Installation of the G610 Hardware for Cat® Terrain Attachment Ready Option for Wheel Dozers{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 Dozer:

824H (S/N: ASX1-UP)

834H (S/N: BTX1-UP)

Introduction

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

The installation includes the following procedures:

• Optional alarm installation

• Display module installation

• Machine radio installation

• Satellite receiver installation

• Setting the language of the software

• Machine dimensions and measure-up

Operation and Maintenance Manual

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

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

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

Important Safety Information

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

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

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

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

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Electrocution Hazard! Keep the machine and attachments a safe distance from electrical power. Stay clear 3 m (10 ft) plus twice the line insulator length. Read and understand the instructions and warnings in the Operation and Maintenance Manual. Failure to follow the instructions and warnings will cause serious injury or death

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

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Accidental engine starting can cause injury or death to personnel working on the equipment. To avoid accidental engine starting, disconnect the battery cable from the negative (−) battery terminal. Completely tape all metal surfaces of the disconnected battery cable end in order to prevent contact with other metal surfaces which could activate the engine electrical system. Place a Do Not Operate tag at the Start/Stop switch location to inform personnel that the equipment is being worked on.

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Personal injury or death can result from sudden machine movement. Sudden movement of the machine can cause injury to persons on or near the machine. Prevent possible injury by performing the procedure that follows before working on the machine. Move the machine to a smooth horizontal location. Move away from working machines and personnel and lower the bucket to the ground. Permit only one operator on the machine. Keep all other personnel away from machine or in view of the operator. Engage the parking brake. Stop the engine. Move the hydraulic control levers to all positions to release the pressure in the hydraulic system.

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 work tools to the ground.

4. Stop the engine.

5. Engage the machine brake.

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

Required Tools

The tools that are listed below are required to install Terrain ARO for wheel dozers.

• 10mm 1/4" drive socket

• 4mm Allen wrench

Parts Lists

The Terrain Installation Groups contain the display module, required hardware, and a USB memory module. The USB memory module contains files for the monitor operating software, system documentation, and a schematic diagram of the system.

The following groups are used:

New - 419-6931 Terrain Installation Gp

Upgrade - 419-6928 Terrain Installation Gp

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

The parts are listed in Table 1.

The following additional required parts are not included in the installation groups. The parts are either provided with a new ARO or else retained from an uninstall of an existing display.

• Four 8T-4136 Bolts

• Four 8T-4121 Hard Washers

• Four 6V-7357 Bolts

• Four 9X-8256 Washer

• One 239-0285 Bracket As (new ARO)

Optional Items

The only optional item available with this kit is the audible alarm. The display must have an audible alarm installed when a site uses Proximity Awareness (Detect). The alarm is optional for other sites.

Table 2 lists the parts contained in the alarm installation kit.

Installing the Optional Alarm

Menu - Opens the main menu

To install the optional alarm, complete these steps:

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Illustration 2	g03789844
Alarm components (50) 383-3027 Harness As (main front) connector "P11" (51) 411-8287 Harness As connector "S1" (52) CAN connector with terminating resistor (53) 444-5691 Alarm (54) 411-8287 Harness As (alarm) connector "P2" (55) Magnetic mounts (1 on all four corners)

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

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

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

3. Attach the alarm to the clean surface.

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

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

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

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

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

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

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

   Notify the office if either of the following conditions exist:

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

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

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

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

Terrain Components

Illustration 3	g03266798
Terrain components (1) 276-1457 Bracket As (2) 320-3181 Bracket As (3) 239-0285 Bracket As

Additional components (not shown) include:

• 353-2794 Satellite Receiver As

• 439-4341 Display Module

Installing the Display Module

Illustration 4	g03262018
Display module mounting bracket with plates installed (3) 239-0285 Bracket (4) 420-5739 Plate (5) 420-5738 Plate

To install the display module, complete these steps:

1. Locate the existing bracket (3) that is at the top front of the cab.

2. Attach the left-hand plate (4) and the right-hand plate (5) to the bracket. Use four M6x1 25 mm bolts and four M6 washers. Install the bolts into the weld nuts on the plates.

   Note: The plates are not interchangeable.

3. Connect the 70-pin connector of the display harness to the display module.

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Illustration 5	g03248080
Display module (6) mounted inside cab

4. Install the display module onto the plates (4) (5). Use four 8T-9364 Bolts and four 5P-4115 Washers .

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

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

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

Using Power Over Ethernet

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

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

• Power: 1-BU

• Ground: 2-BK

Installing the Satellite Receiver

Illustration 7	g03266377
Satellite receiver installation components (1) 276-1457 Bracket (9) 353-2794 Satellite Receiver (10) 8T-4136 Bolt (11) 8T-4121 Washer (12) 276-1456 Cover (13) 6V-6317 Bolt (M10) (14) 6V-5839 Washer

1. Locate the bracket (1) for the satellite receiver (9) .

   The bracket is already mounted on the top of the Roll Over Protective Structure (ROPS).

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

3. Remove the cover (12) from the bracket (1) by removing the four bolts (13) and the four washers (14). Save these parts.

4. Mount the satellite receiver onto the bracket (1). Use four bolts (10) and four washers (11) .

5. Tighten the bolts to Caterpillar standard torque specifications.

6. Reattach the cover (13) to the bracket (1). Use the bolts and the washers that were removed in Step 3.

7. Tighten the bolts to Caterpillar standard torque specifications.

8. Connect the receiver cable to the satellite receiver (10) .

Machine ID Worksheet Entries

Enter the following information for future reference:

Machine ID Number____________________

Machine Name____________________

Display Serial Number____________________

Machine Dimensions____________________

Radio Serial Number____________________

Application (Grade or Ore) ____________________

Grade Tolerance (provided by site)____________________

Using a Serial Harness

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

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

$ GPS Over CAN =0

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

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

Setting the Language

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

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

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

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

Menu - Opens the main menu

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

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Illustration 8	g03747546
"Select Language File" dialog

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

   The "Select Language File" dialog appears.

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

   • English (default)

   • French

   • Spanish

   • Swedish

   • Portuguese

   • Russian

   • Mongolian

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

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

3. Select "OK".

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

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

Using the Machine Configuration Utility

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

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

ReferenceFor information on adding the machine in Cat^® MineStar System, refer to Systems Operation, RENR9562, "Terrain User Guide".

Performing the Dimension Measurements and Measure-up

Illustration 9	g03473596
Machine Dimensions - Side View

Illustration 10	g03473597
Sample MCU screen shot

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

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

1. On the machine, measure the machine receiver offsets.
   • The "X" measurement that is taken to the right of the centerline of the machine is a positive number.

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

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

   • The "Y" measurement that is taken behind the front axle is a negative number.

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   Illustration 11	g03790019
   Measuring for the phase center (16) (9) 353-2794 Satellite Receiver (16) Phase center

   1. GPS x - Measure the distance from the phase center (16) of the satellite receiver (9) 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 satellite receiver.

   2. GPS y - Measure the distance from the phase center (16) of the satellite receiver (9) to the center of the back axle of the machine.

   3. GPS z - Measure the distance from the phase center (16) of the satellite receiver (9) to the bottom of the wheels.

2. On the machine, measure the machine dimensions:

   1. 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.

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

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.