Installation of Cat® Detect Object Detection for 854G, 854K, 992G, 992K, and 993K {1408, 7347, 7348} Caterpillar

Machine Control and Guidance Products

CAT DETECT (S/N: DTK1-UP)

Wheel Dozer

854G (S/N: AMP1-UP; A4W1-UP; 1JW1-UP)

854K (S/N: 2211-UP)

Wheel Loader

992G (S/N: 7HR1-UP; AZX1-UP; ADZ1-UP)

992K (S/N: H4C1-UP)

993K (S/N: Z9K1-UP)

Introduction

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

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

Important Safety Information

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

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

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

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

Therefore, the warnings in this publication and the warnings that are on the productare 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 productwill not be damaged or the productwill not be made unsafe by the operation, lubrication, maintenance, or repair procedures used.

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

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Be sure all personnel are clear of the equipment while the equipment is being lowered. Failure to stay clear of the equipment while the equipment is being lowered may result in personal injury.

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

Required Parts

854K/992K Radar and Vision

Table 1

Required Parts
Part Number	Description
462-5010	Monitor Kit
450-5316	Display Mounting Kit
462-2934	Object Detector Gp
393-6289	Object Detection Kit

Table 2

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

Table 3

Contents of the 450-5316 Display Mounting Kit
Quantity	Part Number	Description
2	7K-1181	Cable Strap
1	398-6859	Plate
4	114-6658	Washer
1	4P-7581	Clip
4	6V-5683	Bolt
1	8T-4224	Hard Washer
2	9X-2616	Screw

Table 4

Contents of the 462-2934 Object Detector Gp
Quantity	Part Number	Description
1	382-1568	Object Detection Wiring Gp
1	433-0585	Object Detector Gp
1	476-8709	Camera Wiring Gp

Table 5

Contents of the 382-1568 Object Detection Wiring Gp
Quantity	Part Number	Description
1	3E-5239	Relay As
40	7K-1181	Cable Strap
1	268-9063	Bracket As
1	279-0441	Plate As
1	283-0659	Cable As
1	290-0106	Bracket
1	367-3249	Cab Harness As
1	368-6732	Monitor Harness As
1	368-6733	Monitor Harness As
1	368-6734	Switch Harness As
1	368-6735	Wiring Harness
1	378-3617	Monitor Harness As
1	396-3529	Monitor Harness As
1	122-5855	Spacer
2	130-8360	Grommet
1	267-8828	Grommet
10	4P-7581	Clip
2	7X-7729	Washer
1	8M-2772	Clip
1	8S-7583	Grommet
8	8T-4121	Hard Washer
4	8T-4133	Nut
2	8T-4136	Bolt
3	8T-4186	Bolt
1	8T-6466	Bolt

Table 6

Contents of the 433-0585 Object Detector Gp
Quantity	Part Number	Description
1	345-7489	Monitor Harness As
1	422-6310	Monitor Software Gp

Table 7

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

Table 8

Contents of the 393-6289 Object Detection Kit
Quantity	Part Number	Description
1	369-7064	Object Detection Box Gp
1	433-0586	Object Detector Gp

854G/K&992G/K Vision Only

Table 9

Required Parts
Part Number	Description
462-5010	Monitor Kit
450-5316	Display Mounting Kit
462-2934	Object Detector Gp

Table 10

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

Table 11

Contents of the 450-5316 Display Mounting Kit
Quantity	Part Number	Description
2	7K-1181	Cable Strap
1	398-6859	Plate
4	114-6658	Washer
1	4P-7581	Clip
4	6V-5683	Bolt
1	8T-4224	Hard Washer
2	9X-2616	Screw

Table 12

Contents of the 462-2934 Object Detector Gp
Quantity	Part Number	Description
1	382-1568	Object Detection Wiring Gp
1	433-0585	Object Detector Gp
1	476-8709	Camera Wiring Gp

Table 13

Contents of the 382-1568 Object Detection Wiring Gp
Quantity	Part Number	Description
1	3E-5239	Relay As
40	7K-1181	Cable Strap
1	268-9063	Bracket As
1	279-0441	Plate As
1	283-0659	Cable As
1	290-0106	Bracket
1	367-3249	Cab Harness As
1	368-6732	Monitor Harness As
1	368-6733	Monitor Harness As
1	368-6734	Switch Harness As
1	368-6735	Wiring Harness
1	378-3617	Monitor Harness As
1	396-3529	Monitor Harness As
1	122-5855	Spacer
2	130-8360	Grommet
1	267-8828	Grommet
10	4P-7581	Clip
2	7X-7729	Washer
1	8M-2772	Clip
1	8S-7583	Grommet
8	8T-4121	Hard Washer
4	8T-4133	Nut
2	8T-4136	Bolt
3	8T-4186	Bolt
1	8T-6466	Bolt

Table 14

Contents of the 433-0585 Object Detector Gp
Quantity	Part Number	Description
1	345-7489	Monitor Harness As
1	422-6310	Monitor Software Gp

Table 15

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

993K Radar and Vision

Table 16

Required Parts
Part Number	Description
462-5010	Monitor Kit
462-2966	Display Mounting Kit
462-2935	Object Detector Gp
430-6102	Object Detection Kit

Table 17

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

Table 18

Contents of the 462-2966 Display Mounting Kit
Quantity	Part Number	Description
2	7K-1181	Cable Strap
1	398-6859	Plate
4	114-6658	Washer
1	4P-7581	Clip
4	6V-5683	Bolt
4	9X-2043	Screw

Table 19

Contents of the 462-2935 Object Detector Gp
Quantity	Part Number	Description
1	382-1572	Object Detection Wiring Gp
1	433-0585	Object Detector Gp
1	476-8709	Camera Wiring Gp

Table 20

Contents of the 382-1572 Object Detection Wiring Gp
Quantity	Part Number	Description
1	3E-5239	Relay As
40	7K-1181	Cable Strap
1	279-0441	Plate As
1	283-0659	Cable As
1	290-0106	Bracket
1	367-3249	Cab Harness As
1	368-6732	Monitor Harness As
1	368-6733	Monitor Harness As
1	368-6734	Switch Harness As
1	368-6735	Wiring Harness
1	378-3617	Monitor Harness As
2	130-8360	Grommet
10	4P-7581	Clip
2	7X-7729	Washer
1	8S-7583	Grommet
2	8T-4136	Bolt
2	8T-4224	Hard Washer

Table 21

Contents of the 433-0585 Object Detector Gp
Quantity	Part Number	Description
1	345-7489	Monitor Harness As
1	422-6310	Monitor Software Gp

Table 22

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

Table 23

Contents of the 430-6102 Object Detection Kit
Quantity	Part Number	Description
1	385-7564	Object Detection Box Gp
1	433-0586	Object Detector Gp

993K Vision Only

Table 24

Required Parts
Part Number	Description
462-5010	Monitor Kit
462-2966	Display Mounting Kit
462-2935	Object Detector Gp

Table 25

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

Table 26

Contents of the 462-2966 Display Mounting Kit
Quantity	Part Number	Description
2	7K-1181	Cable Strap
1	398-6859	Plate
4	114-6658	Washer
1	4P-7581	Clip
4	6V-5683	Bolt
4	9X-2043	Screw

Table 27

Contents of the 462-2935 Object Detector Gp
Quantity	Part Number	Description
1	382-1572	Object Detection Wiring Gp
1	433-0585	Object Detector Gp
1	476-8709	Camera Wiring Gp

Table 28

Contents of the 382-1572 Object Detection Wiring Gp
Quantity	Part Number	Description
1	3E-5239	Relay As
40	7K-1181	Cable Strap
1	279-0441	Plate As
1	283-0659	Cable As
1	290-0106	Bracket
1	367-3249	Cab Harness As
1	368-6732	Monitor Harness As
1	368-6733	Monitor Harness As
1	368-6734	Switch Harness As
1	368-6735	Wiring Harness
1	378-3617	Monitor Harness As
2	130-8360	Grommet
10	4P-7581	Clip
2	7X-7729	Washer
1	8S-7583	Grommet
2	8T-4136	Bolt
2	8T-4224	Hard Washer

Table 29

Contents of the 433-0585 Object Detector Gp
Quantity	Part Number	Description
1	345-7489	Monitor Harness As
1	422-6310	Monitor Software Gp

Table 30

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

Prepare the Machine

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Do not attempt to disassemble or assemble this machine until you read and understand the disassembly and assembly instructions. Improper disassembly and assembly procedures could result in injury or death.

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Sudden movement or accidental starting of the machine can cause personal injury or death to persons on or near the machine. To prevent personal injury or death, perform the following: Park the machine on a smooth level surface. Lower the blade and or attachments to the ground. Stop the engine and engage the parking brake. Block the wheels and install the steering frame lock. Turn the battery disconnect switch to the OFF position and remove the key. Place a Special Instruction, SEHS7332, "Do Not Operate" tag at the battery disconnect switch location to inform personnel that the machine is being worked on.

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Before service work is begun, park the machine on a hard level surface. Block the wheels of the machine so unexpected movement will not occur. Unexpected movement of the machine can cause personal injury or death.

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

Illustration 1	g02477941
(1) View of right-hand console located below window

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

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

3. Set the parking brake.

4. Turn the start switch and the disconnect switch to the OFF position.

5. Remove covers for electronics bay.

6. Remove the right-hand console cover and unbolt the console face.

7. Remove the right-hand rear post or C post cover.

8. Remove the HVAC console located behind the seat

9. Remove the HVAC / Radio console from the upper right side of the cab.

10. Remove the buddy seat cover and remove the slide stop bolt.

Note: If the machine is equipped with a WAVS system, the camera cables can be reused for the object detection system camera.

Installation Procedure

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

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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 kill. Read and understand the manufacturer's instruction and your employer's safety practices. Keep your head out of the fumes. Use ventilation, exhaust at the arc, or both, to keep fumes and gases from your breathing zone and the general area. Wear correct eye, ear and body protection. Do not touch live electric parts. Refer to the American National Standard Z49.1, "Safety in Welding and Cutting" published by the American Welding Society, 2501 N.W. 7th Street, Miami, Florida 33125: OSHA Safety and Health Standards, 29 CFR 1910, available from U.S. Dept. of Labor, Washington D.C. 20210.

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NOTICE
Before carrying out arc welding on the machine or on any equipment attached to the machine, disconnect all power and ground leads from the batteries in order to avoid possible damage to electronic components.

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

993K Display Bracket

1. If the machine is equipped with a WAVS system, remove the display and display mounting bracket from the cab.

2. Locate the four bosses on the A-post.
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   Illustration 2	g06125596
   (2) 370-4178 Bracket (3) 9X-2043 Screws

3. Attach the 370-4178 Bracket (2) to the A-Post using the four 9X-2043 Screws (3) and four 9X-2038 Washers.

992/854/993G Display Bracket

1. If the machine is equipped with a WAVS system, remove the display and display mounting bracket from the cab.
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   Illustration 3	g02460857

2. Locate the two weld bosses in the front right or A pillar of the ROPS. The bosses are located as shown in Illustration 3.
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   Table 31

   Call out	Approximate Dimension
   A	180 mm (7.1 inch)
   B	21.74 mm (0.856 inch)
   C	33.5 mm (1.32 inch)

   Note: If the machine does not already have the weld bosses, use Illustration 3 and Table 31 to find the locations of the two M8 by 1.25mm bosses. Weld the bosses into position.

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   Illustration 4	g02460936
   (4) 398-6859 Plate (5) 8T-4224 Hard Washers (6) 9X-2040 Screws

3. Attach the bracket (4) to the ROPS pillar using two screws (6) and two washers (5).

Display Mounting

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Illustration 5	g02460824
(7) 361-2256 Bracket (8) 355-9048 Monitor Display Gp

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Illustration 6	g02460828
(9) 096-6166 Hard Washers

1. Attach the display (8) to the bracket (7) using the four washers (9) and provided bolts.

Sensor Mounting

Note: These instructions are for full kits only. Object detection sensors are not included in vision only kits.

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

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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 kill. Read and understand the manufacturer's instruction and your employer's safety practices. Keep your head out of the fumes. Use ventilation, exhaust at the arc, or both, to keep fumes and gases from your breathing zone and the general area. Wear correct eye, ear and body protection. Do not touch live electric parts. Refer to the American National Standard Z49.1, "Safety in Welding and Cutting" published by the American Welding Society, 2501 N.W. 7th Street, Miami, Florida 33125: OSHA Safety and Health Standards, 29 CFR 1910, available from U.S. Dept. of Labor, Washington D.C. 20210.

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NOTICE
Before carrying out arc welding on the machine or on any equipment attached to the machine, disconnect all power and ground leads from the batteries in order to avoid possible damage to electronic components.

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

Illustration 7	g02454697
(10) 8X-6102 Blocks

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Illustration 8	g02454800
(10) 8X-6102 Block

1. Remove and cut out the plates or grind off the high points so the blocks (10) will sit level.

   Note: The bottom edges of the middle weld block might need to be ground in order to sit level on the bumper.

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   Illustration 9	g02454723
   (10) 8X-6102 Blocks

2. Weld the three blocks (10) to the bumper in the locations shown in Illustration 9 and dimensions in Table 32.
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   Table 32

   Callouts	Dimensions
   D	92.5 mm (3.64 inch)
   E	217.5 mm (8.56 inch)
   F	770 mm (30.3 inch)
   G	925 mm (36.4 inch)

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   Illustration 10	g02454800
   (10) 8X-6102 Block

3. Paint the blocks (10).
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   Illustration 11	g02460538
   (10) 8X-6102 Blocks (11) 363-7101 Brackets (12) 8T-4139 Bolts (13) 5P-1075 Hard Washers

4. Attach the brackets (11) to the blocks (10) using two bolts (12) and two washers (13) per bracket and block pair.
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   Illustration 12	g02455039
   Grill to be removed shown in red

5. Remove the lower grill shown in Illustration 12.
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   Illustration 13	g02455057
   (14) 310-1898 Clip (15) 4P-7429 Clip

6. Attach the clips (14), (15) in the locations shown in Illustration 13.

Rear Harness

Note: These instructions are for full kits only. Object detection sensors are not included in vision only kits.

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Illustration 14	g02455057
(14) 310-1898 Clip (15) 4P-7429 Clip

1. Begin routing the 367-6288 Chassis Harness As at the rear of the machine. Leave enough harness that the wires connecting to the object detection sensors will not be under stress. Attach the 367-6288 Chassis Harness As to the ladder clips (14), (15) using the supplied tie straps.
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   Illustration 15	g02460760
   (16) Harness routing location (harness not shown in this Illustration)

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   Illustration 16	g02460639
   (17) 367-6288 Chassis Harness As

2. Continue routing the chassis harness going above the frame in the area (16) shown in Illustrations 15 and 16. Follow along the existing harness in this location using tie straps to secure the chassis harness (17) to the existing harness.
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   Illustration 17	g02460619
   (A) Detail Area

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   Illustration 18	g02460657
   Detail view A (18) Cover

3. Follow the existing harness. Remove cover (18) from the machine. The cover location is shown in Illustrations 17 and 18.
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   Illustration 19	g02460658
   Detail view A with cover removed

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   Illustration 20	g02455077
   (17) 367-6288 Chassis Harness As

4. Route the chassis harness (17) along the main harness up towards the cab of the machine. Use tie straps to secure the chassis harness (17) to the machine main harness.
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   Illustration 21	g02478278
   (17) 367-6288 Chassis Harness As (19) 368-6733 Monitor Harness As

5. Continue routing the chassis harness (17) up to the electronics bay on the right-hand side of the machine. Drill two 38.1 mm (1.50 inch) holes in the electronics bay wall in the approximate locations shown in Illustration 21.

6. Install the bulk head connector into the electronics bay wall in the right side hole drilled in Step 5. Use tie straps to secure the excess harness (if any exists) to the itself to avoid damage and entanglement.

Camera Cable

If the machine is not equipped with a WAVS system, use this section to install and route the camera cable. WAVS camera cable can be reused if it is in good working order.

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Illustration 22	g02479517
(20) 274-4478 Cable As (shown attached to existing harness with slack to attach to the camera when installed)

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Illustration 23	g02455279
(20) 274-4478 Cable As

1. Starting at the rear of the machine, route the cable (20) to the right side of the hood following the existing harness, shown in Illustration 22, down to the frame. Leave enough slack to connect with the camera on the bracket that will be installed in the "Camera Mounting" section of this manual. Follow the existing harness up to the cab connector as shown in Illustration 23. Attach cable (20) to main harness using tie straps.
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   Illustration 24	g02455316
   (21) Compartment (shown with door removed)

2. Route the camera cable (20) up underneath the cab and into the compartment (21) with a small access door just below the secondary cab exit on the right-hand side. There are two holes in the cavity, the top one will be used for the camera cable. Attach the camera bulk head connector to the top hole.
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   Illustration 25	g02480058
   (22) 251-8248 Communication Cable As

3. Connect the cab camera cable (22) to the bulk head connector and route the cable (22) through the pass through in the side compartment (21), into the cab.
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   Illustration 26	g02432816
   Camera Cable Routed with Existing Harness (22) 251-8248 Communication Cable As

4. Follow the existing harness in the rear right corner of the cab. Using 7K-1181 Cable Straps, secure the cable (22) to the existing harness.
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   Illustration 27	g02485206
   (22) 251-8248 Communication Cable As (23) 319-6827 Sensor Harness As

5. Continue routing the cable (22) up along the cab ceiling. Connect the adapter harness (23) to the cable (22). Route the harness (23) to the 355-9048 Monitor Display Gp (8).

6. Connect the harness (23) to the 355-9048 Monitor Display Gp (20).

Electronics Bay and Cab Harness

Illustration 28	g02478278
(17) 367-6288 Chassis Harness As (19) 368-6733 Monitor Harness As

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Illustration 29	g02478256
This Illustration is an example, some machines may differ (19) 368-6733 Monitor Harness As (from electronics bay to cab) (24) CDL Junction block (25) Power Relay (26) Ground Stud (28) Hole for rear harness bulk head (29) Power Convertor location

1. Locate a suitable place to mount the 340-7161 Power Converter inside the electronics bay and install the power convertor. An example location (29) is shown in Illustration 29.
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   Illustration 30	g02478319
   (19) 368-6733 Monitor Harness As (Cab harness from electronics bay to cab) (30) Rear Object Detection bulk head connector

2. Install the 368-6732 Cab Harness As into the electronics bay and connect the 368-6732 Cab Harness As to the bulk head connector (30).

3. Connect the 368-6732 Cab Harness As to the 340-7161 Power Converter using the appropriately labeled connector.
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   Illustration 31	g02481816

4. Connect the 368-6732 Cab Harness As to the CDL junction block. For 854 and 992 machines, install the wire 892-CD1-BR(Brown)into pin 1 of Junction Block 1. Install wire 893-CD2-GN(Green)into pin 1 of Junction Block 2.

   For 993 machines, install the wire 892-CD1-BR(Brown)into pin 20 of the MC-C46 connector (Transmission J1 connector). Install wire 893-CD2-GN(Green)into pin 10 of the MC-C46 connector (Transmission J1 connector).

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   Illustration 32	g02479437

5. Connect 109-P1-RD(Red)to the 106-RD(Red)(unswitched) side of the main relay. Connect 308-P3-YL(Yellow)to the 112-PU(Purple)(switched) side of the main relay. Connect the ground wire to the ground stud (26) located in the electronics bay.
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   Illustration 33	g02477920
   (19) 368-6733 Monitor Harness As

6. Drill a hole large enough (approximately 38.1 mm (1.50 inch) to pass the 368-6733 Monitor Harness As (19) through in the right rear corner of the cab.

   Note: Be careful to drill only the intended material and not to damage any other components or wires.

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   Illustration 34	g02477931
   (19) 368-6733 Monitor Harness As

7. Connect the 368-6733 Monitor Harness As (19) to electronics bay harness by feeding the connector through the left-hand hole that was drilled in Step 5 of "Rear Harness" and then connecting it. Install the 7Y-8169 Grommet into the hole to protect the harness.
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   Illustration 35	g02485317

8. Route the rest of the 368-6733 Monitor Harness As (19) up through the access hole that was drilled and inside the cab. Follow the existing harness in the rear right corner of the cab. Using 7K-1181 Cable Straps to secure the monitor harness (19) to the existing harness. Install two 7Y-8169 Grommets into the cab access hole.
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   Illustration 36	g02485421
   (19) 368-6733 Monitor Harness As

9. Continue routing the 368-6733 Monitor Harness As (19) up along the cab ceiling to the 355-9048 Monitor Display Gp (8).

10. Connect the 368-6733 Monitor Harness As to the 355-9048 Monitor Display Gp (8).

Object Detection Sensor Mounting

Note: These instructions are for full kits only. Object detection sensors are not included in vision only kits.

Illustration 37	g02477982

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Illustration 38	g02485424
(31) 5P-4116 Hard Washers (32) 8T-4971 Bolts (33) 198-4775 Hard Washers (34) 8T-4139 Bolts (35) 5P-1075 Hard Washers

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Illustration 39	g02434857
View of 340-0575 Object Detection Sensor Gp

1. Install three 340-0575 Object Detection Sensor Gp onto the three brackets using four 8T-4971 Bolts (32), 5P-4116 Hard Washers (31), 198-4775 Hard Washers (33). The window on the object detection sensors should be facing outwards to the area behind the machine.

2. Connect the object detection sensors to the harness.

Assemble the Camera

Illustration 40	g02461122
(36) Nuts (37) Screws (38) Camera Brackets (39) Screw (40) Camera (41) Nut

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

   Refer to Illustration 40.

   Note: Do not tighten the nuts (36). The nuts will be used in the following procedure in order to attach the camera to the bracket for the camera.

Camera Mounting

Note: If the machine is equipped with a WAVS system, the camera cable may be reused for the object detection system if the cable is in working order.

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Illustration 41	g02455217
Cut out decal place as shown

1. Inorder to mount the object detection system camera, a cut out must be made in the rear decal plate located at the top of the grill in the back of the machine. Use Illustration 41 and Table 33 for details on cutting the decal plate.

   Note: Not all machines are equipped with a decal plate like the one shown in Step 1.

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   Table 33

   Callouts	Dimensions
   H	822.5 mm (32.38 inch)
   I	205 mm (8.1 inch)
   J	35 mm (1.4 inch)

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   Illustration 42	g02455178
   Bottom view of camera mounting (42) 279-0441 Plate As

2. Position the 279-0441 Plate As (42) in the position shown in Illustration 42. Attach the 279-0441 Plate As (42) to the machine with welds (W1) along the edges where material allows as shown in Illustration 42.
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   Table 34

   Weld Specifications
   Weld	Specifications
   W1	5 mm (0.20 inch) Fillet Weld

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   Illustration 43	g02460696
   (36) Camera Nuts (43) 290-0106 Bracket (44) 8T-4136 Bolts (45) 7X-7729 Washers

3. Bolt the 290-0106 Bracket (43) to the plate (42) using two 8T-4136 Bolts (44) and two 7X-7729 Washers (45).

4. Attach the camera to the 290-0106 Bracket (43) using the two nuts (36) that were installed on the camera in "Assemble the Camera".
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   Illustration 44	g02461118
   (20) 274-4478 Cable As (46) 8S-7583 Grommet

5. Install the 8S-7583 Grommet (46) into the plate as shown in Illustration 44. Route the cable (20) through the bracket (42) and 8S-7583 Grommet (46) as shown in Illustration 44 and plug the camera cable (20) into the camera (40).

Reassemble Machine

1. Install any components onto the machine that were previously removed for installation of the object detection system.

Adjust the Object Detection Sensors

Note: These instructions are for full kits only. Object detection sensors are not included in vision only kits.

There are two angle adjustments for the object detection sensors. The adjustments are the azimuth or horizontal adjustment and the elevation or the vertical adjustment. The angles that are provided in Table 35 are the angles that were found to work best.

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

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

Table 35

993/992/854 Object Detection Sensor Angles
Left and Right Rear Object Detection Sensors		Middle Rear Object Detection Sensor
Azimuth (deg)	Elevation (deg)	Azimuth (deg)	Elevation (deg)
0	30 down	0	10 down

Azimuth Adjustment Procedure

Note: These instructions are for full kits only. Object detection sensors are not included in vision only kits.

Table 36

Required Tools
Tool	Quantity
13 mm Wrench	1
Protractor	1

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Illustration 45	g02486199

1. Loosen the two azimuth adjustment bolts (47) on the brackets for the object detection sensors.

2. Use a protractor in order to set the proper azimuth angle or adjust the angle to fine-tune the system. Refer to the angles listed in Table 35.

3. Carefully tighten the two azimuth adjustment bolts (47) on the brackets for the object detection sensors.

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

5. Proceed to the "Elevation Adjustment Procedure".

Elevation Adjustment Procedure

Note: These instructions are for full kits only. Object detection sensors are not included in vision only kits.

Illustration 46	g02486239
(48) Elevation adjustment bolts for object detection sensor

Table 37

Required Tools
Tool	Quantity
10 mm Wrench	1
Inclinometer or Digital Level	1

1. Loosen the four adjustment bolts (48) on the bracket for the object detection sensor.

2. Use an inclinometer or a digital level in order to set the proper elevation angle or adjust the angle to fine- tune the system. Refer to the angles that is listed in Table 35.

3. Carefully tighten the four azimuth adjustment bolts (48) on the brackets for the object detection sensors.

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

Camera Adjustment Procedure

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

• View of an object on the ground 12 m (40 ft) behind the bumper of the machine.

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

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

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

• Cover any safety messages or other important information.

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

• Obstruct the visibility of the operator.

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

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

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

Flash the Software onto the Display

The display is shipped without the application software installed. Use the following procedure in order to flash the application software into the display.

Required Material

• Caterpillar Electronic Technician Cat (ET).

• Communication Adapter 2.

• 345-7489 Monitor Harness As.

• Software from SIS web Service Software Files. Refer to Table 38 for more information.

Software

Table 38

Part Number	System	Notes
368-0289	Object Detection System	Radar and Vision
368-0290	Object Detection System (Vision Only)	Vision

Perform the following procedure in order to flash program the ECM. The ECM is flashed in order to upgrade the software. Flash programming of the ECM must be done if the ECM has been replaced. Caterpillar Electronic Technician (Cat ET) contains the program WinFlash. WinFlash is used in order to load the software into the ECM.

Procedure

1. Ensure that the key start switch and the disconnect switch are in the OFF position.

2. Disconnect the center 12-pin connector from the display.

3. Connect the 345-7489 Monitor Harness As between the system harness for the display and the center connector on the display.

4. Connect the 7X-1425 Data Link Cable As between the 7X-1700 Communication Adapter Gp and Cat ET.

   Note: The 345-7489 Monitor Harness As will no longer allow Cat ET to flash the display. Keep the 345-7489 Monitor Harness As as a service tool in case the display is replaced.

5. Connect the 139-4166 Data Link Cable As between the 7X-1700 Communication Adapter Gp and the diagnostic connector of the 345-7489 Monitor Harness As.

6. Use WinFlash in order to load the software.

7. Disconnect the 345-7489 Monitor Harness As from the system harness for the display and the center connector on the display.

8. Connect the 12-pin connector of the system harness to the center connector of the display.

9. Turn the disconnect switch and the key start switch to the ON position.

10. Verify that the display turns on and the object detection system starts. Refer to the "System Information" section of this manual in order to ensure that the system is operating properly.

Calibrate the Object Detection Sensors

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

• Initial installation of the Cat Detect object detection system

• Any of the object detection sensors were replaced.

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

This procedure is used in order to validate that the object detection sensors for the system have been installed and adjusted correctly. The procedure will utilize a target. The target will be used in order to explore the limits of object detection sensor coverage.

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

Table 39

Test Equipment	Quantity
Digital Level	1
Survey Paint	1
Person	1
Two-way Radios	2
50 foot tape measure	1

Machine Preparation

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

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

2. Set the parking brake.

3. Turn the disconnect switch to the ON position

4. Start the machine.

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

6. While the machine is parked in the large wide open area check for any surrounding obstacles like bumps, and so on, by observing the display for any flashing areas in the radar detection area. The situations that are listed in Table 40 can cause false targets to be detected and are listed in order of precedence:
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   Table 40

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

Calibration Procedure

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

• Rear

Rear of the Machine

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

• 1 m (3 ft)

• 1.5 m (5 ft)

• 3 m (10 ft)

• 6 m (20 ft)

• 9 m (30 ft)

• 12 m (40 ft)

• 15 m (50 ft)

The object will be moved close to the machine and parallel to the rear of the machine and the display is checked for the object detection. The object will then be moved perpendicular to the rear of the machine as shown in Illustration 47. The object should start close to the machine for the first pass and work away from the machine with each successive pass. Stop the passes once the object is no longer detected.

Illustration 47	g02408498
Testing the object detection coverage area at the rear of the machine

The person in the cab of the machine will inform the person moving the object when to mark the coverage start/stop point. The start/stop points must be marked when the object first appears or first disappears from radar coverage on the display. The designated reference point for the rear radar will be the center of the machine. The distance from the initial perpendicular detection must be measured and should be approximately 1 m (3.3 ft) from the rear of the machine. Refer to Illustration 48.

Illustration 48	g02477456

If the detection area is not approximately 12 m (40 ft) long by 12 m (40 ft) wide, or the coverage area contains holes, adjust the angles of the brackets for the object detection sensors. Refer to the "Adjust the Object Detection Sensors" section of this manual for additional information regarding the adjustment of the brackets.

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

Operate the machine to determine if additional adjustment is required.

System Information

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

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

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

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

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

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

Effects on System Operation

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

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

Environmental - Weather conditions such as rain, snow, and sleet can create road conditions that may cause mud to build up on the face of the object detection sensor. The moisture in the mud can reduce the effectiveness of the coverage of the object detection sensor. The mud absorbs the RF energy that is emitted by the object detection sensors. If an accumulation of mud is observed on the object detection sensors, then clean the surface of the sensor. Refer to the Operation and Maintenance Manual, SEBU8624, "Object Detection Sensor - Clean/Inspect" manual for addition information on how to clean the sensors.

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

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

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

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

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

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

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

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

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

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

Power ON/OFF

Illustration 49	g03798907
Object Detection as the system feature set.

Power is supplied to the system when the operator turns the machine keyswitch to the ON position. A screen similar to Illustration 49 appears. The screen contains the CAT logo and the system feature set available with the software installed. The system feature set will read either "Vision" or "Object Detection".

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

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

Illustration 50	g03406276

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

Illustration 51	g03406367
System Status Indicator

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

• The system status indicator will turn green.

• The cameras will be active.

• The proximity bar will be active.

Note: Ensure that the model of machine listed to the right of the "Zone Directional Radar Indicator" matches the machine that is being operated. If the correct machine does not appear, contact your Cat dealer or refer to the Special Instruction or System Operations manual. Refer to Illustration 51.

If the self-test fails, the system status indicator will turn red, the camera screens will be active, and the object detection sensor screen will be disabled. If the self-test fails, contact your Cat dealer or refer to the Special Instruction or System Operations manual.

Display Navigation

Illustration 52	g03406762
(1) Camera View (2) Alarm Acknowledge Button (3) Reference Line Button (4) System Menu Button (5) Alarm Acknowledged Indicator (6) Indicator for the System (7) Proximity Indicator Bar (8) Product ID (9) Zone Directional Indicator

Display Buttons

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

Back - Used to return to the previous menu.

Home - Used to return to the main screen.

Scroll Up - Used to scroll up through choices

OK - Used to lock choice of selection

Scroll Down - Used to scroll down through choices

Reference Line Button - Toggles the reference line on and off

Day Mode - Used to activate display brightness for day use

Night Mode - Used to activate display brightness for night use

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

Manual Brightness Increase - Used to adjust brightness up manually

Manual Brightness Decrease - Used to adjust brightness down manually

Illustration 53	g03408324

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

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

Illustration 54	g03408355
Day Mode Screen Selected

Illustration 55	g03408357
Manual Brightness Screen (10) Manual Decrease Adjustment Button (11) Manual Increase Adjustment Button

Illustration 56	g03408361
Night Mode Screen Selected

System Configuration

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

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

• Display

• System Information

• Settings

• Diagnostics

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

Navigation between parameters is accomplished by pressing the top and bottom parts of the arrows button. Any changes that are made to parameters will not become active until the operator has pressed the "OK" button to exit the edit mode. An example of the configuration screen is shown in Illustration 57.

Illustration 57	g03408448

Illustration 57 shows the view that appears on the display when the configure screen is accessed for the first time. The "Change Settings" box will be located opposite the "OK" button to indicate the purpose of the button. The "Change Screens" box will be located opposite the tab button to indicate the purpose of the button.

Configure Parameters

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

Illustration 58	g03408477

Display consists of language selection and brightness selection. Refer to Illustration 58

Illustration 59	g03408526
System Information Screen

System Information provides the following information:

• Machine Model

• Product ID

• Software Version

• OS Version

• SW Release Date

• Unit Serial Number

• Hardware P/N

• System Hardware Description

Illustration 60	g03408536
Settings Selection Screen

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

• Auto Dim

• Alarm Mode

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

Illustration 61	g03408552
Diagnostics Selection Screen

Illustration 62	g03408558
Diagnostics Signal Page

Illustration 63	g03408581
Diagnostics Detail Screen

In the display screen, language is an option. To change the language, select "Language". Refer to illustration 58.

Illustration 64	g03408478
Language Screen

The display supports the following list of languages:

• English

• French

• Indonesian

• Portuguese

• Spanish

Refer to Illustration 64.

Illustration 65	g03408468
Setting Selection Screen

Under the setting screen, select "Auto Dim". Refer to Illustration 65. The auto dim feature will reduce the display and video brightness by one third of the current brightness setting. When night mode is selected, the system will stop providing video and the entire screen will be dimmed.

Illustration 66	g03408480

Auto dimming can be either "Enabled" or "Disabled". Refer to Illustration 66.

Illustration 67	g03408469

Under the setting screen, select "Alarm Mode". Refer to Illustration 65 The "Object Detection Alarm Mode" parameter configures the audible alarm mode. The alarm mode will be "Continuous" by default. "Discrete" alarming can be selected to reduce the length of audible alarming.

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