Installation of G610 Hardware for Cat® Terrain for Hydraulic Front Shovels{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)

Introduction

This Special Instruction provides information for installing the following Cat^® Terrain for grading and loading hardware components on hydraulic front shovels:

• 389-0329 Terrain Installation Gp

• 389-0345 Electronics Gp

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

The installation includes the following procedures:

• Receiver installation

• Angle sensor installations

• Pressure switch installation

• Machine radio installation

• Display module installation

• Battery backup installation

• Power supply wiring and fuse installation

• Harness installations

• Optional alarm installation

• Calibration and measure-up procedures

Operation and Maintenance Manual

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

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

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

Important Safety Information

Work safely. Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools to perform these functions properly.

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

When a tool, procedure, work method, or operating technique that Caterpillar does not recommend is used, ensure that you and others are safe during use. Additionally, ensure that the product will not be damaged or made unsafe by the operation, lubrication, maintenance, or repair procedures that are used.

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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.

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Personal injury or death can result from fumes, gases and ultraviolet rays from the weld arc. Welding can cause fumes, burn skin and produce ultraviolet rays. Keep your head out of the fumes. Use ventilation, exhaust at the arc, or both, to keep fumes and gases from your breathing area. Wear eye, ear and body protection before working. Protect yourself and others; read and understand this warning. Fumes and gases can be dangerous to your health. Ultraviolet rays from the weld arc can injure eyes and burn skin. Electric shock can cause death. Read and understand the manufacturer's instructions and your employer's safety practices. Do not touch live electrical parts. See "American National Standard Z49.1, Safety in Welding and Cutting" published by the American Welding Society. American Welding Society 2501 N.W. 7th Street Miami, Florida 33125 See "OSHA Safety and Health Standards, 29 CFR 1910", available from U.S. Department of Labor. U.S. Department of Labor Washington, D.C. 20210

Illustration 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 that is smooth, level, and out of direct sunlight.

2. Move away from other working machines and personnel.

3. Lower the bucket to the ground.

4. Stop the engine.

5. Engage the machine brake.

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

Required Tools

The tools that are listed in Table 1 are required to install Terrain on hydraulic front shovels. The list contains the recommended Caterpillar service tools, as well as general-purpose tools with no specified part number.

Table 1

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

Parts Lists

The 389-0345 Terrain Electronics Ar contains two receivers, the display, and a USB memory module. The USB memory module contains files for the monitor operating software, system documentation, and a schematic diagram of the system.

Table 2

Contents of the 389-0345 Terrain Electronics Ar
Part Number	Part Name	Notes
353-2794	Satellite Receiver	MS992 receiver (2 each)
392-9004	USB Memory Module	Contains operational files and documentation
439-4341	Display Module	G610 display module with loaded operating system

The 389-0329 Terrain Installation Ar contains the four kits that are listed in Table 3. Use these kits during the installation of the Terrain system. Tables 4 through 7 describe the contents of the kits.

Table 3

Contents of 389-0329 Terrain Installation Ar
Part Number	Part Name	Notes
167-8604	Monitor Mounting Gp	Dash mounting group for display
291-2179	Receiver Mounting Gp
389-0332	Monitor Mounting Gp	Display mounting group
389-0342	Wiring Gp

Table 4

Contents of 167-8604 Monitor Mounting Gp
QTY	Part Number	Part Name	Notes
4	0S-0509	Bolt	3/8-16
1	147-3417	Mount	Ceiling or dash mount
4	3Y-7829	Boss	Weld, 3/8-16
4	5M-2894	Hard Washer
4	8X-7422	Boss	Weld, 3/8-16

Table 5

Contents of 291-2179 Receiver Mounting Gp
QTY	Part Number	Part Name	Notes
6	5D-0353	Bolt
6	6V-8801	Nut
8	7X-0346	Bolt
8	7X-0448	Nut
8	8M-2770	Clip
4	8T-4121	Hard Washer
8	8T-4122	Hard Washer
4	8T-4195	Bolt	M10
12	8T-4896	Hard Washer
1	146-0841	Plate
1	289-9630	Plate

Table 6

Contents of 389-0332 Monitor Mounting Gp
Qty	Part Number	Part Name	Notes
4	4M-5282	Bolt	1/4-20 Display bracket to Dash bracket
6	7K-1181	Cable Strap
8	8C-5607	Isolation Mount
4	8C-5608	Spacer
4	8T-4205	Hard Washer	Display to bracket
4	8T-9364	Bolt	1/4-20 Display to bracket
4	9X-6165	Washer	Display bracket to Dash bracket
2	130-5300	Clip
1	383-3032	Bracket

Table 7

Contents of 389-0342 Machine Wiring Gp (Terrain)
QTY	Part Number	Part Name	Notes
4	2L-8067	Terminal
4	2L-8071	Terminal
4	2L-8079	Terminal
2	3S-8665	Clip	Harness
3	5P-6264	Grommet
27	8M-2773	Clip
4	8T-0325	Bolt	M5 For battery
4	8T-0328	Hard Washer	For battery
1	167-8703	Wire	Power supply
1	167-8984	Battery
1	265-8147	Wiring Harness	Fuse
1	278-7396	Wire
1	285-6651	Wiring Harness
	285-6655	Chassis Harness As	Chassis
1	285-6657	Wiring Harness	Receiver jumper
1	383-3027	Wiring Harness	Main front
1	383-3028	Wiring Harness	Main rear
1	389-0333	Cable As

Satellite Receiver Mast Parts

Use the parts in Table 8 to fabricate a mast for the receiver. These parts are not included in the 389-0345 Terrain Electronics Ar .

Table 8

GPS Receiver Mast Parts (Not included in the 389-0320 Terrain Installation Ar )
QTY	Part Number	Part Name	Description
1	8T-2647 (1)	Tube	Receiver mounting
4	147-3448 (1)	Gusset	Receiver mounting
		Angle Iron (2 in)	Harness protection

( 1 )

Refer to Special Instruction, REHS1729, "CAES Receiver Mast Fabrication"

Optional Items

The optional items in Table 9 may also be required during the installation. These parts are not provided in the 389-0329 Terrain Installation Gp .

Table 9

Optional parts needed for Terrain installation (Not included in the 389-0345 Terrain Electronics Ar )
Part Number	Part Name	Notes
3E-5239	Relay	Used for optional Reverse Auto-Calibration option
4C-4200	Paint	CAT Yellow
7K-1181	Cable Strap	Straps for securing harness
7T-1099	Link	Weld links for harness routing
141-5830	Silicone Sealant	RTV for grommets
147-3417	Mount	Display ceiling or dash mount assembly

Audible Alarm

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

Table 10 lists the parts contained in the alarm installation kit.

Table 10

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

System Overview

Most users will install a Terrain dual antenna system onto a hydraulic front shovel. The primary components include two receivers, various inclination sensors, pressure switches, and a display module.

Illustration 2	g03790026
Primary Terrain components for dual receiver machines (1) Satellite receiver (2) G610 display module (3) (4) Pressure sensor (5) Machine body pitch and roll sensor (6) Boom tilt sensor (7) Stick tilt sensor (8) Bucket tilt sensor (9) Data radio (customer supplied)

Illustration 3	g03190696
Side view showing location of major components (1) Satellite receiver (2) G610 display module (3) (4) Pressure sensor (customer supplied) (5) Machine body pitch and roll sensor (6) Boom tilt sensor (7) Stick tilt sensor (8) Bucket tilt sensor (9) Data radio (customer supplied)

Illustration 2 shows the primary components and 3 shows the side view of a shovel listing the locations of the components.

Illustration 4	g03769716
Representation of cables, harnesses, and main system components

Illustration 4 shows the general position of the cables, harnesses, and Terrain components that are described within this Special Instruction.

Refer to the Terrain G610 System Diagram in the following folder on the USB memory module for a complete wiring schematic of the Terrain system:

• 02 System Documentation\System Diagrams\v5.x

Summary of Welding and Potential Welding by Sections

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

Table 11

Welding	Section
Yes	Receiver installation
Possible	Machine radio installation
Possible	Main rear harness installation
Possible	Display module installation
Possible	Main front harness installation
No	Optional alarm installation
Yes	Battery backup installation
No	Power harness and fuse installation

Installing the Receivers

Note: This installation procedure requires welding.

Note: Ensure that harnesses are routed and restrained in a manner that does not create a trip hazard.

The terms receiver, GPS or GNSS receiver, satellite receiver, and positioning module are synonymous. This manual uses the terms receiver and satellite receiver.

Table 12

Installation Parts List for 353-2794 Satellite Receiver
QTY	Part #	Part Name	Notes
2			The site must build suitable masts for the receivers.
8	8T-4121	Hard Washer (Receiver)	M10 Washer for receiver
8	8T-4195	Bolt	M10 Bolt for receiver
16	8T-9380	Bolt	7/16-14 Bolts to attach masts to machine
16	8T-5360	Hard Washer	7/16-14 Washers to attach masts to machine
2	147-3449	Plate	Utilized to build masts for the receivers
2	156-8045	Plate	On machine base plate that must be welded to machine and is used to attach receiver masts to machine
2	285-6657	Wiring Harness	Receiver harness (jumper) (optional)
2	353-2794	Satellite Receiver	MS990 receiver

To install the GNSS receivers, complete these steps:

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

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

2. Attach the 156-8045 Plate to the counterbalance that is on the machine.

   1. Park the machine on a level surface with the bucket on the ground.

   2. Check that the mounting plates are level in the front, back, left, and right. These checks ensure that the masts will be mounted vertically.

      ReferenceRefer to Special Instruction, REHS1729, "CAES Receiver Mast Fabrication" for instructions that detail the construction of two 4 foot masts for the two receivers.

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   Illustration 5	g03453358
   156-8045 Plate mounted to machine with receiver mast mounted to plate

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

      Consider the following requirements when choosing the location:

      • Position the plates as near to the sides of the counterbalance as possible.

      • Make sure that the receivers will not extend past the sides of the counterbalance. If the receivers extend too far, the receivers may get damaged.

      • Position the plates so that the receivers will avoid possible overhead obstructions.

      • Position the plates so that the receivers are high enough to receive clear signals from the satellites.

      • Do not position the plates so the receivers are so high the machine cannot enter a height-restricted area such as the shop.

      Note: There is no requirement to attach the plates to the highest point of the counterbalance.

3. Weld the plates securely to the counterbalance to minimize movement and vibration.

4. Attach the receiver masts to the plates. Use the 8T-9380 Bolts (7/16-14) and the 8T-5360 Washers .

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Illustration 6	g03453359
Receivers mounted to masts

5. Attach a receiver to each of the masts. Use four 8T-4195 Bolts and four 8T-4121 Hard Washers .

   Mount the receivers to allow the operator to easily see the LEDs when outside of the cab. The location may be determined by site preference.

6. The 285-6657 Wiring Harness may be installed at this time. Refer to ""Installing the Harnesses" " for detailed instructions.

Installing the Angle Sensors

Terrain uses an angle sensor to determine the pitch and the roll of the excavator. The system also uses three angle sensors to determine the tilt positions of the boom, stick, and bucket relative to the machine centerline.

Table 13

Position and Angle Sensors Parts List
Part Number	Part Name	Notes
4C-4198	Paint	Optional Caterpillar Medium Gloss Black: Used to paint welded areas
4C-4200	Paint	Optional Caterpillar High Gloss Yellow: Used to paint welded areas
333-2850	Sensor Wiring	Sensor installation group with mounting hardware

Previous to version 3.2, CAESultra for excavators used the following sensors:

AS7 Single Axis Sensor - Used to measure the tilt of the boom, stick, and bucket

AS7 Dual Axis Sensor - Used to measure the pitch of the machine body

Version 3.2 and later systems use the following sensors:

AS450C - Used to measure the tilt of the boom, stick, and bucket

AS460C - Used to measure the pitch of the machine body

Refer to Table 14 for the reference document for your application.

Table 14

Reference Document for Various Applications
Application	Reference
CAESultra v4.0 and later machine	Special Instruction, REHS4456, "Installation of the Pitch and Roll Angle Sensor for CAESultra"
Terrain v4.5 and later machine	Special Instruction, REHS7229, "Installation of the Pitch and Roll Angle Sensor for Cat® Terrain"
Programming the angle sensors	Systems Operation, UENR2509, "Cat® Terrain for Grading and Loading", "As-Built Surfaces"

The feedback from these four sensors provides an accurate representation on the display module of the boom, stick, and bucket positions relative to the ground.

Illustration 7	g03453360
AS450 Angle Sensor

All of the sensors have the same physical appearance as the sensor that is shown in Illustration 7. The only difference is that the 312-0755 Angle Sensor has a decal on the sensor that indicates the pitch and roll of the sensor.

The basic installation procedure for the sensors is as follows:

1. Park the machine on firm, level ground.

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

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

3. Determine the mounting location for the sensors.

4. Temporarily route the sensor harnesses to ensure that the harnesses can be connected at the proposed locations.

   ReferenceRefer to ""Installing the Harnesses" " for additional information.

5. Weld bosses to the machine for the intended locations of the sensors.

6. Mount the bracket assemblies to the weld bosses.

7. Connect the sensors to the harness assemblies.

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Illustration 8	g01805993
Cutaway view of a typical sensor (46) 8T-4171 Bolt (M6), 5P-4115 Hard Washer (47) 322-0222 Cover (48) 322-0221 Bracket (49) 312-0754 Angle Sensor (AS450C) or 312-0755 Angle Sensor (AS460C) (50) 5C-7261 Nut (M8) and 8T-4224 Hard Washer (51) 8T-4136 Bolt and 8T-4121 Hard Washer (52) 9R-2060 Boss

8. Install the 322-0222 Covers on the brackets.

Installing the Pitch and Roll Angle Sensor

Note: This procedure requires welding.

The 312-0755 Angle Sensor is used to measure the pitch and the roll of the machine. Check the label on the sensor before installation.

Consider the following requirements when choosing the location for the sensor:

• Select a central, level mounting location that is square to the machine.

• Select a location that protects the sensor from damage.

• Orient the 322-0221 Bracket for the angle sensor so that the harness points towards the rear of the machine.

• Select a solid mounting location so that the only measurement is the machine body pitch and roll.

• Select a mounting location that is clear of the boom movement.

• Select a mounting location that the 311-8688 Sensor Harness can reach from the display module.

To install the pitch and roll angle sensor, complete these steps:

1. Park the machine on firm, level ground.

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

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

3. Verify the label on the sensor.

4. Bolt the 9R-2060 Bosses to the 322-0221 Bracket using the 8T-4136 Bolts (M10) and 8T-4121 Hard Washers .

   Use the sensor bracket and bosses as a template to locate the welding points for the bosses.

5. Tack weld the bosses to the body.

6. Remove the 322-0221 Bracket and finish welding the bosses to the machine.

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

8. Once the paint has dried, bolt the 322-0221 Bracket to the machine using 8T-4136 Bolts (M10) and 8T-4121 Hard Washers .

9. Torque the bolts to 25 ± 6 N·m (18.4 ± 4.4 lb ft).

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Illustration 9	g03453361
Installed 312-0755 Angle Sensor for pitch and roll

10. Bolt the 312-0755 Angle Sensor to the 322-0221 Bracket using the 5C-7261 Nuts (M8) and the 8T-4224 Hard Washers .

11. Torque the nuts to 25 ± 6 N·m (18.4 ± 4.4 lb ft).

Installing the Boom Angle Sensor

Note: This procedure requires welding.

The 312-0754 Angle Sensor is used to measure the tilt of the boom.

To install the boom angle sensor, complete these steps:

1. Place the machine on firm, level ground.

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

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

3. Verify the label on the sensor.

4. Select a location on the boom for the 322-0221 Bracket .

   Consider the following requirements when choosing the location for the sensor before welding the bracket.

   • Ensure that the mounting bracket is parallel to the centerline of the boom. The boom may require a welded spacer so that the mounting bracket is parallel to the centerline of the boom.

   • Ensure that the face of the mounting bracket is vertical when the bracket is mounted.

   • Ensure that the mounting bracket is free from obstructions throughout the full boom movement.

   • Ensure that the cables can be attached to the angle sensor.

   • Ensure that the cables are protected from damage throughout the full boom movement.

5. Bolt the 9R-2060 Bosses to the 322-0221 Bracket . Use 8T-4136 Bolts (M10) and 8T-4121 Hard Washers . Use the sensor bracket and bosses as a template to locate the welding points for the bosses.

6. Position the 322-0221 Bracket adhering to the notes above from Step 4. The orientation of the sensor cable will be compensated for when the calibration procedure is performed.

7. Tack weld the bosses to the boom ensuring the following:
   • Never weld across the boom or the stick of the machine.

   • Always weld in a lengthwise direction.

   • Never weld within 75 mm (3 inch) of an existing weld.

8. Remove the 322-0221 Bracket and finish welding the bosses to the boom.

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

10. Once the paint has dried, bolt the 322-0221 Bracket to the machine. Use 8T-4136 Bolts (M10) and 8T-4121 Hard Washers .

11. Torque the bolts to 25 ± 6 N·m (18.4 ± 4.4 lb ft).

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Illustration 10	g01452862
312-0754 Angle Sensor installed on the boom

12. Bolt the 312-0754 Angle Sensor to the 322-0221 Bracket using the 5C-7261 Nuts (M8) and the 8T-4224 Hard Washers .

13. Torque the nuts to 25 ± 6 N·m (18.4 ± 4.4 lb ft).

Installing the Stick Angle Sensor

Note: This procedure requires welding.

The 312-0754 Angle Sensor is used to measure the tilt of the stick.

To install the stick angle sensor, complete these steps:

1. Place the machine on firm, level ground.

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

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

3. Verify the label on the sensor.

4. Select a location on the stick for the 322-0221 Bracket .

   Consider the following requirements when choosing the location for the sensor before welding the bracket:

   • Ensure that the mounting bracket is parallel to the centerline of the stick. The stick may require a welded spacer so that the mounting bracket is parallel to the centerline of the stick.

   • Ensure that the face of the mounting bracket is vertical when the bracket is mounted.

   • Ensure that the mounting bracket is free from any obstruction throughout the full stick movement.

   • Ensure that the cables can easily attach to the tilt sensor and that the cables are protected from damage throughout the full stick movement.

5. Bolt the 9R-2060 Bosses to the 322-0221 Bracket using 8T-4136 Bolts (M10) and 8T-4121 Hard Washers .

   Use the sensor bracket and bosses as a template to locate the boss welding points.

6. Position the 322-0221 Bracket adhering to the notes above from Step 4. The orientation of the sensor cable will be compensated for when the calibration procedure is performed.

7. Tack weld the bosses to the stick ensuring the following:
   • Never weld across the boom or the stick of the machine.

   • Always weld in a lengthwise direction.

   • Never weld within 75 mm (3 inch) of an existing weld.

8. Remove the 322-0221 Bracket and finish welding the bosses to the stick.

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

10. Once the paint has dried, bolt the 322-0221 Bracket to the machine using 8T-4136 Bolts (M10) and 8T-4121 Hard Washers .

11. Torque the bolts to 25 ± 6 N·m (18.4 ± 4.4 lb ft).

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Illustration 11	g01820693
312-0754 Angle Sensor (31) installed with the harness routing down to the bucket sensor (32)

12. Bolt the 312-0754 Angle Sensor to the 322-0221 Bracket using the 5C-7261 Nuts (M8) and the 8T-4224 Hard Washers .

13. Torque the nuts to 25 ± 6 N·m (18.4 ± 4.4 lb ft).

Installing the Bucket Angle Sensor

Note: This procedure requires welding.

The 312-0754 Angle Sensor is used to measure the tilt of the bucket.

To install the bucket angle sensor, complete these steps:

1. Place the machine on firm, level ground.

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

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

3. Verify the label on the sensor.

4. Select a location on either the bucket or the bucket linkage for the 322-0221 Bracket . The bucket linkage is the linkage that is at the end of the bucket ram and the stick.

   Consider the following requirements when choosing the location for the sensor before welding the bracket.

   • Ensure that the face of the mounting bracket is vertical when the bracket is mounted.

   • Ensure that the bucket linkage or the bucket can move throughout the full movement without damage to the mounting bracket or the cables.

   • Mount the sensor on the bucket link with the connector towards the stick link pin.

   • Find a protected location on the back side of the bucket if the sensor is mounted on the bucket.

5. Bolt the 9R-2060 Bosses to the 322-0221 Bracket using 8T-4136 Bolts (M10) and 8T-4121 Hard Washers .

   Use the sensor bracket and bosses as a template to locate the boss welding points.

6. Position the 322-0221 Bracket adhering to the notes above from Step 4.

7. Tack weld the bosses to the bucket or to the bucket linkage ensuring the following:
   • Always weld in a lengthwise direction.

   • Never weld within 75 mm (3 inch) of an existing weld.

8. Remove the 322-0221 Bracket and finish welding the bosses to the boom.

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

10. Once the paint has dried, bolt the 322-0221 Bracket to the machine using 8T-4136 Bolts (M10) and 8T-4121 Hard Washers .

11. Torque the bolts to 25 ± 6 N·m (18.4 ± 4.4 lb ft).

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Illustration 12	g01452871
The 312-0754 Angle Sensor (32) installed on back of bucket

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Illustration 13	g01452872
The 312-0754 Angle Sensor (32) installed inside housing of bucket

12. Bolt the 312-0754 Angle Sensor to the 322-0221 Bracket using the 5C-7261 Nuts (M8) and the 8T-4224 Hard Washers .

13. Torque the nuts to 25 ± 6 N·m (18.4 ± 4.4 lb ft).

14. Provide additional protection for the angle sensor, ensure that the movement of the machine is not inhibited by the device, and that there is adequate movement for the cables around the linkages.

Installing the Pressure Sensors

The 364-5409 Pressure Switch , also called a dig sensor or pressure sensor, is sold separately or as part of the high accuracy dipper positioning system and replaces all previous dig sensors. The new sensors improve accuracy of the dig count, accuracy of material identification, and are reliable for longer than earlier dig sensors.

The pressure sensors, which are included in the 451-8741 Pressure Sensor Gp , are used on excavators and hydraulic front shovels that are running the G610 display module, a dual antenna positioning system, and have full body and linkage sensors.

ReferenceFor complete installation and configuration information for the new pressure sensor, refer to Special Instruction, REHS9110, "Release Notes for Cat^® Terrain v5.2 On-board Software", "New Hydraulic Pressure Sensor".

Configuring Sensors for Load Switches

Configure the items in Table 15 for the load switch to utilize the pressure switches for the loading functionality.

Table 15

Parameter	Value	Notes
Input Switch 5	Enabled	This switch corresponds to Pin 37 of the D3:C4 Nav 10.4 monitor display or pin 68 on the G610 display module.
Action	Load	This setting defines the action of the switch input.
Switch State	Normally Open	This setting defines whether an input switch is Normally Closed or Normally Open.
Debounce On Duration	300 (default)	This setting specifies the minimum amount of time that must elapse (from the last switch transition) before the "Switch On" state change is accepted by the on-board software. This value may vary by switch specifications.
Debounce Off Duration	300 (default)	This parameter specifies the minimum amount of time that must elapse (from the last switch transition) before the "Switch Off" state change is accepted by the on-board software. This time may vary by switch specifications.
Min Repeat Rate	300 (default)	This setting specifies the minimum time (in milliseconds) that is allowed between two successive sets of changes to a switch. This time may vary by machine loading characteristics.
Point Switch Type	0	This setting is not required for configuring the excavator load switch.
Activity Switch Down	0	This setting is not required for configuring the excavator load switch.
Activity Switch Up	0	This setting is not required for configuring the excavator load switch.

Installing the Machine Radio

Note: Welding may be required during this installation.

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

To install a machine radio, complete these steps:

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

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

2. Determine the mounting procedure for the radio.

   Suggested mounting procedures include:

   • Utilize the existing light brackets (if equipped).

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

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

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

   Consider the following requirements when choosing the location:

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

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

4. Install the machine radio in the desired location.

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Illustration 14	g03474679
389-0333 Cable As (Radio) (A) "P2" to Ethernet of customer supplied radio for power (B) "P1" to main rear harness

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

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

Using Power Over Ethernet

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

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

• Power: 1-BU

• Ground: 2-BK

Installing the Display Module

Note: Welding may be required during this installation.

Table 16

Parts List for Installation of Display
Part Number	Part Name	Notes
167-8604	Monitor Mounting Gp	Parts and brackets for mounting display to dash or to ceiling
389-0322	Terrain Installation Gp	U-bracket with mounting hardware
439-4341	Display Module	G610 display module with loaded operating system

To install the display module on the machine, complete these steps:

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

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

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

   Consider the following requirements when choosing the location:

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

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

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

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

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

3. Verify that the location for the display does not result in any of the following:
   • Blocking the view of safety films within the cab

   • Preventing the operator from safely entering or exiting the cab

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

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

   • Impeding the use of any operator controls within the cab

   • Exposing the display to excessive glare from direct sunlight

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

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Illustration 15	g03453368
(1A) 383-3032 Bracket (1B) 147-3417 Mount (1C) Site fabricated display module mount pedestal

4. Determine the mounting procedure for the display. Sites can use the ceiling/dash adapter or can fabricate either a custom adapter or a mounting pedestal using the bracket assembly as a template to mark the bolt pattern.

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Illustration 16	g01310403
The exploded view of 150-1893 Vibration Isolator Mounting Group is shown. (1) 439-4341 Display Module (34) 389-3032 Bracket (35) 8T-4205 Hard Washer (36) 8T-9364 Bolt (1/4-20) (39) 8C-5607 Isolation Mount (40) 8C-5608 Spacer (41) 9X-6165 Washer (42) 4M-5282 Bolt (1/4-20)

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Illustration 17	g01273003
167-8604 Monitor Mounting Group (A) 147-3417 Mount (B) 0S-0509 Bolt (3/8-16) (C) 5M-2894 Hard Washer

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Illustration 18	g03453369
Isolation mounts installed to 389-3032 Bracket

5. Assemble the eight isolation mounts (39) and the four spacers (40) to the u-shaped 383-3032 Bracket using four washers (41) and four bolts (42). Refer to Illustration 18.

   Refer to Illustration 16 for a detailed view of the shock mount detail when attaching the display module to the 383-3032 Bracket . Refer to Illustration 17 if using the ceiling/dash adapter.

6. Tighten the bolts to Caterpillar standard torque specifications.

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Illustration 19	g03453370

7. Mount the display module.

   The display module in Illustration 19 is mounted in the front upper right corner of the cab using a site fabricated ceiling bracket.

   Depending on the machine and the location of the display module, the installation may require customizing by modifying the ceiling/dash adapter mount.

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Illustration 20	g03455989
Display tilted after installation of lower bolts to ease installation of cables

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

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

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

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

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Illustration 21	g03455990
G610 harness installation (2) G610 Display (2a) P1 (70-pin) of 383-3027 Harness As (2b) (not used) (2c) P3 of 383-3027 Harness As to USB port (2d) P2 of 383-3027 Harness As to power port

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

    ReferenceRefer to ""Installing the Main Front and Main Rear Harness" " for the correct procedure in routing the main front harness.

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

    2. Connect the gray P1 (key A) 12-pin connector (2c) to the USB port (middle).

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

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

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Illustration 22	g03453371
383-3027 Wiring Harness installed on bracket (9) 383-3027 Wiring Harness (main front) (34) 389-3032 Bracket (46) 130-5300 Clips (47) Receptacle

11. Secure the connection for the service cable.

    The 389-0322 Monitor Mounting Group also contains a 130-5300 Clip . Referring to Illustration 22, use this clip to secure the service connection for the serial cable. Choose a location that is convenient to service personnel but does not obstruct the view of the operator. Choose the location that is best for the site.

Battery Backup

Illustration 23	g03453372
Mounted 167-8984 Battery Gp (backup)

The battery backup supplies the on-board software with temporary power. Power is supplied for a short time in the event of an abrupt, unplanned loss of power to the machine.

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

Installing the Battery Backup

Note: This procedure may require welding.

To install the battery backup, complete these steps:

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

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

2. Consider the following requirements when choosing the location:
   • Do not place the battery backup in any location that prevents normal, safe functioning of the machine.

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

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

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

   • Ensure adequate accessibility to the battery.

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

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

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

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

6. Remove the mounting blocks from the battery backup.

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

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

9. Permanently weld the mounting blocks.

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

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

12. Tighten the bolts to Caterpillar standard torque specifications.

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

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

Note: This procedure may require welding.

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

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

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

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

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

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

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

7. Tighten the bolts to Caterpillar standard torque specifications.

Installing the Fuse Harness

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

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

To install the fuse harness, complete these steps:

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

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

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

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

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

3. Connect the fuse harness.

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

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

Installing the Power Supply Wire and Fuses

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

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

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

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Illustration 27	g01268941
Electrical schematic for installing power harness and fuses

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

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

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

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

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

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

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

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

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

Installing the Terrain Harnesses

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NOTICE
Harness installations may require welding. If welding is required, disconnect the battery backup unit (BBU) from the power supply. Failure to follow this instruction may result in damage to the display or to the BBU.

Consider the following when installing the harnesses:

• Route and restrain harnesses in a manner that does not create a trip hazard.

• Do not extend either the serial cables or the CAN cables. If any cable is not of sufficient length, contact your Caterpillar Technical Communicator for detailed instructions as to how to proceed with the installation.

• Do not cut off any part of any harness unless instructed to do so. Bundle, tie wrap, and store any extra harness in a convenient place.

• The harnesses are marked with tape at the location of the last splice. If the harness is cut, do not cut the harness shorter than the tape. If the harness is cut shorter than the tape, then the spliced wires could be cut.

ReferenceDuring the installations, refer to Illustration 4 in the ""System Overview" " section for a basic overview of the components and harnesses that are to be installed.

This section describes the installation of the harnesses listed in Table 17.

Table 17

Harnesses for Dual Receiver Installation
Part Number	Part Name	Notes
167-8703	Wire	System power
243-4108	Sensor Harness	3 foot
311-8687	Sensor Harness
311-8688	Sensor Harness
278-7396	Wire	Non-TC900B radio
285-6655	Chassis Harness	System, 75 foot
285-6656	Wiring Harness	HEX crossover harness for second receiver
285-6657	Wiring Harness	For MS992 receiver, 2 each
311-8690	Harness As	HEX extension harness
383-3027	Wiring Harness	Main front
383-3028	Wiring Harness	Main rear

Installing the Main Front and Main Rear Harnesses

Table 18

Part Number	Part Name	Notes
167-8984	Battery	Battery backup
285-6655	Harness As	System chassis
383-3027	Wiring Harness	Main front
383-3028	Wiring Harness	Main rear
439-4341	Display Module	G610 display module with loaded operating system

To install the main front and main rear harness, complete these steps while referring to Table 18:

1. The main front harness connects between the display module, power at the battery, and the main rear harness.

2. From the monitor, route the main front harness to the location of the battery and connect the 3-pin connector. The connectors on both the battery and the main front harness are matched.

3. Route the 12-pin connector on the main front harness to the location under the cab where the main rear harness is to be installed.

4. Connect the 12-pin connector on the main front harness to the 12-pin connector on the main rear harness.

5. The main rear harness connects between the main front harness, the radio harness, the battery (if required), and the chassis harness.

6. Locate the 12-pin connector on the main rear harness in a location that provides easy connection to the chassis harness.

   Choose a location that provides easy access for connecting the 285-6649 Harness As . This harness is used for performing the Terrain sensor and receiver calibration.

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Illustration 28	g03453373
Front harness securely clamped

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

Installing the Auxiliary Harness

Table 19

Part Number	Part Name	Notes
151-6320	Wire Removal Tool
155-2269	Connector Plug
285-6655	Chassis Harness	Chassis
383-3027	Wiring Harness	Main front
383-3028	Wiring Harness	Main rear
439-4341	Display Module	G610 display module with loaded operating system

Table 20

Table for Wires for Auxiliary Harness
Wire Color	Signal	From P9 Pin	To
BU	SW +24	1	P3 pin 12
BU	DIG 6	2	P1 pin 69
YL	CAN2 HI	3	P3 pin 6
GN	CAN 2 LO	4	P3 pin 5
PU	DIG 5	5	P1 pin 67
BK	- BAT	6	P3 pin 11

Use the auxiliary harness to connect the pressure switches and the various system sensors to the 383-3027 Wiring Harness (main front).

Illustration 29	g03453374
Detailed view of the auxiliary harness (53) Bare wires connect into the mating connector of P9 of 383-3027 Wiring Harness (main front). (54) Connection to 311-8688 Sensor Harness (55) Connection to switch harness (56) 155-2269 Connector Plug to connect to wire 105 (pin 58) from main front harness.

To install the Auxiliary Harness, complete these steps while referring to Table 19 and the wiring chart in Table 20:

1. Terminate wires from the auxiliary harness using a green stripped Deuctsh pin and connector.

2. Plug the harness into P9 on the 383-3027 Wiring Harness and route harness.

3. Connect the auxiliary harness to the switch harness.

4. Locate the 12-pin connector on the main rear harness in a location that provides ease of connection to the chassis harness.

   The location must also provide ready access for connecting a service cable during the sensor and the receiver calibration procedures.

Installing the Chassis Harness and the Receiver Harnesses

Table 21

Part Number	Part Name	Notes
285-6655	Chassis Harness	System harness (75 foot)
285-6656	Wiring Harness	HEX crossover harness (second receiver)
285-6657	Wiring Harness	For MS992 receiver (2 each)
383-3028	Wiring Harness	Main front
311-8690	Control Harness	HEX extension harness

Table 22

353-2794 Receiver Harness Installation Parts List
QTY	Part Number	Part Name	Notes
8	5D-0353	Locking Bolt	3/18-16 Bolts for clips to secure harness
8	6V-8801	Nut	3/18-16 nuts for clips
8	8M-2770	Clip	Used to clip harness down to The harness is connected between the main rear harness and the rear of the machine where the receivers are located. Additionally, use these instructions to connect the second receiver chassis harness and the two receiver harnesses.mast
16	8T-4896	Hard Washer	3/18-16 washers for clips

To install and connect the receiver chassis harness and the receiver harnesses, complete these steps while referring to Tables 21 and 22.

Permanently mount the receiver harnesses in a safe position that protects the harnesses from mechanical damage.

1. Route the harnesses.

   Consider the following points when routing the harnesses:

   • Route the harnesses and secure the harnesses so that no service panels are obstructed.

   • Protect the harnesses when passing over or through any sharp metal edges.

   • Avoid locations that are near a source of heat.

2. Connect one receiver harness to the left receiver observing the following:
   • Fasten the harness near the connector to reduce strain on the connector.

   • Fasten the harness down the mast using the included clips, bolts, washers, and nuts.

   • Fasten the 12-pin connector in an area that is secure, yet still accessible.

   Note: Left and right are defined from behind the machine and looking forward toward the cab.

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Illustration 30	g03453375
Receiver harness routing down the mast of the receiver

3. Connect the second receiver harness to the right receiver observing the following:
   • Fasten the harness near the connector to reduce the strain on the connector.

   • Fasten the harness down the mast using the included clips, bolts, washers, and nuts.

4. Connect the second receiver harness to the right receiver harness. Route this harness over to the left receiver.

   Note: On large machines, the 311-8690 Harness As (receiver extension) may be needed.

5. Connect the chassis harness to the 12-pin connector on the left receiver harness.

6. Connect the 8-pin connector to the second receiver harness or to the control harness, if required.

7. Route the chassis harness from the rear of the machine to the location in the cab of the main rear harness.

   Any extra harness can be stored in the body of the machine near this harness.

8. Secure the harness with clips and cable ties.

9. Connect the chassis harness to the 12-pin connector of the main rear harness.

10. Create a coil for any excess harness. Use cable ties to secure the harness.

11. Check that all connectors are tight.

Installing the Sensor Harnesses

Table 23

QTY	Part Number	Part Name	Notes
4	102-8805	Receptacle Kit
1	134-2540	Receptacle	CAN terminator
4	243-4108	Sensor Harness As
1	276-4084	Harness As
2	311-8687	Sensor Harness	16 M, one bare end
2	311-8688	Sensor Harness	8 M, one bare end
3	312-0754	Angle Sensor	Boom, stick, bucket
1	312-0755	Angle Sensor	Pitch and roll

Table 24

Pin Number	Signal Name	Wire Reference 311-8687 Harness	Wire Color 243-4108 Harness
1 (1)	+ Battery	BR-105	RD
2	Spare	BU-A741	BU
3	CAN HI	GN-F711	GN
4	CAN LO	GY-F712	WH
5	Spare	PU-A742	BR
6 (1)	Ground	BK-229	BK

( 1 )

Use larger green-striped socket

Note: If a 389-0331 Tool Group (service kit) is available, utilize the 291-1502 Harness As with the 291-1386 Harness As (Hex Sensor) to program the 312-0754 Angle Sensor as boom, stick, and bucket sensors before mounting on the machine. If not done, then once the sensors are installed, each of the sensors will need to be disconnected and programmed one sensor at a time.

ReferenceFor information on programming the locations of the arm sensors, refer to the section entitled ""Selecting the Location of the Sensor" " .

ReferenceFor information on the 389-0331 Tool Group (service kit), refer to Special Instruction, REHS7255, "Cat^® Terrain Service Kit".

Use the following steps to connect the angle sensors from the main harness:

Refer to Table 23, Table 24, and Illustration 31.

Illustration 31	g03190877
Angle sensor wiring diagram (A) Harnesses with bare ends (B) Body pitch and roll sensor and harnesses located on body (C) Boom sensor and harnesses located on the boom (D) Stick sensor and harnesses located on the stick (E) Bucket sensor, harness, and CAN terminator located on the bucket or nearby on the stick (23) 276-4084 Wiring Harness (system harness adapter) (24) 311-8688 Sensor Harness (HEX) (8 m) (one bare end) (25) 311-8687 Sensor Harness (HEX) (16 m) (one bare end) (26) 311-8687 Sensor Harness (HEX) (16 m) (one bare end (27) 311-8688 Sensor Harness (HEX) (8 m) (one bare end) (28) 243-4108 Sensor Harness (short) (29) 312-0755 Angle Sensor (AS460C pitch and roll) (30) 312-0754 Angle Sensor (AS450 boom) (31) 312-0754 Angle Sensor (AS450C stick) (32) 312-0754 Angle Sensor (AS450C bucket) (33) 134-2540 Receptacle

Consider the following points when routing the harnesses:

• Utilize the routing of the hydraulic lines to route the harnesses correctly. This action will ensure that enough harness is available throughout all machine movements.

• Make sure that the harness is protected from mechanical damage.

• Route the harness so that the harness does not prevent access to any service panels.

• If the harness passes over or through any sharp metal edges, protect the harness at those locations.

• Secure the harness. Use cable ties.

• Secure the harness near each connector to reduce strain on the connector.

• Avoid locations that are near a source of heat.

Due to the location of the Y splits on the angle sensor harnesses and the need to shorten and install ends on the harnesses, use the following sequence to install the harnesses:

• Bucket sensor to the stick sensor

• Stick sensor to the boom sensor

• Boom sensor to the body pitch and roll sensor

• Body pitch and roll sensor back to the main harness

Note: This sequence may be altered as required by the site or the specific installation.

1. Connect the short sensor harness to the bucket sensor.

2. Route the short sensor harness to an 8 m sensor harness. This harness will route toward the stick sensor. Use care to route the harness away from any potential pinch points. Secure the harness to the machine. Use tie straps.

   Note: The connection between the 8 m harness and the short harness may be either on the bucket or on the stick, as required.

3. Install the adapter harness and the CAN terminator on the other Y-end of the 8 m harness. Secure the harness to the machine.

4. Route and attach the 8 m harness over the machine linkage. The harness will route from the bucket sensor location back to the stick sensor. Follow the hose routing. Use as much of the machine as possible to protect the harness. Use the clips and the tie straps to secure the harness.

5. Connect another short sensor harness to the stick sensor and route the harness. Ensure that the 8 m harness from the bucket sensor and a 16 m harness that will route to the boom sensor can be connected.

6. Ensure that the 16 m harness can connect to the short harness to the stick sensor and the 8 m harness to the bucket sensor.

7. Cut the 8 m harness for the bucket sensor to an appropriate length at the bare end. Use a receptacle kit to attach a connector to the bare end of the harness.

8. Install a piece of 125-7876 Heat Shrink Tube over the end of the cut braiding. This action ensures that the braiding does not fray.

9. Attach the wires to the connector pins as specified in Table 24.

   Note: In the receptacle kit, use the pins with a green stripe for the red and black wires. Use the remaining pins for the remaining wires.

10. Connect the 8 m and 16 m harnesses together. Ensure that the short harness to the stick sensor is connected.

11. Route the 16 m sensor harness. Attach the harness over the machine linkage. Route the harness from the stick sensor location back to the boom sensor. Follow the hose routing and use as much of the machine as possible to protect the harness. Use the clips and the plastic straps to secure the harness.

12. Connect another short harness to the boom sensor. Route the harness to ensure that the 16 m harness from the stick sensor and a new 16 m harness that will route toward the body sensor can be connected.

13. Ensure that the 16 m harness that leads to the body can connect with both the short harness to the boom sensor and the 16 m harness that goes to the stick sensor and the bucket sensor.

14. Cut the 16 m harness for the stick sensor and the bucket sensor to an appropriate length at the bare end. Use a receptacle kit to attach a connector to the bare end of the harness.

15. Install a piece of 125-7876 Heat Shrink Tube over the end of the cut braiding to prevent the braiding from fraying.

16. Attach the wires to the connector pins as specified in Table 24.

    Note: In the receptacle kit, use the pins with a green stripe for the red and black wires. Use the remaining pins for the remaining wires.

17. Connect the two 16 m harnesses together ensuring that the short harness to the boom sensor is connected.

18. Attach the 16 m sensor harness observing the following:
    • Route the harness over the machine linkage from the boom sensor location to the body pitch and roll sensor.

    • Follow the hose routing and use as much of the machine as possible to protect the harness.

    • Use the clips and the plastic straps to secure the harness.

19. Connect another short harness to the body pitch and roll sensor.

    Ensure that the location of the harness allows the 16 m harness from the boom sensor and an 8 m harness that will route toward the system wiring harness can be connected.

20. Ensure that the 8 m harness that leads to the system wiring harness can connect with both the short harness to the body sensor and the 16 m harness that goes to the boom, stick, and bucket sensors.

21. Cut the 16 m harness for the boom, stick, and bucket sensors to an appropriate length at the bare end. Use a receptacle kit to attach a connector to the bare end of the harness.

22. Install a piece of 125-7876 Heat Shrink Tube over the end of the cut braiding to prevent the braiding from fraying.

23. Attach the wires to the connector pins. Refer to Table 24.

    Note: In the receptacle kit, use the pins with a green stripe for the red and black wires. Use the remaining pins for the remaining wires.

24. Connect the 8 m harness and the 16 m harnesses together. Ensure that the short harness to the body sensor is connected.

25. Attach the 8 m sensor harness observing the following:
    • Route the harness over the machine from the body sensor location back to the system wiring harness.

    • Follow the hose routing and use as much of the machine as possible to protect the harness.

    • Use the clips and the plastic straps to secure the harness.

26. At the system wiring harness, ensure that the 8 m harness that leads to the angle sensors is in a location that the 8 m harness can be cut to length and can be connected to the system wiring harness.

27. Cut the 8 m harness for the angle sensors to an appropriate length at the bare end. Use a receptacle kit to attach a connector to the bare end of the harness.

28. Install a piece of 125-7876 Heat Shrink Tube over the end of the cut braiding to prevent the braiding from fraying.

29. Attach the wires to the connector pins. Refer to Table 24.

    Note: In the receptacle kit, use the pins with a green stripe for the red and black wires. Use the remaining pins for the remaining wires.

30. Connect the system wiring harness and the 8 m harnesses together.

31. Verify that all of the connectors are tight and that all of the harnesses are secured.

Installing the Optional Alarm

Menu - Opens the main menu

To install the optional alarm, complete these steps:

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Illustration 32	g03789844
Alarm components (50) 383-3027 Harness As (main front) connector "P11" (51) 411-8287 Harness As connector "S1" (52) CAN connector with terminating resistor (53) 444-5691 Alarm (54) 411-8287 Harness As (alarm) connector "P2" (55) Magnetic mounts (1 on all four corners)

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

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

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

3. Attach the alarm to the clean surface.

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

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

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

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

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

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

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

   Notify the office if either of the following conditions exist:

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

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

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

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

Performing the Initial Power Checks

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

To verify the power connections, complete these steps:

1. Remove any lockout/ tagout device.

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

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

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

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

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

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

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

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

8. Lockout/ tagout the machine, as required.

Machine ID Worksheet Entries

Enter the following information for future reference:

Machine ID Number____________________

Machine Name____________________

Display Serial Number____________________

Machine Dimensions____________________

Radio Serial Number____________________

Application (Grade or Ore) ____________________

Grade Tolerance (provided by site)____________________

Setting the Language

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

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

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

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

Menu - Opens the main menu

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

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Illustration 33	g03747546
"Select Language File" dialog

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

   The "Select Language File" dialog appears.

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

   • English (default)

   • French

   • Spanish

   • Swedish

   • Portuguese

   • Russian

   • Mongolian

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

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

3. Select "OK".

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

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

Using the Machine Configuration Utility

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

ReferenceFor more information about 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, "Cat^® Terrain User Guide".

Programming the Sensors

When installers attach sensors to a machine, there are four stages of work:

• Installation

• Configuration

• Programming

• Calibration

The order in which these stages occur depends on the preferred workflow of the installer and the type of machine. For example, since sensors must be programmed with no other sensors attached to the harness, installers working on a very large machine might program all sensors before attaching the sensors to the arm.

Sensors can be placed in various locations on the machine or programmed as replacements for other sensors. The two possible programming options are:

• Programming a new AS4xx sensor

• Programming an AS4xx sensor to replace an AS7 sensor

Replacing a Sensor

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NOTICE
Ensure that only one sensor is connected to the harness during the configuration. Failure to connect only one sensor at a time could render the sensors unusable.

Before the arm sensors can be used, specify the segment of the arm to which each sensor is mounted. Only one arm sensor at a time can be connected to the system harness during the configuration procedure.

Once all of the arm sensors have been configured, each 243-4108 Sensor Harness As can be reconnected for the boom, the stick, and the bucket. The 322-0222 Covers can then be installed on the sensors by using 8T-4171 Bolts (M6) and 5P-4115 Hard Washers.

Replacing AS4xx Sensors

If the 312-0754 Angle Sensors (AS450) have not yet been programmed as boom, stick and bucket, follow the directions in Special Instruction, REHS7232, "Replacement of the Position and Inclination Sensors for Cat^® Terrain". If the sensors have been configured, then continue to ""Calibration Overview" ".

Note: If the arm sensor is removed, remount the sensor on the arm segment for which the sensor was configured or reprogram the sensor.

Replacing an AS7 Sensor with an AS4xx Sensor

If replacing an AS7 sensor with an AS4xx sensor, Refer to Special Instruction, REHS7232, "Replacement of the Position and Inclination Sensors for Cat^® Terrain".

Programming and Calibrating Sensors on Dual Antenna Machines

For information about programming and calibrating sensors on a single antenna machine, refer to Special Instruction, REHS7229, "Installation of the Pitch and Roll Angle Sensor for Cat^® Terrain", "Programming Angle Sensors".

When installers attach sensors to a dual antenna machine, there are four stages of work:

• Installation

• Configuration

• Programming

• Calibration

The order in which these stages occur depends on the preferred workflow of the installer and the type of machine. For example, since sensors must be programmed with no other sensors attached to the harness, installers working on a very large machine might program all sensors before attaching the sensors to the arm.

Sensors can be placed in various locations on the machine or programmed as replacements for other sensors. The two possible programming options are:

• Programming a new AS4xx sensor

• Programming an AS4xx sensor to replace an AS7 sensor

This section covers the instructions for both options.

Replacing a Sensor

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NOTICE
Ensure that only one sensor is connected to the harness during the configuration. Failure to connect only one sensor at a time could render the sensors unusable.

Before the arm sensors can be used, specify the segment of the arm to which each sensor is mounted. Only one arm sensor at a time can be connected to the system harness during the configuration procedure.

Once all of the arm sensors have been configured, each 243-4108 Sensor Harness As can be reconnected for the boom, the stick, and the bucket. The 322-0222 Covers can then be installed on the sensors by using 8T-4171 Bolts (M6) and 5P-4115 Hard Washers.

Replacing AS4xx Sensors

If the 312-0754 Angle Sensors (AS450) have not yet been programmed as boom, stick and bucket, follow the directions in Special Instruction, REHS7232, "Replacement of the Position and Inclination Sensors for Cat^® Terrain". If the sensors have been configured, then continue to ""Calibration Overview" ".

Note: If the arm sensor is removed, remount the sensor on the arm segment for which the sensor was configured or reprogram the sensor.

Replacing an AS7 Sensor with an AS4xx Sensor

If replacing an AS7 sensor with an AS4xx sensor, Refer to Special Instruction, REHS7232, "Replacement of the Position and Inclination Sensors for Cat^® Terrain".

Modifying the Machine Configuration File

Before selecting the location of the sensor, enter the type of sensors expected by the machine configuration file as follows:

1. Open the MCU.

2. Select the machine name.

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

4. Select Communications > Comms Port Settings > CAN Sensor Port.

   D3:C4 Nav 10.4 Display - Select CAN Sensor Port =1.

   G610 Display - The port number is hardcoded. The user does not need to do anything for this setting

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Illustration 34	g03737915

5. Select Machine > Sensors.

   The relevant "Use <sensor name> Sensor" settings appear in the right-hand pane.

6. In "Calibration File Name", enter the correct name for the calibration file. The default name is "calibration.txt".

To use an AS450 sensor to measure inclination on a boom, stick or bucket, refer to ""Enabling the Calibration Menu" ".

To use an AS460 sensor on the body of the machine to measure pitch and roll:

1. Select the "Use Roll Sensor" checkbox to enable this function.

2. Select "AS460" from the "Type" drop-down box.

3. Select the "Use Pitch Sensor" checkbox to enable this function.

4. Select "AS460" from the "Type" drop-down box.

5. Select "Pitch Sensor Offset" to enable this function.

   Note: Leave the "Offset" value set to zero at this stage.

   For a dual antenna machine, the "Use AS7 Sensor" setting appears. This setting lets the system instruct a programmable sensor to behave as either an AS7 sensor or an AS4xx sensor.

6. Perform one of the following tasks for the selected sensor:

   AS4xx sensor - Disable the "Use AS7 Sensor" setting

   AS7 sensor - Enable the "Use AS7 Sensor" setting.

7. Select "File".

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

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

   ReferenceFor step 9 through step 10, refer to Systems Operation, KENR8277, "Cat^® Terrain for Grading and Loading".

10. Restart the on-board software and verify the accuracy of the receiver as follows:

    1. Move the machine origin to a known point.

    2. Compare the Northing, Easting, and Elevation.

11. If setting the system up to use Body, Avoidance and Path regions around the machine, complete a system measure-up procedure in Fleet office software.

    The Body, Avoidance, and Path regions around the machine running Terrain software are drawn using values stored in the office software and not the dimensions stored in the Terrain software. Users should make sure that both sets of dimensions match so that inconsistencies do not arise in other functions of the system that use dimensions.

    ReferenceFor detailed instruction for completing this critical measure-up procedure, refer to Special Instruction, REHS7347, "Cat^® MineStar Machine Dimension Measure-Up Procedure - Command For Hauling ".

12. Select "Send to MineStar".

13. Restart the on-board software.

Enabling the Calibration Menu

Before selecting the location of the sensor:

1. Open the master configuration file "master.txt" in the on-board software on the G610 display module.

2. Configure the following:

   $ Calibration Menu =1

3. Save the master.txt file.

4. Restart the on-board software.

   The "Calibration" menu can now be opened from the main menu.

   Note: If a calibration file cannot be found, then the system automatically enables the "Calibration" menu. If this setting is not set in the master.txt file, then the "Calibration" menu is disabled after a calibration file has been written.

Selecting the Location of the Sensor

Note: Ensure that only one sensor is connected to the harness during this procedure. Failure to connect only one sensor at a time could render the sensors unusable.

Menu - Opens the main menu

To select the location of the sensor, complete these steps:

1. Within the on-board software, open the main menu.

2. Select "Calibration".

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Illustration 35	g02289773

3. Select "Sensors". The "Change Sensor Type" dialog appears.

   Note: The "Current Sensor" field shows the current configuration of the sensor.

To use an AS450 sensor to measure the inclination on a boom, stick or bucket:

1. Touch the appropriate radio button in the "New type" box.

2. When the correct selection is shown, touch the "Change" button.

   The "Inform" dialog appears indicating whether the change was successful.

3. Touch "OK".

   The "Inform" dialog closes and the "Change Sensor Type" dialog appears again.

4. Confirm that the "Current Sensor" field shows the new sensor location correctly and that the "Raw" value updates in the adjacent field.

5. Touch "Done".

   The "Change Sensor Type" dialog closes.

To use an AS460 sensor to measure pitch and roll on the body of a machine:

1. Open Diagnostics > Sensors.

   Note: Do not open the Calibration > Set Sensor Ids window because the machine configuration file settings will overwrite the "Set Sensor Ids" settings.

2. Verify that both pitch and roll appear and that raw data is coming in.

Replacing a Sensor (If Needed)

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NOTICE
Ensure that only one sensor is connected to the harness during the configuration. Failure to connect only one sensor at a time could render the sensors unusable.

Before the arm sensors can be used, specify the segment of the arm to which each sensor is mounted. Only one arm sensor at a time can be connected to the system harness during the configuration procedure.

Once all of the arm sensors have been configured, each 243-4108 Sensor Harness As can be reconnected for the boom, the stick, and the bucket. The 322-0222 Covers can then be installed on the sensors by using 8T-4171 Bolts (M6) and 5P-4115 Hard Washers.

Replacing AS4xx Sensors

If the 312-0754 Angle Sensors (AS450) have not yet been programmed as boom, stick and bucket, follow the directions in Special Instruction, REHS7232, "Replacement of the Position and Inclination Sensors for Cat^® Terrain". If the sensors have been configured, then continue to ""Calibration Overview" ".

Note: If the arm sensor is removed, remount the sensor on the arm segment for which the sensor was configured or reprogram the sensor.

Replacing an AS7 Sensor with an AS4xx Sensor

If replacing an AS7 sensor with an AS4xx sensor, Refer to Special Instruction, REHS7232, "Replacement of the Position and Inclination Sensors for Cat^® Terrain".

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 more information about 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, "Cat^® Terrain User Guide".

Performing the Dimension Measurements and Measure-up

Illustration 36	g03473737
Machine Dimensions - Side View

Illustration 37	g03473738
Sample MCU screen shot

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

ReferenceRefer to the side view in Illustration 36 and the sample MCU screen shot Illustration 37 as a reference guide and template to record the GPS receiver offsets and the machine dimensions.

The system components must be calibrated after installation and before operation. The calibration information is used for various purposes including the following:

• Bucket positioning

• Current elevation

• Coverage

• Material identification

• Machine graphics

Note: The calibrations that are in this section assume that all system hardware components have been installed.

The completed calibration process provides the following information:

• Relative position of the slave receiver to the master receiver

• Relative position of the master receiver to the center of the boom pivot

• Relative position of the slave receiver to the center of the boom pivot

• Alignment of the machine relative to the two receivers

• Machine body pitch sensor offset angle

• Boom, stick, and bucket tilt sensor offset angles

• Boom, stick, and bucket dimensions

• Machine body dimensions

• Boom pivot height above the ground

Before Calibrating

Before calibrating the machine, complete these steps to set up the machine in the office software:

1. Open the MCU.

2. Select the machine name.

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

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

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

   ReferenceFor step 5 through step 6, refer to Systems Operation, UENR2509, "Cat^® Terrain for Grading and Loading".

6. Restart the on-board software and verify the accuracy of the receiver as follows:

   1. Move the machine origin to a known point.

   2. Compare the Northing, Easting, and Elevation.

7. If setting the system up to use Body, Avoidance and Path regions around the machine, complete a system measure-up procedure in Fleet office software.

   The Body, Avoidance, and Path regions around the machine running Terrain software are drawn using values stored in the office software and not the dimensions stored in the Terrain software. Users should make sure that both sets of dimensions match so that inconsistencies do not arise in other functions of the system that use dimensions.

   ReferenceFor detailed instruction for completing this critical measure-up procedure, refer to Special Instruction, REHS7347, "Cat^® MineStar Machine Dimension Measure-Up Procedure - Command For Hauling ".

Calibration Overview

Illustration 38	g01197383
"Linkage Calibration Wizard" flowchart

Use the Linkage Calibration Wizard to calibrate the machine. There are two calibrations (Linkage and GPS) that must be completed. Both of these calibrations consist of individual calibrations and are required measurements that appear on successive pages as the wizard progresses.

The on-board software provides both graphical elements and step by step written instructions on each page of the wizard. The instructions are designed to ensure that calibration information can be entered correctly. As each step of the process is completed, the wizard opens up the next page. The calibration process can be canceled at any time.

The graphical elements found in the wizard include red and blue arrows. Red arrows indicate calibration information that is used in calculations that require accurate measurements. Blue arrows indicate calibration information that is used for graphics only.

Each arrow is associated with an entry button. The buttons are labeled with a value. The value of the label indicates the current calibration value. This value is edited by selecting the associated button.

After the calibrations are completed, a calibration summary provides an overview of the results of the calibration. The calibration summary allows access to any stage of the calibration procedure.

The calibration results are stored on-board in the display module in the calibration text ("Calibration.txt") file. This text file is not written until after completion of the calibration wizard.

The calibration values can be modified at any time after the initial calibration is completed. When any value is modified, a new text file is written and the existing file is archived.

Illustration 38 provides a basic overview of the calibration process. Titles in bold print correspond to later subsections that provide a detailed explanation of each step of the calibration process. The flow is slightly different depending on whether the bucket sensor is mounted on the linkage or is mounted on the bucket.

Preparing for the Calibration

Required Equipment

Illustration 39	g01423229
Calibration kit

The 291-1414 Tool Gp (calibration kit), shown in Illustration 39 and consisting of the items listed in Table 25, is required for calibration of a dual antenna machine with MS990 receivers.

Table 25

Callout	Part Number	Part Description
57	43169-10 (Trimble PN)	Range pole and bipod
58	285-6649	GPS receiver cable
59	254-7377	3- jaw chuck
60	See Note	Water level tube
61	6V-9449	Carrying case
62	289-9631	Plate
63	Not specified	Tape measure, not included in the supplied kit

Illustration 40	g01827883

Note: The water level tube (60) that is shown in Illustration 40 is a simple device. This device is used to measure the vertical offset between linkage points. When the tube is not being used, the tube is filled with water. Caps are placed on the tube ends to stop the water from escaping.

ReferenceFor instructions on measuring the height difference, refer to the section entitled ""Measuring the Height Difference Using the Water Level Tube " ".

Machine Requirements

The following measures must be observed during the calibration procedures:

• Park the machine on flat ground.

• The machine must be able to rotate through 180 degrees without the tracks moving.

• The boom, the stick, and the bucket must be able to extend in at least one direction fully.

• Continue to run the machine throughout the calibration procedure.

Calibrating the Linkage

Note: This calibration section assumes that all system hardware components have been installed.

Menu - Opens the main menu

To start the linkage calibration, complete these steps:

1. Start the on-board software and open the main menu.

2. Select "Calibration". The "Calibration" submenu appears.

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Illustration 41	g01200763
Linkage Calibration wizard > Machine Calibrations - Dimensions

3. Select "Linkage Calibration Wizard" from the Calibration menu. The first page of the Linkage calibration, entitled "Machine Calibration - Dimensions", appears.

Specifying the Machine Body Dimensions

Specify the machine body dimensions using the first page of the linkage calibration wizard entitled "Machine Calibration - Dimensions". These dimensions include the width of the machine body, the height of the machine body, and the height of the boom pin.

Illustration 42	g01270875
Exploded view of "Machine Calibration - Dimensions" page

To specify the machine body dimensions, complete these steps:

1. Select the leftmost calibration button (67) on the "Machine Calibration - Dimensions" page. Using the pop-up keypad, enter the body width of the machine. The on-board software uses the body width to display machine icons to the correct scale.

2. Select the rightmost calibration button (68). Using the popup keypad, enter the body length of the machine. The body length is also used for displaying correctly scaled machine icons.

3. Select the lower calibration button (69). Enter the boom pin height above the ground. The boom pin height is the vertical distance from the track of the machine on the ground to the center of the boom pivot.

   Note: Boom pin height is used for current elevation updates and must be measured accurately.

4. After the three machine body dimensions have been entered, select the "Next" button. The "Pitch Angle Calibration" page appears. Alternatively, select the "Reset" button to reset all machine body dimensions to the original values.

Calibrating the Pitch Angle Sensor

The pitch sensor, which is mounted on the body of the machine, provides the on-board software with the pitch of the body. The body pitch is used in determining the machine pitch and the boom pivot position. The boom pivot position is used in determining the bucket position.

Illustration 43	g01203463
"Pitch Angle Calibration" page

Use the "Pitch Angle Calibration" to determine the pitch angle offset. The pitch angle offset adjusts the raw pitch sensor value to the actual machine body pitch value. This page appears after the machine calibration dimensions have been entered and the "Next" button is selected.

Reference""Specifying the Machine Body Dimensions" "

To calibrate the pitch angle, complete these steps:

1. Park the machine on a flat area of ground. Locate the machine such that the body can be rotated through 180 degrees without moving the tracks. Data from a GPS/GNSS reference station is not required.

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Illustration 44	g01203467
The information window after sampling is complete

2. Select the "Start" button. The information window in the "Pitch Angle Calibration" page turns red. This color indicates that the on-board software is sampling the pitch sensor values. The information window turns yellow when sampling is complete.

   Note: The on-board software requires 50 pitch sensor samples. Do not move the machine while sampling is in progress.

3. Follow the instructions in the information window and, without moving the tracks, rotate the machine through 180 degrees until the angle is 0 (zero). When the machine has rotated within +/- 2 degrees of the full 180 degrees, the information window turns green and the "End" button activates.

4. Select the "End" button. The information window turns red as the on-board software samples the pitch sensor values. When sampling is complete, the information window turns green. The "Last Sample" field shows the offset angle that has been determined from the first set of samples.

5. Select the "Add" button. The offset angle from the "Last Sample" field appears in the "Avg Offset Angle" field. The "Samples" field increments to "1".

   The "Last Sample" field displays the results for the current calibration. The "Avg Offset Angle" field displays the average of all the added offset angles.

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Illustration 45	g01203471

6. To ensure accuracy, perform multiple pitch offset angle calibrations by selecting the "Start" button and repeating steps 3 through 5.

   Each time another offset angle calibration is performed, the "Samples" field increments by one count.

7. When a satisfactory "Avg Offset Angle" is displayed, select the "Next" button. The "Boom Calibration - Dimensions" page appears.

   If a satisfactory "Avg Offset Angle" is not displayed, then select "Reset" to start the pitch angle calibration again. At that time, both the "Avg Offset Angle" field and the "Samples" field are reset to 0 (zero).

Specifying the Boom Dimensions

Use the "Boom Calibration - Dimensions" page to specify the width, height, and length dimensions of the boom of the machine.

Note: Before measuring any dimensions, ensure that the bucket is placed on the ground so that any leakage from the cylinders does not affect the dimension that is being measured.

This page appears after the pitch offset angle dimensions have been entered and the "Next" button is selected.

Reference""Calibrating the Pitch Angle Sensor" "

To specify the boom dimensions, complete these steps:

Illustration 46	g03453378
Boom Calibration - Dimensions page

1. Select the leftmost calibration button (70) on the "Boom Calibration - Dimensions" page. Enter the boom width of the machine. The on-board software uses the boom width to display machine icons to the correct scale.

2. Select the rightmost calibration button (71). Enter the boom height of the machine. Measure the boom height when the boom is roughly level. The boom height is the vertical distance from the uppermost point of the boom to the line joining the two ends of the boom. The boom height is also used for displaying correctly scaled machine icons.

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Illustration 47	g01453112
Measuring the boom length

3. Select the lower calibration button (72). Enter the boom length. The boom length (73) is the distance from the center of the boom pivot to the center of the stick pivot.

   Note: Boom length is used to determine bucket position and must be measured accurately.

4. After the three boom dimensions have been entered, select the "Next" button. The "Boom Calibration - Angles" page appears. Alternatively, select the "Reset" button to reset all boom calibration values to the original values.

Calibrating the Boom Angle Sensor

The boom tilt sensor that is mounted on the side of the boom measures the angle of the boom. The boom angle is used in determining the bucket position of the machine.

Use the "Boom Calibration - Angles" page to establish the boom offset angle. This page appears after the boom calibration dimensions have been entered and the "Next" button is selected.

Reference""Specifying the Boom Dimensions" "

The boom offset angle adjusts the raw tilt sensor value to the correct boom angle value.

Illustration 48	g01453163
Calculating the offset angle

The offset angle is calculated during the boom calibration process. The arrow in Illustration 48 indicates the angle between the boom sensor and the line between the boom pin and stick pin

The boom offset angle is determined using the water level tube to measure the difference in height between the center of the boom pivot and the center of the stick pivot. The height difference is then compared with the raw sensor data to determine the boom offset angle.

Note: A survey or other device can also be utilized to measure the height difference of these pivots.

ReferenceFor instructions on measuring the height difference, refer to the section entitled ""Measuring the Height Difference Using the Water Level Tube " ".

Illustration 49	g01452775
Boom Calibration - Angles page

Perform the Boom Angle calibration as follows:

1. Use the toggle button that is located just above the "Add" button to specify on which side of the boom the tilt sensor is mounted.

   Toggle the button to "Left" if the tilt sensor is mounted on the left side of the boom as seen from the cab toward the bucket. Toggle the button to "Right" if the tilt sensor is mounted on the right side of the boom.

2. Lower the boom until the boom pivot and the stick pivot are roughly level with each other.

3. Place the bucket on the ground so that any leakage from the cylinders does not affect the angle that is being measured.

4. Using the water level tube, measure the difference in height between the center of the boom pivot and the center of the stick pivot.

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Illustration 50	g01453143
Front Shovel Boom Calibration - Angles

5. Select the "Height Difference" button. Enter the height difference as measured using the water level tube.

   If the center of the stick pivot is higher than the center of the boom pivot, then enter the height difference as a positive value. If the center of the stick pivot is lower than the center of the boom pivot, then enter the height difference as a negative value.

   After this measurement has been entered, the system calculates the offset angle and displays the calculated value in the "Last Sample" field.

6. Select the "Add" button. The offset angle from the "Last Sample" field appears in the "Average Offset" field. The "Samples" field increments to "1".

7. To ensure greater accuracy, perform multiple samples. Take at least four samples. Additional samples are performed by moving the boom up or down and repeating steps 4 through 6. When the "Add" button is selected, the "Average Offset" field updates with an average of all offset angle samples that have been performed. Each time a new average is calculated, the "Samples" field increases by one count.

8. When a satisfactory average angle offset is displayed, select the "Next" button. The "Stick Calibration – Dimensions" page appears. Alternatively, select the "Reset" button to reset the average offset angle to the previous value and reset the "Samples" field to 0 (zero).

Specifying the Stick Dimensions

Use the "Stick Calibration – Dimensions" page to specify the height, width, and length dimensions of the stick.

Note: Before measuring any dimensions, ensure that the bucket is placed on the ground so that any leakage from the cylinders does not affect the dimension that is being measured.

This page appears after the boom offset angle has been established and the "Next" button is selected.

Reference""Calibrating the Boom Angle Sensor" "

Illustration 51	g03419876
Stick Calibration - Dimensions page

To perform the stick dimensions calibration, complete these steps:

1. Select the leftmost calibration button (74) on the "Stick Calibration - Dimensions" page. Enter the stick width of the machine. The on-board software uses the stick width to display machine icons to the correct scale.

2. Select the rightmost calibration button (75). Enter the stick height of the machine. The stick height is the thickest part of the stick. The stick height is also used for displaying correctly scaled machine icons.

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Illustration 52	g01453269
Measuring the stick length

3. Select the lower calibration button (76). Enter the stick length of the machine. The stick length (77) is the distance from the center of the stick pivot to the center of the bucket pivot.

   Note: The stick length is used to determine bucket position and must be measured accurately.

4. After the stick dimensions have been entered, select the "Next" button. The "Stick Calibration – Angles" page appears. Alternatively, select the "Reset" button to return all stick calibration values to the original values.

Calibrating the Stick Angle Sensor

The stick tilt sensor, which is mounted on the side of the stick, measures the angle of the stick. The stick angle is used in determining the bucket position.

The "Stick Calibration - Angles" page is used to establish the stick offset angle. The stick offset angle adjusts the raw tilt sensor value to the correct stick angle value. This page appears after the machine stick dimensions have been entered and the "Next" button is selected.

Reference""Specifying the Stick Dimensions" "

The stick offset angle is determined by using the water level tube to measure the height difference between the center of the stick pivot and the center of the bucket pivot. The height difference is then compared with the raw sensor data to determine the stick offset angle.

ReferenceFor instructions on measuring the height difference, refer to the section entitled ""Measuring the Height Difference Using the Water Level Tube " ".

Illustration 53	g01452779
Stick Calibration - Angles page

Note: To access the pivots and measure the height difference, position the stick over high ground or use a ladder, if needed.

To perform the stick angle calibration, complete these steps:

1. Use the toggle button that is located just above the "Add" button to specify on which side of the stick the tilt sensor is mounted.

   Toggle the button to "Left" if the tilt sensor is mounted on the left side of the stick as viewed from the cab toward the bucket. Toggle the button to "Right" if the tilt sensor is mounted on the right side of the stick.

2. Move the stick until the stick pivot and the bucket pivot are roughly level with each other.

   Note: Place the bucket on the ground so that any leakage from the cylinders does not affect the angle that is being measured.

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Illustration 54	g01453278
Front Shovel Stick Calibrators - Angles

3. Using the water level tube, measure the difference in height between the center of the stick pivot and the center of the bucket pivot.

4. Select the "Height Difference" button. Enter the height difference as measured using the water level tube. If the center of the bucket pivot is higher than the center of the stick pivot, then enter the height difference as a positive value. If the center of the bucket pivot is lower than the center of the stick pivot, then enter the height difference as a negative value. After this measurement has been entered, the system calculates the offset angle and displays the calculated value in the "Last Sample" field (81) .

5. Select the "Add" button. The offset angle from the "Last Sample" field appears in the "Average Offset" field. The "Sample Count" field increments to "1".

6. To ensure greater accuracy, perform multiple sample measurements. Take at least four samples. Additional samples are performed by moving the stick up or down and repeating steps 3 through 5.

   When the "Add" button is selected, the "Average Offset" field updates with an average of all offset angle samples that have been performed. Each time a new average is calculated, the "Sample Count" field increases by one count.

7. When a satisfactory offset angle for the stick tilt sensor is displayed, select the "Next" button. The "Bucket Sensor Mount" dialog page appears. Alternatively, select the "Reset" button to reset the Average Offset to the previous value and reset the Sample Count to 0 (zero).

Mounting the Bucket Sensor

Illustration 55	g03453379
"Bucket Sensor Mount" dialog page

Use the "Bucket Sensor Mount" dialog to select the mounting location for the bucket sensor. This dialog appears after the stick offset angle has been established and the "Next" button is selected.

Reference""Calibrating the Stick Angle Sensor" "

Mount the bucket sensor either on the bucket or else on the bucket linkage. The calibration sequence and the corresponding page that is displayed is based on the location selected in this dialog.

For a front shovel installation, mount the bucket sensor in a location that has direct reference to the bucket tooth. Select "No" in the dialog and continue with the next section ""Specifying the Bucket Dimensions" ".

Specifying the Bucket Dimensions

Use the "Bucket Calibration – Dimensions" page to specify the width, height, and length dimensions of the machine bucket. This page appears when "No" is selected on the "Bucket Sensor Mount" dialog page.

Reference""Mounting the Bucket Sensor" "

Illustration 56	g01452802
Bucket Calibration - Dimensions page

Perform the calibration for a bucket-mounted bucket sensor as follows:

Illustration 57	g01828293
Measuring the width (81) of the front shovel bucket

1. Select the leftmost calibration button (78) on the "Bucket Calibration - Dimensions" page. Enter the width (81) of the bucket cutting edge.

   Note: The bucket cutting edge width is used for coverage and must be measured accurately.

2. Select the rightmost calibration button (79). Enter the bucket height. The bucket height, which is also known as the "struck capacity", is the bucket volume below the strike off plane. The on-board software uses the bucket height to display machine icons to the correct scale.

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Illustration 58	g01828295
Front shovel bucket length dimension

3. Select the lower calibration button (80). Enter the bucket length. The bucket length (82) is the distance from the center of the bucket pivot to the center of the bucket cutting edge.

   Note: Bucket length is used to determine bucket tip position and must be measured accurately.

4. When all bucket dimensions have been entered, select the "Next" button. The "Bucket Calibration – Angles" page appears. Alternatively, select the "Reset" button to reset all bucket calibration values to the original values.

Calibrating the Bucket Angle Sensor

The bucket tilt sensor, which is mounted on the side of the bucket, measures the angle of the bucket. The bucket angle is used in determining the bucket tip position

Use the "Bucket Calibration - Angles " page to establish the bucket offset angle. The bucket offset angle adjusts the raw tilt sensor value to the correct bucket angle value. This page appears after all bucket dimensions have been entered and the "Next" button is selected.

Reference""Specifying the Bucket Dimensions" "

The bucket offset angle is determined by using the water level tube to measure the height difference between the center of the bucket pivot and the center of the bucket tip. The height difference is then compared with the raw sensor data to determine the bucket offset angle.

Note: Before measuring any dimensions, ensure that the bucket is placed on the ground so that any leakage from the cylinders does not affect the angles that are being measured.

ReferenceFor instructions on measuring the height difference, refer to the section entitled ""Measuring the Height Difference Using the Water Level Tube" ".

Illustration 59	g01452807
Bucket Calibration - Angles page

The "Bucket Calibration - Angles " calibration is completed as follows:

1. Use the toggle button that is located just above the "Add" button to specify to which side of the bucket the tilt sensor is mounted.

   Toggle the button to "Left" if the tilt sensor is mounted on the left side of the bucket as viewed from the cab toward the bucket. Toggle the button to "Right" if the tilt sensor is mounted on the right side of the bucket.

2. When calibrating a tilt sensor that is mounted on a front shovel bucket, curl the bucket until the center of the bucket pivot is roughly level with the bucket cutting edge.

   When calibrating a front shovel bucket, ensure that the bucket is closed and that the bucket open/close pivot is not used in the measurement.

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Illustration 60	g01453345

3. Using the water level tube, measure the difference in height between the center of the bucket pivot and the bucket cutting edge.

4. Select the "Height Difference" button. Enter the height difference as measured using the water level tube. If the bucket cutting edge is higher than the center of the bucket pivot, then enter the height difference as a positive value. If the cutting edge is below the center of the bucket pivot, then enter the height difference as a negative value. After this measurement has been entered, the system calculates the offset angle and displays the calculated value in the "Last Sample" field.

5. Select the "Add" button. The offset angle from the "Last Sample" field appears in the "Average Offset Angle" field. The "Samples" field increments to "1".

6. To ensure greater accuracy, perform multiple samples. Take at least four samples. Additional samples are performed by curling the bucket either in or out and repeating steps 3 to 5.

   Note: Do not take measurements when the angle between the stick end and the bucket tip are within 45 degrees of vertical. If measurements are taken under these conditions, errors can be introduced to the calibration process.

   When the"Add" button is selected, the "Average Offset Angle" field updates with an average of all offset angle calibrations that have been performed. Each time the systems calculates a new average, the "Samples" field increases by one count.

7. When a satisfactory average offset angle is displayed, select the"Next" button. The "GPS Calibration" page appears. Alternatively, select the "Reset" button to reset the "Average Offset Angle" to the previous value and reset the "Samples" field to 0 (zero).

   After the bucket calibration for the bucket mounted tilt sensor is completed, proceed to the section entitled ""GPS Calibration" ".

Bucket Calibration - Fixed Angle

The "Bucket Calibration - Fixed Angle" is not used in a front shovel installation.

GPS Calibration

Note: This calibration section assumes that all system hardware components have been installed.

The "GPS Calibration" determines the following relationships:

• Relative position of the slave receiver to the master receiver

• Relative position of the receivers to the center of the boom pivot

• Machine alignment relative to the two receivers

Communicating with the Receiver

On the G610 display module, day to day communication with the satellite receiver occurs automatically over a CAN bus. However, for calibration the current harness limits the installer to calibrating a receiver using a serial port.

To enable the display module to use a serial port for calibrating the receiver:

1. Open the master.txt file.

2. Add "$ GPS Over CAN =0" to the master.txt file to disable the on-board software from using the CAN bus for calibrating the receiver.

3. Save the master.txt file and reboot the display module.

4. Calibrate the machine. The calibration process is described in the following sections:
   • ""Specifying the Parameters" "

   • ""Calibrating the Receiver" "

   • ""Completing the Calibration" "

5. Once the system is calibrated, open the master.txt file and edit "$ GPS Over CAN =1" to enable the on-board software to use the CAN bus for day to day receiver communications.

6. Save the master.txt file and reboot the on-board software.

Specifying the Parameters

Use the "GPS Calibration" setup to specify the following calibration parameters:

• Minimum accuracy for position samples used in the calibration

• Number of samples that must be taken during the calibration

• Height of the receiver above the center of the boom pivot when the receiver is located over the boom pivot

Illustration 61	g01204092
Initial "GPS Calibration" page

To prepare for the calibration, complete these steps:

1. Select the "Advanced" button on the "GPS Calibration" page. The "GPS Calibration Setup" dialog appears.

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Illustration 62	g03453380
The "GPS Calibration Setup" dialog.

Note: Position error is an estimate of the position accuracy. Later versions of receiver firmware provide position error with each position update. The calibration is suspended when the accuracy is not acceptable.

Note: If the position error is unavailable, then the calibration requires a "fixed real time kinematic" (RTK) position mode.

2. If the maximum acceptable position error used in the calibration needs to be modified, then select the "GPS Accuracy" button.

3. If the number of positions that must be observed during calibration is to be modified, then select the "GPS Samples" button.

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Illustration 63	g01324863

4. Measure the distance (A) from the base of the range pole to the top of the lower housing on the receiver. Enter the measurement into the "Boom Pin Pole Height" field.

5. Select "OK" to save the calibration setup and return to the "GPS Calibration" wizard. Alternatively, select "Cancel" to exit without saving any changes.

Calibrating the Receiver

To perform the "GPS Calibration", complete these steps:

1. Position the machine with the bucket tip on the ground. Ensure that there is sufficient room to extend the boom, stick, and bucket fully.

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Illustration 64	g01204095
"GPS Calibration" dialog after "Pin Pole Height" has been entered

2. With the two receivers in the normal working positions, select the "Start" button. The information window turns red indicating that the on-board software is taking position samples and machine body pitch samples.

   The progress bar graphically indicates the sampling progress. The value next to the bar indicates how many position samples are still to be taken.

   The following fields can be observed below the progress bar:

   East - Displays the current averaged difference between master receiver easting and the slave receiver easting

   North - Displays the current averaged difference between master receiver northing and slave receiver northing

   Elevation - Displays the current averaged difference between master receiver elevation and the slave receiver elevation

   Distance - Displays the current averaged slope distance between the master receiver and the slave receiver

3. Once the initial set of position measurements are taken, instructions prompt the user to move the slave antenna to the boom pin.

   ReferenceFor instructions on locating the slave receiver at the boom pin, refer to the section entitled ""Locating the Slave Receiver at the Boom Pivot" ".

   Note: During this process, both receivers have been powered down and lost communications with the radio and the display module. The receivers have also lost positioning signals. Ensure that the system has had enough time to reacquire communications before continuing.

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Illustration 65	g01204096
"GPS Calibration" dialog after sampling is complete

4. Disconnect the 12-pin connector of the 383-3027 Harness As (main rear) from the 285-6655 Harness As (chassis). Connect the 285-6649 Harness As (HEX calibration) between the main rear harness and the chassis harness.

5. Locate the range pole and receiver at the boom pin using the 3-jaw chuck and the range pole target. The range pole must be set up to the right of the center of the boom pin center.

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Illustration 66	g01827937
Slave receiver mounted on the right side of the boom pivot

6. Once the slave receiver is in position, select the "Start" button on the "GPS Calibration" page. The on-board software begins sampling again.

   When the system has finished sampling positions, the "GPS Offset from Boom Pin Center" dialog appears.

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Illustration 67	g03453382
"GPS Offset from Boom Pin Center" dialog

7. Select the button to the right of "Offset:" on the "GPS Offset from Boom Pin Center" page. Enter the distance from the boom pin center to the center of the range pole.

   ReferenceFor detailed instructions for measuring the offset, see the section entitled ""Measuring the Distance from the Center of the Boom Pivot to the Range Pole" ".

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Illustration 68	g01204101
"GPS Calibration" page after boom width has been entered

8. Select "OK" on the "GPS Offset from Boom Pin Center" page. The offset is saved and the "GPS Offset from Boom Pin Center" page is closed. The information window in the "GPS Calibration" page turns green and contains instructions to position the receiver at the bucket tip.

   Note: Ensure that the range pole is positioned in line with the boom center and bucket center. The range pole does not have to be exactly on the edge of the bucket tip. The purpose of this set of observations is to determine the longitudinal axis of the machine.

9. Confirm that the boom, stick, and bucket are extended. Confirm that the bucket tip is on the ground. Use the bipod to position the range pole at the center point of the bucket tip.

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Illustration 69	g03453383
Range pole set up at the center of the bucket tip

10. Select the "Start" button on the "GPS Calibration" page. The information window turns red while the on-board software samples receiver data. When the sampling is complete, the information window in the "GPS Calibration" dialog turns green. The window contains instructions to return the slave receiver to the original (normal) position on the machine.

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Illustration 70	g01204104
The "GPS Calibration" dialog after sampling is complete

11. Install the slave receiver to the machine in the normal operating position. Use the four 8T-4195 Bolts .

12. Reconnect the receiver. Use the installed receiver cable.

13. Remove the 12-pin connectors of the 285-6649 Harness As .

14. Reconnect the connectors of the main rear harness to the chassis harness.

    Note: During this process, both receivers have been powered down and lost communications with the radio and the display module. The receivers have also lost positioning signals. Ensure that the system has had enough time to reacquire communications before you continue.

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Illustration 71	g01204106
The "GPS Calibration" page indicating to rotate the machine

15. Select the "Start" button in the "GPS Calibration" page. The information window turns yellow. The instructions in the information window require the machine to be rotated 180 degrees to the angle of 0 (zero).

    Rotate the machine 180 degrees. Monitor the Progress bar and the value next to the progress bar while rotating the machine the full 180 degrees.

16. Select the "Start" button. The information window turns red while the on-board software samples positioning data. When sampling is complete, the information window turns green.

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Illustration 72	g01204108
"GPS Calibration" dialog after completing the receiver calibration

17. The "GPS Calibration" dialog indicates that the "Next" button is to be selected. Select the "Next" button. The "Calibration Summary" page appears.

Completing the Positioning Calibration

The calibration summary provides a complete summary of all calibration values from both the linkage calibration and the receiver calibration. No calibration information has been written to the calibration file at this stage.

Illustration 73	g03453384
The "Calibration Summary" page

The following information is displayed in the "Calibration Summary" page.

Pitch/Machine group box - Reports the machine dimensions and the result of the machine pitch calibration

Boom, Stick, and Bucket group boxes - Report the results and entries for both dimension calibrations and for angle calibrations

Antenna Positions - Displays the results of the receiver calibration

Ant 1 - Shows the offset of the master antenna in the X, Y, and Z planes, from the center of the boom pivot

Ant 2 - Shows the offset of the slave antenna, in the X, Y, and Z planes, from the center of the boom pivot

Illustration 74	g01271073
Reference frame for machine offsets (104) Master antenna (105) Horizontal distance from master antenna in Y direction (106) Slave antenna (107) Horizontal distance from master antenna in X position (108) Vertical distance (elevation) from master antenna in Z direction

The machine reference frame is centered on the boom pivot center point. The Y axis is the longitudinal axis of the machine. The X axis is from the left side of the machine to the right side of the machine. The Z axis is the vertical axis of the machine.

Calibration Settings

Calibration values are written as settings in the calibration.txt file and edited using the calibration wizard. The keys cannot be entered manually.

The following settings are written to the calibration file:

AntX 0 - Specifies the horizontal distance in the X axis from the master antenna to the center of the boom pivot

AntY 0 - Specifies the horizontal distance in the Y axis from the master antenna to the center of the boom pivot

AntZ 0 - Specifies the horizontal distance in the Y axis from the master antenna to the center of the boom pivot

AntX 1 - Specifies the horizontal distance in the X axis from the slave antenna to the center of the boom pivot

AntY 1 - Specifies the horizontal distance in the Y axis from the slave antenna to the center of the boom pivot

AntZ 1 - Specifies the vertical distance from the slave antenna to the center of the boom pivot

Boom Sensor Left - Specifies of the boom to which the boom tilt sensor is mounted

Boom Sensor Offset - Specifies the offset angle that is applied to the raw boom angle

Bucket Sensor Left - Specifies side of the bucket to which the bucket tilt sensor is mounted

Bucket Sensor Offset - Specifies the offset angle that is applied to the raw bucket angle

Excavator Boom Height - Specifies the boom height of the machine

Excavator Boom Length - Specifies the boom length of the machine

Excavator Boom Width - Specifies the boom width of the machine

Excavator Boom Pin Height - Specifies the height of the center of the boom pin above the machine track on the ground

Excavator Bucket Height - Specifies the bucket height of the machine

Excavator Bucket Length - Specifies the bucket length of the machine

Excavator Bucket Pins Length - Specifies the distance between the pins of the bucket.

Excavator Bucket Pins To Tip Angle - Specifies the angle formed between the bucket tip and the pins of the bucket.

Excavator Bucket Width - Specifies the bucket width of the machine

Excavator Bucket Sensor On Link - Specifies that the tilt sensor for the bucket is installed on the bucket link

Excavator Cylinder To Bucket Length - Specifies the length of the cylinder to bucket link

Excavator Machine Length - Specifies the length of the body of the machine

Excavator Machine Width - Specifies the width of the body of the machine

Excavator Stick Height - Specifies the stick height of the machine

Excavator Stick Length - Specifies the stick length of the machine

Excavator Stick Link To Bucket Length - Specifies the distance from the center of the bucket link pivot on the stick to center of the bucket pivot

Excavator Stick To Cylinder Link Length - Specifies the distance from the center of the bucket link pivot on the stick to the center of the cylinder link

Excavator Stick To Link Angle - Specifies the angle from the center of the pivots from the stick, bucket, and bucket link on the stick

Excavator Stick Width - Specifies the stick width of the machine

Pitch Sensor Offset - Specifies the offset angle that is applied to the raw machine pitch angle

Roll Sensor Offset - Specifies the offset angle that is applied to the raw roll angle

Stick Sensor Left - Specifies side of the stick to which the stick tilt sensor is mounted

Stick Sensor Offset - Specifies the offset angle that is applied to the raw stick angle

General Procedures

The following general procedures are described in the sections below:

• Modifying the calibration values

• Modifying the machine body dimensions and the pitch angle offset

• Modifying the boom calibrations

• Modifying the stick calibrations

• Modifying the bucket calibrations

• Modifying the GPS calibration

• Terminating the GPS calibration

• Measuring the height difference using the water level tube

• Measuring the distance from the boom pivot center to the range pole

Modifying the Calibration Values

If the calibration menu is enabled, then any part of the machine calibration can be edited or changed at any time. When any part of the calibration is modified, then a new calibration file is written and the existing calibration file is archived.

Use the "Calibration Summary" page to review all calibration results. Use the "Modify" button in the associated group box in the calibration summary to perform the following tasks:

• Edit dimensions for a specific calibration

• Reset and repeat a specific calibration

• Add additional calibration sets to a specific calibration

Menu - Opens the main menu

To modify the calibration values, complete these steps:

1. Select "Calibration" from the main menu in the on-board software. The "Calibration" submenu appears.

2. Select "Calibration Summary" from the calibration submenu. The "Calibration Summary" page appears.

Modifying the Machine Body Dimensions and the Pitch Angle Offset

To modify the machine body dimension and/or pitch angle offset, complete these steps:

1. Select the "Modify" button in the "Pitch/Machine" group box. The "Machine Calibration - Dimensions" page appears.

2. Follow the steps detailed in the sections entitled ""Specifying the Machine Body Dimensions" " and ""Calibrating the Pitch Angle Sensor" ".

3. If the modifications are complete, follow the steps detailed in the section entitled ""Completing the Positioning Calibration" ". Alternatively, select the "Cancel" button to escape from the procedure without writing to the calibration file.

   Reference""Terminating the Positioning Calibration" "

Modifying the Boom Calibration

To modify the machine boom dimension and/or the boom angle offset, complete these steps:

1. Select the "Modify" button in the "Boom" group box. The "Boom Calibration - Dimensions" page appears.

2. Select the calibration that is to be changed, and then enter the new calibration value.

   ReferenceFor detailed instructions, refer to the steps in the sections entitled ""Specifying the Boom Dimensions" " and ""Calibrating the Boom Angle Sensor" ".

3. Continue this same process with each value that is to be changed. When all modifications are complete, follow the steps detailed in the section entitled ""Completing the Positioning Calibration" ". Alternatively, select the "Cancel" button to escape from the procedure without writing changes to the calibration file.

   Reference""Terminating the Positioning Calibration" "

Modifying the Stick Calibration

To modify the machine stick dimension and/or stick angle offset, complete these steps:

1. Select the "Modify" button in the "Stick" group box. The "Stick Calibration - Dimensions" page appears.

2. Select the calibration that is to be changed, and then enter the new calibration value. For detailed instruction, refer to the steps in the section entitled""Specifying the Stick Dimensions" " and the section entitled ""Calibrating the Stick Angle Sensor" "

3. Continue this same process with each value that is to be changed. When all modifications are complete, follow the steps detailed in the section entitled ""Completing the Positioning Calibration" ". Alternatively, select the "Cancel" button to escape from the procedure without writing changes to the calibration file.

   Reference""Terminating the Positioning Calibration" "

Modifying the Bucket Calibration

To modify the machine bucket dimension and/or bucket angle offset, complete these steps:

1. Select the "Modify" button in the "Bucket" group box. The "Bucket Sensor Mount" dialog page appears.

2. Select the calibration that is to be changed, and then enter the new calibration value. For detailed instruction, refer to the steps in the section entitled ""Mounting the Bucket Sensor" "

3. Continue this same process with each value that is to be changed. When all modifications are complete, follow the steps detailed in the section entitled ""Completing the Positioning Calibration" ". Alternatively, select the "Cancel" button to escape from the procedure without writing changes to the calibration file.

   Reference""Terminating the Positioning Calibration" "

Modifying the Machine Positioning Calibration

To modify the machine positioning calibration, complete these steps:

1. Enable the G610 display module to use a serial port for calibrating the receiver:

   1. Open the "master.txt "file.

   2. Add "$ GPS Over CAN =0" to the master.txt file to disable the on-board software from using the CAN bus for calibrating the receiver.

   3. Save the master.txt file and reboot the display module.

2. Select the "Modify" button in the "Antenna Positions" group box. The "GPS Calibration" page appears.

3. Select the calibration that is to be changed, and then enter the new calibration value. For detailed instructions, refer to the steps in the section entitled ""GPS Calibration" ".

4. Continue this same process with each value that is to be changed. When all modifications are complete, follow the steps detailed in the section entitled ""Completing the Positioning Calibration" ". Alternatively, select the "Cancel" button to escape from the procedure without writing changes to the calibration file.

   Reference""Terminating the Positioning Calibration" "

5. Once the system is calibrated, open the master.txt file and edit "$ GPS Over CAN =1" to enable the on-board software to use the CAN bus for day to day receiver communications

6. Save the master.txt file and reboot the on-board software.

Terminating the Positioning Calibration

To terminate the positioning calibration at any stage, complete these steps:

1. Select the "Cancel" button at any stage to exit the calibration.

   The "Confirm Calibration Cancel " dialog appears.

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Illustration 75	g03453385
Confirm cancellation of the calibration

2. Select one of the following buttons:

   Yes - Confirm the cancellation. The calibration procedure ends, the calibration dialogs close, and the "Calibration Summary" page appears.

   No - Return to the calibration procedure.

Measuring the Height Difference Using the Water Level Tube

This section describes the general procedure for measuring the height difference using a water level tube. The water level tube measurements require two people.

Note: The water level tube is a rudimentary way to measure the height difference between two objects. Other, more accurate methods, such as a laser level or an optical survey device can be used to measure the vertical offset if these devices are available on the site.

To measure the height differences using a water tube, complete these steps:

1. Remove the caps from both ends of the water level tube.

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Illustration 76	g03453386
Water level at each end of the water tube is the same

2. Hold the two ends of the tube together. The water levels (109) must be identical at both ends of the tube. If the levels are not identical, check that there are no air bubbles in the tube and no kinks restricting the water flow.

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Illustration 77	g01271126
The water level in the water tube is held level with the center of the boom pivot

3. Hold one end of the water level tube so that the water level in the tube is level with the center of the first pivot (110) point.

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Illustration 78	g01271142
Measuring the vertical distance from the water level to the center of the stick pivot. The measured height difference (112) is 95 cm.

4. While maintaining the water level at the center of the first pivot (110) point, hold the second end of the water level tube next to the center of the second pivot (111) point.

5. When the water level is steady, measure the vertical distance (112) from the center of second pivot point to the water level (113) in the water level tube. This measurement is the height difference that is required for the calibration.

Measuring the Distance from the Center of the Boom Pivot to the Range Pole

This section describes the general procedure for measuring the distance from the boom pivot center to the range pole.

This measurement is crucial to machine bucket position and must be measured accurately.

To measure the distance from the range pole target to the center of the boom pivot, complete these steps:

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Illustration 79	g01271347
Mark in line with the center of the bucket

1. Measure the width of the boom pin (115). Divide the width of the boom pin in half (114) .

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Illustration 80	g03453387
Slave receiver mounted to the right of center of the boom

2. In some machines, the tool for finding the center of the boom pivot is part of the boom pin. In other machines, the tool is a screw-in attachment. Find, or place, the tool at the right or left of the center of the boom pivot. If there is not enough space, place the tool away from, but still in line with, the center of the boom pivot. The center of the boom pin compared to the base of the range pole in the Y direction must be zero.

3. Measure the distance from the center of the boom pin to the range pole target.

4. Add the value calculated in Step 1 to the distance in Step 3. This is the "Offset" entered into the "GPS Offset from Boom Pin Center".

5. Insert the range pole target into the boom pin center finder.

6. Set up the range pole on the range pole target. Ensure that the range pole is vertical.

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Illustration 81	g01271352
Measuring the horizontal distance (117) from the center of the boom pivot to the center of the range pole

7. Measure the distance (117) from the marked centerline (116) of the boom pivot to the center (118) of the range pole.

   This value is the "Offset" entered into the "GPS Offset from Boom Pin Center".

Locating the Slave Receiver at the Boom Pivot

This section describes the general procedure for locating the slave receiver over the boom pivot for the positioning calibration.

To locate the slave receiver at the boom pivot, complete these steps:

1. Disconnect the installed 285-6657 Wiring Harness from the slave (right) receiver.

2. Disconnect the 12-pin connector of the 290-1918 Harness As from the 285-6655 Chassis Harness .

3. Connect the 285-6649 HEX Calibration Harness between the 290-1918 Harness As and the 285-6655 Chassis Harness .

4. Remove the slave receiver from the machine mast.

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Illustration 82	g03453388
Bottom of the receiver with the Calibration Plate attached (119) 8T-4195 Bolts (120) Threaded hole for range pole. (121) 289-9631 Plate (122) Receiver

5. Use four bolts (119) from the receiver Mast Mount to mount the receiver to the plate (121) .

6. Screw the range pole into the threaded hole (120) of the calibration plate (121) that is attached to the bottom of the receiver.

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Illustration 83	g01827944
Slave receiver mounted on the range pole (121) 289-9631 Plate (122) Receiver (123) Range pole (124) Range pole bipod

7. Connect the slave receiver to the main harness in the cab, using the calibration harness that is in the calibration kit.

8. The calibration kit contains a device that is used for locating the center of the boom pin during the calibration process.

   Use the following steps to locate the 3-jaw chuck and the range pole target into the bolt hole in the center of the boom pivot of the machine:

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   Illustration 84	g03453390
   Parts for the 3-jaw chuck (125) 3-jaw chuck (126) Range pole target (127) Allen wrench (128) Chuck key

   1. Insert the center tool pins into the bore of the boom pin on the left side of the machine.

   2. Using the chuck key, increase the diameter until the locating pins are snug against the inner bore of the pin.

      Note: Do not over-torque the chuck as this action will bend the locating pins.

   3. Install the range pole target into the end of the chuck.

   4. Measure the distance from the center of the boom pin to the target. Record this value for later use in the calibration.
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   Illustration 85	g03453391
   The 3-jaw chuck. (128) Chuck key (129) Chuck jaw identity number (130) Inner threaded holes for the chuck jaws (131) Chuck jaw

   5. The 3-jaw chuck can be used for pin bores of up to 3 inches (75mm). The jaws of the chuck are numbered and the corresponding location (129) for each jaw is also marked on the chuck near where the jaw is installed.

      For machines with larger pins, the chuck jaws (131) may be removed and, as shown in Illustration 85, inserted in the outer threaded holes. Use the Allen wrench in the kit to remove the pins and reinstall the pins in the outer set of holes.

      Note: After relocating the jaws, ensure that the jaws move in and move out at equal distances from the center.

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Illustration 86	g03453392
Range pole that is located at boom pivot

9. Place the bottom point (132) of the range pole into the range pole target (126). Level and secure the range pole using the bipod.

   For added stability, perform the following actions:

   • Locate the area where the bipod joins the pole as high a possible up the pole.

   • Secure the pole using ropes, tie downs, or bungy cords.

Calibration Checklist

This section contains a printable checklist for using on the machine while taking measurements for the calibration process.

Ensure that the dimensions that are coded red in the calibration wizard are measured accurately.

The form below in Illustration 36 includes all of the dimensions that must be measured for the machine calibration when the tilt sensor is mounted on the bucket linkage. Complete all of the calibration dimension measurements and enter the dimensions into the spaces provided on the form. Enter the values from the form into the calibration pages as the calibration wizard is stepped through.

Note: There are some measurements on the form that are not required when the bucket tilt sensor is mounted on the bucket.

Note: Use a photocopy of the form to avoid climbing in and out of the cab during the calibration.

Illustration 87	g01455537