Installation Procedure for Mounting the Rear Radars On Certain Cat<SUP>&reg;</SUP> Products {1408, 1439, 5660, 7347} Caterpillar


Installation Procedure for Mounting the Rear Radars On Certain Cat® Products {1408, 1439, 5660, 7347}

Usage:

854K 221


Machine Control and Guidance Products
CAT DETECT (S/N: DTK1-UP)
CATDETECT-OBJECTDETEC (S/N: DTJ1-UP)
CATDETECT-VISIONONLY (S/N: DTL1-UP)
Wheel Dozer
844K (S/N: MBE1-UP; M4R1-UP; KLS1-UP; K4Y1-UP)
854K (S/N: 2211-UP; KK31-UP; RM31-UP; KK61-UP; RM61-UP; H9K1-UP; H8M1-UP)
Wheel Loader
990K (S/N: DJK1-UP; A9P1-UP; M9P1-UP; K9X1-UP)
992K (S/N: 8801-UP; KK21-UP; RM21-UP; KK41-UP; RM51-UP; H4C1-UP; ZMX1-UP)
993K (S/N: LWA1-UP; Z4D1-UP; Z8D1-UP; Z9K1-UP; RDM1-UP; MCZ1-UP; Z4Z1-UP; Z8Z1-UP)
994K (S/N: MM91-UP; MRK1-UP; SMX1-UP)

Introduction

This Special Instruction provides the installation of the object detection system on machines ordered with the vision only option from the factory. The machines must have a 459-2220 Monitor Display Gp installed inorder to run the object detection application software.

For additional camera installation refer to the Special Instruction, REHS9778, "Installation Procedure For Mounting Front Camera On Certain Cat® Products".

Each required parts second are specific to certain models and certain regions. Ensure that the object detection sensor is approved for the region the machine will operate in. For operation refer to Special Instruction, SEBU8838, "Cat® Detect Object Detection, Gen III System, Touch Screen.".

Important Safety Information

Do not perform any procedure in this Special Instruction until you have read this Special Instruction and you understand this information. Use only proper tools and observe all precautions that pertain to the use of those tools. Failure to follow these procedures can result in personal injury. The following procedures should be observed.

Work safely. Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs.

A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools to perform these functions properly.

Safety precautions and warnings are provided in this instruction and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.

Therefore, the warnings in this publication and the warnings that are on the product are not all inclusive. Ensure that any tool, procedure, work method, or operating technique you use that is not recommended by Caterpillar is safe.

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

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

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


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

Personal injury or death can result from 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 and level location that is away from working machines and personnel.

Ground all implements.

Engage the parking brake. Stop the engine.

Move the hydraulic control levers to all positions to release the pressure in the hydraulic system.

To avoid accidental engine starting, turn the battery disconnect switch to the OFF position. Remove the key for the battery disconnect switch. Use a secure padlock in order to lock the battery compartment access door.

Place a "Do Not Operate" tag at the Start/Stop switch location to inform personnel that the equipment is being worked on.


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

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


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

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

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


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

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


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

Failure to use an approved access system during installation and removal of components could result in slipping and falling which could result in personal injury or death. To prevent injury or death, use an approved access system to reach the appropriate mounting locations of the components. Do not climb on the machine. Maintain three-points of contact and/or use a safety harness.


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

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


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

Personal injury or death could result without observing the following information:

Environmental conditions, installation, and topographical factors can affect the proper operation of the object detection system. The following information must be considered.


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

Personal injury or death can occur from heavy components falling during removal or installation.

Properly support the component with a suitable lifting device during removal or installation.


  • Only mount the machine and dismount the machine at locations that have steps and/or handholds.

  • Inspect the steps and the handholds before mounting and dismounting. Clean the steps and the handholds, if necessary. Repair the steps and the handholds, if necessary.


Illustration 1g00037367

  • Face the machine when you are mounting and dismounting.

  • Maintain a three-point contact with the steps and the handholds. Three-point contact is maintained when two feet and one hand are in contact or one foot and two hands are in contact.

  • Never get on a moving machine or off a moving machine.

  • Never jump off the machine.

  • Do not try to climb on the machine or climb off the machine when you are carrying tools or supplies. Use a hand line to pull equipment up to the operators platform.

  • Do not use any of the controls as handholds as you are climbing into the machine or exiting the machine .

Note: Caterpillar recommends that each customer conducts a risk assessment for remote control operation and establish layers of protection in and around the area of the remote controlled machine and establish safe job site procedures. Examples may include personnel training, warning signs, and barricades.

Note: Prior to operation of the machine read the Operation and Maintenance Manual.

Prepare the Machine

Follow the below procedure to prepare the machine for the GNNS mast bracket installation:

  1. Park the machine on a hard level surface.

  2. Apply parking brake.

  3. Turn the engine key to the OFF position.

  4. Isolate the electrical system by turning the battery disconnect switch to the OFF position.


    Illustration 2g00104545

  5. Attach a "Do Not Operate" warning tag or a similar warning tag to the start switch or to the controls before you service the equipment. These warning tags are available from your Caterpillar dealer.

Required Tools

The tools required for mounting the radar are listed in Table 1.

Table 1
Part Number  Description 
222-3048  3/8 inch Impact Wrench 
222-3059  Air Ratchet 
  3/8 inch Extensions (Various Lengths) 
241-0860  Socket (10-MM) 
241-0862  Socket (13-MM) 
241-0870  Socket (5/8-IN) 
  Torx bits/wrenches (T15, T20, T45, T50) 
6V-6193  Diagonal Cutter 
6V-6194  Needle Nose Pliers 
4C-5877  Installer Tool 
1U-7574  Hex Wrench (3/32 INCH) 
1U-7576  Hex Wrench (5/32 INCH) 
  Small Screwdriver and Large Screwdriver 
4C-4200  Paint (YELLOW) 
4C-4030  Thread Lock Compound 
  Cat® Electronic Technician (Cat ET) 2015A or newer 

Required Parts

Note: A 340-7161 Power Converter must be installed to power the object detection sensors. This component may not be installed at the factory if depending on machine arrangement. Always check arrangement options, parts book, and verify 12 vdc power is available at the machine interface harness for the object detection sensors. The 340-7161 Power Converter may need to be ordered separately.

The required parts for the different machine models are listed in the following tables. Find the correct machine model and order the required parts from the appropriate list.

Table 2
994K Post Factory with C5 Object Detection Sensor 
Qty  Part Number  Description 
5P-1076  Hard Washer 
10  7K-1181  Cable Strap 
8T-4139  Bolt 
12  8T-4971  Bolt 
12  9X-2038  Washer 
12  198-4775  Hard Washer 
204-2281  Cable Strap 
363-7101  Bracket 
415-4840  Alarm Harness As 
416-8328  Object Detection Box Gp 
464-7684  Object Detection Sensor Gp 

Table 3
993K Post Factory with C5 Object Detection Sensor 
Qty  Part Number  Description 
5P-1076  Hard Washer 
7K-1181  Cable Strap 
8T-4139  Bolt 
12  8T-4971  Bolt 
12  9X-2038  Washer 
12  198-4775  Hard Washer 
363-7101  Bracket 
488-7389  Alarm Harness As 
416-8328  Object Detection Box Gp 
464-7684  Object Detection Sensor Gp 

Table 4
992K / 854K Post Factory with C5 Object Detection Sensor 
Qty  Part Number  Description 
4P-7428  Clip 
5P-1076  Hard Washer 
7K-1181  Cable Strap 
8T-4139  Bolt 
12  8T-4971  Bolt 
12  9X-2038  Washer 
132-5789  Clip 
12  198-4775  Hard Washer 
363-7101  Bracket 
369-7065  Wiring Harness 
416-8328  Object Detection Box Gp 
464-7684  Object Detection Sensor Gp 

Table 5
990K / 844K Post Factory with C6 Object Detection Sensor 
Qty  Part Number  Description 
5P-1076  Hard Washer 
7K-1181  Cable Strap 
8T-4139  Bolt 
12  8T-4971  Bolt 
12  9X-2038  Washer 
12  198-4775  Hard Washer 
363-7101  Bracket 
488-7389  Alarm Harness As 
416-8328  Object Detection Box Gp 
397-2994  Object Detection Sensor Gp 

Required Software and Configurations

Installation of the Object Detection system will require the Radar system supporting software installed in Object Detection display. Vision system software will not support the Radar system. Refer to SIS Web for the most recent software release. Display part numbers and software release versions are referenced below. Refer to Special Instruction, REHS7353, "Procedure for Installing Object Detection Software on Monitor Display Group" for instructions on flashing the display.

Note: To avoid software upgrade issues 502-4019 Engine Ratings Electronic Software Gp (Display Application Erase file) should be loaded onto the display prior to flashing the radar application file. Failure to do so can result in the flash failing and Cat® Electronic Technician (Cat ET) errors.

Table 6
Object Detection Version  Support  Flash File Part Number 
Display Application Erase  Application removal prior to software upgrade for the 459-2220 Monitor Display Gp, 441-5131 Display Module Gp, 373-2281 Display Module Gp (Electronic Control Groups)  502-4019 Engine Ratings Electronic Software Gp (.fl2) 
4.3  Rear Radar Systems Dec 2015  500-1693 Monitor Software Gp (.fl2) 
4.3.1  Rear Radar Systems Aug 2016  509-9962 Monitor Software Gp (.fl2) 
4.3.3  Rear Radar Systems Aug 2017  540-6791 Monitor Software Gp (.fl2) 

Installation Procedure

Installation of Object Detection Sensor into the 416-8328 Object Detection Box Gp

Follow the below procedure to install the object detection sensor into 416-8328 Object Detection Box Gp:



    Illustration 3g06255003
    994K Rear View
    (1) 416-8340 Outer Frame
    (2) 335-4416 Screw
    (3) 454-9630 Holder
    (4) 461-3288 Rivet

  1. Remove 416-8340 Outer Frame (1) by removing six 335-4416 Screws (2).

  2. Remove 454-9630 Holder (3).

  3. Install 397-2994 Object Detection Sensor Gp or 464-7684 Object Detection Sensor Gp into the holder.

  4. Insert 461-3288 Rivet (4) through the holder and into the object detection sensor.

  5. Route the sensor harness through the bottom of the enclosure and seal as required.

  6. Reinstall 454-9630 Holder (3).

  7. Reinstall 416-8340 Outer Frame using the six 335-4416 Screws (2).

Installation of the Object Detection Sensor Group to the Machine

Follow the below procedure to install the object detection sensor group to the machine:



    Illustration 4g06193570
    Typical example
    (1) Fan guard

  1. Remove six 8T-4185 Bolts securing the fan guard (1) to the loader.

  2. Remove fan guard (1). Set the fan guard (1) and 8T-4185 Bolts aside for reinstallation later.


    Illustration 5g06193571
    Sensor assembly
    (2) 416-8328 Object Detection Box Gp
    (3) 8T-4971 Bolt
    (4) 9X-6165 Washer
    (5) 363-7101 Bracket

  3. Attach the 416-8328 Object Detection Box Gp (2) to the 363-7101 Bracket (5) with four 8T-4971 Bolts (3), four 9X-6165 Washers (4), and four 198-4775 Hard Washers. Place the four 198-4775 Hard Washers between the 416-8328 Object Detection Box Gp (2) and the 363-7101 Bracket (5). The four 9X-6165 Washers (4) will be placed between the 8T-4971 Bolts (3) and the 363-7101 Bracket (5). Refer to Illustration 5.

    Note: Snug the bolts but do not fully tighten. After the installation is completed, final adjustments will be necessary.



    Illustration 6g06193572
    Sensor assembly mounting
    (5) 363-7101 Bracket
    (6) 5P-1076 Hard Washers
    (7) 8T-4139 Bolts
    (8) 8X-6102 Block

  4. Mount all three Sensor assemblies to the rear bumper of the loader. Attach the 363-7101 Bracket (5) to the 8X-6102 Block (8) on the rear bumper. Use two 8T-4139 Bolts (7) and two 5P-1076 Hard Washers (6). Refer to Illustration 6. Repeat Step 4 for the two remaining sensor assemblies.

    Note: Snug the bolts but do not fully tighten. After the installation is completed, final adjustments will be necessary.



    Illustration 7g06193603
    Right rear side of the rear bumper
    (9) Alarm Harness As
    (10) 7K-1181 Cable Straps
    (11) 7T-1099 Links

  5. Connect the RR-C1 connector of the Alarm Harness As (9) to the right rear sensor assembly. Route the remaining portions of the harness down the back side of the rear bumper to the other sensor assemblies. Attach the Alarm Harness As (9) to the 7T-1099 Links (11) on the rear bumper using 7K-1181 Cable Straps (10).


    Illustration 8g06193718
    Left rear side of the rear bumper
    (9) Alarm Harness As
    (10) 7K-1181 Cable Straps
    (11) 7T-1099 Links

  6. Connect the RR-C2 connector of the Alarm Harness As (9) to the center sensor assembly. Connect the RR-C3 connector of the Alarm Harness As (9) to the left rear sensor assembly. Attach the Alarm Harness As (9) to the 7T-1099 Links (11) on the rear bumper using 7K-1181 Cable Straps (10).


    Illustration 9g06193731
    Center of the rear bumper
    (9) Alarm Harness As
    (10) 7K-1181 Cable Straps

  7. Route the RR-C5 connector of the Alarm Harness As (9) through the opening in the rear grille. Attach the Alarm Harness As (9) to the 472-4092 Front Harness As using a 7K-1181 Cable Straps (10) as shown in Illustration 10.


    Illustration 10g06193739
    Left rear frame rail
    (9) Alarm Harness As
    (10) 7K-1181 Cable Straps
    (12) 8T-4195 Bolt
    (13) 8T-4121 Hard Washer
    (14) 204-8000 Cable Tie Mounting
    (15) RR-C5 of Alarm Harness As
    (16) R-C2 of 424-7106 Chassis Harness As

  8. Connect the RR-C5 connector of the Alarm Harness As (9) to the R-C2 of the 424-7106 Chassis Harness As (15). Secure the Alarm Harness As (9) to the 472-4092 Front Harness As using a 7K-1181 Cable Strap (10) just behind the RR-C5 connector. Attach a 204-8000 Cable Tie Mounting (14) to the left side frame using a 8T-4195 Bolt (12) and a 8T-4121 Hard Washer (13) as shown in Illustration 10. Secure the Alarm Harness As (9) to the 204-8000 Cable Tie Mounting (14) using a 7K-1181 Cable Strap (10).


    Illustration 11g06193742

  9. Reinstall the fan guard (1) using the hardware set aside in Step 2.

  10. To set the angle and azimuth refer to Section "Adjustment Angles of the Object Detection Sensors".

    Note: For additional information on radar adjustment refer to "Azimuth Adjustment Procedure" and "Elevation Adjustment Procedure" of UENR1274.

    Note: To check and set the angle, use a Magnetic Angle Finder or 437-4620 Protractor.

  11. Once the hardware installation is completed, software supporting the radars must be installed. Refer to SIS Web for the latest software. The latest software will be listed in the Object Detection software Service Magazine for the Cat touch screen display. The Object Detection serial number prefixes are S/N:DTK and ; S/N:DTJ. For Software Flashing Instructions refer to the Touch Screen Display section of Special Instruction, REHS7353, "Procedure for Installing Object Detection Software on Monitor Display Group".

Object Detection Sensor Location

Object Detection Sensor Location for different machine models are given in illustrations below:



Illustration 12g06255006
994K


Illustration 13g06255005
993K


Illustration 14g06255009
992K / 854K


Illustration 15g06255010
990K / 844K

Adjustment Angles of the Object Detection Sensors

After installation the sensor angles must be adjusted. The recommended values are listed in Table 7.

Table 7
Machine  Object Detection Sensor Name  Sensor Part Number  Radar Location 
Left Center  Right 
Angle (Down/Up) Azimuth (Left/Right) Angle (Down/Up) Azimuth (Left/Right)  Angle (Down/Up)  Azimuth (Left/Right) 
990K / 844K  C6  397-2994  6 Down  0 Down  6 Down 
992K / 854K  C4  365-1271  30 Down  5 Down  30 Down 
C5 464-7684  30 Down  5 Down  30 Down 
993K  C4  365-1271  30 Down  5 Down  30 Down 
C5 464-7684  30 Down  5 Down  30 Down 
994K  C4  365-1271  30 Down  10 Down  30 Down 
C5 464-7684  30 Down  10 Down  30 Down 

Configuration

After the software is installed, the configuration must be verified and adjusted as required by connecting with Cat ET through the CDL service port.

The following parameters should be reviewed:

Camera System

Camera 1 Location - Primary rear camera and the location must be set to "Rear".

Camera 2 Location - Optional front camera and the location must be set to "Front" if a second camera is connected.

Automatic Camera View Dimming Enable Status - This enables/disables the automatic reduction in screen brightness when the system is not in the active state. The states can be active (green status icon), stand-by (yellow status icon), or fault (red status icon). Refer to machine Operation and Maintenance Manual or Operation and Maintenance Manual, SEBU8838, "Cat® Detect Object Detection, Gen III System, Touch Screen".

Radar System

Object Detection Alarm Mode - Audible alarm type that will be played from the display based on detections. Object detection alarm mode can be set to "Continuous" or "Discrete". Continuous mode will alarm at the three most sever detection levels and will result in a constant tone for level five detections. Discrete mode will alarm in the two most sever detection zones and will only produce a short tones. Refer to machine Operation and Maintenance Manual or Operation and Maintenance Manual, SEBU8838, "Cat® Detect Object Detection, Gen III System, Touch Screen" for full details.

Object Detection System Radar Type Configuration Code - Sets the Object Detection Sensor radar communication. The three radar series use unique communication protocols. The default type will be the current factory installation. If the machine was built when an older version was the factory standard, this parameter will need to be adjusted. A key cycle is required for this value to be accepted. This value is only used for certain machine models now.

Note: This parameter is only available in version 4.3.1 and later software.

Note: Failure to configure the "Object Detection System Radar Type Configuration Code" properly will result in false diagnostics such as the 2348-09.

"Object Detection System Radar Type Configuration Code" parameters are listed in Table 8.

Table 8
Supported Object Detection System Radar Type Configuration Code Value in Cat ET  Number of Object Detection Sensors  Sensor Part Number  Machine Model  Cat ET Default 
30  3 - C4 Series  365-1271  990K / 844K  32 
31  3 - C5 Series  464-7684  990K / 844K  32 
32  3 - C6 Series  397-2994  990K / 844K  32 


Illustration 16g06255011
Example of a configuration parameters

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