Installation of G610 Hardware for Cat® Terrain for Wheel Tractor-Scrapers {7605} Caterpillar

Machine Control and Guidance Products

TERRAIN GRADING (S/N: TFE1-UP)

TERRAIN LOADING (S/N: TFL1-UP)

TERRAIN OFFICE (S/N: TER1-UP)

Wheel Tractor-Scraper

All

Introduction

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

• 389-0329 Installation Gp

• 389-0320 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

• Initial power checks

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

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

Note: Three-point contact can be both feet and one hand or a single foot and two hands.

Do not mount a moving machine. Do not dismount a moving machine. Never jump off the machine. Do not try to mount the machine when you carry tools or supplies. Do not try to dismount the machine when you are carrying tools or supplies. Use a hand line to pull equipment onto the platform. Do not use any controls as handholds when you enter the cab or when you exit the cab.

General Preparation

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

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

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

2. Move away from other working machines and personnel.

3. Lower the bowl to the ground.

4. Stop the engine.

5. Engage the machine brake.

6. Position wheel chocks.

7. Power the machine down.

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

Required Tools

The tools listed in Table 1 are required to install Terrain on wheel tractor-scrapers. 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 Ar contains the receiver, the display, and a USB memory module drive. The USB memory module contains files for the monitor operating software, system documentation, and a schematic diagram of the system.

The 389-0320 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.

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 389-0320 Terrain Installation Ar.

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	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.

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   Illustration 4	g00992402
   The mast is mounted on a 620 G-Series wheel tractor- scraper.

2. Position the 353-2794 Satellite Receiver. Attach the assembly to a 4 foot antenna mast directly behind the bowl of the machine close to the rear axle.

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

   Consider the following requirements when choosing the location:

   • The mounting location should not impede normal operation of the machine.

   • The mounting location should not impede the fueling of the machine.

   • The mounting location should be rigid enough to avoid excess vibration and flexing of the sheet metal.

   • The mounting location should provide the satellite receiver with an unobstructed view of the sky.

   Additionally, consider the following when choosing the location:

   • Length of the 285-6657 Wiring Harness for the receiver

   • Visibility of the indicator lights on the satellite receiver

   • Direct or mirrored views of the operator

3. Route and loosely install the 285-6657 Harness As prior to mounting the mast for the satellite receiver.
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   Illustration 5	g03790023
   (1) 353-2794 Satellite Receiver shown on centerline of the machine (track-type tractor is shown for illustration)

4. Weld the 156-8045 Plate as close as possible to the centerline of the machine. Position the plate directly behind the bowl close to the rear axle. This plate will be attached to the 147-3449 Plate of the 4 foot antenna mast.

   Note: As per Caterpillar guidelines, welding the 147-3449 Plate of the 4 foot mast directly to the machine is not an approved procedure.

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   Illustration 6	g01516253
   (16) 147-3448 Gusset (17) 8T-2647 Tube (18) 8T-9380 Bolt (19) 8T-5360 Washer (20) 147-3449 Plate (21) 156-8045 Plate

5. Position the plate (20) of the 4 foot mast that was fabricated in Step 2 over the threaded plate (21). Secure the two plates together using eight bolts (18) and eight washers (19).

6. Apply anti-seize compound to the threads of the bolts.

7. Tighten the bolts to Caterpillar standard torque specifications.

8. Attach the satellite receiver to the 289-9630 Plate. Use four 8T-4195 Bolts (M10) and four 8T-4121 Hard Washers. These parts are included in the 291-5398 Receiver Mounting Gp.

   Note: Mount the satellite receiver in a location that enables the operator to view the LEDs when outside the cab. The site may have a preferred location. The recommended orientation is to have the LEDs visible from the rear of the machine.

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   Illustration 7	g01516314
   Wiring harness mounting hardware (13) 285-6657 Harness As (receiver) (22) 8M-2770 Clip (23) 5D-0353 Locking Bolt (24) 6V-8801 Nut (25) 8T-4896 Hard Washer

9. Attach the receiver harness (13) to the connector on the satellite receiver. Route the harness down the 4 foot mast.

10. Secure the receiver harness in multiple locations on the 4 foot mast. Use the parts from Table 12 at each point. These parts are included in the 291-5398 Receiver Mounting Gp.
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    Table 12

    Parts from 291-5398 Receiver Mounting Group to secure receiver harness
    Qty	Part Number	Description
    1	8M-2770	Clip
    1	5D-0353	Locking Bolt (3/8-16)
    1	6V-8801	Nut
    2	8T-4896	Hard Washer

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    Illustration 8	g01516315
    Harness routing (12) 285-6655 Chassis Harness As (75-FT) (13) 285-6657 Harness As (receiver) (14) 285-6651 Harness As (CAN terminator)

11. Connect the 12-pin connector of the receiver harness (13) to the 12-pin connector of the chassis harness (12).

12. Connect the CAN terminator (14) to the 8-pin connector near the end of the chassis harness.
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    Illustration 9	g00992430
    The exposed receiver harness is covered with rubber tubing.

13. Route the chassis harness.

    Route the harness along the side of the bowl to the mounting location of the 383-3028 Harness As (main rear) (7). This location is near the cab. Follow the route of the existing hydraulic hoses from the back of the wheel tractor-scraper. This routing is the recommended routing for the harness.

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    Illustration 10	g00992418
    A close-up view of the harness trough fabricated from 2 inch angle iron stock

14. Secure the chassis harness.

    Use optional 2 inch angle iron along the side of the bowl to create a channel for routing the harness.

15. 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 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 11	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

Note: Welding may be required during this installation.

The 383-3028 Harness As (rear main) routes from the 383-3027 Harness As (rear front) to either the 389-0333 Cable As (radio) or else to the 285-6655 Harness As (20-FT) (chassis).

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.

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

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

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

6. 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.

7. Connect the 6-pin connector of the main rear harness to the 6-pin connector of the 278-7396 Wire.

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 12	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. Determine the option that will be used for the installation.
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   Illustration 13	g01516333
   Contents of 167-8604 Monitor Mounting Group (26) 8X-7422 Boss (27) 147-3417 Mount (28) 3Y-7829 Boss (29) 5M-2894 Hard Washer (30) 0S-0509 Bolt

2. Attach the bosses (26) to the mount (27). Use the mounting hardware in Table 4.

   If mounting the display to the ceiling, then score the padding, the lining, or the insulation. Remove the scored material. Remove enough insulation to allow sufficient space for welding the bosses.

   Note: Use the optional 3Y-7829 Bosses (28) with the 8X-7422 Bosses (26) if additional length is needed to install the mount (27).

3. Mark the location of the bosses. Use the mount as a template.

4. Remove the bolts, washers, and bosses from the mount.

5. Weld the bosses to the marked locations.

6. Mount the 389-3032 Bracket to the bosses. Use the four bolts and four washers that were removed in Step 4.
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   Illustration 14	g03790257
   The exploded view of 150-1893 Vibration Isolator Mounting Group is shown. (21) 439-4341 Display Module (34) 389-3032 Bracket (35) 8T-4205 Hard Washer (36) 8T-9364 Bolt (1/4-20) (39) 8C-5607 Isolation Mount (40) 8C-5608 Spacer (41) 9X-6165 Washer (42) 4M-5282 Bolt (1/4-20)

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   Illustration 15	g03455987
   Isolation mounts installed to 389-3032 Bracket

7. Assemble the eight isolation mounts (39) and the four spacers (40) to the u-shaped bracket (34). Use four washers (41) and four bolts (42). Refer to Illustration 14.

8. Tighten the bolts to Caterpillar standard torque specifications.

9. Attach the u-shaped bracket (34) to the 147-3417 Mount. Use four 4M-5282 Bolts and four 9X-6165 Washers from the 389-0332 Monitor Mounting Gp.

10. Tighten the bolts to Caterpillar standard torque specifications.

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

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

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    Illustration 16	g03455989
    Display tilted after installation of lower bolts to ease installation of cables

12. Attach the 439-4341 Display Module to the 389-3032 Bracket. Install the lower 8T-9364 Bolts and 8T-4205 Hard Washers first to allow the display to tilt and make it easier to install the harnesses.

    Note: The remaining bolts and washers will be connected beginning in Step 14 after the harnesses are installed.

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    Illustration 17	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

13. Install the 383-3027 Harness As 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).

14. 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 18	g03455991
    (9) 383-3027 Harness As (34) 389-3032 Bracket (46) 130-5300 Clips (47) Receptacle

15. 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 18.

16. Install the 370-4060 Receptacle to the 237-0164 Plug of the front harness.

17. Attach the 237-0164 Plug to the clip (46). Refer to Illustration 18.

18. Install the receptacle (47) to the 237-0164 Plug of the 383-3027 Harness As.

19. Attach the 237-0164 Plug to the 130-5300 Clip. Refer to Illustration 18.

Installing the Main Front Harness

The 383-3027 Harness As (main front) routes between the 439-4341 Display Module, 167-8984 Battery (backup), power, and the 383-3028 Harness As.

To install the main front harness, complete these steps:

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

   1. Start routing the harness at the display.

   2. Route the harness either behind the dash or else through the headliner and down the support post.

   3. Route the harness through the floor plate to the battery backup (3) and to the connections of the rear main harness (6) that was installed earlier.
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   Illustration 19	g00993694
   Main front harness routed through floor plate

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 20	g01513994
   The main front harness is shown securely clamped. (9) 383-3027 Harness As (main front) (46) 8M-2773 Clip

4. As shown in Illustration 20, secure the main front harness (9). 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 389-0335 Machine Wiring Group.

Installing the Optional Alarm

Menu - Opens the main menu

To install the optional alarm, complete these steps:

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Illustration 21	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 22	g03455994
The installed 167-8984 Battery (Battery Backup) is shown.

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 23	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 24	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 25	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.

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

1. Turn the key start switch to the OFF position.
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   Illustration 26	g01268941
   Electrical schematic for installing power harness and fuses

2. Referring to Illustration 26, route the 167-8703 Wire from the 167-8984 Battery to the Run relay.

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

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

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

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

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

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

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

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

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 27	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 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 Administration and Configuration Guide".

Performing the Dimension Measurements and Measure-up

Illustration 28	g06122911
Machine Dimensions - Side View

Note: The satellite receiver is shown mounted on the cab in Illustration 28. The correct mounting location for the receiver is on the bowl mounted to a 4 foot Mast.

Illustration 29	g06122914
Machine Dimensions - Top View

Reference: Refer to the side view in Illustration 28 and the sample MCU screen shot Illustration 29 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 30	g03790017
   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 (10) 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 axle of the machine.

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

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

   Scraper Cut Width - Measure the distance between the outside edges of the cutting edge of the scraper bowl measured parallel to the scraper cutting edge.

   Scraper Wheel Base - Measure the distance between the center line of the rear wheel axle and the center line of the front wheel axle measured parallel to the center line of the machine.

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.