Installation of G610 Hardware for Cat<SUP>&reg;</SUP> Terrain for Motor Graders, Wheel Dozers, and Wheel Loaders {7605} Caterpillar


Installation of G610 Hardware for Cat® Terrain for Motor Graders, Wheel Dozers, and Wheel Loaders {7605}

Usage:

120 10R


Machine Control and Guidance Products
TERRAIN GRADING (S/N: TFE1-UP)
TERRAIN LOADING (S/N: TFL1-UP)
TERRAIN OFFICE (S/N: TER1-UP)
Motor Grader
All
Wheel Dozer
All
Wheel Loader
All

Introduction

This Special Instruction provides information for installing the following Cat®Terrain for grading and loading hardware components on the listed wheel loaders, wheel dozers, and motor graders:

The installation requires welding, cutting holes, using electrical tools, and using mechanical tools. After a technician has completed the first installation process, future installations should require 6 to 8 hours for completion.

The installation includes the following procedures:

  • Receiver, receiver harness, and chassis harness installation

  • Machine radio installation

  • Main rear harness installation

  • Display module installation

  • Main front harness installation

  • Optional alarm installation

  • Battery backup installation

  • Power supply wiring and fuse Installation

  • Dimension measurements and measure-up

Operation and Maintenance Manual

The operation of Terrain for grading and loading on-board software is covered in the Operation and Maintenance Manual, SEBU8822, "Cat® Terrain for Grading and Loading". Refer to this manual for more information.

Open the 392-9004 USB Memory Module containing the Terrain operational files and documentation.

Print the Operation and Maintenance Manual of the desired language and secure the manual in the cab of the machine.

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. Additionally, ensure that the product will not be damaged or made unsafe by the operation, lubrication, maintenance, or repair procedures that are used.

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

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.


------ DANGER! ------

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


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

Machine swings. Stay back. Crushing hazard could cause serious injury or death.


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

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.


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

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.


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

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

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

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

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

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

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

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

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

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



Illustration 1g00037860

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 both feet and one hand or a single 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

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

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:

  1. Move the machine to a suitable location. The location should be smooth, level, and out of direct sunlight.

  2. Move away from other working machines and personnel.

  3. Lower the bucket to the ground.

  4. Stop the engine.

  5. Engage the machine brake.

  6. When possible, maintain ownership of the machine keys.

Required Tools

The tools in Table 1 are required to install the Terrain on wheel loaders, wheel dozers, and motor graders. The list contains the recommended Caterpillar service tools, as well as general-purpose tools with no specified part number.

Table 1
Required tools For Installation of Terrain 
Part Number  Description 
9S-1748  Socket Wrench Set (1/2 Inch Drive) 
199-6156  Socket Wrench Set (1/2 Inch Drive) 
194-3584  Socket Wrench Set (Torx screw) 
1U-7230  Hand Tool Gp (Screwdrivers) 
8T-9293  Torque Wrench (1/2 inch Drive) 
9S-3263  Thread Lock Compound 
1U-9369  Measuring Tape 
389-0331  Terrain Service Kit 
Not specified  Drill Bit Set 
Not specified  Electricians Hole Punch Set 
Not specified  Fish Tape 
Not specified  Cable Ties/Clips 
Not specified  Tap Set 

Parts Lists

The 389-0344 Terrain Electronics Ar contains the receiver, the display, and a USB memory module. The USB memory module contains files for the monitor operating software, system documentation, and a schematic diagram of the system.

Table 2
Contents of the 389-0344 Terrain Electronics Ar 
Part Number  Part Name  Notes 
353-2794  Satellite Receiver  MS992 receiver 
392-9004  USB Memory Module  Contains operational files and documentation 
439-4341  Display Module  G610 Display with loaded operating system 

The 389-0318 Terrain Installation Ar contains the four kits that are listed in Table 3. The kits are broken down in Tables 4 through 7.

Table 3
Contents of 389-0318 Terrain Installation Arrangement 
Part Number  Part Name  Description 
167-8604  Monitor Mounting Gp  Dash/ceiling mounting group for display 
291-2176  Receiver Mounting Gp   
389-0332  Monitor Mounting Gp  Display mounting group 
389-0335  Machine Wiring Gp  Terrain 

Table 4
Contents of 167-8604 Monitor Mounting Gp 
Qty  Part Number  Part Name  Notes 
0S-0509  Bolt  3/8-16 
5M-2894  Hard Washer   
8X-7422  Boss  3/8-16 
147-3417  Mount As   

Table 5
Contents of 291-2176 Receiver Mounting Gp 
QTY  Part Number  Part Name  Description 
0L-1169  Bolt  5/8-11 
5K-5962  Boss  5/8-11 
5P-4624  Bolt  5/8-11 
8T-4121  Hard Washer   
8T-4195  Bolt  M10 
289-9633  Plate   

Table 6
Contents of 389-0332 Monitor Mounting Gp 
Qty  Part Number  Part Name  Notes 
4M-5282  Bolt  1/4-20
Display bracket to dash bracket 
7K-1181  Cable Strap   
8C-5607  Isolation Mount   
8C-5608  Spacer   
8T-4205  Hard Washer  Display to bracket 
8T-9364  Bolt  1/4-20
Display to bracket 
9X-6165  Washer  Display bracket to dash bracket 
130-5300  Clip   
389-3032  Bracket   

Table 7
Contents of 389-0335 Terrain Wiring Gp 
QTY  Part Number  Part Name  Description 
2L-8067  Terminal   
2L-8071  Terminal   
2L-8079  Terminal   
3S-8665  Clip  For harness 
5P-6264  Grommet   
15  8M-2773  Clip   
8T-0325  Bolt  M5
For battery 
8T-0328  Hard Washer  For battery 
167-8703  Wire  Power supply 
167-8984  Battery   
265-8147  Harness  Fuse 
278-7396  Wire   
285-6651  Harness As  CAN terminator 
285-6657  Harness As  Receiver jumper 
290-2928  Harness As   
292-1120  Mounting Block  For battery 
383-3027  Harness As   
383-3028  Harness As   
389-0333  Cable As   

Optional Items

The optional items in Table 8 may also be required during the installation. These parts are not provided in the 389-0344 Terrain Electronics Ar.

Table 8
Optional parts needed for Terrain installation
(Not included in the 389-0344 Terrain Electronics Ar) 
Part Number  Part Name  Description 
3E-5239  Relay  Used for Reverse Auto-Calibration option 
4C-4200  Paint  CAT Yellow 
7K-1181  Cable Strap  Straps for securing harness 
7T-1099  Link  Weld links for harness routing 
141-5830  Silicone Sealant  RTV for grommets 

Audible Alarm

The display must have an audible alarm installed when a site uses Proximity Awareness (Detect). The alarm is optional for other sites.

Table 9 lists the parts contained in the alarm installation kit.

Table 9
435-4719 Alarm Gp Basic (Terrain) 
Part Number  Part Name  Notes 
441-8287  Harness As  Connects to audible alarm and 383-3027 Wiring Harness (main front) 
444-5691  Alarm As  Audible CAN alarm 

System Overview

The primary Terrain components include a receiver, various inclination sensors, pressure switches, and a display module.



Illustration 2g03384880
Terrain system components
(1) 393-2794 Satellite Receiver
(2) 439-4341 Display Module (G610)

Illustration 2 shows the primary Terrain components.



Illustration 3g06122827
Representation of cables, harnesses, and main system components

Illustration 3 shows the connections between the cables, harnesses, and the Terrain components that are described within this instruction. Refer to the Terrain CAES G610 System Diagram in the following folder on the USB memory module for a complete wiring schematic of the Terrain system:

  • 02 System Documentation\System Diagrams\v5.x

Note: If the machine is in the following list, then ensure that the machine does not have the Terrain ARO option from the factory. If the machine has the Terrain ARO option, then refer to Special Instruction, REHS3653, "Installation of Cat® Terrain Attachment Ready Option for Wheel Dozers" for installation instructions.

  • 824H Wheel Dozer

  • 834H Wheel Dozer

Note: If the machine is in the following list, then ensure that the machine does not have the Terrain ARO option from the factory. If the machine does have the Terrain ARO option, then refer to Special Instruction, REHS4699, "Installation of Cat® Terrain Attachment Ready Option for Large Wheel Loaders and Large Wheel Dozers" for installation instructions.

  • 854K Wheel Dozer

  • 992K Large Wheel Loader

  • 993K Large Wheel Loader

  • 994F Large Wheel Loader

Summary of Welding and Potential Welding by Sections


NOTICE

Welding on the machine or jump starting the machine can damage the electronics in the display or the battery backup unit (BBU). To avoid damaging the electronics or BBU, disconnect the BBU from the power supply before welding or jump starting. If welding, reconnect the BBU to the power supply once welding is finished. If jump starting, reconnect the BBU to the power supply once the machine starts and the jumpers have been disconnected.


Table 10
Welding  Section 
Yes  Receiver, receiver harness, and chassis harness 
Possible  Machine radio installation 
Possible  Mounting and connecting the radio harness 
Possible  Main rear harness assembly installation 
Possible  Display module installation 
Possible  Main front harness assembly installation  
No  Optional alarm installation 
Yes  Battery backup installation 
No  Power supply wiring and fuse installation 

Installing the Receiver, Receiver Harness, and Chassis Harness

Note: This installation procedure requires welding.

The terms receiver, GPS or GNSS receiver, satellite receiver, and Positioning Module (PM) are synonymous. This manual uses the terms receiver and satellite receiver.



Illustration 4g03455977
The 353-2794 Satellite Receiver is shown mounted on the top side of the ROPS.

The 353-2794 Satellite Receiver must be mounted on top of the Roll Over Protection Structure (ROPS) as close to the centerline of the machine as practical. This location allows the 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 satellite receiver. This method eliminates the need for welding, drilling, or tapping the machine.

  1. Disconnect the battery backup unit (BBU) from the power supply before commencing any welding.

    Failure to follow this instruction may result in damage to the display or to the BBU.



    Illustration 5g03790023
    (1) 353-2794 Satellite Receiver shown on centerline of the machine

  2. Weld the 5k-5962 Boss (5/8-11) as close as possible to the centerline of the machine on top of the ROPS.


    Illustration 6g03455979
    The 5K-5962 Boss is shown welded to the ROPS of the machine.

  3. Position the 289-9633 Plate over the boss and fasten with the 5P-4624 Bolt.

  4. Apply anti-seize compound to the bolt thread.

  5. Tighten the bolt to Caterpillar standard torque specifications.

  6. If required, the tube on the 289-9633 Plate 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.


    Illustration 7g03455980
    The 353-2794 Satellite Receiver is shown mounted on the top side of the ROPS using the shortened 289-9633 Plate

  7. Attach the satellite receiver to the 289-9633 Plate using four 8T-4195 Bolts (M10) and four 8T-4121 Hard Washers.

    These parts are included in the 291-2176 Receiver Mounting Gp.

  8. Mount the satellite receiver to allow the operator easy visibility of the LEDs when outside of the cab. This location may be determined by site preference.

  9. Attach the 285-6657 Harness As (receiver) (13) to the connector on the satellite receiver. Route the harness across the roof to the ROPS post.


    Illustration 8g03455981
    The optional 7T-1099 Links are shown. These weld links are attached to the ROPS. The links are used for routing the receiver harness across the roof of the cab.

  10. Secure the receiver harness using 3S-8665 Clips, 8M-2773 Clips, or 7K-1181 Cable Straps.

  11. 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 389-0335 Machine Wiring Gp.

  12. Connect the 12-pin connector of the receiver harness to the 12-pin connector of the 290-2928 Harness As (main rear).


    Illustration 9g03455982
    (12) 290-2928 Harness As (chassis)
    (13) 285-6657 Harness As (receiver)
    (14) 285-6651 Harness As (CAN terminator)

  13. Connect the CAN terminator (14) to the 8-pin connector near the end of the chassis harness (12).


    Illustration 10g03455983
    The chassis harness is shown routed down the ROPS post.

  14. Route the chassis harness (12) down the back of the left ROPS post to the mounting location of the 383-3028 Harness As (main rear).

    This location is beneath the floor plate of the cab. This is the recommended routing.

  15. Secure the chassis harness using 3S-8665 Clips, 8M-2773 Clips, or 7K-1181 Cable Straps.

  16. 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 389-0335 Machine Wiring Gp.

  17. If available, use the ROPS harness guide bracket to protect the harness. Refer to Illustration 10.

Installing the Machine Radio

Note: Welding may be required during this installation.

A machine radio is not supplied with Terrain. The customer must supply the machine radio. Use the 389-0333 Cable As to connect the third-party radio to the main front harness.

To install a machine radio, complete these steps:

  1. If welding is required, disconnect the battery backup unit (BBU) from the power supply before commencing any welding.

    Failure to follow this instruction may result in damage to the display or to the BBU.

  2. Determine the mounting procedure for the radio.

    Suggested mounting procedures include:

    • Utilize the existing light brackets (if equipped).

    • Weld bosses to the machine and use a radio mounting bracket.

    • Mount the radio inside the cab and mount an external antenna outside the cab.

  3. Determine the mounting location on the machine for the radio.

    Consider the following requirements when choosing the location:

    • Mount the radio at least 3 feet from the satellite receiver or any other transmitting radio or antenna on the machine. This location maximizes reception of the radio.

    • Ensure that the radio antenna has 360 degrees of visibility.

  4. Install the machine radio in the desired location.


    Illustration 11g03474679
    389-0333 Cable As (Radio)
    (A) "P2" to Ethernet of customer supplied radio for power
    (B) "P1" to main rear harness

  5. Connect the standard RJ-45 Ethernet connector "P2" (A) to the customer-supplied radio. This connector also supplies power to the radio.

  6. Connect the 12-pin (key D) connector "P1" (B) of the 389-0333 Cable As to the main rear harness.

Using Power Over Ethernet

Power over Ethernet (PoE) technology describes a system that safely passes both electrical power and data on the same Ethernet cable.

If utilizing PoE technology, then move the following wires from the 2-pin DT connector to the 12-pin DT connector of the radio harness:

  • Power: 1-BU(Blue)

  • Ground: 2-BK(Black)

Installing the Main Rear Harness

Note: Welding may be required during this installation.

The 383-3028 Harness As (main rear) routes from the 383-3027 Harness As (main front) to either the 389-0333 Harness As (radio) or else to the 290-2928 Harness As (20-FT) (chassis).

  1. Route the main rear harness.

  2. Connect the 12-pin connectors of the main front harness to the main rear harness.

  3. Route the main rear harness under the floor plate toward the main front harness that is located near the dash.

  4. Secure the main rear harness using 3S-8665 Clips, 8M-2773 Clips, or 7K-1181 Cable Straps.

  5. 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 389-0335 Machine Wiring Gp.

Installing the Display Module

Note: Welding may be required during this installation.

If the machine is in the following list, then refer to Special Instruction, REHS3653, "Installation of Cat® Terrain Attachment Ready Option for Wheel Dozers" for alternative display mounting options.

  • 824H Wheel Dozer

  • 834H Wheel Dozer

If the machine is in the following list, then refer to Special Instruction, REHS4855, "Installation of Cat® Terrain Attachment Ready Option for Large Wheel Loaders and Large Wheel Dozers" for alternative display mounting options

  • 854K Wheel Dozer

  • 992K Large Wheel Loader

  • 993K Large Wheel Loader

  • 994F Large Wheel Loader

To mount the display on the machine, complete these steps:

  1. Disconnect the battery backup unit (BBU) from the power supply before commencing any welding.

    Failure to follow this instruction may result in damage to the display or to the BBU.

  2. Position the display within the cab of the machine.

    Consider the following requirements when choosing the location:

    • Place the display within 1.2 m (4 ft) of the eyes of the operator.

    • Choose a location that does not block the operator from seeing risk areas around the machine.

    • Locate the display near the plane that the operator normally views during operations that benefit most from the use of the Terrain system. Ideally, locate the display no more than 30 degrees from this viewing angle.

    • Locate the display where the operator can easily see both the work in progress the information on the display.

    • Ensure that there is easy access to the touch screen from the normal sitting position of the operator

  3. Verify that the location for the display does not result in any of the following:

    • Blocking the view of safety films within the cab

    • Preventing the operator from safely entering or exiting the cab

    • Preventing the operator from seeing the view from the mirrors or the direct view out of the cab

    • Causing discomfort to the resting position of the arms or legs

    • Impeding the use of any operator controls within the cab

    • Exposing the display to excessive glare from direct sunlight

    Note: The display is mounted on a u-shaped bracket that can be tilted approximately 20 degrees to minimize glare from direct sunlight.



    Illustration 12g02980737
    Typical display mounting location


    Illustration 13g02980738
    The optional mounting location is shown on a compactor. The display is mounted in the front upper right corner of the cab using a site fabricated ceiling bracket.

  4. Determine which of the following options to use for installing the 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.


    Illustration 14g01516333
    Contents of 167-8604 Monitor Mounting Gp
    (26) 8X-7422 Boss
    (27) 147-3417 Mount
    (28) 3Y-7829 Boss
    (29) 5M-2894 Hard Washer
    (30) 0S-0509 Bolt

  5. Attach the bosses (26) to the mount (27). Use the mounting hardware in Table 4.

    Note: If mounting the display to the ceiling, then score the padding, the lining, or the insulation material. Remove the scored material. Remove enough material to allow sufficient space for welding the bosses.

    Note: Use the optional bosses (28) with the bosses (26) if additional length is needed to install the mount (27).

  6. Mark the location of the bosses using the 147-3417 Mount as a template.

  7. Remove the bolts, washers, and bosses from the 147-3417 Mount.

  8. Weld the bosses to the marked locations.

  9. Mount the 383-3032 Bracket to the bosses. Use the four bolts and four washers that were removed in Step 7.


    Illustration 15g03790257
    The exploded view of 150-1893 Vibration Isolator Mounting Gp is shown.
    (2) 439-4341 Display Module
    (34) 383-3032 Bracket
    (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)


    Illustration 16g03455987
    389-3032 Bracket for mounting display module with isolation mounts installed

  10. Assemble the eight isolation mounts (39) and the four spacers (40) to the u-shaped 383-3032 Bracket using four washers (41) and four bolts (42). Refer to Illustration 15.

  11. Tighten the bolts to Caterpillar standard torque specifications.


    Illustration 17g01513379
    Ceiling/dash adapter
    (43) 147-3417 Mount
    (44) 4M-5282 Bolts (1/4-20)
    (45) 9X-6165 Washers

  12. Attach the 383-3032 Bracket to the mount (43). Use four bolts (44) and four washers (45) from the 389-0322 Monitor Mounting Gp. Refer to Illustration 17.

  13. Tighten the bolts to Caterpillar standard torque specifications.


    Illustration 18g03455989
    Display tilted after installation of lower bolts to ease installation of cables

  14. Attach the display module to the 389-3032 Bracket. Install the lower 8T-9364 Bolts and 8T-4205 Hard Washers first to allow the display to tilt and ease installation of the harnesses.

    Note: The remaining bolts and washers will be connected after the harnesses are installed.

  15. Remove the 126-1774 Connector Cover from the 70-pin connector of the main front harness.

    Note: The connector cover is removed because this cover limits the ability to adjust the angle of the display.



    Illustration 19g03455990
    G610 harness installation
    (2) G610 Display
    (2a) P1 (70-pin) of 383-3027 Harness As
    (2b) (not used)
    (2c) P3 of 383-3027 Harness As to Power port
    (2d) P2 of 383-3027 Harness As to USB port

  16. Install the main front harness connectors to the display (2).

    1. Connect the P1 70-pin connector (2a) to the display.

    2. Connect the gray P3 (key A) 12-pin connector (2c) to the Power port (middle).

      Note: The top 12-pin connector port (2b) is not used.

    3. Connect the black P2 (key B) 12-pin connector (2d) to the USB port (bottom).

  17. Install the third 8T-9364 Bolt (1/4-20) and 8T-4205 Hard Washer to the left-hand top of the display.


    Illustration 20g03455991
    383-3027 Harness As installed on bracket
    (9) 383-3027 Harness As
    (34) 389-3032 Bracket
    (46) 130-5300 Clips
    (47) 370-4060 Receptacle

  18. Attach the clip (46) to the outside of the bracket (34). Use the last 8T-9364 Bolt (1/4-20) and 8T-4205 Hard Washer. Refer to Illustration 20.

  19. Install the receptacle (47) to the 237-0164 Plug of the 383-3027 Harness As.

  20. Attach the 237-0164 Plug to the 130-5300 Clip. Refer to Illustration 20.

Installing the Main Front Harness

The 383-3027 Harness As (main front) is routed between the display, power, and the connection to the 383-3028 Harness As (main rear).

To install the main front harness, complete these steps:

  1. Route the main front harness as follows to ensure that there is no need to remove the 70-pin connector from the harness:

    1. Start routing the harness at the display.

    2. Route the harness behind the dash and through the floor plate or through the headliner and then down a support post to the floor plate.

    3. Continue routing the harness to the battery backup and to the main rear harness connection.

  2. Connect the 12-pin connector of the main front harness to the 12-pin connector of the main rear harness.

  3. Route the 3-pin power connection to the mounting location of the battery backup. This 3-pin connector breaks off from the main front harness.


    Illustration 21g01513994
    The main front harness is shown securely clamped.
    (9) main front harness
    (46) 8M-2773 Clip

  4. Secure the main front harness (9) using 3S-8665 Clips, 8M-2773 Clips (46), or 7K-1181 Cable Straps. Refer to Illustration 21.

  5. 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 389-0335 Machine Wiring Gp.

Installing the Optional Alarm

Menu - Opens the main menu

To install the optional alarm, complete these steps:



    Illustration 22g03789844
    Alarm components
    (50) 383-3027 Harness As (main front) connector "P11"
    (51) 411-8287 Harness As connector "S1"
    (52) CAN connector with terminating resistor
    (53) 444-5691 Alarm
    (54) 411-8287 Harness As (alarm) connector "P2"
    (55) Magnetic mounts (1 on all four corners)

  1. Select a metallic location within the cab to mount the alarm.

    The location must provide ready access to connector "P11" (50) of the main front wiring harness.

  2. Clean and smooth the area on which the magnetic mounts (55) of the alarm (53) will attach.

  3. Attach the alarm to the clean surface.

  4. Connect the alarm to the main front harness as follows:

    1. Connect the alarm harness connector "P2" (54) to the alarm.

    2. Connect the alarm harness connector "S1" (51) to the main front harness connector "P11" (50).

      Note: The CAN connector (52) comes pre-installed with a terminating resistor.

  5. Verify the operation of the alarm using one of the following methods:

    Startup - Start the on-board software and listen for a short audible sound.

    Buzzer Test - Open the main menu and select "Diagnostics" > "Buzzer Test" and listen for a short audible sound.

    Notify the office if either of the following conditions exist:

    • The alarm is connected, but no audible sound is heard.

    • The alarm volume is either too loud or too quiet.

  6. In the MCU, set up Machine > Alarms.

  7. In the MCU, set up Detect > Alarms to allow the operator to mute, acknowledge, or filter audible alarms.

Battery Backup



Illustration 23g03455994
167-8984 Battery Gp (backup) mounted inside the cab below the floor plate

The battery backup supplies the on-board software 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 backup stores power for approximately 5 minutes. This delay provides enough time for the operator to shut down the on-board software safely.

Installing the Battery Backup

Note: This procedure may require welding.

To install the battery backup, complete these steps:

  1. If welding is required, disconnect the battery backup unit (BBU) from the power supply.

    Failure to follow this instruction may result in damage to the display or to the BBU.

  2. Consider the following requirements when choosing the location:

    • Do not place the battery backup in any location that prevents normal, safe functioning of the machine.

    • Provide sufficient area to coil the standard, unaltered length of the 383-3027 Harness As (main front) to prevent a trip hazard.

    • Ensure that the power supply lead from the front main harness can reach the battery backup.

    • Choose an area that accommodates the overall dimensions of two 292-1120 Mounting Blocks while attached to the battery backup.

    • Ensure adequate accessibility to the battery.


    Illustration 24g01817855
    Exploded view of mounting for battery backup
    (3) 167-8984 Battery Gp (backup)
    (3C) 8T-0325 Bolts (M5)
    (3D) 8T-0328 Hard Washers
    (3E) 292-1120 Mounting Blocks

  3. Bolt the two mounting blocks (3E) to the battery backup (3) using the bolts (3C) and the hard washers (3D).

  4. Score and remove padding, lining, or insulation material. Remove enough material to allow room to weld the mounting blocks.

  5. Use the mounting blocks as a template to locate the welding points for the blocks. Outline the outside edges of the mounting blocks.

  6. Remove the mounting blocks from the battery backup.

  7. Tack weld the mounting blocks in the marked locations.

  8. Verify that the flange holes of the battery line up with the tapped holes in the mounting blocks.

  9. Permanently weld the mounting blocks.

  10. Once the welding has cooled, paint the bosses to prevent the bosses from rusting.

  11. Once the paint has dried, bolt the battery backup to the machine using the bolts (3C) and the hard washers (3D).

  12. Tighten the bolts to Caterpillar standard torque specifications.

If this installation is new and is using a TC900C/CR900 radio, then the installation is complete. If the harnesses and MS990 receiver are being updated using a currently installed TC900B radio, then continue with this installation.

If the machine has a currently installed TC900B radio, complete these steps:

Note: This procedure may require welding.

  1. If welding is required, disconnect the battery backup unit (BBU) from the power supply.

    Failure to follow this instruction may result in damage to the display or to the BBU.

  2. Locate a 205-4285 Power Converter (12V/24V Inverter) near the battery.

  3. To ensure accurate placement of the converter, attach the two 5 mm bosses to the converter and tack weld the bosses in place.

  4. Remove the converter from the bosses and finish welding the bosses to the machine.

  5. Once the welding has cooled, paint the bosses to prevent the bosses from rusting.

  6. Once the paint has dried, bolt the converter to the bosses.

  7. Tighten the bolts to Caterpillar standard torque specifications.

Installing the Fuse Harness



Illustration 25g03469418
265-8147 Harness As (fuse harness)

The 265-8147 Harness As is a three wire in-line connection that protects the Terrain hardware components. The fuse harness can be mounted on either side of the battery. The design of the connectors ensures a correct connection to the mating connector.

To install the fuse harness, complete these steps:

  1. Choose a location for the harness on the machine that allows the fuses to be easily replaced.


    Illustration 26g03469217
    Fuse harness connected at location (B) between main front harness and battery backup
    (1) From power supply wire
    (Loc A) Connection between power supply wire and battery backup
    (2) Battery backup
    (3) 265-8147 Harness As
    (4) From main front harness
    (Loc B) Connection between main front harness and battery backup

  2. Choose one of the following locations to install the fuse harness:

    Location A (Loc A) - Between the power supply wire (1) and the battery backup (2)

    Location B (Loc B) - Between the main front harness (4) and the battery backup (2)

    Either location is acceptable.

  3. Connect the fuse harness.

    1. Connect one end of the fuse harness to the mating connector of the desired location, either power (A) or main front harness (B).

    2. Connect the opposite end of the fuse harness to the mating connector on the battery backup.

Installing the Power Harness and Fuses

The 167-8703 Wire As (power supply) is provided with the 389-0333 Machine Wiring Gp. The power supply wire connects to the 167-8984 Battery Gp (battery backup) and to the machine power supply. The power and the key switched power are connected through a 10 amp fuse.

To install the power supply wire and fuses, complete these steps:

  1. Turn the key start switch to the OFF position.


    Illustration 27g01268941
    Electrical schematic for installing power harness and fuses

  2. Referring to Illustration 27, route the 167-8703 Wire from the 167-8984 Battery to the Run relay.

    The two fuses that are shown can be supplied by utilizing the 265-8147 Harness As.

    Note: If the Run relay is not easily accessible, use the key start switch as a substitute connection point.

  3. For the following steps, use a 2L-8067 Terminal, a 2L-8071 Terminal, or a 2L-8079 Terminal.

    These terminals are included in the 389-0333 Machine Wiring Gp.

    1. Connect the RD "+24 volt" wire to the supply side of the Run relay.

    2. Connect the PK "Switched +24 volt" wire to the switched side of the Run relay.

    3. Connect the BK "Ground" wire to a ground lug.

  4. Confirm that there is a 10 amp fuse in each of the 265-8147 Fuse Holders.

Performing the Initial Power Checks


NOTICE

Prior to performing this test, ensure that the machine is not locked out/ tagged out. If so, then all voltages will read 0 V. Ensure that additional precautions are taken to alert personnel that you are working on the machine with live voltages. Lockout/ tagout the machine when this check is complete, as needed.


To verify the power connections, complete these steps:

  1. Remove any lockout/ tagout device.

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

  3. On the power cable from the key start switch, check for 24 V between pin A, (+) battery power and pin B, (-) battery power.

    Note: The pinouts are embossed on the underside of the molded plug.

  4. Check for 0 V between pin B and pin C, (+) switched power.

  5. Turn the key start switch to the ON position.

    Note: Do not turn the key all the way to the START position.

  6. Check for 24 V between pin B and pin C.

  7. After power has been verified, connect the 3-pin connector of the 167-8703 Wire to the 3-pin connector of the 265-8147 Fuse Harness that is located near the 167-8984 Battery.

  8. Lockout/ tagout the machine, as required.

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 or Ore) ____________________

Grade Tolerance (provided by site)____________________

Setting the Language

There are two ways to select the language that appears on the display module:

  • The office selects the language file by sending a file activate of the specific language file from the office to the machine.

  • The operator selects the language file through the "Select Language File" dialog.

Note: The on-board software receives tasks from other applications such as Task List Manager. These tasks can be sent in any language that is supported by the keyboard and operating system being used in the office. The on-board software receives these tasks in any language that the operating system supports.

Menu - Opens the main menu

To use the "Select Language File" dialog to set a new language on the display, complete these steps:



    Illustration 28g03747546
    "Select Language File" dialog

  1. From the main menu, select "System" > "Select" > "Select Language File".

    The "Select Language File" dialog appears.

    By default, the following languages are listed in the "Select Language File" dialog:

    • English (default)

    • French

    • Spanish

    • Swedish

    • Portuguese

    • Russian

    • Mongolian

  2. Select the language that will be used on the display module.

    For example, to use the Spanish language, select "5.0 Spanish".

  3. Select "OK".

    Note: When the operator shuts down the on-board software, the selected language file is saved.

Reference: For information on advanced tasks such as editing the "Set Language File" dialog, installing a new language in the MCU, and using resource files and language identifiers, refer to Systems Operation, KEN8277, "Language Support".

Using the Machine Configuration Utility

The Machine Configuration Utility (MCU) is a tool that configures advanced machine settings. The software replaces the previous method of editing the machine configuration file (mach_cfg.txt) file by hand.

Reference: For information on using the MCU, select Start > All Programs > Cat MineStar System and Tools > Machine Configuration Utility.

Reference: For information on adding the machine in Cat MineStar System, refer to Systems Operation, RENR9562, "Cat® Terrain User Guide".

Performing the Dimension Measurements and Measure-up

To set up the machine in the office, complete these steps:

  1. On the machine, measure the machine GPS receiver offsets and the machine dimensions.

    Reference: Refer to "Performing the Calibrations" in this document for your specific machine and "Machine Dimensions" in the MCU Help file for additional information.

  2. In the MCU, complete the following steps:

    1. Open the MCU.

    2. Select the machine name.

    3. Select Machine > Machine Dimensions. Enter the dimensions.

    4. In the menu bar, select File > Send to Cat MineStar System.

  3. Ask the Terrain Site Champion to send out a site-specific application file for the satellite receiver.

  4. Restart the on-board system and verify the accuracy of the satellite receiver as follows:

    1. Move the machine origin to a known point.

    2. Compare the Northing, Easting, and Elevation.

Performing the Calibrations


NOTICE

Enter correct details. Any errors transfer directly into the finished as-built surface file. All measurements are in meters.


Phase Center

When a measurement refers to the phase center, the phase center is located 12.8 cm (5.0 inch) from the bottom of the receiver.



Illustration 29g03790024
Measuring for the phase center (56)
( 1) 353-2794 Receiver
(56) Phase center

X and Y Measurements

  • The "X" measurement that is taken to the right of the centerline of the machine is a positive number.

  • The "X" measurement that is taken to the left of the centerline of the machine is a negative number.

  • 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 is a negative number.

Calibrating Motor Graders



Illustration 30g03473836


Illustration 31g03473837

Reference: Refer to the side view in Illustration 30 and the sample MCU screen shot Illustration 31 as a reference guide and template to record the machine receiver offsets and the machine dimensions.

To calibrate a motor grader, complete these steps:

  1. On the machine, measure the machine GPS receiver offsets.

    1. GPS x - Measure the distance from the phase center (56) of the receiver (1) to the centerline of the machine.

    2. GPS y - Measure the distance from the phase center (56) of the receiver (1) to the center of the rear axle of the machine.

    3. GPS z - Measure the distance from the phase center (56) of the receiver (1) to the bottom of the wheels.

  2. On the machine, measure the following machine dimensions:

    1. Grader Blade Length - Measure the distance between the outside edges of the cutting edge of the blade measured parallel to the blade cutting edge.

    2. Grader Blade Position - Measure the distance between the center line of the rear wheel axles and the center of the blade circle measured parallel to the center line of the machine.

    3. Grader Wheel Base - Measure the distance between the center line of the rear wheel axle and the center line of the front wheel axle measured parallel to the center line of the machine.

Calibrating Wheel Loaders



Illustration 32g03473780


Illustration 33g03473781

Reference: Refer to the side view in Illustration 32 and the sample MCU screen shot Illustration 33 as a reference guide and template to record the machine receiver offsets and the machine dimensions.

To calibrate a wheel loader, complete these steps:

  1. On the machine, measure the machine GPS receiver offsets.

    1. GPS x - Measure the distance from the phase center (56) of the receiver (1) to the centerline of the machine.

      Note: The phase center is located 12.8 cm (5.0 inch) from the bottom of the receiver.

    2. GPS y - Measure the distance from the phase center (56) of the receiver (1) to the center of the front axle of the machine.

    3. GPS z - Measure the distance from the phase center (56) of the receiver (1) of the receiver (10) to the bottom of the wheels.

  2. On the machine, measure the following machine dimensions:

    1. Loader Bucket Width - Measure the distance between the outer edges of the bucket, measured across the cutting edge of the bucket.

    2. Loader Wheel Base - Measure the distance between the center line of the rear wheel axle and the center line of the front wheel axle measured parallel to the center line of the machine.

    3. Loader Maximum Reach - Measure the distance between the center line of the front axle and the maximum reach of the machine measured parallel to the machine center line.

    4. Loader Wheel Radius: Measure the distance between the center line of an axle and the outer edge of a tire measured perpendicular to the axle center line.

Calibrating Wheel Dozers



Illustration 34g03473596
Machine Dimensions - Side View


Illustration 35g03473597
Sample MCU screen shot

Reference: Refer to the side view in Illustration 34 and the sample MCU screen shot Illustration 35 as a reference guide and template to record the machine receiver offsets and the machine dimensions.

To calibrate a wheel dozer, complete these steps:

  1. Measure the machine GPS receiver offsets.

    1. GPS x - Measure the distance from the phase center (56) of the receiver (1) to the centerline of the machine.

    2. GPS y - Measure the distance from the phase center (56) of the receiver (1) to the center of the front axle of the machine.

    3. GPS z - Measure the distance from the phase center (56) of the receiver (1) to the bottom of the wheels.

  2. On the machine, measure the following machine dimensions:

    1. Dozer Blade Position - Measure the distance between the center line of the rear idler axle and the front outside edge of the cutting edge of the blade measured parallel to the center line of the machine.

    2. Dozer Blade Width - Measure the distance between the outside edges of the cutting edge of the blade measured parallel to the blade cutting edge.

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