Installation of G610 Hardware for Cat® Terrain 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

All

Introduction

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

• 389-0322 Installation Gp

• 389-0344 Installation 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, receiver harness, and chassis harness installation

• Machine radio installation

• Main rear harness installation

• Display module installation

• Main front harness installation

• Optional alarm installation

• Battery backup installation

• Power supply wiring and fuse Installation

• Dimension measurements 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 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 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.

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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 mounting the machine. Use steps and handholds whenever dismounting the machine. Before mounting the machine, clean the step and the handholds. Inspect the step and handholds. Make all necessary repairs.

Face the machine whenever mounting the machine and whenever dismounting the machine. Maintain a three-point contact with the step and with handholds.

Note: Three-point contact can be both feet and one hand. Three-point contact can also be 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 carrying tools or supplies. Do not try to dismount the machine when carrying tools or supplies. Use a hand line to pull equipment onto the platform. Do not use any controls as handholds when entering the cab or when exiting 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 blade to the ground.

4. Lower the ripper to the ground.

5. Stop the engine.

6. Engage the machine brake.

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

Required Tools

The tools in Table 1 are required to install Terrain on track-type tractors. The list contains the recommended Caterpillar service tools, as well as general-purpose tools without a specified part number.

Parts Lists

The 389-0344 Terrain Electronics kit contains the receiver, the display module, 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 389-0322 Terrain Electronics 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.

Optional Items

The optional items in Table 8 may also be required during the installation. These parts are not provided in the 389-0344 Terrain Electronics kits.

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 9 lists the parts contained in the alarm installation kit.

System Overview

The primary Terrain components include a satellite receiver, various inclination sensors, pressure switches, and a display module.

Illustration 2	g03384880
Terrain system components (1) 353-2794 Satellite Receiver (2) 439-4341 Display Module (G610 display)

Illustration 2 shows the primary Terrain components.

Illustration 3	g06122827
Representation of cables, harnesses, and main system components

Illustration 3 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

Installing the Receiver, Receiver Harness, and Chassis Harness

Note: This installation procedure requires welding.

The terms receiver, GPS or GNSS receiver, satellite receiver, and Positioning Module (PM) are synonymous. This manual uses the terms receiver and satellite receiver.

To install the GNSS receiver, 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. Determine the location for the receiver.

   Consider the following requirements when choosing the location:

   • Mount the receiver on top of the Rollover Protective Structure (ROPS) as close to the centerline of the machine as practical.

   • Ensure that the receiver has an unobstructed view of the sky.

   • Mount the receiver in a location that enables the operator to view the LEDs when outside the cab. The site may have a preferred location.
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   Illustration 4	g03790023
   (1) 353-2794 Satellite Receiver shown on centerline of the machine

3. Weld the 5k-5962 Boss (5/8-11) as close as possible to the centerline of the machine on top of the ROPS.
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   Illustration 5	g03455979
   The 5K-5962 Boss is shown welded to the ROPS of the machine.

4. Position the 289-9633 Plate over the Boss and fasten with the 5P-4624 Bolt.

5. Apply anti-seize compound to the bolt thread.

6. Tighten the bolt to Caterpillar standard torque specifications.
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   Illustration 6	g03455977
   The 353-2794 Satellite Receiver is shown mounted on the top side of the ROPS.

7. Attach the satellite receiver to the 289-9633 Plate. Use four 8T-4195 Bolts (M10) and four 8T-4121 Hard Washers. These parts are included in the 291-2176 Receiver Mounting Gp.
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   Illustration 7	g03455980
   The satellite receiver is shown mounted on the top side of the ROPS using the shortened 289-9633 Plate

8. Alternatively, the tube on the 289-9633 Plate can be shortened to 100 mm. Follow the correct cutting procedures. If the tube is cut, then use the 0L-1169 Bolt (5/8-11).
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   Illustration 8	g01434549
   (12) 290-2928 Harness As (chassis) (13) 285-6657 Harness As (receiver)

9. Attach the chassis harness (12) to the connector on the satellite receiver. Route the chassis harness across the roof to the left ROPS post.
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   Illustration 9	g03455981
   The optional 7T-1099 Links are shown. These weld links are attached to the ROPS. The links are used for routing the receiver harness across the roof of the cab.

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   Illustration 10	g03455982
   (12) 290-2928 Harness As (chassis) (13) 285-6657 Harness As (receiver) (14) 285-6651 Harness As CAN terminator harness

10. Secure the receiver harness (13). Use 3S-8665 Clips, 8M-2773 Clips, or 7K-1181 Cable Straps.

    If the receiver harness passes through any holes in the machine, protect the harness. Use a protective wrap or use a 5P-6264 Grommet. These parts are included in the 389-0335 Machine Wiring Gp.

11. Connect the 12-pin connector of the receiver harness to the 12-pin connector of the chassis harness.

12. Connect the CAN terminator harness (14) to the 8-pin connector near the end of the chassis harness.
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    Illustration 11	g03455983
    The chassis harness (12) is shown routed down the ROPS.

13. Route the chassis harness down the back of the left ROPS post to the mounting location of the main rear harness. This location is beneath the floor plate of the cab. This method is the recommended routing.

14. If available, use the ROPS harness guide bracket to protect the harness.

15. Secure the chassis harness. Use 3S-8665 Clips, 8M-2773 Clips, or 7K-1181 Cable Straps.

    If the chassis harness passes through any holes in the machine, protect the harness. Use a protective wrap or use a 5P-6264 Grommet. These parts are included in the 389-0335 Machine Wiring Gp.

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 12	g03473636
   389-0333 Cable As (Radio) (15) "P2" to Ethernet of customer supplied radio for power (16) "P1" to main rear harness

5. Connect the standard RJ-45 Ethernet connector "P2" (15) to the customer-supplied radio. This connector also supplies power to the radio.

6. Connect the 12-pin (key D) connector "P1" (16) 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 Main Rear Harness

Illustration 13	g01434667
(6) 383-3028 Harness As (main rear) (9) 383-3027 Harness As (main front) (12) 290-2928 Harness As (20-FT) (chassis)

Note: Welding may be required during this installation.

To install the main rear harness, 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. Route the main rear harness.

   The main rear harness (6) routes from the main front harness (9) to either the radio harness or else to the chassis harness (12).

3. Connect the 12-pin connectors of the main rear harness to the chassis harness.

4. Route the main rear harness under the floor plate toward the main front harness that is located near the dash.

5. As shown in Illustration 13, secure the main rear harness using 3S-8665 Clips, 8M-2773 Clips, or 7K-1181 Cable Straps.

6. If the main rear harness passes through any holes in the machine, protect the harness.

   Use a protective wrap or use a 5P-6264 Grommet. These parts are included in the 389-0335 Machine Wiring Gp.

Installing the Display Module

Note: Welding may be required during this installation.

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.

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

Illustration 14	g03455984
The display is shown installed on the dash panel.

Either of the following options can be used to install the display:

• Mount the display to the top side of the dash panel.

• Mount the display using the 8X-7422 Bosses.

To install the display, complete these steps:

1. Proceed with the appropriate step depending on the chosen option.

   • If the 147-3452 Display Bracket will be mounted to the top side of the dash panel, then proceed to Step 2.

   • If the 147-3452 Display Bracket will be mounted to the bosses, then proceed to Step 7.
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   Illustration 15	g03455985
   Removing plastic cover on dash

2. Remove the plastic cover from the top side of the dash.
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   Illustration 16	g03455986
   Support bracket

3. Remove the support bracket that is under the plastic cover. Save the bolts and the washers.

4. Install either 147-3452 Bracket or the 169-0676 Bracket to the dash.

   1. Use the mounting holes that were used by the support bracket.

   2. Use the bolts and washers that were removed in Step 3.

   3. Install the bolts in the following order: lower outside first, then lower center, and finally the back bolts.

5. Tighten the bolts to Caterpillar standard torque specifications.

6. Proceed to Step 14 to continue with the procedure to mount the display to the dash panel.

7. Drill four 3/8 inch holes in the 147-3452 Bracket.

   Note: Use the optional 147-3417 Mount or the Dash Mount As as an alternative to modifying the 147-3452 Bracket.

8. Attach the 8X-7422 Bosses to the 147-3452 Bracket. Use four 0S-0509 Bolts (3/8-16) and four 5M-2894 Hard Washers.

9. Tighten the bolts to Caterpillar standard torque specifications.

10. Mark the location of the bosses using the bracket as a template.

11. Remove the bolts, washers, and bosses from the bracket.

12. Weld the bosses to the marked locations.

13. Mount the bracket to the bosses using the four bolts and four washers that were removed in Step 11.
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    Illustration 17	g01513986
    The exploded view of 150-1893 Vibration Isolator Mounting Gp is shown. (1) 439-4341 Display Module (G610) (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 18	g03455987
    Isolation mounts installed to 389-3032 Bracket

14. 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 17.
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    Illustration 19	g03455988
    (34) 389-3032 Bracket (37) 147-3452 Bracket

15. Attach the bracket (37) to the bracket (34) using the four 5S-7349 Bolts and 9X-6165 Washers from the 389-0332 Monitor Mounting Group.

16. Tighten the bolts to Caterpillar standard torque specifications.
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    Illustration 20	g03455989
    Display tilted after installation of lower bolts to ease installation of cables

17. Attach the display to the bracket (34).

    Install the lower 8T-9364 Bolts and 8T-4205 Hard Washers first to allow the display to tilt and gain access to the harnesses.

    The remaining bolts and washers will be connected beginning in Step 20 after the harnesses are installed.

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

    The 126-1774 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 (main front) (2b) (not used) (2c) P3 of the main front harness to the power port (2d) P2 of the main front harness to the USB port

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

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

    2. Connect the gray P3 (key A) 12-pin connector (2c) to the Power 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 USB port (bottom).

20. Install the third 8T-9364 Bolt (1/4-20) and 8T-4205 Hard Washer to the left-hand top of the display.
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    Illustration 22	g03455991
    383-3027 Harness As installed on bracket (9) 383-3027 Harness As (main front) (34) 389-3032 Bracket (46) 130-5300 Clips (47) 370-4060 Receptacle

21. Attach the clip (46) to the outside of the bracket (34). Use the last 8T-9364 Bolt (1/4-20) and 8T-4205 Hard Washer. Refer to Illustration 22.

22. Install the receptacle (47) to the 237-0164 Plug of the main front harness.

23. Attach the 237-0164 Plug to the 130-5300 Clip. Refer to Illustration 22.

Installing the Main Front Harness

Illustration 23	g01473133
(3) 167-8984 Battery (backup) (6) 383-3028 Harness As (main rear) (9) 383-3027 Harness As (main front)

The main front harness (9) routes between the G610 display, the battery backup, and the main rear harness (6).

To route the main front harness, complete these steps:

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Illustration 24	g03455992
The installed main front harness is shown.

1. Route the main front harness as follows to ensure that there is no need to remove the 70-pin connector from the harness:

   1. Start routing the harness at the display.

   2. Route the harness behind the dash.

   3. Route the harness through the floor plate to the battery backup (3) and to the connections of the rear main harness (6).

2. Connect the 12-pin connector of the main front harness to the 12-pin connector of the main rear harness.

3. Route the 3-pin power connector to the mounting location of the battery backup. This 3-pin connector breaks off from the main front harness.
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   Illustration 25	g03455993
   The main front harness is shown securely clamped. (9) 383-3027 Harness As (main front) (46) 8M-2773 Clip

4. As shown in Illustration 25, secure the main front harness. Use 3S-8665 Clips, 8M-2773 Clips, or 7K-1181 Cable Straps.

   If the harness passes through any holes in the machine, protect the harness.

   Use a protective wrap or use a 5P-6264 Grommet. These parts are included in the 389-0335 Machine Wiring Gp.

Installing the Optional Alarm

Menu - Opens the main menu

To install the optional alarm, complete these steps:

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Illustration 26	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.

Battery Backup

Illustration 27	g03455994
The 167-8984 Battery Gp (backup) mounted inside the cab below the floor plate

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 access to the battery.
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   Illustration 28	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 29	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 30	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)

   Either location is acceptable.

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.

Illustration 31	g01275837
(A) Power harness (black cable) from the buddy seat compartment (overhead) (B) Unswitched +24 V power source, tied to +battery side (C) Switched power source, tied to power relay/key start switch side

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

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Illustration 32	g01272040

1. Cut a 31.75 mm (1.25 inch) hole in the floor to route the power harness to the electrical cabinet.

   The electrical cabinet is located below the cab. The 3-pin connector remains at the 167-8984 Battery location. The three flying leads are routed through the hole to the electrical cabinet.

2. Turn the key start switch to the OFF position.
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   Illustration 33	g01268941
   Electrical schematic for installing power harness and fuses

3. Referring to Illustration 33, 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.

4. 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.

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

Performing the Initial Power Checks

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:

Show/hide table

Illustration 34	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, "Cat^® Terrain User Guide".

Performing the Dimension Measurements and Measure-up

Illustration 35	g03473540
Machine Dimensions - Side View

Illustration 36	g03455995
Sample MCU screen shot

Reference: Refer to the side view in Illustration 35 and the sample MCU screen shot Illustration 36 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.
   Show/hide table

   Illustration 37	g03790024
   Measuring for the phase center (56) ( 1) 353-2794 Receiver (56) Phase center

   1. GPS x - Measure the distance from the phase center (56) of the receiver (1) 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 (56) of the receiver (1) to the center of the rear idler.

   3. GPS z - Measure the distance from the phase center (56) of the receiver (1) 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:

   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.