210 |
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| Illustration 1 | g00037860 |
Use steps and handholds whenever you mount the machine. Use steps and handholds whenever you dismount the machine. Before you mount the machine, clean the step and the handholds. Inspect the step and handholds. Make all necessary repairs.
Face the machine whenever you mount the machine and whenever you dismount the machine. Maintain a three-point contact with the step and with handholds.
Note: Three-point contact can be two feet and one hand. Three-point contact can also be one foot and two hands.
Do not mount a moving machine. Do not dismount a moving machine. Never jump off the machine. Do not try to mount the machine when you carry tools or supplies. Do not try to dismount the machine when you are carrying tools or supplies. Use a hand line to pull equipment onto the platform. Do not use any controls as handholds when you enter the cab or when you exit the cab.
General Preparation
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Personal injury or death can result from sudden machine movement. Sudden movement of the machine can cause injury to persons on or near the machine. Prevent possible injury by performing the procedure that follows before working on the machine. Move the machine to a smooth horizontal location. Move away from working machines and personnel and lower the implement to the ground. Permit only one operator on the machine. Keep all other personnel away from machine or in view of the operator. Engage the parking brake. Stop the engine. Move the hydraulic control levers to all positions to release the pressure in the hydraulic system. |
In addition to the normal safety precautions that are taken in the day to day operation of heavy machinery, the following steps are recommended:
- Move the machine to a suitable location. The location should be smooth, level, and out of direct sunlight.
- Move away from other working machines and personnel.
- Lower the bucket to the ground.
- Stop the engine.
- Engage the machine brake.
- When possible, maintain ownership of the machine keys.
Required Tools
The tools that are listed in Table 1 will be required to install the CAESultra system on Wheel Loaders, Wheel Dozers, Landfill Compactors, and Motor Graders. The list contains the recommended Caterpillar service tools, and general-purpose tools with no specified part number.
| Part Number | Description |
| Wrench Set (Socket) (1/2 Inch Drive) | |
| Metric Wrench Set (Socket) (1/2 Inch Drive) | |
| Wrench Set (Socket) (Torx screw) | |
| Hand Tool Group (Screwdrivers) | |
| Torque Wrench (1/2 inch Drive) | |
| Thread Lock Compound | |
| Tape Measure | |
| CAES Service Kit | |
| Not specified | Drill Bit Set |
| Not specified | Hole Punch Set |
| Not specified | Fish Tape |
| Not specified | Cable Ties/Clips |
| Not specified | Tap Set |
Optional Items
The optional items in Table 2 may also be required during the installation. These parts are not provided in the 285-6661 CAES Installation Ar Installation kits.
| Optional parts needed for CAES installation
(Not included in the 285-6661 CAES Installation Ar) |
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| Part Number | Part Name | Description |
| Relay As | Used for Reverse Auto-Calibration option | |
| Paint | CAT Yellow | |
| Cable Strap | Straps for securing harness | |
| Link | Weld links for harness routing | |
| Silicone Sealant | RTV for grommets | |
| Alarm Gp | Annunciator | |
| Electrical Converter Gp | 24V/12V converter for use with TC900B radios | |
| Radio Harness As | Extension harness for radio or receiver | |
Parts Lists
The 285-6658 CAES Electronics Ar contains the receiver, the display, and a software CD.
| Contents of the 285-6658 CAES Electronics Ar | ||
| Part Number | Part Name | Description |
| Satellite Receiver As | MS9xx GNSS Receiver | |
| Monitor Software Gp | Software CD | |
| Monitor Display Gp | D3:C4 Nav 10.4 Display | |
The 285-6661 CAES Installation Ar contains the four kits that are listed in Table 4. These kits are used during the installation of the CAESultra system. The kits are broken down in Tables 5 through 8.
| Contents of 285-6661 CAES Installation Ar | ||
| Part Number | Part Name | Description |
| Monitor Mounting Gp | Dash/Ceiling mounting group for display | |
| Monitor Mounting Gp | Display mounting group | |
| Receiver Mounting Gp | ||
| CAES Wiring Gp | ||
| Contents of 167-8604 Monitor Mounting Gp | |||
| QTY | Part Number | Part Name | Description |
| 4 | Bolt | 3/8-16 | |
| 4 | Boss | 3/8-16 | |
| 4 | Hard Washer | ||
| 4 | Boss | 3/8-16 | |
| 1 | Mount As | ||
| Contents of 225-5362 Monitor Mounting Gp | |||
| QTY | Part Number | Part Name | Description |
| 4 | Bolt | 1/4-20
Display bracket to Dash/Ceiling bracket |
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| 6 | Cable Strap | ||
| 8 | Isolation Mount | ||
| 4 | Spacer | ||
| 4 | Hard Washer | Display to bracket | |
| 4 | Bolt | 1/4-20
Display to bracket |
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| 4 | Washer | Display bracket to Dash/Ceiling bracket | |
| 2 | Clip | ||
| 1 | Bracket As | ||
| Contents of 291-2176 Receiver Mounting Gp | |||
| QTY | Part Number | Part Name | Description |
| 1 | Bolt | 5/8-11 | |
| 4 | Hard Washer | ||
| 4 | Bolt | M10 | |
| 1 | Boss | 5/8-11 | |
| 1 | Bolt | 5/8-11 | |
| 1 | Plate As | ||
| Contents of 291-2177 CAES Wiring Gp | |||
| QTY | Part Number | Part Name | Description |
| 4 | Terminal | ||
| 4 | Terminal | ||
| 4 | Terminal | ||
| 2 | Clip | Harness | |
| 3 | Grommet | ||
| 15 | Clip | ||
| 4 | Bolt | M5
For Battery Gp |
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| 4 | Hard Washer | For Battery Gp | |
| 1 | Wire As | Power Supply | |
| 1 | Battery Gp | ||
| 1 | Harness As | Fuse | |
| 1 | Wire As | ||
| 1 | Wiring Harness | CAN Terminator | |
| 1 | Wiring Harness | GNSS Jumper | |
| 1 | Front Harness As | ||
| 1 | Rear Harness As | ||
| 1 | Chassis Harness As | ||
| 2 | Mounting Block | For Battery Gp | |
CAESultra Components
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| Illustration 2 | g01477954 |
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Representation of cables, harnesses, and main CAESultra components. This illustration is not drawn to scale. (1) (2) (3) (4) (5) TC900B or TC900C Radio (6) (7) (8) (9) (10) (11) Service Connection for the keyboard (12) (13) (14) (15) Service Connection: Serial Cable | |
Illustration 2 shows the connections between the cables, harnesses, and the CAESultra components that are described within this instruction.
Note: This illustration is only a representation. The illustration does not accurately reflect the relative dimensions or sizes of any of the cables, harnesses, or components.
Note: If the machine is in the following list, then ensure that the machine does not have the CAES ARO option from the factory. If the machine has this option, then refer to Special Instruction, REHS2581, "CAESultra Installation for Landfill Compactors & Wheel Dozers with CAESultra ARO" for installation instructions.
- 824H Wheel Dozer
- 834H Wheel Dozer
- 826H Landfill Compactor
- 836H Landfill Compactor
Note: If the machine is in the following list, then ensure that the machine does not have the CAES ARO option from the factory. If the machine does have this option, then refer to Special Instruction, REHS2582, "CAESultra Installation for Large Wheel Loaders with CAESultra ARO" for installation instructions.
- 854K Wheel Dozer
- 992K Large Wheel Loader
- 993K Large Wheel Loader
- 994F Large Wheel Loader
Illustration 3 shows a complete wiring schematic for the CAESultra v3.2 system.
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| Illustration 3 | g01477972 |
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| Illustration 4 | g01514048 |
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CAESultra System Components (1) (5) TC900B or TC900C Radio (10) | |
Note: Ensure that the harnesses are routed and restrained in a manner that does not create a trip hazard.
Note: Do not extend either the serial cables or the CAN cables. If any cable is not of sufficient length, then contact your Caterpillar distributor for detailed instructions as to how to proceed with your installation.
Summary of Welding and Potential Welding by Sections
| Welding | Section |
|---|---|
| Yes | GNSS Receiver, GNSS Receiver Harness, and Chassis Harness Section |
| Possible | Machine Radio Installation |
| Possible | Mounting and Connecting the Radio Harness |
| Possible | Rear Harness Assembly Installation |
| Possible | Operator Display Installation |
| Possible | Front Harness Assembly Installation |
| Yes | Battery Backup Installation |
| No | Power Harness & Fuse Installation |
GNSS Receiver, GNSS Receiver Harness, and Chassis Harness Installation
Note: This installation procedure requires welding.
Note: The terms "GNSS Receiver", Satellite Receiver As, and "Positioning Module" are synonymous. This manual uses the terms GNSS Receiver and Satellite Receiver As.
The 291-1913 Satellite Receiver As must be mounted on top of the ROPS as close to the centerline of the machine as practical. This location allows the GNSS receiver to have an unobstructed view of the sky.
Note: On a 992G Wheel Loader, Caterpillar recommends using the existing threaded hole of the front lifting eye for mounting the GNSS receiver. This method eliminates the need for welding, drilling, or tapping the machine.
Note: Before welding on the ROPS of the machine, contact the DSN for recommended ROPS mounting locations.
- Weld the 5k-5962 Boss (5/8-11) as close as possible to the centerline of the machine on top of the ROPS.
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Illustration 6 g01434535 The 5K-5962 Boss is shown welded to the roof of the machine. - Position the 289-9633 Plate As over the Boss and fasten with the 5P-4624 Bolt.
Note: Apply anti-seize compound to the bolt thread.
Note: Tighten the bolt to Caterpillar standard torque specifications.
Note: If required, the tube on the 289-9633 Plate As can be shortened to 100 mm Follow the correct cutting procedures. If the tube is cut, then the 0L-1169 Bolt (5/8-11) should be used.
- Attach the 291-1913 Satellite Receiver As to the 289-9633 Plate As. Use four 8T-4195 Bolts (M10) and four 8T-4121 Hard Washers. These parts are included in the 291-2176 Receiver Mounting Gp.
Note: The 291-1913 Satellite Receiver As should be mounted to allow the operator easy visibility of the LEDs when outside of the cab. This location may be determined by site preference.
- Attach the 285-6657 Wiring Harness (13) to the connector on the 291-1913 Satellite Receiver As. Route the harness across the roof to the ROPS post.
- Secure the 285-6657 Wiring Harness for the GNSS Receiver. Use 3S-8665 Clips, 8M-2773 Clips, or 7K-1181 Cable Straps. If the harness passes through any holes in the machine, protect the harness. Use a protective wrap or use a 5P-6264 Grommet. These parts are included in the 291-2177 Machine Wiring Gp.
- Connect the 12-pin connector of the 285-6657 Wiring Harness to the 12-pin connector of the 290-2928 Chassis Harness As.
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Illustration 7 g01435010 (12) 290-2928 Chassis Harness As
(13)285-6657 Wiring Harness for the GNSS Receiver
(14)285-6651 Wiring Harness - Connect the 285-6651 Wiring Harness (14) to the 8-pin connector near the end of the 290-2928 Chassis Harness As (12).
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Illustration 8 g01470994 The 290-2928 Chassis Harness As (12) is shown routed down the ROPS post. - Route the 290-2928 Chassis Harness As (12) down the back of the left ROPS post to the mounting location of the 290-1918 Rear Harness As. This location is beneath the floor plate of the cab. This method is the recommended routing.
- Secure the 290-2928 Chassis Harness As. Use 3S-8665 Clips, 8M-2773 Clips, or 7K-1181 Cable Straps. If the harness passes through any holes in the machine, protect the harness. Use a protective wrap or use a 5P-6264 Grommet. These parts are included in the 291-2177 Machine Wiring Gp.
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| Illustration 5 | g01434517 |
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(10) The | |
Note: If available, use the ROPS harness guide bracket to protect the harness. Refer to Illustration 8.
Machine Radio Installation
The 322-7178 Radio Mounting Gp or the 167-8602 Radio Mounting Gp are not required for third-party radios. These groups are only used for TCxxx radios or CRxxx radios.
Note: If using a Third Party Radio solution, the "Machine Radio Installation" section can be skipped.
| Contents of 322-7187 Radio Mounting Gp
(Not included in the 285-6661 CAES Installation Ar) |
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| Part Number | Part Name | Description |
| Radio Mounting Gp | ||
| Radio Harness As | 17 ft | |
| Contents of 167-8602 Radio Mounting Gp
(Not included in the 285-6661 CAES Installation Ar) |
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| QTY | Part Number | Part Name | Description |
| 3 | Bolt | 1/4-20 | |
| 2 | Bolt | 1/4-20 | |
| 6 | Isolation Mount | Rubber shock mount | |
| 3 | Spacer | ||
| 2 | Hard Washer | ||
| 4 | Hard Washer | ||
| 4 | Bolt | M8 | |
| 4 | Boss | M8 | |
| 2 | Grommet | ||
| 3 | Washer | ||
| 1 | Mounting Bracket | Lower mounting bracket | |
| 1 | Plate | Mounting plate assembly | |
| 1 | Bracket As | Main bracket assembly | |
| Contents of TC Radio Kit (1) | |||
| QTY | Part Number | Part Name | Description |
| 6 | Cap Screw | 5/16-24 | |
| 1 | (1) | Radio Gp | |
| (1) | The radio group is selected according to the region where the machine is to be used. |
Note: Welding may be required during this installation.
There are two options for installing the machine radio.
- The radio can be mounted by utilizing the lighting mounts.
- The radio can be mounted by utilizing the 9R-2160 Bosses.
- Determine the option that will be used for the installation.
- If the bracket will be mounted to the existing lighting mounts of the machine, then proceed to Step 2.
- If the bracket will be mounted to the bosses, then proceed to Step 5
- Remove the bolts from the light brackets that are on either side of the machine.
Note: On Wheel Loaders, Caterpillar recommends using the existing threaded holes of the backup light brackets.
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Illustration 9 g01513323 The radio is shown mounted to the 149-8196 Plate (37) via the lighting mounts. - Install the 149-8196 Plate (37). Use the bolts that were removed in Step 2.
Note: Tighten the bolts to Caterpillar standard torque specifications.
- Proceed to Step 10.
Note: Mount the radio at least 3 ft away from the GNSS receiver or from any other transmitting radio or antenna on the machine. This location maximizes reception of the radio. Also, ensure that the radio antenna has 360 degrees of visibility.
- Attach the four 9R-2160 Bosses to the 149-8196 Plate. Use four 8T-7547 Bolts (1/4 - 20) and four 8T-4224 Hard Washers.
- Mark the location of the bosses. Use the plate as a template.
- Remove the bosses from the plate.
- Weld the bosses to the locations that you marked.
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Illustration 10 g01434661 The radio is shown mounted using the 9R-2160 Bosses and the149-8196 Plate . - Mount the plate to the bosses. Use four 8T-7547 Bolts (1/4 - 20) and four 8T-4224 Hard Washers.
Note: Tighten the bolts to Caterpillar standard torque specifications.
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Illustration 11 g01471352 Radio and mounting bracket
(5) Radio
(37)149-8196 Plate
(38)167-8610 Bracket As
(39)8C-5607 Isolation Mount
(40)8C-5608 Spacer
(41)9X-6165 Washer
(42)4M-5282 Bolt - Attach the radio to the 167-8610 Bracket As. Use four 167-8999 Bolts. The bolts are included with the radio.
Note: Ensure that the radio has been properly configured and that the correct firmware has been installed before mounting the radio. Refer to Special Instruction, REHS2585, "MCG Flash User Guide".
- Attach the 140-7480 Mounting Bracket to the bottom of the radio. Use the remaining two 167-8999 Bolts. The bolts are included with the radio.
- Attach the 140-7480 Mounting Bracket to the 167-8610 Bracket As . Use two 5S-7349 Bolts (1/4-20) and two 8T-4205 Hard Washers.
Note: If the 211-0100 Antenna has been removed from the radio, install the antenna on the radio. Use a
38 mm (1.5 in) wrench. Torque the antenna to8 N·m (6 lb ft) . - Assemble the six 8C-5607 Isolation Mounts and the three 8C-5608 Spacers to the 167-8610 Bracket As. Refer to Illustration 11.
- Mount the 167-8610 Bracket As to the 149-8196 Plate. Use three 4M-5282 Bolts (1/4-20) and three 9X-6165 Washers.
Routing and Connecting the Radio Harness
Perform the following procedure after the radio has been mounted.
- Connect the 285-6654 Radio Harness to the radio.
- Route the 285-6654 Radio Harness down the ROPS post to the 290-1918 Rear Harness As. This assembly is near the base of the ROPS support.
Note: A 9V-2818 Grommet should be used to protect the harness if the harness is being routed through any drilled holes. These grommets are included in the 167-8602 Radio Mounting Gp.
Note: If extra length is needed for routing, then install the optional 285-6653 Radio Harness As.
Rear Harness Assembly Installation
The 290-1918 Rear Harness As routes from the 290-1917 Front Harness As to either the 285-6654 Radio Harness As or else to the optional 285-6653 Radio Harness As and the 290-1918 Rear Harness As.
- Route the 290-1918 Rear Harness As .
- Connect the 8-pin and the 12-pin connectors of the 290-1918 Rear Harness As (6) to the 8-pin connector of the 285-6654 Radio Harness As (8) and to the 12-pin connector of the 290-2928 Chassis Harness As (12).
- Route the 290-1918 Rear Harness As under the floor plate towards the 290-1917 Front Harness As.
Note: Route the harness in a location for ease of connection to the optional 205-4285 Electrical Converter Gp if needed for a TC900B radio.
- Secure the 290-1918 Rear Harness As. Use 3S-8665 Clips, 8M-2773 Clips, or 7K-1181 Cable Straps. If the harness passes through any holes in the machine, protect the harness. Use a protective wrap or use a 5P-6264 Grommet. These parts are included in the 291-2177 Machine Wiring Gp.
Use one of the following methods to connect the 6-pin connector of the 290-1918 Rear Harness As.
- If a TC900C or newer radio is being used on the machine, then proceed to Step 5.
- If a TC900B radio or older is being used on the machine, then a 205-4285 Electrical Converter Gp is needed. Proceed to Step 7.
- Connect the 6-pin connector of the 290-1918 Rear Harness As to the 6-pin connector of the 278-7396 Wire As.
- The installation of the 290-1918 Rear Harness As is complete. Proceed to the "Operator Display Installation" section.
- Mount the 205-4285 Electrical Converter Gp on the machine. There are several acceptable mounting locations for the Converter. The following criteria must be considered when the location is selected.
- The location should support the overall dimensions of the Converter. The dimensions are
115 mm (4.5 in) by77 mm (3.0 in) . - The location should accommodate both the standard length and the unaltered length of the 290-1918 Rear Harness As.
- The location should have adequate accessibility.
- The location should not interfere with normal, safe functioning of the machine.
Note: The recommended mounting location of the Converter is inside the cab below the floor plate.
- Attach the flanges of the Converter to the two 5 mm bosses. Use two 5 mm Bolts and two washers.
- Position the Converter in the desired location.
- Mark the location of the bosses. Use the Converter as a template.
- Remove the Converter from the bosses.
- Weld the bosses to the marked locations.
- Fasten the Converter to the machine. Use two 5 mm bolts and two washers.
Note: Tighten the bolts to Caterpillar standard torque specifications.
- The location should support the overall dimensions of the Converter. The dimensions are
Operator Display Installation
Note: If the machine is in the following list, then refer to Special Instruction, REHS2581, "CAESultra Installation for Landfill Compactors and Wheel Dozers with CAESultra ARO" for alternative display mounting options.
- 824H Wheel Dozer
- 834H Wheel Dozer
- 826H Landfill Compactor
- 836H Landfill Compactor
Note: If the machine is in the following list, then refer to Special Instruction, REHS2582, "CAESultra Installation for Large Wheel Loaders with Satellite Receiver As ARO" for alternative display mounting options
- 854K Wheel Dozer
- 992K Large Wheel Loader
- 993K Large Wheel Loader
- 994F Large Wheel Loader
Position the 291-2199 Monitor Display Gp (D3:C4 Nav 10.4) within the cab of the machine. Consider the following requirements when choosing the location:
- The display should be placed within
1.2 m (4 ft) of the eyes of the operator. - The display should be in a location that does not block the visibility of the operator to risk areas around the machine.
- The display should be located near the plane that the operator normally views during operations that benefit most from the use of CAES. Ideally, the display should be located no more than 30 degrees from this viewing angle.
Also, consider the following when choosing the location for the display:
- Ease of reference to work in progress
- Accessibility to the touch screen
- Operator comfort (resting position of the arm, leg)
- View of safety films within the cab
- Direct or mirrored views of the operator
- Ability of operator to enter or exit the cab
- Exposure of the screen to excessive glare from the sun
- Use of operator controls
The display is mounted on a u-shaped bracket. The bracket can be tilted approximately 20 degrees to minimize glare from direct sunlight.
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| Illustration 12 | g01514052 |
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Typical display mounting location | |
There are two options for installing the D3:C4 Nav 10.4 Display.
- The display can be mounted to the top side of the dash panel.
- The display can be mounted to the bottom side of the roof.
- Determine the option that will be used for the installation.
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Illustration 14 g01516333 Contents of 167-8604 Monitor Mounting Gp
(26)8X-7422 Boss
(27)147-3417 Mount As
(28)3Y-7829 Boss
(29)5M-2894 Hard Washer
(30)0S-0509 Bolt - Attach the 8X-7422 Bosses (26) to the 147-3417 Mount As (27). Use the mounting hardware in Table 13.
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Table 13 Contents of 167-8604 Monitor Mounting Gp QTY Part Number Part Name Description 4 0S-0509 Bolt 3/8-16 4 3Y-7829 Boss 3/8-16 4 5M-2894 Hard Washer 4 8X-7422 Boss 3/8-16 1 147-3417 Mount As Note: If mounting the display to the ceiling, then score the padding, the lining, or the insulation. Remove the scored material. Remove enough insulation to allow sufficient space for welding the bosses.
Note: Use the optional 3Y-7829 Bosses (28) with the 8X-7422 Bosses (26) if more length is needed to mount the 147-3417 Mount As (27) properly.
- Mark the location of the bosses. Use the 147-3417 Mount As as a template.
- Remove the bolts, washers, and bosses from the 147-3417 Mount As.
- Weld the bosses to the marked locations.
- Mount the 221-3453 Bracket As to the bosses. Use the four bolts and four washers that were removed in Step 4.
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Illustration 15 g01513986 The exploded view of 150-1893 Vibration Isolator Mounting Gp is shown.
(1)291-2199 Monitor Display Gp (D3:C4 Nav 10.4)
(34)221-3453 Bracket As
(35)8T-4205 Hard Washer
(36)8T-9364 Bolt (1/4-20)
(39)8C-5607 Isolation Mount
(40)8C-5608 Spacer
(41)9X-6165 Washer
(42)4M-5282 Bolt (1/4-20) - Assemble the eight 8C-5607 Isolation Mounts (39) and the four 8C-5608 Spacers (40) to the u-shaped 221-3453 Bracket As. Use four 9X-6165 Washers (41) and four 4M-5282 Bolts (42). Refer to Illustration 15.
Note: Tighten the bolts to Caterpillar standard torque specifications.
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Illustration 16 g01513379 Ceiling/Dash adapter
(43)147-3417 Mount As
(44)4M-5282 Bolts (1/4-20)
(45)9X-6165 Washers - Attach the 221-3453 Bracket As to the 147-3417 Mount As (43). Use four 4M-5282 Bolts (44) and four 9X-6165 Washers (45) from the 225-5362 Monitor Mounting Gp. Refer to Illustration 16.
Note: Tighten the bolts to Caterpillar standard torque specifications.
- Remove the 126-1774 Connector Cover from the 70-pin connector of the 290-1917 Front Harness As.
Note: The 126-1774 Connector Cover is removed because this cover limits the ability to adjust the angle of the display.
- Connect the 70-pin connector of the 290-1917 Front Harness As to the 291-2199 Monitor Display Gp.
- Attach the 291-2199 Monitor Display Gp to the 221-3453 Bracket As. Use three of the four 8T-9364 Bolts and 8T-4205 Hard Washers.
Note: The fourth bolt and washer will be connected in Step 12.
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Illustration 17 g01513992 (9) 290-1917 Front Harness As
(34)221-3453 Bracket As
(46)130-5300 Clips
(47) Dust covers - Attach the two 130-5300 Clips (46) to the outside of the 221-3453 Bracket As (34). Use the last 8T-9364 Bolt (1/4-20) and 8T-4205 Hard Washer. Refer to Illustration 17.
- Attach the 4-pin and the 6-pin service connector dust covers (47) that are on the 290-1917 Front Harness As (9) to the 130-5300 Clips (46). Refer to Illustration 17.
- Secure the two ring terminal wires that are on the 290-1917 Front Harness As near the 70-pin connector. Alternatively, install the optional 167-8709 Alarm Gp.
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| Illustration 13 | g01514067 |
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The optional mounting location is shown on a compactor. The display is mounted in front upper right corner of the cab using a site fabricated ceiling bracket. | |
Front Harness Assembly Installation
The 290-1917 Front Harness As routes between the 291-2199 Monitor Display Gp (D3:C4 Nav 10.4), 167-8984 Battery Gp, power, and the 290-1918 Rear Harness As.
- Route the 290-1917 Front Harness As . For ease of routing, start routing the harness at the display. Continue routing the harness to the 167-8984 Battery Gp and to the connection of the 290-1918 Rear Harness As . This method of routing ensures that there is no need to remove the 70-pin connector.
- Route the 290-1917 Front Harness As from the display to the intended location of the connection for the 290-1918 Rear Harness As. The harness can be routed either behind the dash and through the floor plate or else the harness can be routed through the headliner and then down a support post to the floor plate.
- Connect the 8-pin connector of the 290-1917 Front Harness As to the 8-pin connector of the 290-1918 Rear Harness As.
- Route the 3-pin power connection to the mounting location of the 167-8984 Battery Gp. This 3-pin connector breaks off from the 290-1917 Front Harness As.
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Illustration 18 g01513994 The 290-1917 Front Main Harness is shown securely clamped.
(9)290-1917 Front Harness As
(46)8M-2773 Clip - As shown in Illustration 18, secure the 290-1917 Front Harness As (9). Use 3S-8665 Clips, 8M-2773 Clips (46), or 7K-1181 Cable Straps. If the harness passes through any holes in the machine, protect the harness. Use a protective wrap or use a 5P-6264 Grommet. These parts are included in the 291-2177 Machine Wiring Gp.
Battery Backup
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| Illustration 19 | g01434701 |
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The installed | |
The 167-8984 Battery Gp (Battery Backup) supplies the CAESultra with temporary power. Power is supplied for a short time in the event of an abrupt, unplanned loss of power to the machine. The battery stores power for approximately 5 minutes. This delay provides enough time for the operator to shut down the CAESultra system safely.
There are several acceptable mounting locations for the 167-8984 Battery Gp on the machine. The location that is chosen should consider the following criteria:
- The overall battery dimensions of
215 mm (8.5 in) by215 mm (8.5 in) - Adequate accommodations for both the standard length and the unaltered length of the 290-1917 Front Harness As
- Adequate accessibility to the battery
- Normal, safe functioning of the machine
Battery Backup Installation
This installation may require welding on the machine.
Perform the following steps to install the 167-8984 Battery Gp (Battery Backup).
- Attach the two 292-1120 Mounting Blocks to the 167-8984 Battery Gp. Use four 8T-0325 Bolts (M5) and four 8T-0328 Hard Washers.
- Position the 167-8984 Battery Gp in the desired location and mark the location of the bosses. Use the 167-8984 Battery Gp as a template.
Note: If required, score and remove padding, lining, or insulation. Remove enough insulation to allow room to weld the bosses.
- Remove the 167-8984 Battery Gp from the bosses.
- Weld the bosses to the marked locations.
- Mount the 167-8984 Battery Gp to the 292-1120 Mounting Blocks. Use four 8T-0325 Bolts (M5) and four 8T-0328 Hard Washers.
Note: Tighten the bolts to Caterpillar standard torque specifications.
- Connect the 3-pin connector of the 290-1917 Front Harness As to the 3-pin connector of the 167-8984 Battery Gp.
Note: The 167-8984 Battery Gp must be located so that the leads of the 167-8703 Wire As can reach the battery.
- Connect the 265-8147 Wiring Harness to the 3-pin connector of the 167-8984 Battery Gp
Note: Do not connect the 3-pin connector of the 167-8703 Wire As from the opposite side of the 265-8147 Wiring Harness until the power is connected and the voltage has been checked.
Power Harness and Fuse Installation
The 167-8703 Wire As (Power Harness) is provided with the 291-2177 CAES Wiring Gp. Use the 167-8703 Wire As to connect the 167-8984 Battery Gp to the power supply of the machine.
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| Illustration 20 | g01479356 |
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Electrical schematic for Power Harness and installation of the fuses | |
- Turn the disconnect switch to the OFF position.
- Route the 167-8703 Wire As from the 167-8984 Battery Gp to the "Run" relay.
Note: Use a 2L-8067 Terminal, a 2L-8071 Terminal or a 2L-8079 Terminal. These Terminals are included in the 291-2177 Machine Wiring Gp.
- Connect the RED "+24 volt" wire to the supply side of the "Run" relay.
- Connect the PINK "Switched +24 volt" wire to the switched side of the "Run" relay.
- Connect the BLACK "Ground" wire to a ground lug.
- Confirm that there is a 10 amp fuse in each of the 265-8147 Fuse Holders.
Note: If the Run relay is not easily accessible, then the key switch may be used as a substitute connection point.
Initial Power Checks
Before applying power to the CAESultra System for the first time, verify the voltage at the following power connections.
Pin A - Positive
Pin B - Negative
Pin C - Switched positive
- Turn off the Key switch.
- Check for 24 volts between Pin A and Pin B.
- Check for zero volts between Pin B and Pin C.
- Turn the key switch to the ON position
Note: Do not turn the key all the way to the START position
- Check for 24 volts between Pin B and Pin C.
- After power has been verified, connect the 3-pin connector of the 167-8703 Wire As to the 3-pin connector of the 265-8147 Fuse Harness that is located near the 167-8984 Battery Gp
Machine ID Worksheet Entries
Enter the following information for future reference:
Machine ID Number____________________
Machine Name____________________
Display Serial Number____________________
Machine Dimensions____________________
Radio Serial Number____________________
Application (Grade, Ore, OrePlus, Compaction)____________________
Grade Tolerance (provided by Mine)____________________
Dimension Measurements and Measure Up for Machines
Wheel Loaders
- Measure the machine GNSS receiver offsets. Reference the offsets to the specific dimensions of the machine for setting up the machine in the office from METSmanager.
Refer to the sample METSmanager screen shot, Illustration 21, as a reference guide and template to record the machine dimensions.
Note: The "X" measurement that is taken to the right of the centerline of the machine will be a positive number. The "X" measurement that is taken to the left of the centerline of the machine will be a negative number.
Note: The "Y" measurement that is taken in front of the front axle will be a positive number. The "Y" measurement that is taken behind the front axle will be a negative number.
- GPS x: Measure the distance from the center of the GNSS Receiver (10) to the centerline of the machine.
- GPS y: Measure the distance from the center of the GNSS Receiver (10) to the center of the front axle of the machine.
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Illustration 22 g01514069 (10) 291-1913 Satellite Receiver As
(48) Top of lower housing - GPS z: Measure the distance from the top of the lower housing (48) of the GNSS Receiver (10) to the bottom of the wheels.
- Bucket Width: Measure the width of the machine from the outside edges of the bucket.
- Wheelbase: Measure the distance from the center of the front axle to the center of the rear axle.
- Maximum Reach: Measure the distance from the center of the front axle to the front edge of the bucket.
- Wheel Radius: Measure the distance from the center of one of the wheels to the outside edge the same wheel.
- Bench Height: Use the site-specific bench height.
- Provide the measurements to the site coordinator. The site coordinator will implement the measurements in the METSmanager office software.
Reference: For Step 3 through Step 5, refer to Systems Operation, KENR6338, "CAESultra Service Manual"
- Ask the site coordinator to send out a "site specific appfile" for the GNSS Receiver.
- Ask the site coordinator to send out an "updated machine configuration" to the machine.
- When the machine has been configured by METSmanager, verify the GNSS accuracy.
- Move the machine origin to a known point.
- Compare the Northing, Easting, and Elevation.
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| Illustration 21 | g01513997 |
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METSmanager screen shot of machine dimensions | |
| NOTICE |
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Enter correct details. Any errors transfer directly into the finished surface. |
Wheel Dozers and Landfill Compactors
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| Illustration 23 | g01513906 |
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METSmanager screen shot of machine dimensions | |
- Measure the machine GNSS receiver offsets. Reference the offsets to the specific dimensions of the machine for setting up the machine in the office from METSmanager.
Refer to the sample METSmanager screen shot, Illustration 23, as a reference guide and template to record the machine dimensions.
Note: The "X" measurement that is taken to the right of the center line of the machine will be a positive number. The "X" measurement that is taken to the left of the center line of the machine will be a negative number.
Note: The "Y" measurement that is taken in front of the front axle will be a positive number. The "Y" measurement that is taken behind the front axle will be a negative number.
- GPS x: Measure the distance from the center of the GNSS Receiver (10) to the centerline of the machine.
- GPS y: Measure the distance from the center of the GNSS Receiver (10) to the center of the front axle of the machine.
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Illustration 24 g01514069 (10) 291-1913 Satellite Receiver As
(48) Top of lower housing - GPS z: Measure the distance from the top of the lower housing (48) of the GNSS Receiver (10) to the bottom of the drums.
Note: When the machine will be used on soft terrain, measure to the bottom of the drum. When the machine will be used on hard terrain, measure to the bottom of the tamper feet.
- Width over drums: Measure the width of the machine from the outside edges of the drums.
- Drum width: Measure the outside width of one drum.
- Wheelbase: Measure the distance between the center of the front axle to the center of the rear axle.
Note: To ensure accurate results, measure both sides of the machine and then average the number.
Reference: Refer to Systems Operation, KENR6338, "CAESultra Service Manual" for the remaining steps.
- Provide the measurements to the site coordinator. The site coordinator will implement the measurements in the METSmanager office software.
- Ask the site coordinator to send out a "site specific appfile" for the GNSS receiver.
- Ask the site coordinator to send out an "updated machine configuration" to the machine.
- When the machine has been configured by METSmanager, verify the GNSS accuracy.
- Move the machine origin to a known point.
- Compare the Northing, Easting, and Elevation.
| NOTICE |
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Enter correct details. Any errors transfer directly into the finished surface. |
Motor Graders
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| Illustration 25 | g01513833 |
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METSmanager screen shot of machine dimensions | |
- Measure the machine GNSS receiver offsets. Reference the offsets to the specific dimensions of the machine for setting up the machine in the office from METSmanager.
Refer to the sample METSmanager screen shot, Illustration 25, as a reference guide and template to record the machine dimensions.
Note: The "X" measurement that is taken to the right of the centerline of the machine will be a positive number. The "X" measurement that is taken to the left of the centerline of the machine will be a negative number.
Note: The "Y" measurement that is taken in front of the rear axle will be a positive number. The "Y" measurement that is taken behind the rear axle will be a negative number.
- GPS x: Measure the distance from the center of the GNSS Receiver (10) to the centerline of the machine.
- GPS y: Measure the distance from the center of the GNSS Receiver (10) to the center of the rear axle of the machine.
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Illustration 26 g01514069 (10) 291-1913 Satellite Receiver As
(48) Top of lower housing - GPS z: Measure the distance from the top of the lower housing (48) of the GNSS Receiver (10) to the bottom of the wheels.
- Blade position: Measure the distance between the center of the blade to the center of the rear axle.
- Machine width: Measure the distance from the outside edge of one wheel to the outside edge of the opposite wheel.
- Wheelbase: Measure the distance between the center of the front axle to the center of the rear axle.
- Blade Length: Measure the outside width of the blade.
Note: To ensure accurate results, measure both sides of the machine and then average the number.
Reference: Refer to Systems Operation, KENR6338, "CAESultra Service Manual" for the remaining .
- Provide the measurements to the site coordinator. The site coordinator will implement the measurements in the METSmanager office software.
- Ask the site coordinator to send out a "site specific appfile" for the GNSS receiver.
- Ask the site coordinator to send out an "updated machine configuration" to the machine.
- When the machine has been configured by METSmanager, verify the GNSS accuracy.
- Move the machine origin to a known point.
- Compare the Northing, Easting, and Elevation.
| NOTICE |
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Enter correct details. Any errors transfer directly into the finished surface. |