Installation of the G610 Hardware for Cat® Terrain v5 Attachment Ready Option for Track-Type Tractors {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)

Track-Type Tractor

D10T (S/N: RJG1-UP)

D11T (S/N: AMA1-UP; GEB1-UP; TPB1-UP; MDG1-UP; JEL1-UP; JNS1-UP)

D9T (S/N: TWG1-UP; RJS1-UP)

Introduction

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

The installation includes the following procedures:

• Optional alarm installation

• Display module installation

• Machine radio installation

• Satellite receiver installation

• Setting the language of the software

• Machine dimensions and measure up

Operation and Maintenance Manual

The operation of Terrain for grading and loading on-board software is covered in the Operation and Maintenance Manual, SEBU8822, "Cat^® Terrain v5 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. Also, 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 product unless you have read and understood the instruction and warnings in the relevant Operation and Maintenance Manuals and relevant service literature. Failure to follow the instructions or heed the warnings could result in injury or death. 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 implement to the ground. Permit only one operator on the machine. Keep all other personnel away from machine or in view of the operator. Engage the parking brake. Stop the engine. Move the hydraulic control levers to all positions to release the pressure in the hydraulic system.

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 product unless you have read and understood the instruction and warnings in the relevant Operation and Maintenance Manuals and relevant service literature. Failure to follow the instructions or heed the warnings could result in injury or death. 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 work tools to the ground.

4. Stop the engine.

5. Engage the machine brake.

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

Required Tools

The tools that are listed below are required to install Terrain ARO for track-type tractors.

• 10mm 1/4" drive socket

• #30 1/4" drive Torx bit

• 4mm Allen wrench

Parts Lists

The 389-0323 Terrain Installation Gp contains the satellite receiver, the display, required hardware, and a USB memory module. The USB memory module contains files for the monitor operating software, system documentation, and a schematic diagram of the system.

The following groups are used:

New - 389-0323 Terrain Installation Gp

Upgrade - 419-7157 Terrain Installation Gp

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

The parts are listed in Table 1.

Optional Items

The only optional item available with this kit is the 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 2 lists the parts contained in the alarm installation kit.

Installing the Optional Alarm

Menu - Opens the main menu

To install the optional alarm, complete these steps:

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Illustration 2	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.

Terrain Components

See "Parts Lists", Table1and "Optional Items", Table 2.

Installing the Display Module

To install the display module, complete these steps:

1. Remove the gray dash cover by removing the six fasteners on the left-hand and right-hand side of the cover.

2. Determine the type of cab for the installation.

   Phase 5 Cab (TWG, MDG, AMA, JEL, JNS) - The left 342-5324 Bracket and the right-hand 342-5326 Bracket are installed to mount the monitor display.

   Phase 4 Cab (RJG, GEB, TPB, RJS) - There are no brackets installed and there is a D3:C4 Nav 10.4 Display installed directly to the dash frame.

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   Illustration 3	g06263830
   Gap between bezel and face of display

3. In a Phase 4 Cab, verify that the display does not have a gap between the bezel and the face of the display.
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   Illustration 4	g06263851
   Dimensions for replacement plates

4. If a gap exists in a Phase 4 Cab, fabricate replacement plates to use in place of the 420-5738 Plate and the 420-5739 Plate to complete the installation.

5. If installed, uninstall the D3:C4 Nav 10.4 monitor display from the 249-0872 Bracket.

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

      Retain the bolts and washers for installation of the G610 display module. The shock mounts will not be used with the new display and may be discarded.

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

      Note: If the blue Ethernet cable is to be reused, the M12 connector must be replaced with a RJ45 plug. If the blue Ethernet cable is to be discarded, use an appropriate Ethernet patch cable.

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

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

7. Disconnect the 325-4732 Monitor Harness As for the monitor display from the machine harness.

   Note: The new 418-4788 Wiring Harness will have the same mating connectors as the machine harness.

8. Connect the 418-4788 Wiring Harness to the machine harness.

9. Install the brackets and plates.

   Phase 4 Cab - install the left-hand 420-5738 Plate and the right-hand 420-5739 Plate using the four 8T-4136 Bolts and 8T-4223 Hard Washers. These brackets install in the same mounting locations that were used by the previous monitor display.

   Phase 5 Cab - Remove the left and right bracket and install the 393-7361 Bracket using the same fasteners in the same locations.

10. Install the u-shaped 420-5737 Bracket where the gray plastic dash cover was removed using six 127-2170 Bolts. The bracket increases the distance between the machine dash and gray plastic cover by 2 inches.

11. Connect the 70-pin plug of the 418-4788 Wiring Harness to the G610 display. Tighten the harness with the 4mm Allen.

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

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

13. Connect the 12-pin receptacle of the 389-0333 Cable to the 12-pin "Radio" plug of the 419-4111 Harness.

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

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

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

    2. Using the four bolts and washers that were removed in Step 5.a, fasten the G610 display to the bracket.

    3. Tighten the bolts to standard Caterpillar torque specifications.

16. If this install is a new ARO install and not an upgrade, install the 353-2794 Satellite Receiver.

    Reference: Refer to "Installing the Satellite Receiver".

17. Reinstall the gray plastic dash cover with the retained fasteners.
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    Illustration 5	g03394918

18. Turn the key start switch to ON to apply power to the display module.

    The display boots up and a "CAT" logo appears on the screen.

19. Complete the installation of the application software.

    Reference: Refer to Special Instruction, REHS9109, "Installation and Configuration of for Cat^® Terrain v5.2 On-board Software".

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 ft 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 6	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(Blue)

• Ground: 2-BK(Black)

Installing the Satellite Receiver

Illustration 7	g03232676
Satellite receiver mounting (3) 261-4983 Plate

To install the satellite receiver, complete these steps:

1. Locate the plate (3) on top of the Roll Over Protective Structure (ROPS).

   Note: The satellite receiver plate is already mounted on the top of the ROPS.

2. Ensure that the satellite receiver has an unobstructed view of the sky.

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

4. Connect the control harness to the satellite receiver.

   Phase 4 cab (RJG, GEB, TPB, RJS) - Connect the AL-C3 connector of the 281-9297 Harness As.

   Phase 5 cab (TWG, MDG, AMA, JEL, JNS) - Connect the AK-C3 connector of the 343-8751 Harness As.

5. Ensure that the control harness is connected to the machine harness.

   Phase 4 - Connect the AL-C1 connector of the 281-9297 Radio Harness As.

   Note: For S/N:GEB443-UP and ; S/N:TPB175-UP, replace this plug with a 3E-5179 Connector Receptacle As and a 3E-5180 Receptacle Lock Wedge to ensure compatibility with the machine harness.

   Phase 5 - Connect the AK-C1 connector of the 343-8751 Radio Harness As.

Installing the Front Harness to the Wiring Harness

Previously, to supply connections for the key switched power and the CAN 2 bus to the Pitch/Roll 311-8688 Sensor Harness, the 290-1916 Auxiliary Harness was required between the G610 display module and the 418-4788 Wiring Harness. This process required using splices.

To wire the harness without the use of splices, complete any of the following three options:

Option 1

Use the 290-1916 Auxiliary Harness between the G610 display module and the 311-8688 Sensor Harness.

1. Obtain a 3E-3376 Connector Receptacle As (4-pin DT).

2. To wire the key switched power connection, replace the socket with a pin on the 290-1916 Auxiliary Harness 105-BR (Brown) wire and insert into pin 1 of the new 4-pin connector.

3. To wire the ground connection, replace the socket with a pin on the 290-1916 Auxiliary Harness 229-BK(Black)(Black) and insert into pin 4 of the new 4-pin connector.

4. Connect the new 4-pin receptacle to the 4-pin plug of the light bar.

5. Run a twisted pair of CAN wires from the 290-1916 Auxiliary Harness to the 12-pin connector "P9" on the back of the G610 display module.

   Note: The CAN(+) and CAN(-) wires must be twisted together as a pair to prevent unwanted noise on the wires. Twisting the wires will reduce the overall length of the wires by approximately 20%.

   CAN 2(+) - Insert F711-GN (Green) wire of the auxiliary harness into pin 6 of the 12-pin plug "P9".

   CAN 2(-) - Insert F12-GY (Gray) wire of the auxiliary harness into pin 5 of the 12-pin plug "P9".

6. Tape back the remaining wires on the 290-1916 Auxiliary Harness as these wires are not needed.

Option 2

This option can only be used if the machine does not have an optional CAN alarm installed. This option requires no additional parts.

1. The wiring for the key switched power connection remains unchanged.

2. To wire the ground connection, remove the black wire from pin 2 of connector "P8" and insert into pin 6 of the same connector.

3. Run a twisted pair of CAN wires from "P8" of the Amatek Gauge to the 12-pin connector "P9" on the back of the G610 display module.

   Note: The CAN(+) and CAN(-) wires must be twisted together as a pair to prevent unwanted noise on the wires. Twisting the wires will reduce the overall length of the wires by approximately 20%.

   CAN 2(+) - Remove the yellow wire from pin 4 of connector "P8" and insert into pin 3 of the same connector. Remove the yellow wire from pin 10 of the 70-pin connector "P1" on the back of the G610 display module and insert into pin 6 of connector "P9" (moves from CAN 3 to CAN 2).

   CAN 2(-) - Remove the green wire from pin 5 of connector "P8" and insert into pin 4 of the same connector. Remove the green wire from pin 20 of the 70-pin connector "P1" on the back of the G610 display module and insert into pin 5 of connector "P9" (moves from CAN 3 to CAN 2).

Option 3

This option consists of the following actions:

• Remove the 4-pin plug "P5" of the light bar connector (not used).

• Replace the connector with a 6-pin plug.

• Run two new twisted wires to CAN 2.

1. Obtain a 155-2273 Connector Plug As (6-pin DT) to use in place of the 4-pin "P5" connector.

2. For key switched power, remove the blue wire from pin 1 of the light bar connector "P5" plug and insert into pin "1" of the new 6-pin plug.

3. For ground, remove the black wire from pin 4 of light bar connector "P5" plug and insert into pin 6 of the new 6-pin plug.

4. Run a twisted pair of CAN wires from the 12-pin connector "P9" on the back of the G610 display module to the new 6-pin plug.

   Note: The CAN(+) and CAN(-) wires must be twisted together as a pair to prevent unwanted noise on the wires. Twisting the wires will reduce the overall length of the wires by approximately 20%.

   CAN 2(+) - Run a new 30 inch yellow wire from pin 6 of t "P9" and insert into pin 3 of the new 6-pin plug.

   CAN 2(-) - Run a new 30 inch green wire from pin 5 of "P9" and insert into pin 4 of the new 6-pin plug.

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)____________________

Using a Serial Harness

On the G610 display module, GPS communication occurs automatically over a CAN bus. If using a non-ARO machine type with MS Series receiver, use CAN GNSS communications. If using an ARO machine type with MS Series receiver, use serial GNSS communications.

To enable the G610 display module to use serial GPS communications, add the following line of code to the master.txt file:

$ GPS Over CAN =0

This line of code disables the on-board software from using the CAN bus for GNSS communications.

Reference: To set up a G610 display module for and MS990 receiver, refer to Special Instruction, REHS2992, "Installation and Configuration of the Cat^® Terrain v5.0 On-board Software", "Setting up an MS990 Receiver".

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 8	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 Spanishlanguage, select "5.0 Spanish".

3. Select "OK".

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

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

Using the Machine Configuration Utility

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

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

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

Performing the Dimension Measurements and Measure-up

Illustration 9	g03473540
Machine Dimensions - Side View

Illustration 10	g03455995
Sample MCU screen shot

Reference: Refer to the side view in Illustration 9 and the sample MCU screen shot Illustration 10 as a reference guide and template to record the machine receiver offsets and the machine dimensions.

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

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

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

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

   • The "Y" measurement that is taken in front of the front axle will be a positive number.

   • The "Y" measurement that is taken behind the front axle is a negative number.
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   Illustration 11	g03790020
   Measuring for the phase center (4) ( 5) 353-2794 Receiver (4) Phase center

   1. GPS x: Measure the distance from the phase center (4) of the receiver (5) to the centerline of the machine.

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

   2. GPS y: Measure the distance from the phase center (4) of the receiver (5) to the center of the rear idler.

   3. GPS z: Measure the distance from the phase center (4) of the receiver (5) to the bottom of the track.

      When the machine is on soft terrain, measure to the bottom of the track shoe. When the machine is on hard terrain, measure to the bottom of the grouser.

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

   Reference: Refer to the side view in Illustration 9 and the sample MCU screen shot Illustration 10 as a reference guide and template to record the machine dimensions.

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

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

   Antenna Count - Enable the Antenna Count setting when using a dual antenna machine, and make visible the Slave GPS X, Y, and Z settings.

3. In the office, enter the machine offsets and the machine dimensions in the MCU.

   1. Open the MCU.

   2. Select the machine name.

   3. Select Machine > Machine Dimensions and enter the dimensions.

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

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

5. Restart the on-board system 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.