Installation of Cat® Terrain Attachment Ready Option for Large Wheel Loaders and Large Wheel Dozers{7605} Caterpillar

Machine Control and Guidance Products:

TERRAIN GRADING (S/N: TFE1-UP)

TERRAIN LOADING (S/N: TFL1-UP)

TERRAIN OFFICE (S/N: TER1-UP)

Wheel Dozer:

854K (S/N: 2211-UP)

Wheel Loader:

992K (S/N: H4C1-UP)

993K (S/N: LWA1-UP)

994F (S/N: 4421-UP)

Introduction

This Special Instruction provides information for installing the Cat ^®Terrain for grading and loading hardware components on the listed large wheel loaders and large wheel dozers equipped with the Cat^® Terrain Attachment Ready Option (ARO).

The installation is separated into the following procedures:

• Monitor display installation

• Machine radio installation

• Satellite receiver installation

• Machine dimensions 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, SEBU8814, "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.

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

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Electrocution Hazard! Keep the machine and attachments a safe distance from electrical power. Stay clear 3 m (10 ft) plus twice the line insulator length. Read and understand the instructions and warnings in the Operation and Maintenance Manual. Failure to follow the instructions and warnings will cause serious injury or death

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

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Accidental engine starting can cause injury or death to personnel working on the equipment. To avoid accidental engine starting, disconnect the battery cable from the negative (−) battery terminal. Completely tape all metal surfaces of the disconnected battery cable end in order to prevent contact with other metal surfaces which could activate the engine electrical system. Place a Do Not Operate tag at the Start/Stop switch location to inform personnel that the equipment is being worked on.

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Personal injury or death can result from sudden machine movement. Sudden movement of the machine can cause injury to persons on or near the machine. Prevent possible injury by performing the procedure that follows before working on the machine. Move the machine to a smooth horizontal location. Move away from working machines and personnel and lower the bucket 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.

Illustration 1	g00037860

Use steps and handholds whenever you mount the machine. Use steps and handholds whenever you dismount the machine. Before you mount the machine, clean the step and the handholds. Inspect the step and handholds. Make all necessary repairs.

Face the machine whenever you mount the machine and whenever you dismount the machine. Maintain a three-point contact with the step and with handholds.

Note: Three-point contact can be 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

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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.

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 work tools 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 that are listed below are required to install Terrain for large wheel loaders and large wheel dozers.

• #30 Torx driver with 1/4" ratchet wrench and extension

• 10mm 1/4" drive socket

• 4mm Allen wrench

Parts Lists

The 389-0323 Terrain Installation Gp contains the satellite receiver, the monitor display, required hardware, 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.

The following groups are used:

New - 419-6931 Terrain Installation Gp

Upgrade - 419-6928 Terrain Installation Gp

The "Upgrade" group reuses the existing satellite receiver. The "New" group includes a new satellite receiver. The installation procedure is identical for both groups except for steps involving the satellite receiver.

The parts are listed in Table 1.

The following additional required parts are not included in the Installation Groups and are either provided with a new ARO or else retained from an uninstall of an existing D3:C4 Nav 10.4 Display:

• Four 8T-4136 Bolts

• Four 8T-4121 Hard Washers

Installing the Monitor Display

1. If installed, uninstall the "D3:C4 Nav 10.4 Display" from the 249-0872 Bracket .

   1. Remove the four bolts and washers from the sides of the bracket.

      Retain the bolts and washers for installation of the G610 Display. The shock mounts may be discarded.

   2. Disconnect the 70-pin plug and (if installed) the M12 Ethernet connector on the end of the blue cable from the D3:C4 Nav 10.4 Display.

      Note: If the blue Ethernet cable is to be reused, the M12 connector must be replaced with an RJ45 plug. Otherwise an appropriate Ethernet patch cable may be used to connect to the broadband radio.

2. Remove the existing hardware.

   1. Remove the 249-0872 Bracket from the D3:C4 Nav 10.4 Display that is on the "A" post. Remove the bracket by removing the five button-head machine screws and the hex head bolt.

      If the bracket is not installed, remove the fasteners from the "A" post and retain all fasteners for use in future steps.

   2. Remove the existing annunciator from the 249-0872 Bracket and disconnect the two wires from the annunciator.

      The wires will not be connected in the new harness and may either be taped back or left bare. The annunciator will not be used with the new monitor display and may be discarded.

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Illustration 2	g03227396

3. Take note of the positioning of the two bracket parts:
   • The 392-3608 Bracket mounts to the right of the G610 Display.

   • The 392-3609 Bracket mounts to the left of the G610 monitor display.

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Illustration 3	g03227398

4. Using the retained fasteners, mount the two brackets to the "A" post, as shown in Illustration 3.

   Note the position of the spacer, receptacle clips, and hex head bolt on the bottom-most fastener.

5. Connect the 70-pin receptacle of the 419-4111 Wiring Harness to the existing 70-pin connector of the D3:C4 Nav 10.4 Display plug.

   Use the 4mm Allen to tighten the receptacle.

6. Connect the 70-pin plug of the 419-4111 Wiring Harness to the G610 Display.

   Use the 4mm Allen to tighten the receptacle.

7. Connect the two 12-pin plugs that are closest to the 70-pin plug of the harness to the USB and CAN receptacles on the G610 Display.

   Note: The 12-pin plugs are keyed and only connect to the correct receptacles.

8. Connect the 12-pin receptacle of the 383-0333 Cable to the 12-pin "Radio" plug of the 419-4111 Wiring Harness .

9. Using one of the retained 12-pin receptacles from the bracket clip, fasten the other 12-pin plug marked "Service" into the clip receptacle. Secure the receptacle sliding the beveled slot onto the beveled flange of the clip.

10. Mount the G610 Display into the bracket assembly. Ensure that the wider border of the face of the monitor display is at the top.

    1. Route the harness behind the monitor display and the top of the dash panel.

    2. Using the four bolts and washers that were removed in Step 1.a, fasten the G610 Display to the bracket. Tighten the bolts to standard Caterpillar torque specifications.

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Illustration 4	g03227397

11. Connect the RJ45 plug of the broadband radio. Connect the plug from either the modified blue Ethernet cable or the new Ethernet patch cable into the RJ45 receptacle on the 383-0333 Cable .

12. If this Installation is a new ARO Installation and not an upgrade, install the 353-2794 Satellite Receiver on the 350-2748 Plate . This plate is mounted on the rear of the cab roof. Use the four 8T-4136 Bolts and 8T-4121 Hard Washers .

    1. To mount the bolts for the satellite receiver from the bottom of the 350-2748 Plate , first remove the plate from the roof of the cab.

    2. Ensure that the position of the connector of the satellite receiver allows the operator to see the LED indicators from within cab.

    3. Tighten the 8T-4136 Bolts to Caterpillar standard torque specifications.

    4. Reinstall the 350-2748 Plate in the original location.

    5. Connect the 3-pin plug of the 167-8984 Battery Gp (battery backup) to the 3-pin receptacle of the 337-5202 Control Harness (ROPS).

    6. Connect the 3-pin receptacle of the battery backup to the 3-pin plug of the ROPS harness.

    7. Connect the round connector of the ROPS harness to the satellite receiver.

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Illustration 5	g03221136

13. Turn the machine keyswitch to ON to apply power to the monitor display. The monitor display boots up and a "CAT" logo appears on the screen.

14. Complete the installation of the application software.

    ReferenceRefer to Special Instruction, REHS7228, "Installation and Configuration of the Cat^® Terrain v4.5 On-board Software".

Installing the Machine Radio

Illustration 6	g03005040
389-0333 Cable As (Radio) (1) P1 to main rear harness (2) P2 to Ethernet of customer supplied radio for power

A machine radio is not supplied with Terrain. The 389-0333 Cable As (Ethernet) connects to the rear main harness using a 12-pin (key D) connector (1). The opposite end of the radio harness employs a standard RJ-45 Ethernet connector (2) with power provided through the connector for a third-party radio.

Note: The 900x radio from previous CAES systems can be replaced by the Cyan radio. The radio, which is country-specific, is ordered separately.

The customer determines the location and mounting procedure for the radio. Suggested mounting procedures include:

• Utilizing existing light brackets (if equipped)

• Welding bosses to the machine and using a radio mounting bracket

• Mounting the radio inside the cab and mount an external antenna outside the cab

Ensure the following when choosing a mounting 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.

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

• Ground: 2-BK

Installing the Satellite Receiver

Perform the following Steps to install the 353-2794 Satellite Receiver .

Illustration 7	g03232837
(3) 253-2587 Plate (4) 8T-4137 Bolts (5) 8T-4121 Hard Washers

1. Locate the 253-2587 Plate (3) for the satellite receiver on top of the ROPS.

   Note: The plate is already mounted on the top of the ROPS. Ensure that the satellite receiver has an unobstructed view of the sky.

2. Remove the four 8T-4137 Bolts (5) and four 8T-4121 Hard Washers (6) to remove the plate from the top-rear of the ROPS. Save these parts. Refer to Illustration 7.

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Illustration 8	g03232937
(8) 353-2794 Satellite Receiver (GPS) (3) 253-2587 Plate (6) 8T-4136 Bolts (4) (7) 8T-4121 Hard Washers

3. Mount the satellite receiver onto the plate (3) using four 8T-4136 Bolts (6) and four 8T-4121 Hard Washers (7) .

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Illustration 9	g03232957
(8) 353-2794 Satellite Receiver (3) 253-2587 Plate (4) 8T-4137 Bolts (4) (5) 8T-4121 Hard Washers

4. Use the four bolts (4) and four hard washers (5) that were removed in Step 2 to mount the plate (3) on the top-rear of the ROPS. Refer to Illustration 9.

   Note: Tighten the bolts to Caterpillar standard torque specifications

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Illustration 10	g03232959
The configuration that is shown applies to 994K, 992K, and 854K machines. (8) 353-2794 Satellite Receiver (3) 253-2587 Plate (9) 263-7745 Control Harness

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Illustration 11	g03232960
The configuration that is shown applies to 993K machines. The 310-3449 Control Harness (10) is used on these machines. (3) 253-2587 Plate (10) Location of satellite receiver (11) 310-3449 Control Harness

5. Connect the control harness (11) to the satellite receiver (8) .

Setting the Language

The operator can use the user interface of the on-board software in either English, French, Spanish, Portuguese, or Swedish. The default is English. Enable one of the non-default languages using a line of code containing a language identifier from Table 2.

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. The on-board software receives these tasks in any language that the operating system supports.

To set the language of the user interface, add the following line to the startcaes.cmd file before running the file:

• SET lang=<language identifier>

Illustration 12	g02340196

The line must be added before the c:\caes\exe line. For example, to set the language of the user interface to Spanish, add the following line as shown in Illustration 12:

• SET lang=esp

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.

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

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

Performing the Dimension Measurements and Measure Up

1. Perform the calibration for the machine as listed in the specific section for your machine in ""Performing the Calibrations" ".

2. Open the MCU.

3. Select the machine name.

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

5. In the Menu Bar, select File > Send to Cat MineStar System.

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

7. 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

Illustration 13	g03231916
Phase center (12) on the satellite receiver

When a measurement refers to the phase center, the phase center (12) is located 12.8 cm (5.0 inch) (double-sided arrow) from the bottom of the satellite receiver.

ReferenceRefer to "Machine Dimensions" in the MCU Help for the following steps:

Calibrating Wheel Loaders

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Illustration 14	g03099718
Wheel loader machine dimensions

1. Measure the machine GPS receiver offsets.

   ReferenceRefer to Illustration 14, as a reference guide and template to record the machine dimensions.

   Note: The "X" measurement that is taken to the right of the centerline of the machine will be a positive number. The "X" measurement that is taken to the left of the centerline of the machine will be a negative number.

   Note: The "Y" measurement that is taken in front of the front axle will be a positive number. The "Y" measurement that is taken behind the front axle will be a negative number.

   1. GPS x: Measure the distance from the phase center of the receiver 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 (48) of the receiver (10) to the center of the front axle of the machine.

   3. GPS z: Measure the distance from the phase center (48) of the receiver (10) to the bottom of the wheels.

   4. Loader Bucket Width: Measure the width of the machine from the outside edges of the bucket.

   5. Loader Wheel Base: Measure the distance from the center of the front axle to the center of the rear axle.

   6. Loader Maximum Reach: Measure the distance from the center of the front axle to the front edge of the bucket.

   7. Loader Wheel Radius: Measure the distance from the center of one of the wheels to the outside edge the same wheel.

Calibrating Wheel Dozers

Illustration 15	g03231957
Wheel dozer machine dimensions

1. Measure the machine GPS receiver offsets.

   Refer to Illustration 15, as a reference guide and template to record the machine dimensions.

   Note: The "X" measurement that is taken to the right of the center line of the machine will be a positive number. The "X" measurement that is taken to the left of the center line of the machine will be a negative number.

   Note: The "Y" measurement that is taken in front of the front axle will be a positive number. The "Y" measurement that is taken behind the front axle will be a negative number.

   1. GPS x: Measure the distance from the phase center of the receiver to the centerline of the machine.

   2. GPS y: Measure the distance from the phase center of the receiver to the center of the front axle of the machine.

   3. GPS z: Measure the distance from the phase center of the receiver to the bottom of the wheels.

   4. Dozer Blade Position Measure the distance between the center of the blade to the center of the rear axle.

   5. Dozer Blade Width Measure the outside width of one blade.