Installation of G610 Hardware for Cat® Terrain for 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 single antenna front shovels:

• 389-0329 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 to complete.

The installation includes the following procedures:

• Receiver, receiver harness, and chassis harness installation

• Wireless 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. Also, ensure that the product will not be damaged or made unsafe by the operation, lubrication, maintenance, or repair procedures that are used.

Show/hide table

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.

Show/hide table

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

Show/hide table

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

Show/hide table

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.

Show/hide table

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.

Show/hide table

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

Show/hide table

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

In addition to the normal safety precautions that are taken in the day to day operation of heavy machinery, the following steps are recommended:

1. Move the machine to a suitable location. The location should be smooth, level, and out of direct sunlight.

2. Move away from other working machines and personnel.

3. Lower the bucket 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 in Table 1 are required to install Terrain on front shovels. The list contains the recommended Caterpillar service tools, and general-purpose tools without a specified part number.

Parts Lists

The 389-0344 Terrain Electronics Ar contains the receiver, 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.

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

Note: During installation, do not extend the serial cables or the CAN cables. If any cable is not of sufficient length, then contact your Caterpillar distributor for detailed instructions as to how to proceed with your installation.

Satellite Receiver Mast Parts

Use the parts in Table 8 to fabricate a mast for the receiver. These parts are not included in the 389-0344 Terrain Electronics Ar.

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 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 10 lists the parts contained in the alarm installation kit.

System Overview

The primary Terrain components include a 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	g06217656
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

Refer to Table 11 for procedures that require welding.

Installing the Receiver, Receiver Harness, and Chassis Harness

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 (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.

   Show/hide table

   Illustration 4	g01266513
   Typical mounting location of 7 ft mast

2. Determine the mounting location of the 7 ft (2.1 m) mast assembly for the satellite receiver.

   Reference: Refer to Special Instruction, REHS1729, "Receiver Mast Fabrication" for instructions that detail the construction of a 7 ft mast for the satellite receiver.

   Consider the following requirements when choosing the location:

   • Locate the mast on the rear counterweight as far to the back and to the center as possible.

   • 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.
   Show/hide table

   Illustration 5	g01275799

3. Drill and tap the mast assembly.

4. Bolt or weld the mast assembly to the rear counterweight.
   Show/hide table

   Illustration 6	g02980759

5. Attach the satellite receiver to the mounting bracket. Use the four 8T-4195 Bolts and the four 8T-4121 Hard Washers from the 291-2179 Receiver Mounting Group.

6. Tighten the bolts to the standard Caterpillar torque specifications.
   Show/hide table

   Illustration 7	g01275807
   Cable tray under the floor grate

7. Attach the 285-6657 Harness As (receiver) to the connector on the satellite receiver and route the harness down the mast.

8. Connect the 285-6655 Harness As (chassis) to the receiver harness. Use cable ties to secure both harnesses to the mast.
   Show/hide table

   Illustration 8	g01275811
   This view is from outside of the cab riser. The supplied grommet is installed.

9. Route the chassis harness under the floor grating. Route the harness toward the cab riser that is below the cab.

   Apply sheathing to any exposed harness that could come in contact with surfaces that are hard, sharp, or coarse during machine operation. This preventive measure will help to prevent damage or premature wear to the harness.

10. Use a hole saw or a punch to cut a 31.75 mm (1.25 inch) hole above the electrical cabinet. The electrical cabinet is located in the cab riser below the operator station.

Note: Gather the excess harness and then secure the harness near the electrical cabinet.

Illustration 9	g01275815
Harness that has been coiled and attached to a weld boss

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.
   Show/hide table

   Illustration 10	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 Main Rear Harness

The 383-3028 Harness As (main rear) routes from the 383-3027 Harness As (main front) to the 290-2928 Harness As (20-FT) (chassis).

To install the main rear harness, complete these steps:

1. Route the main rear harness.

2. Connect the 12-pin connectors of the main rear harness (6) to the chassis harness.

3. Route the main rear harness toward the main front harness.

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

5. 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 389-0342 Machine Wiring Gp.

   Note: Ensure that the harness is routed and restrained in a manner that does not create a trip hazard.

Installing the Display Module

Note: Welding may be required during this installation.

To mount the display on the machine, 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. 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.

4. Use the bracket assembly as a template to mark the bolt pattern and then drill the holes for the display mount.

5. Remove the blank cover plate from the console to gain access to the inside area of the console.
   Show/hide table

   Illustration 11	g03773109
   Mounting hole pattern with 31.75 mm (1.25 inch) hole for the harness

6. Mark the console and then drill the holes. Be careful not to damage the wires when drilling through the electrical panel.

7. Attach the 147-3417 Mount. Use the four bolts, washers, and nuts that are supplied.

8. Tighten the bolts to the standard Caterpillar torque specifications.
   Show/hide table

   Illustration 12	g03790257
   The exploded view of 150-1893 Vibration Isolator Mounting Group is shown. (2) 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)

   Show/hide table

   Illustration 13	g03455987
   Isolation mounts installed to 389-3032 Bracket

9. 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 12.

10. Tighten the bolts to the standard Caterpillar torque specifications.
    Show/hide table

    Illustration 14	g02980757
    The display is shown installed in the cab

11. Attach the display to the 389-3032 Bracket with the four 5S-7349 Bolts and 9X-6165 Washers from the 389-0332 Monitor Mounting Group.

12. Tighten the bolts to the standard Caterpillar torque specifications.

13. 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.

    Show/hide table

    Illustration 15	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

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

    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).

Installing the Main Front Harness

The 383-3027 Harness As (main front) is routed between the display, power, and the connection to the 383-3028 Harness As (main rear).

To install the main front harness, complete these steps:

Show/hide table

Illustration 16	g01275842
Main front harness routing

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. Continue routing the harness through the floor plate to power and to the main rear harness connection.

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 167-8984 Battery (backup). This 3-pin connector breaks off from the front main harness.

4. Secure the front main harness. Use 3S-8665 Clips, 8M-2773 Clips, (46) or 7K-1181 Cable Straps.

5. 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 389-0342 Machine Wiring Gp.

   Note: Ensure that the harness is routed and restrained in a manner that does not create a trip hazard.

Installing the Optional Alarm

Menu - Opens the main menu

To install the optional alarm, complete these steps:

Show/hide table

Illustration 17	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 18	g03473676
The installed 167-8984 Battery Gp (battery 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 access to the battery.
   Show/hide table

   Illustration 19	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 20	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.
   Show/hide table

   Illustration 21	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 Harness and Fuses

The 167-8703 Wire As (power harness) 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 22	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 harness and fuses, complete these steps:

Show/hide table

Illustration 23	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.
   Show/hide table

   Illustration 24	g01268941
   Electrical schematic for installing power harness and fuses

3. Referring to Illustration 24, 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. The harness 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 25	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.

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

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 26	g03775198
Machine Dimensions - Side View

Illustration 27	g03775203
Machine Dimensions - Top View

Reference: Refer to the side view in Illustration 26 and the top view in Illustration 27 as a reference guide to record the measurements.

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 28	g03790280
   Measuring for the phase center (5) ( 1) 353-2794 Receiver (5) Phase center

   1. GPS x - Measure the distance from the phase center (5) 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 (5) of the receiver (1) to the centerline of the center of rotation for the machine.

   3. GPS z - Measure the distance from the phase center (5) 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 machine dimensions.

   1. Cable Shovel Point Sheave - Measure the distance between the center of rotation of the shovel and the outer edge of the point sheave measured parallel to the center line of the machine.

   2. Toe Radius - Measure from the center of rotation of the machine to the toe of the dig face. Measured parallel to the center line of the machine. Measure the toe radius along with the maximum bucket reach. Determine the crest and toe lines respectfully, when exporting progress lines in Cat MineStar System. The mine must survey the actual toe and crest lines to determine what the real numbers should be in toe radius.

   3. Front Shovel Bucket Width - Measure between the outer edges of the bucket measured across the cutting edge of the bucket.

   4. Front Shovel Machine Width - Measure between the outside edges of the front shovel (single antenna) machine body (not including hand rails) measured perpendicular to the machine center line.

   5. Front Shovel Max Reach - Measure the distance between the front shovel center of rotation and the maximum reach of the machine measured parallel to the center line of the machine. Measure the maximum bucket reach along with the toe radius. Determine the crest and toe lines respectively, when exporting progress lines in Cat MineStar System. The mine must survey the actual toe and crest lines to determine what the real numbers should be in this field.

   6. Front Shovel Track Length - Measure between the front outside edge and rear outside edge of the track measured parallel to the track.

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 by completing these steps:

   1. Move the machine origin to a known point.

   2. Compare the Northing, Easting, and Elevation.