Procedure to Install Machine Automation System on R1600H Load Haul Dump Machines {7000, 7600} Caterpillar

Load Haul Dump

R1600H (S/N: 9SD1-185)

Introduction

This special instruction covers the procedure to install Machine Automation System (MAS) on R1600H (S/N: 9SD1-185) Load Haul Dump machines. This supplemental product support literature should be used with the appropriate Service Manual and the appropriate Parts Manual that is available for this standard machine.

Read the entire Special Instruction. Understand the information before you perform any procedures. Understand the information before you order any parts.

Safety Section

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.

Ensure that all personnel are safe when using a tool, procedure, work method, or operating technique not recommended by Caterpillar. Ensure that the product will not be damaged or the product made unsafe by the operation, lubrication, maintenance, or the repair procedures that are used.

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Hot oil and hot components can cause personal injury. Do not allow hot oil or hot components to contact the skin.

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Personal injury or death can result from machine articulation or movement. Machine frames can move and a person can be crushed. Connect the steering frame lock between the front and rear frames before working on the machine. Before operating the machine, place the steering frame lock in the stored position. Failure to place the steering frame lock into the stored position before operating can result in loss of steering.

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Personal injury can result from flame cutting or welding on painted areas. The effect of gasses from burned paint is a hazard to the person doing the cutting or welding. Do not flame cut or weld on painted areas.

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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

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NOTICE
Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

Reference Section

Reference: Service Manual, RENR8594, "Machining and Welding Information for Load Haul Dumps".

Reference: Special Instruction, REHS1841, "General Welding Procedures".

Reference: Disassembly and Assembly, UENR1457, "R1600H Load Haul Dump Machine Systems".

Parts Required

The parts that you order will depend upon whether your machine includes ROPS or FOPS. We recommend that you consult with your Caterpillar Dealer before ordering parts for this special instruction.

Table 1

Parts Required for R1600H (S/N: 9SD1-185) with ROPS
Qty	Part Number	Description
1	366-4013 OR 423-8805	Camera and Mounting Gp (Front 78º) OR Camera and Mounting Gp (Front 115º)
1	366-7696	Communication Radio Gp
1	469-4093	Command Installation Ar (ROPS)

Table 2

Parts Required for R1600H (S/N: 9SD1-185) with FOPS
Qty	Part Number	Description
1	366-4013 OR 423-8805	Camera and Mounting Gp (Front 78º) OR Camera and Mounting Gp (Front 115º)
1	366-7696	Communication Radio Gp
1	469-4094	Command Installation Ar (FOPS)

Prerequisites

Machine Inspection

This sheet is to be competed prior to installation of Command for Underground systems on used equipment. This information provides a base line of the machine specifications and condition.

Table 3

Date Machine Inspected	Inspected By		Job No	Location of Machine
Owners Name	Address			Phone Number
Equipment Attachments		Model	Serial No	Arrangement No
Customer Machine No		Operators Compartment	A/C Cab [___]	FOPS [___]
SMR Reading		Machine in Operating Condition	Yes [___] No [___]
Are Pictures included with this report (Preferred)			Yes [___] No [___]
Where was inspection carried out			Surface [___] Workshop [___] Underground [___]
Ref No	Description	Items to check	Comments
1	VIMS	VIMS installation	Is VIMS and harness fitted? Yes [___] No [___]
2	Remote Control	Remote control interface must be installed & operational, including: hydraulic interface valve harnesses
3	Remove Guards & Clean	Remove guards as required and clean machine for thorough inspection
4	Front Frame (Not Engine End)	Lift cylinder & tilt cylinder should not have excessive movement
5	Hydraulic Brake System	Service and park brake system to be as per specifications and functional
6	Steering Valves and Lines	1. Check system for leaks, report location, and severity. Operate system to ensure correct operation 2. Check damage and correct installation of hosing 3. Check & record steering relief pressure 4. Check & record steering cycle time. Ensure that times are within specification	Is reversible steering fitted? Yes [___] No [___] Steering relief pressure [_____] psi Steering cycle time left to right [_____] sec Steering cycle time right to left [_____] sec
7	Articulation	Check steering cylinder pins & hitch bearings for excessive wear or movement
8	Radiator Guard	No radiator guard damage that may inhibit new Command radiator top cover being installed
9	Firewall & Engine Covers	Ensure that firewalls are installed as Command component are installed
10	Hydraulic Tank	Cavity above hydraulic tank must be clear to allow installation of interface control module, ECM, and harnesses
11	Main Hydraulic Valve and Pilot Control Valve	1. Check valve for leaks 2. Check relief valve pressures and record all readings 3. Inspect and report condition of pilot control valve 4. Check main relief pressure 5. Check tilt head & rod end pressures 6. Check main line relief pressure. Check raise & crowd cycle times	Main relief pressure [_____] psi Tilt head end relief pressure [_____] psi Tilt rod end relief pressure [_____] psi Main line relief pressure [_____] psi Raise cycle time [_____] sec Crowd Cycle time [_____] sec
12	Electrical	Check harnesses are installed and secured correctly
13	Active & Logged Codes	Check & rectify any logged and/or active codes: Engine ECM, Power Train ECM, EMS ECM, EAM/VIMS ECM
14	Rims & Tires	Tires should be in good condition & within recommended wear limits
15	Front Mud Guards	Front mudguards to be in good condition to prevent damage and splashing to front camera & LADAR
16	Cab	Cab roof top and hand rails must not be bent or damaged to allow installation of LADAR mounting brackets
17	Tow Hitch	Ensure that brake release system is operational if applicable. (For stope retrieval reasons)

Table 4

Non-Standard Customer Additions
Ref No	Description	Comments

Machine Preparation

1. Move the machine to a hard level surface away from operating machines and away from personnel.

2. Engage the parking brake. Place wheel blocks in front of the wheels and behind the wheels.

3. Stop the engine.

4. De-grease and pressure clean machine.

5. Raise lift arms and install locking pins.

6. Install the steering frame lock. Refer to Disassembly and Assembly, "Steering Frame Lock - Remove and Install".

7. Turn the key start switch and the battery disconnect switch to the OFF position. If there is no battery disconnect switch, remove the negative battery cable at the battery. Disconnect the battery if welding on the machine frame is required.

8. Remove radiator cover and deck cover group.

9. Remove firewall covers.

10. Remove cabin pressurizer and covers.

11. Remove upper cab lighting.

12. Remove front frame covers.

13. Remove the fire extinguisher and the fire extinguisher mounting bracket (if fitted).

Frame Modifications

Parts for Frame Modifications

Table 5

Parts for Frame Modifications(1)
Qty	Part No	Description
4	2Y-5829	Nut
6	5P-7970	Nut
1	7T-1099	Link
2	163-5831	Boss
1	292-7180	Grommet
1	346-2415	Plate
1	443-3798	Tapped Block

(1)	These parts are part of 469-4093 Command Installation Ar (ROPS) and 469-4094 Command Installation Ar (FOPS)

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Illustration 1	g06016036
View of Left Side of Front Frame (1) 7T-1099 Link (A) 41 ± 3 mm (1.61 ± 0.12 inch) (B) 80 ± 3 mm (3.15 ± 0.12 inch)

1. Weld Link (1) in position on the frame. Refer to Illustration 1 and Table 6.
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   Table 6

   Item	Description
   W1	3 mm (0.12 inch) fillet weld

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   Illustration 2	g06016037
   View of Front Frame (2) 346-2415 Plate (C) 60 ± 1 mm (2.4 ± 0.04 inch) (D) 55 ± 1 mm (2.17 ± 0.04 inch)

2. Weld 346-2415 Plate (2) in position on the frame. Refer to Illustration 2 and Table 7.
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   Table 7

   Item	Description
   W2	6 mm (0.24 inch) fillet weld all around

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   Illustration 3	g06023668
   Modifications to 370-2654 Plate (if required) (3) 370-2654 Plate (4) Hatched area to be removed (if required) (E) 125 mm (4.9 inch) (F) 48 mm (1.9 inch)

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   Illustration 4	g06016038
   Location of 370-2654 Plate (3) 370-2654 Plate (5) 370-2665 Guard As (G) 179 ± 1 mm (7.0 ± 0.04 inch) (H) 560 ± 1 mm (22.0 ± 0.04 inch)

3. Modify 370-2654 Plate (3) and weld in position on the frame (if required). Refer to Illustration 3, Illustration 4, and Table 8.
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   Table 8

   Item	Description
   W3	5 mm (0.20 inch) fillet weld all around

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   Illustration 5	g03832229
   View of Left Side of Rear Frame (5) 370-2665 Guard As (J) 132 mm (5.2 inch) (K) 55 mm (2.2 inch) (L) 170 mm (6.7 inch) (M) 616 mm (24.3 inch) (N) 416 mm (16.4 inch) (P) 375 mm (15 inch) (Q) 405 mm (16 inch) (R) 455 mm (18 inch)

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   Illustration 6	g03864179
   View of Left Side of Rear Frame Modifications Required to 370-2665 Guard As (5) 370-2665 Guard As (6) 9.5 mm (0.374 inch) hole (7) 10.5 mm (0.413 inch) hole

4. Drill four 9.5 mm (0.374 inch) holes in Guard As (5) at locations (6). Drill four 10.5 mm (0.413 inch) holes in Guard As (5) at locations (7). Refer to Illustration 5 and Illustration 6.
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   Illustration 7	g06023664
   View of Left Side of Rear Frame Modifications Required to 370-2665 Guard As (5) 370-2665 Guard As (8) 5P-7970 Nut (9) 2Y-5829 Nut

5. Weld four 5P-7970 Nut (8) into position. Weld four 2Y-5829 Nut (9) into position. Refer to Illustration 7 and Table 9.
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   Table 9

   Item	Description
   W4	3 mm (0.12 inch) fillet weld
   W5	3 mm (0.12 inch) fillet weld

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   Illustration 8	g03833587
   View of Left Side of Rear Frame Modifications Required to 370-2665 Guard As (5) 370-2665 Guard As (S) 15 mm (0.59 inch) (T) 165 mm (6.5 inch) (U) 75 mm (2.95 inch)

6. Drill two 9.5 mm (0.374 inch) holes in 370-2665 Guard As (5). Refer to Illustration 8.
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   Illustration 9	g06016039
   View of Left Side of Rear Frame Modifications Required to 370-2665 Guard As (5) 370-2665 Guard As (10) Hatched area to be removed (if required) (11) 45 degree cut (12) 5P-7970 Nut (behind guard) (13) 443-4992 Plate (V) 360 ± 1 mm (14.17 ± 0.04 inch) (W) 390 ± 1 mm (15.35 ± 0.04 inch) (X) 500 mm (19.7 inch)

7. Weld two 5P-7970 Nut (12) into position. Modify plate (11) (if required) or weld new 443-4992 Plate (13) into position. Refer to Illustration 9 and Table 10.
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   Table 10

   Item	Description
   W6	3 mm (0.12 inch) fillet weld
   W7	5 mm (0.20 inch) fillet weld

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   Illustration 10	g06016041
   View of Rear Frame Transmission Compartment Modifications Required to Frame (14) 163-5831 Boss (15) 45 Degree angle (16) 443-3798 Tapped Block (17) Slot (18) 292-7180 Grommet (Y) 30 mm (1.18 inch) (Z) 75 mm (3 inch) (AA) 202 ± 1 mm (7.95 ± 0.04 inch) (AB) 107 ± 1 mm (4.21 ± 0.04 inch) (AC) 167 mm (6.58 inch)

8. Weld Boss (14) into position. Weld tapped block (16) into position. Refer to Illustration 10 and Table 11.
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   Table 11

   Item	Description
   W8	3 mm (0.12 inch) fillet weld
   W9	6 mm (0.24 inch) fillet weld all around

9. Modify existing hole in frame to form slot (17). The angle (15) for the slot is 45 degrees. Refer to Illustration 10 and Table 11.

10. Install 292-7180 Grommet (18) to Slot (17).
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    Illustration 11	g06016043
    View of Left Side Rear Frame Behind Articulation Modifications Required to Frame (19) 163-5831 Boss (AD) 6 ± 3 mm (0.24 ± 0.12 inch) (AE) 6 ± 3 mm (0.24 ± 0.12 inch)

11. Weld Boss (19) into position. Refer to Illustration 11 and Table 12.
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    Table 12

    Item	Description
    W10	3 mm (0.12 inch) fillet weld

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    Illustration 12	g06018774
    Modifications to 370-2693 Cover As Transmission (20) 15 mm (0.6 inch) Radius (21) Remove this Section (22) 30 mm (1.18 inch) Radius (23) 370-2693 Cover As (AF) 605 ± 1 mm (23.82 ± 0.04 inch)

12. Trim excess section (21) off Transmission Cover As (23). Refer to Illustration 12.
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    Illustration 13	g06014373
    Modifications to 386-0027 Mount As Hydraulic Tank (24) Drill and tap 3/8-16 (25) 386-0027 Mount As (AG) 72.5 mm (2.85 inch) (AH) 300 mm (11.81 inch)

13. Drill and tap one hole (24), in 386-0027 Mount As (25) (if required). Refer to Illustration 13.
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    Illustration 14	g03864161
    View of Rear Frame Transmission Compartment Modifications to Fire System Mount (30) 451-8249 Mount

14. If a fire system has been installed, remove and discard existing mount and install fire suppression nozzle mount (30), using existing hardware. Refer to Illustration 14.

Wiring Modifications

Parts for Wiring Modifications

Table 13

Parts for Wiring Modifications(1)
Qty	Part No	Description
1	5S-7379	Bolt
1	8T-4896	Hard Washer
1	116-0118	Clip
1	384-0010	Rear Harness As (Revision 05 or Higher)

(1)	These parts are part of 469-4093 Command Installation Ar (ROPS) and 469-4094 Command Installation Ar (FOPS)

Check that 384-0007 Lighting Harness As is revision four or higher.

Check that 385-7800 Panel Harness As is revision two or higher.

Check that 385-7801 Cab Harness As is revision two or higher.

Check that 385-7802 Cab Harness As is revision two or higher.

Check that 384-0010 Rear Harness As is revision five or higher.

Install Clip for 384-0010 Rear Harness As

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Illustration 15	g06139765
View of Left Side Rear Frame Behind Articulation (1) 384-0010 Rear Harness As (2) 163-5831 Boss (3) 5S-7379 Bolt (4) 8T-4896 Hard Washer (5) 116-0118 Clip

1. Install Clip (5) to Boss (2), with one Bolt (3) and one Washer (4).

2. Install receptacle of Harness (1) to Clip (5).

Machine Functionality Check

The functionality of the electrical system should be verified after harness replacements. The checks include but are not limited to

• Check the engine starts

• Check the park brake releases and check that the park brake applies

• Check the machine operation for Forward, Reverse, First gear, Second gear, Third gear, and Forth gear

• Check the machine lighting

Connect Cat ^® Electronic Technician (Cat ET) and check "Active" and "Logged" codes. Rectify before commencing the Command for Underground installation.

MAS Installation Procedure

Note: Cleanliness is an important factor. Before the removal procedure, clean the exterior of the component thoroughly. Cleaning the exterior will help to prevent dirt from entering the internal mechanism.

Parts for MAS Installation

Table 14

Parts for Cab Lighting(1)
Qty	Part Number	Description
1	9M-4136	Spacer
2	219-6488	Flood Lamp Gp

(1)	These parts are part of 469-4093 Command Installation Ar (ROPS) and 469-4094 Command Installation Ar (FOPS)

Table 15

Part for Warning Lights(1)
Qty	Part Number	Description
1	459-6794	Cover As

(1)	This part is part of 469-4093 Command Installation Ar (ROPS) and 469-4094 Command Installation Ar (FOPS)

Table 16

Part for Articulation Sensor(1)
Qty	Part Number	Description
1	392-8092	Plate

(1)	This part is part of 469-4093 Command Installation Ar (ROPS) and 469-4094 Command Installation Ar (FOPS)

Table 17

Parts for 338-6691 Sensor Mounting Gp(1)
Qty	Part Number	Description
1	3B-4615	Cotter Pin
3	5S-7379	Bolt
1	6H-4006	Grommet
2	6V-8801	Nut
3	8C-4982	Bolt
6	8T-4896	Hard Washer
1	324-2101	Coupling
1	329-0711	Rotary Sensor
1	329-0779	Spacer
1	329-0780	Stud
1	338-6518	Plate
1	338-6519	Plate
1	338-6693	Rod As

(1)	These parts are part of 444-7230 Onboard Installation Ar (ROPS) and 444-7231 Onboard Installation Ar (FOPS)

Table 18

Parts for 366-3987 Plate and Film Gp(1)
Qty	Part Number	Description
4	4B-4158	Drive Screw
1	336-5837	Film Warning (Crush Hazard)
1	354-8706	Identification Plate (Year of Manufacture)
1	370-2486	Film Identification (Beacon, Horn)
1	380-0053	Serial Number Plate

(1)	These parts are part of 444-7230 Onboard Installation Ar (ROPS) and 444-7231 Onboard Installation Ar (FOPS)

Table 19

Parts for 366-3992 Camera Wiring Gp(1)
Qty	Part Number	Description
5	5P-9085	Clip
5	6K-0806	Cable Strap
2	033-8248	Clip
1	283-0657	Cable As
1	304-7877	Cable As
3	333-8153	Connection Assembly
1	336-6687	Protective Cap

(1)	These parts are part of 444-7230 Onboard Installation Ar (ROPS) only.

Table 20

Parts for 366-4011 Camera and Mounting Gp (ROPS) Rear(1)
Qty	Part Number	Description
2	5C-9553	Bolt
1	5M-3062	Bolt
1	8M-2772	Clip
1	8T-4896	Hard Washer
2	9X-8256	Washer
1	333-8153	Connection Assembly
1	336-6897	Camera Gp
1	361-8488	Plate

(1)	These parts are part of 444-7230 Onboard Installation Ar (ROPS) only.

Table 21

Parts for 366-4013 Camera and Mounting Gp (Front 78º)
Qty	Part Number	Description
4	1S-9593	Cable Strap
3	5C-9553	Bolt
4	5S-7379	Bolt
4	8T-4896	Hard Washer
3	9X-8256	Washer
1	333-8153	Connection Assembly
1	336-6897	Camera Gp 78º
1	361-8408	Plate
1	366-4014	Mount As

Table 22

Parts for 366-7696 Communication Radio Gp
Qty	Part Number	Description
1	366-7696	Communication Radio Gp

Table 23

Parts for 370-2413 Communication Wiring Gp(1)
Qty	Part Number	Description
6	2B-0941	Spacer
3	3S-2093	Cable Strap
1	4K-6177	Clip
2	4L-6454	Bolt
2	4L-9337	Bolt
3	4S-1962	Clip
6	6V-8801	Nut
9	7K-1181	Cable Strap
4	8T-2501	Bolt
14	8T-4896	Hard Washer
10	033-8248	Clip
1	363-3405	Cable
1	370-2289	Cap
1	370-2594	Cable
1	379-9807	Cable As

(1)	These parts are part of 444-7230 Onboard Installation Ar (ROPS) only.

Table 24

Parts for 370-2414 Radio Mounting Gp(1)
Qty	Part Number	Description
2	5C-9553	Bolt
4	8T-4189	Bolt
2	8T-4200	Bolt
6	8T-4224	Hard Washer
4	8T-6912	Bolt
8	8T-9655	Isolation Mount
4	9N-0869	Hard Washer
2	9X-8256	Washer
1	116-0118	Clip
1	361-8470	Mount As
1	361-8472	Plate
4	361-8502	Spacer
1	385-9683	Cover

(1)	These parts are part of 444-7230 Onboard Installation Ar (ROPS) and 444-7231 Onboard Installation Ar (FOPS)

Table 25

Parts for 370-2489 Rotary Switch Gp(1)
Qty	Part Number	Description
1	292-0358	Rotary Switch Gp

(1)	These parts are part of 444-7230 Onboard Installation Ar (ROPS) and 444-7231 Onboard Installation Ar (FOPS)

Table 26

Parts for 370-2545 Electrical Converter Gp(1)
Qty	Part Number	Description
8	4M-5281	Bolt
8	5P-4115	Hard Washer
5	5S-7379	Bolt
5	8T-4896	Hard Washer
2	326-7068	Electrical Converter
1	370-2547	Mount As

(1)	These parts are part of 444-7230 Onboard Installation Ar (ROPS) and 444-7231 Onboard Installation Ar (FOPS)

Table 27

Parts for 370-2593 Circuit Breaker Gp(1)
Qty	Part Number	Description
2	3S-2093	Cable Strap
4	5S-7349	Bolt
2	8T-2502	Bolt
4	8T-4205	Hard Washer
2	8T-4896	Hard Washer
4	8T-9405	Bolt
1	329-0931	Circuit Breaker Panel Gp
1	338-6509	Plate
1	338-6510	Cover
1	379-9810	Cable As

(1)	These parts are part of 444-7230 Onboard Installation Ar (ROPS) and 444-7231 Onboard Installation Ar (FOPS)

Table 28

Parts for 379-9821 LADAR Sensor and Mounting Gp (ROPS) Front(1)
Qty	Part Number	Description
1	5C-2890	Nut
4	5C-9553	Bolt
6	5P-1075	Hard Washer
4	5P-4115	Hard Washer
2	5S-7383	Bolt
2	6V-8801	Nut
4	7I-2272	Bolt
2	8T-2502	Bolt
1	8T-2947	Bolt
4	8T-4197	Bolt
8	8T-9655	Isolation Mount
4	8T-9658	Spacer
4	9N-0869	Hard Washer
1	9X-8256	Washer
4	096-0192	Lockwasher
1	370-2559	Mount As
1	379-9816	Sensor Mount As
1	379-9820	Sensor
1	379-9950	Sensor Mount As
1	379-9951	Sensor Mount As
1	424-8442	Protective Cover

(1)	These parts are part of 444-7230 Onboard Installation Ar (ROPS) only.

Table 29

Parts for 379-9822 LADAR Sensor and Mounting Gp (ROPS) Rear(1)
Qty	Part Number	Description
1	5C-2890	Nut
4	5C-9553	Bolt
6	5P-1075	Hard Washer
4	5P-4115	Hard Washer
2	5S-7383	Bolt
2	6V-8801	Nut
4	7I-2272	Bolt
2	8T-2502	Bolt
1	8T-2947	Bolt
8	8T-9655	Isolation Mount
4	8T-9658	Spacer
4	9N-0869	Hard Washer
1	9X-8256	Washer
4	096-0192	Lockwasher
4	099-3649	Bolt
1	370-2559	Mount As
1	379-9820	Sensor
1	379-9905	Mount As
1	379-9950	Sensor Mount As
1	379-9951	Sensor Mount As
1	424-8443	Protective Cover

(1)	These parts are part of 444-7230 Onboard Installation Ar (ROPS) only.

Table 30

Parts for 379-9911 LADAR Sensor and Mounting Gp (FOPS) Front(1)
Qty	Part Number	Description
1	5C-2890	Nut
4	5C-9553	Bolt
4	5P-4115	Hard Washer
4	6V-5219	Bolt
4	7I-2272	Bolt
4	8T-2502	Bolt
4	8T-4896	Hard Washer
1	8T-4971	Bolt
8	8T-9655	Isolation Mount
4	8T-9658	Spacer
4	9N-0869	Hard Washer
1	9X-8256	Washer
4	096-0192	Lockwasher
1	370-2559	Mount As
1	379-9820	Sensor
1	379-9913	Sensor Mount As
1	379-9950	Sensor Mount As
1	379-9951	Sensor Mount As
1	424-8442	Protective Cover

(1)	These parts are part of 444-7231 Onboard Installation Ar (FOPS) only.

Table 31

Parts for 379-9939 Camera and Mounting Gp (FOPS) Rear(1)
Qty	Part Number	Description
2	5C-9553	Bolt
2	9X-8256	Washer
1	323-5828	Clip
1	333-8153	Connection Assembly
1	336-6897	Camera Gp
1	361-8488	Plate

(1)	These parts are part of 444-7231 Onboard Installation Ar (FOPS) only.

Table 32

Parts for 379-9940 LADAR Sensor and Mounting Gp (FOPS) Rear(1)
Qty	Part Number	Description
4	5C-9553	Bolt
4	5P-1075	Hard Washer
4	5P-4115	Hard Washer
1	5S-7383	Bolt
1	6V-8225	Nut
1	6V-8801	Nut
4	7I-2272	Bolt
2	8T-2502	Bolt
4	8T-4197	Bolt
1	8T-4971	Bolt
8	8T-9655	Isolation Mount
4	8T-9658	Spacer
4	9N-0869	Hard Washer
1	9X-8256	Washer
4	096-0192	Lockwasher
1	370-2559	Mount As
1	379-9820	Sensor
1	379-9941	Sensor Mount As
1	379-9950	Sensor Mount As
1	379-9951	Sensor Mount As
1	424-8443	Protective Cover

(1)	These parts are part of 444-7231 Onboard Installation Ar (FOPS) only.

Table 33

Parts for 380-0044 Sensor Wiring Gp(1)
Qty	Part Number	Description
2	5P-9085	Clip
2	379-9909	Cable As

(1)	These parts are part of 444-7230 Onboard Installation Ar (ROPS) and 444-7231 Onboard Installation Ar (FOPS)

Table 34

Parts for 423-8805 Camera Gp (Front 115º)
Qty	Part Number	Description
4	1S-9593	Cable Strap
3	5C-9553	Bolt
4	5S-7379	Bolt
4	8T-4896	Hard Washer
3	9X-8256	Washer
1	333-8153	Connection Assembly
1	336-6684	Camera Gp 115º
1	361-8408	Plate
1	366-4014	Mount As

Table 35

Parts for 433-6827 Radio Wiring Gp(1)
Qty	Part Number	Description
2	5C-8312	Nut
6	5W-2226	Strap
2	8C-6364	Bolt
2	8T-0328	Hard Washer
2	8T-3998	Bolt
4	096-6166	Hard Washer
1	379-9909	Cable As
1	385-9680	Cable As
2	433-1624	Electronic Filter
2	433-5107	Cable As
1	433-5127	Plate
2	433-6830	Cable As

(1)	These parts are part of 444-7230 Onboard Installation Ar (ROPS) and 444-7231 Onboard Installation Ar (FOPS)

Table 36

Parts for 435-1510 Computer Mounting Gp(1)
Qty	Part Number	Description
4	8T-4896	Hard Washer
4	9B-7237	Bolt
1	370-2549	Mount As

(1)	These parts are part of 444-7230 Onboard Installation Ar (ROPS) and 444-7231 Onboard Installation Ar (FOPS)

Table 37

Parts for 436-0204 Warning Lighting Gp(1)
Qty	Part Number	Description
4	4L-6454	Bolt
1	5S-7379	Bolt
1	6V-8801	Nut
6	8C-4982	Bolt
6	8T-4896	Hard Washer
2	130-5300	Clip
6	245-9167	Nut
6	305-3890	Screw
1	310-3397	Lighting
1	310-3398	Lighting
2	324-2119	Shield
1	361-8494	Plate

(1)	These parts are part of 444-7230 Onboard Installation Ar (ROPS) and 444-7231 Onboard Installation Ar (FOPS)

Table 38

Parts for 439-4823 Camera Wiring Gp Front(1)
Qty	Part Number	Description
2	2D-6235	Locknut
2	6K-0806	Cable Strap
1	6V-8801	Nut
1	8T-2502	Bolt
2	8T-4205	Hard Washer
2	8T-4896	Hard Washer
2	8T-9364	Bolt
2	033-8248	Clip
1	333-8153	Connection Assembly
1	366-3991	Cable As
1	366-4019	Plate

(1)	These parts are part of 444-7230 Onboard Installation Ar (ROPS) and 444-7231 Onboard Installation Ar (FOPS)

Table 39

Parts for 439-4824 Communication Wiring Gp (FOPS)(1)
Qty	Part Number	Description
2	2B-0941	Spacer
7	3S-2093	Cable Strap
3	4K-6177	Clip
2	5M-3062	Bolt
9	7K-1181	Cable Strap
2	7X-0288	Bolt
4	8T-4896	Hard Washer
6	033-8248	Clip
1	363-3405	Cable
1	370-2289	Cap
1	370-2594	Cable
1	379-9807	Cable As

(1)	These parts are part of 444-7231 Onboard Installation Ar (FOPS) only.

Table 40

Parts for 439-4825 Camera Wiring Gp (FOPS)(1)
Qty	Part Number	Description
5	5P-9085	Clip
5	6K-0806	Cable Strap
1	033-8248	Clip
1	304-7877	Cable As
3	333-8153	Connection Assembly
1	336-6687	Protective Cap
1	370-2591	Cable As

(1)	These parts are part of 444-7231 Onboard Installation Ar (FOPS) only.

Table 41

Parts for 443-3785 Communication Wiring Gp(1)
Qty	Part Number	Description
1	2B-0941	Spacer
2	4B-5324	Washer
1	4L-6454	Bolt
2	4L-9337	Bolt
1	5P-1075	Hard Washer
1	5P-7854	Clip
1	5P-8182	Grommet
5	5S-7379	Bolt
4	5W-2226	Strap
1	6D-4246	Clip
1	6V-1889	Clip
1	6V-8801	Nut
1	8M-2772	Clip
1	8T-2502	Bolt
9	8T-4896	Hard Washer
1	9M-8406	Clip
2	9X-6258	Screw
1	116-0118	Clip
5	130-5300	Clip
1	259-8973	Clip
1	259-8974	Clip
1	443-3784	Chassis Harness As

(1)	These parts are part of 444-7230 Onboard Installation Ar (ROPS) and 444-7231 Onboard Installation Ar (FOPS)

Table 42

Parts for 443-3786 Communication Wiring Gp(1)
Qty	Part Number	Description
4	3S-2093	Cable Strap
1	3V-9862	Spacer
2	4M-5281	Bolt
3	5P-1075	Hard Washer
2	5P-7468	Clip
2	5P-7469	Clip
1	5P-8182	Grommet
1	6V-1874	Grommet
1	6V-8801	Nut
1	7X-0343	Bolt
1	8T-2525	Grommet
1	8T-4122	Hard Washer
2	8T-4205	Hard Washer
2	9B-7237	Bolt
1	259-8973	Clip
1	259-8974	Clip
1	333-8153	Connection Assembly
2	336-6687	Protective Cap
1	366-4019	Plate
4	442-5010	Cable As
1	442-5800	Cable As
3	443-0283	Cable As

(1)	These parts are part of 444-7230 Onboard Installation Ar (ROPS) and 444-7231 Onboard Installation Ar (FOPS)

Table 43

Parts for 450-0680 Communication Wiring Gp(1)
Qty	Part Number	Description
3	4K-6177	Clip
2	4M-6425	Bolt
2	5C-7261	Nut
2	5P-4116	Hard Washer
2	6K-0806	Cable Strap
3	7X-2537	Bolt
1	8R-3600	Angle
5	8T-4224	Hard Washer
2	033-8248	Clip
2	321-4725	Adapter
1	460-0953	Cable As
1	460-0954	Cable As

(1)	These parts are part of 444-7230 Onboard Installation Ar (ROPS) and 444-7231 Onboard Installation Ar (FOPS)

Table 44

Parts for 450-2751 Electronic Control and Mounting Gp(1)
Qty	Part Number	Description
1	425-4816	Electronic Control Mounting Gp

(1)	These parts are part of 444-7230 Onboard Installation Ar (ROPS) and 444-7231 Onboard Installation Ar (FOPS)

Table 45

Parts for 425-4816 Electronic Control Mounting Gp(1)
Qty	Part Number	Description
4	8T-8442	Bolt
4	9X-8267	Washer
4	208-8469	Locknut
4	223-5994	Spring Washer
4	434-6708	Mount
4	459-1233	Control

(1)	These parts are part of 450-2751 Electronic Control and Mounting Gp

Table 46

Parts for 459-8791 Antenna and Mounting Gp(1)
Qty	Part Number	Description
4	4M-6425	Bolt
4	8T-4224	Hard Washer
6	9X-8256	Washer
6	095-0742	Screw
2	303-3846	Antenna
2	329-0695	Seal Pad
2	459-8792	Mount As

(1)	These parts are part of 444-7230 Onboard Installation Ar (ROPS) and 444-7231 Onboard Installation Ar (FOPS)

Table 47

Parts for 460-1568 Sensor Wiring Gp(1)
Qty	Part Number	Description
1	6H-4006	Grommet
1	326-7031	Sensor Harness As

(1)	These parts are part of 444-7230 Onboard Installation Ar (ROPS) and 444-7231 Onboard Installation Ar (FOPS)

Table 48

Parts for 489-0362 Interface Module Gp(1)
Qty	Part Number	Description
1	335-4414	Plug As
1	385-9765	Interface Box As
2	417-9104	Cable
1	417-9105	Cable As
1	489-0361	Interface Module Gp

(1)	These parts are part of 444-7230 Onboard Installation Ar (ROPS) and 444-7231 Onboard Installation Ar (FOPS)

MAS Preassembly

Refer to machine-specific parts manual for parts assembly.

Assemble Front Camera and Mounting

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Illustration 16	g03834739
366-4013 Camera and Mounting Gp 78 degrees Front, or 423-8805 Camera and Mounting Gp 115 degrees Front (1) 336-6897 Camera Gp 78 degrees or 336-6684 Camera Gp 115 degrees (2) 333-8153 Connection Assembly (3) 1S-9593 Cable Strap (4) 366-4014 Mount As

1. Assemble 366-4013 Camera and Mounting Gp 78 degrees , or 423-8805 Camera and Mounting Gp 115 degrees, using items (1) through (4). Refer to Illustration 16.

   • Apply Bostik Never-Seez Marine Grade to all bolt threads prior to installation

   • Do not use M22 nut provided with Item (2)

   • Torque bolts in item (2) to 1.7 ± 0.4 N·m (15 ± 3.5 lb in)

   • Secure camera cable to item (4) with four 1S-9593 Cable Strap (3)

Assemble Warning Lights

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Illustration 17	g03844735
436-0204 Warning Lighting Gp (1) 459-6794 Cover As (2) 4L-6454 Bolt (3) 8T-4896 Hard Washer (4) 310-3398 Lighting Amber (5) 361-8494 Plate (6) 310-3397 Lighting Red (7) 324-2119 Shield (8) 130-5300 Clip (9) 5S-7379 Bolt (10) 6V-8801 Nut (11) 305-3890 Screw (12) 8C-4982 Bolt (13) 245-9167 Nut

1. Assemble items (2) through (13) to 459-6794 Cover As (1). Refer to Illustration 17.

   • Apply Lanotec Type A Grease to all connectors prior to installation

   • Apply Bostik Never-Seez Marine Grade to all bolt threads prior to installation

   • Lens must be removed for installation of lights

   • Ensure that O-ring seal is retained correctly before reinstalling the lenses

   • Torque screws (11) and bolts (12) to 1.7 ± 0.4 N·m (15 ± 3.5 lb in)

LADAR Sensor Preassembly

Assemble Rear LADAR Sensors FOPS

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Illustration 18	g03844196
379-9940 Ladar Sensor and Mounting Gp FOPS Rear (1) 379-9941 Sensor Mount As (2) 424-8443 Protective Cover (3) 5P-1075 Hard Washer (4) 5S-7383 Bolt (5) 6V-8801 Nut (6) 096-0192 Lockwasher (7) 7I-2272 Bolt (8) 379-9951 Sensor Mount As (9) 379-9950 Sensor Mount As (10) 8T-2502 Bolt (11) 9X-8256 Washer (12) 8T-4971 Bolt (13) 6V-8225 Nut (14) 379-9820 Sensor (15) 5C-9553 Bolt (16) 5P-4115 Hard Washer (17) 370-2559 Mount As (18) 8T-4197 Bolt (19) 8T-9655 Isolation Mount (20) 8T-9658 Spacer (21) 9N-0869 Hard Washer

1. Assemble items (2) through (21) to 379-9941 Sensor Mount As (1). Refer to Illustration 18.

   • Apply Bostik Never-Seez Marine Grade to all bolt threads prior to installation

   • Torque bolts (7) to 5.9 ± 0.2 N·m (4.35 ± 0.15 lb ft)

Assemble Rear LADAR Sensors ROPS

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Illustration 19	g03844240
379-9822 Ladar Sensor and Mounting Gp ROPS Rear (1) 379-9905 Mount As (2) 096-0192 Lockwasher (3) 7I-2272 Bolt (4) 379-9951 Sensor Mount As (5) 9X-8256 Washer (6) 5C-2890 Nut (7) 8T-2947 Bolt (8) 5P-1075 Hard Washer (9) 5S-7383 Bolt (10) 6V-8801 Nut (11) 424-8443 Protective Cover (12) 8T-2502 Bolt (13) 379-9950 Sensor Mount As (14) 379-9820 Sensor (15) 370-2559 Mount As (16) 5C-9553 Bolt (17) 5P-4115 Hard Washer (18) 099-3649 Bolt (19) 9N-0869 Hard Washer (20) 8T-9658 Spacer (21) 8T-9655 Isolation Mount

1. Assemble items (2) through (21) to 379-9905 Mount As (1). Refer to Illustration 19.

   • Apply Bostik Never-Seez Marine Grade to all bolt threads prior to installation

   • Torque bolts (3) to 5.9 ± 0.2 N·m (4.35 ± 0.15 lb ft)

Assemble Rear Camera and Mounting ROPS

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Illustration 20	g03844756
366-4011 Camera and Mounting Gp ROPS Rear (1) 379-9905 Mount As (2) 333-8153 Connection Assembly (3) 361-8488 Plate (4) 5C-9553 Bolt (5) 9X-8256 Washer (6) 5M-3062 Bolt (7) 8M-2772 Clip (8) 8T-4896 Hard Washer (9) 336-6897 Camera Gp

1. Assemble items (2) through (9) to 379-9905 Mount As (1). Refer to Illustration 20.

   • Apply Bostik Never-Seez Marine Grade to all bolt threads prior to installation

   • Apply Lanotec Type A Grease to connector on Camera Gp (9) prior to installation

   • Do not use M22 nut provided with item (2)

   • Torque bolts in item (2) to 1.7 ± 0.4 N·m (15 ± 3.5 lb in)

Assemble Rear Camera and Mounting FOPS

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Illustration 21	g03844777
379-9939 Camera and Mounting Gp FOPS Rear (1) 379-9941 Sensor Mount As (2) 333-8153 Connection Assembly (3) 361-8488 Plate (4) 5C-9553 Bolt (5) 9X-8256 Washer (6) 323-5828 Clip (7) 336-6897 Camera Gp

1. Assemble items (2) through (7) to 379-9941 Sensor Mount As (1). Refer to Illustration 21.

   • Apply Bostik Never-Seez Marine Grade to all bolt threads prior to installation

   • Apply Lanotec Type A Grease to connector on Camera Gp (7) prior to installation

   • Do not use M22 nut provided with item (2)

   • Torque bolts in item (2) to 1.7 ± 0.4 N·m (15 ± 3.5 lb in)

Adjust Rear LADAR Angle

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Illustration 22	g03835812
LADAR Mounting Bracket Slot

1. Adjust rear LADAR angle so that the mounting bracket slots align.

Align Rear Camera

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Illustration 23	g03834718

1. Align rear camera. Ensure that text behind lens glass is correctly orientated and horizontal.

Assemble Front LADAR Sensors FOPS

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Illustration 24	g03844782
379-9911 Ladar Sensor and Mounting Gp FOPS Front (1) 379-9913 Sensor Mount As (2) 424-8442 Protective Cover (3) 8T-4896 Hard Washer (4) 8T-2502 Bolt (5) 096-0192 Lockwasher (6) 7I-2272 Bolt (7) 379-9951 Sensor Mount As (8) 379-9950 Sensor Mount As (9) 5C-9553 Bolt (10) 5P-4115 Hard Washer (11) 379-9820 Sensor (12) 5C-2890 Nut (13) 8T-4971 Bolt (14) 9X-8256 Washer (15) 6V-5219 Bolt (16) 9N-0869 Hard Washer (17) 8T-9658 Spacer (18) 8T-9655 Isolation Mount (19) 370-2559 Mount As

1. Assemble items (2) through (19) to 379-9913 Sensor Mount As (1). Refer to Illustration 24.

   • Apply Bostik Never-Seez Marine Grade to all bolt threads prior to installation

   • Torque bolts (6) to 5.9 ± 0.2 N·m (4.35 ± 0.15 lb ft)

Assemble Front LADAR Sensors ROPS

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Illustration 25	g03845292
379-9821 Ladar Sensor and Mounting Gp ROPS Front (1) 379-9816 Sensor Mount As (2) 424-8442 Protective Cover (3) 5P-1075 Hard Washer (4) 8T-2502 Bolt (5) 5S-7383 Bolt (6) 6V-8801 Nut (7) 096-0192 Lockwasher (8) 7I-2272 Bolt (9) 379-9951 Sensor Mount As (10) 379-9950 Sensor Mount As (11) 5C-9553 Bolt (12) 5P-4115 Hard Washer (13) 379-9820 Sensor (14) 9N-0869 Hard Washer (15) 8T-9658 Spacer (16) 8T-9655 Isolation Mount (17) 8T-4197 Bolt (18) 370-2559 Mount As (19) 5C-2890 Nut (20) 8T-2947 Bolt (21) 9X-8256 Washer

1. Assemble items (2) through (21) to 379-9816 Sensor Mount As (1). Refer to Illustration 25.

   • Apply Bostik Never-Seez Marine Grade to all bolt threads prior to installation

   • Torque bolts (8) to 5.9 ± 0.2 N·m (4.35 ± 0.15 lb ft)

Adjust Front LADAR Angle

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Illustration 26	g03835812
LADAR Mounting Bracket Slot

1. Adjust front LADAR angle so that the mounting bracket slots align.

Assemble Radio Wiring

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Illustration 27	g03859619
370-2414 Radio Mounting Gp (1) 361-8470 Mount As (2) 361-8502 Spacer (3) 8T-9655 Isolation Mount (4) 8T-6912 Bolt (5) 9N-0869 Hard Washer (6) 8T-4189 Bolt (7) 8T-4224 Hard Washer (8) 5C-9553 Bolt (9) 9X-8256 Washer (10) 385-9683 Cover (11) 116-0118 Clip (12) 8T-4200 Bolt (13) 361-8472 Plate

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Illustration 28	g06008314
433-6827 Radio Wiring Gp (1) 361-8470 Plate (14) 433-5127 Plate (15) 5W-2226 Strap (16) 8C-6364 Bolt (17) 8T-0328 Hard Washer (18) 433-1624 Electronic Filter (19) 433-1624 Electronic Filter (20) 096-6166 Hard Washer (21) 5C-8312 Nut (22) 8T-3998 Bolt (23) 433-5107 Cable As (24) 366-7696 Communication Radio Gp (25) 433-6830 Cable As Auxiliary Antenna Output (26) 433-6830 Cable As Main Antenna Output (27) 385-9680 Cable As (28) 379-9909 Cable As

1. Assemble items (2) through (28) to 361-8470 Mount As (1). Refer to Illustration 27 and Illustration 28.

   • Apply Bostik Never-Seez Marine Grade to all bolt threads prior to installation

   • Apply Lanotec Type A Grease to all connectors prior to installation

   • Connect Radio output Auxiliary (25) to "RF OUT" side of filter (18)

   • Connect Radio output Main (26) to "RF OUT" side of filter (19)

   • Do Not install 385-9683 Cover (10) during this step

Assemble Rotary Sensor and Wiring

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Illustration 29	g03851047
338-6691 Sensor Mounting Gp (1) 329-0711 Rotary Sensor (2) 329-0779 Spacer (3) 8C-4982 Bolt (4) 324-2101 Coupling (5) 338-6518 Plate

1. Assemble items (1) through (4), to 338-6518 Plate (5). Refer to Illustration 29.

   • Apply Bostik Never-Seez Marine Grade to bolt threads (3) prior to installation

   • Ensure that connector orientation for Rotary Sensor (1) is facing towards the rear of the machine

   • Ensure slot in spacer (2) is aligned correctly, facing towards operator station door, to allow access to coupling retaining screws

Assemble Electrical Converters

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Illustration 30	g03843763
370-2545 Electrical Converter Gp (1) 370-2549 Mount As (2) 326-7068 Electrical Converter (3) 5S-7379 Bolt and 8T-4896 Hard Washer (4) 4M-5281 Bolt and 5P-4115 Hard Washer (5) 370-2547 Mount As

1. Assemble items (2) through (5) to 370-2549 Mount As (1). Refer to Illustration 30.

   • Apply Bostik Never-Seez Marine Grade to all bolt threads prior to installation

Assemble Electronic Control Mounting

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Illustration 31	g03861439
425-4816 Electronic Control Mounting Gp (resilient mounts) (1) 370-2549 Mount As (2) 434-6708 Mount (3) 208-8469 Locknut (4) 9X-8267 Washer

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Illustration 32	g03861443

1. Install eight items (2) through (4) (resilient mounts), to 370-2549 Mount As (1), where highlighted. Refer to Illustration 31 and Illustration 32.

   • Do not grip rubber section of mount with tooling when tightening

MAS Installation

Refer to machine-specific parts manual for parts assembly.

Note: Apply Lanotec Type A Grease to all electrical and Radio Frequency (RF) cable connections prior to installation.

Install Rotary Switch

Illustration 33	g03841023
370-2489 Rotary Switch Gp (1) 292-0358 Rotary Switch Gp

Install 292-0358 Rotary Switch Gp (1). Refer to Illustration 33.

• Torque mounting nut on Rotary Switch (1) to 6.75 N·m (5 lb ft)

• Install connector at rear of switch

• Refer to machine-specific schematic for switch connection details

Install Command for Underground Antenna and Mounting

Illustration 34	g03848643
459-8791 Antenna and Mounting Gp (1) 095-0742 Screw (2) 9X-8256 Washer (3) 303-3846 Antenna (4) 329-0695 Seal Pad (5) 4M-6425 Bolt (6) 8T-4224 Hard Washer (7) 459-8792 Mount As

Install items (1) through (7) to radiator housing. Refer to Illustration 34.

• Apply Bostik Never-Seez Marine Grade to all bolt threads prior to installation

• Install mounts (7) to radiator housing

• Remove top screws from antenna to release antenna covers from antenna bases

• Place antenna bases on to Seal Pads (4)

• Place left antenna 460-0953 Cable As and right antenna 460-0954 Cable As, under Seal Pads (4)

• Apply Lanotec Type A Grease to pins, sockets, and threads prior to installation

• Connect left antenna 460-0953 Cable As and right antenna 460-0954 Cable As to antennas (3)

• Install Seal Pads (4) and antenna bases over mounts (7) and secure with three 095-0742 Screw (1), and three 9X-8256 Washer (2) per antenna

• Replace antenna covers (3) over antenna bases and tighten top screws

• Apply Loctite® 243 to top screws prior to installation

Install Rear Communication Wiring

Illustration 35	g03849379
450-0680 Communication Wiring Gp (1) 4K-6177 Clip (2) 8T-4224 Hard Washer (3) 5C-7261 Nut (4) 7X-2537 Bolt (5) 321-4725 Adapter (6) 6K-0806 Cable Strap (7) 8R-3600 Angle (8) 4M-6425 Bolt (9) 033-8248 Clip (10) 5P-4116 Hard Washer (11) 460-0953 Cable As Left Side (12) 460-0954 Cable As Right Side

Install items (1) through (12) to rear frame and radiator housing. Refer to Illustration 35.

• Apply Bostik Never-Seez Marine Grade to all bolt threads prior to installation

• Apply Lanotec Type A Grease to all connectors prior to installation

• Torque item (5) to 200 ± 40 N·m (150 ± 30 lb ft)

Install Radio Mounting

Illustration 36	g03865337
Exploded View of Radio Mount

Illustration 37	g06008316
370-2414 Radio Mounting Gp (1) 361-8502 Spacer (2) 8T-9655 Isolation Mount (3) 8T-6912 Bolt (4) 9N-0869 Hard Washer (5) "N" Type connector (6) Ethernet cable (7) Power connection

Install Radio Mount using items (1) through (4). Refer to Illustration 36 and Illustration 37.

• Apply Lanotec Type A Grease to all connectors prior to installation

• Connect Wiring Gp Communication to "N" Type connectors at radio bulkhead mounts (5)

• Connect Ethernet cable to radio bulkhead mount (6)

• Locate Radio power connection and connect to power connection at radio bulkhead mount (7)

• Install 385-9683 Cover to Radio Mounting Gp

Install Warning Lighting

Illustration 38	g03835184
436-0204 Warning Lighting Gp (1) 459-6794 Cover As (2) Red light (3) Amber light

Install 459-6794 Cover As (1). Refer to Illustration 38.

• Install 459-6794 Cover As (1) on machine. Locate power connection to Lighting Gp Warning, and connect Red light (2) and Amber light (3)

• Refer to machine-specific schematic for connection details

Install Front Camera and Mounting

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Illustration 39	g06013334
366-4013 Camera and Mounting Gp 78 degrees Front, or 423-8805 Camera and Mounting Gp 115 degrees Front (1) 366-4014 Mount As (2) 5C-9553 Bolt (3) 9X-8256 Washer (4) 361-8408 Plate (5) 5S-7379 Bolt (6) 8T-4896 Hard Washer

1. Install 366-4013 Camera and Mounting Gp 78 degrees Front, or 423-8805 Camera and Mounting Gp 115 degrees Front on front frame with items (1) through (6). Refer to Illustration 39.

   • Apply Bostik Never-Seez Marine Grade to all bolt threads prior to installation
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   Illustration 40	g03847271

2. Align front camera (1). Refer to Illustration 40.

   • Ensure that text behind the camera lens glass is correctly orientated and horizontal

Install Articulation Sensor Mounting

Illustration 41	g03861845
338-6691 Sensor Mounting Gp (1) 338-6519 Plate (2) 5S-7379 Bolt (3) 8T-4896 Hard Washer (4) 6V-8801 Nut (5) 329-0780 Stud (6) 338-6518 Plate (7) 3B-4615 Cotter Pin (8) 338-6693 Rod As (9) 6H-4006 Grommet (10) 329-0711 Rotary Sensor

1. Install items (1) through (10). Refer to Illustration 41.

   • Remove bolts retaining right side neutralizer and install Plate (6)

   • Install right side neutralizer retaining bolts. Replace bottom bolt with Stud (5), Nut (4), and Washers (3)

   • ( 9) to Plate (1)

   • Secure Plate (1) to front frame with Bolts (2), and Washers (3)

   • Push Rod (8) through Grommet (9). Install Washer (3) and Cotter Pin (7). Attach Rod (8) to Coupling on Rotary Sensor (10)
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   Illustration 42	g03851800
   460-1568 Sensor Wiring Gp and 392-8092 Plate (11) 392-8092 Plate (12) 6H-4006 Grommet (13) 326-7031 Sensor Harness As

2. Install 460-1568 Sensor Wiring Gp.

3. Install Grommet (12) to Plate (11).

4. Install Plate (11) using existing hardware.

5. Pass Harness (13) through Grommet (12).

6. Install Harness (13) to Rotary Sensor (10).

   Refer to Illustration 42.

   • Apply Lanotec Type A Grease to all connectors prior to installation

Install Front Camera Wiring

Illustration 43	g03849390
439-4823 Camera Wiring Gp (highlighted)

Illustration 44	g03850160
439-4823 Camera Wiring Gp (highlighted) (1) 8T-4896 Hard Washer (2) 033-8248 Clip (3) 8T-2502 Bolt (4) 6V-8801 Nut (5) 6K-0806 Cable Strap (6) 366-3991 Cable As (7) 366-4019 Plate (8) 8T-9364 Bolt (9) 8T-4205 Hard Washer (10) 2D-6235 Locknut (11) 333-8153 Connection Assembly (12) 336-6897 Camera Gp 78 degrees or 336-6684 Camera Gp115 degrees (13) 366-4014 Mount As

Install items (1) through (13) on front frame. Refer to Illustration 43 and Illustration 44.

• Apply Bostik Never-Seez Marine Grade to all bolt threads prior to installation

• Apply Lanotec Type A Grease to all connectors prior to installation

• Do not use M22 nut provided with item (11)

• Torque bolts in item (11) to 1.7 ± 0.4 N·m (15 ± 3.5 lb in)

Install Computer Mounting and Electronic Control

Illustration 45	g03841036
435-1510 Computer Mounting Gp (1) 370-2549 Mount As (2) 9B-7237 Bolt (3) 8T-4896 Hard Washer

1. Install 370-2549 Mount As (1) to hydraulic oil tank using four 9B-7237 Bolt (2) and four 8T-4896 Hard Washer (3). Refer to Illustration 45.

   • Apply Bostik Never-Seez Marine Grade to all bolt threads prior to installation
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   Illustration 46	g06008846
   450-2751 Electronic Control and Mounting Gp (4) 425-4816 Electronic Control Mounting Gp

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   Illustration 47	g03843738
   425-4816 Electronic Control Mounting Gp (5) 459-1233 Control (6) 436-8712 Spacer (7) 8T-8442 Bolt (8) 223-5994 Spring Washer (9) Resilient Mount

2. Install items (5) through (8) of 425-4816 Electronic Control Mounting Gp to resilient mount assemblies (9) that were installed previously. Refer to Illustration 46 and Illustration 47.

Install Automation Interface Control Module

Illustration 48	g06009438
(1) 437-0385 Interface Module Gp

Illustration 49	g06009437
437-0385 Interface Module Gp (2) 437-0381 Interface Module Gp (3) 436-8712 Spacer (4) 8T-8442 Bolt (5) 223-5994 Spring Washer (6) Resilient Mount

1. Install items (2) through (5) of 437-0385 Interface Module Gp to resilient mount assemblies (6) that were installed previously. Refer to Illustration 48 and Illustration 49.

   • Apply Bostik Never-Seez Marine Grade to all bolt threads prior to installation

   • Apply Lanotec Type A Grease to all connectors prior to installation

Install Circuit Breaker

Illustration 50	g03851805
370-2593 Circuit Breaker Gp (1) 338-6510 Cover (2) 5S-7349 Bolt (3) 8T-4205 Hard Washer (4) 8T-9405 Bolt (5) 338-6509 Plate (6) 8T-2502 Bolt (7) 8T-4896 Hard Washer (8) 329-0931 Circuit Breaker Panel Gp (9) 379-9810 Cable As (10) 3S-2093 Cable Strap

Install items (1) through (10). Refer to Illustration 50.

• Apply Bostik Never-Seez Marine Grade to all bolt threads prior to installation

• Apply Lanotec Type A Grease to all connectors prior to installation

• Torque Bolt (4) to 1.7 ± 0.4 N·m (15 ± 3.5 lb in)

• Do not connect 379-9810 Cable As (9) at this time

Install MAS Communication Wiring

Illustration 51	g06016731
443-3785 Communication Wiring Gp MAS (highlighted) (1) 425-4816 Electronic Control Mounting Gp Automation (ECM) (2) 5S-7379 Bolt (3) 8T-4896 Hard Washer (4) 9M-8406 Clip (5) 130-5300 Clip (6) 5W-2226 Strap (7) 8M-2772 Clip (8) 5P-7854 Clip (9) 8T-2502 Bolt (10) 5P-8182 Grommet (11) 259-8874 Plate (12) 259-8973 Clip (13) 5P-1075 Hard Washer (14) 4L-9337 Bolt (15) 6D-4246 Clip (16) 6V-1889 Clip (17) Existing bolt (18) Existing washer (19) Existing bolt (20) Existing washer (21) 2B-0941 Spacer (22) 116-0118 Clip (23) 4L-6454 Bolt (24) 6V-8801 Nut (25) 4B-5324 Washer (26) 9X-6258 Screw (27) 443-3784 Chassis Harness As

1. Remove existing items (17) to (20). Retain for installation purposes.

2. Install items (2) through (27).

3. Install Clip (5) with items (17) and (18) that were removed previously.

4. Install earth terminals with items (19) and (20) that were removed previously.

   Refer to Illustration 51.

• Apply Bostik Never-Seez Marine Grade to all bolt threads prior to installation

• Apply Lanotec Type A Grease to all connectors prior to installation

• Connect Communication Wiring Gp, beginning at transmission main wiring harness bulkhead, to the Automation ECM (1)

• Install Clip (4), closest to the Automation ECM (1)

• Install Clip (12) to secure wiring harness (27) to mounting plate

• Torque wiring harness mounting screws (26) to 0.90 ± 0.10 N·m (8 ± 0.9 lb in)

Install Cable As from Circuit Breaker Gp

Illustration 52	g03835977
379-9810 Cable As from Circuit Breaker Gp

Install 379-9810 Cable As from Circuit Breaker Gp to Main power stud or relay.

• Apply Lanotec Type A Grease to all connectors prior to installation

• Connect lug to main power stud or relay

• Secure bulkhead connector to transmission bulkhead

Install Communication Wiring

Illustration 53	g03860901
443-3786 Communication Wiring Gp MAS (highlighted) (1) 425-4816 Electronic Control Mounting Gp Automation (ECM) (2) 3S-2093 Cable Strap (3) 442-5010 Cable As (4) 366-4019 Plate (5) 4M-5281 Bolt (6) 8T-4205 Hard Washer (7) 333-8153 Connection Assembly (8) 336-6687 Protective Cap (9) 5P-7468 Clip (10) 5P-7469 Clip (11) 8T-2525 Grommet (12) 5P-1075 Hard Washer (13) 9B-7237 Bolt (14) 6V-1874 Grommet (15) 6V-8801 Nut (16) 5P-8182 Grommet (17) 259-8974 Clip (18) 259-8973 Clip (19) 3V-9862 Spacer (20) 8T-4122 Hard Washer (21) 7X-0343 Bolt (22) 443-0283 Cable As (23) 443-0283 Cable As (24) 443-0283 Cable As (25) 442-5010 Cable As (26) 442-5010 Cable As (27) 442-5010 Cable As (28) 442-5800 Cable As (29) Front Camera (30) Service Port (31) Front LADAR (32) Rear Camera (33) Rear LADAR (34) Camera 3 (35) Onboard Radio (36) Camera 4 (37) Ethernet Service Port

1. Install items (2) through (28).

2. Connect item (3) to port (36).

3. Connect item (22) to port (35).

4. Connect item (23) to port (33).

5. Connect item (24) to port (31).

6. Connect item (25) to port (34).

7. Connect item (26) to port (32).

8. Connect item (27) to port (29).

9. Connect item (28) to port (37).

   Refer to Illustration 53.

• Apply Bostik Never-Seez Marine Grade to all bolt threads prior to installation

• Apply Lanotec Type A Grease to all connectors prior to installation

• Do not use M22 nut provided with item (7)

• Torque bolts in item (1) to 1.7 ± 0.4 N·m (15 ± 3.5 lb in)

Install Front and Rear LADAR Sensors

Illustration 54	g03835983
Typical Example Front LADAR Gp

1. Install front LADAR Gp on machine. Refer to “Assemble Front LADAR Sensors” in this publication.
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   Illustration 55	g03835984
   Typical Example of Rear LADAR Gp

2. Install rear LADAR Gp on machine. Refer to “Assemble Rear LADAR Sensors” in this publication.

Install Communication Wiring and Camera Wiring ROPS

Illustration 56	g06016680
370-2413 Communication Wiring Gp ROPS (highlighted) (1) 8T-2501 Bolt (2) 8T-4896 Hard Washer (3) 2B-0941 Spacer (4) 033-8248 Clip (5) 6V-8801 Nut (6) 379-9807 Cable As (7) 4L-6454 Bolt (8) 363-3405 Cable (9) 3S-2093 Cable Strap (10) 7K-1181 Cable Strap (11) Onboard Radio (12) Rear LADAR (13) Front LADAR (14) 4S-1962 Clip (15) 4L-9337 Bolt (16) 4K-6177 Clip (17) 370-2289 Cap (18) 370-2594 Cable

Illustration 57	g06012538
366-3992 Camera Wiring Gp ROPS (highlighted) (4) 033-8248 Clip (19) 333-8153 Connection Assembly (20) 336-6687 Protective Cap (21) 283-0657 Cable As (22) 5P-9085 Clip (23) 8T-4199 Bolt (24) 8T-4224 Hard Washer (25) 6K-0806 Cable Strap (26) 304-7877 Cable As

Install items (1) through (26). Refer to illustrations 56 and 57.

• Apply Bostik Never-Seez Marine Grade to all bolt threads prior to installation

• Apply Lanotec Type A Grease to all connectors prior to installation

• Do not use M22 nut provided with item (19)

• Torque bolts in item (19) to 1.7 ± 0.4 N·m (15 ± 3.5 lb in)

• Connect Ethernet cables and camera cables to bulkhead at transmission

• Run cabling around cab and connect to front & rear LADAR and rear camera bulkhead

Install Communication Wiring and Camera Wiring FOPS

Illustration 58	g06016700
439-4824 Communication Wiring Gp FOPS (highlighted) (1) 3S-2093 Cable Strap (2) 4K-6177 Clip (3) 8T-4896 Hard Washer (4) 2B-0941 Spacer (5) 7X-0288 Bolt (6) 033-8248 Clip (7) 5M-3062 Bolt (8) 7K-1181 Cable Strap (9) 363-3405 Cable (10) 379-9807 Cable As (11) Onboard Radio (12) Rear LADAR (13) Front LADAR (14) 370-2289 Cap (15) 370-2594 Cable

Illustration 59	g06012548
439-4825 Camera Wiring Gp FOPS (highlighted) (6) 033-8248 Clip (16) 333-8153 Connection Assembly (17) 336-6687 Protective Cap (18) 370-2591 Cable As (19) 5P-9085 Clip (20) 8T-4199 Bolt (21) 8T-4224 Hard Washer (22) 6K-0806 Cable Strap (23) 304-7877 Cable As

Install items (1) through (23). Refer to Illustration 58 and Illustration 59.

• Apply Bostik Never-Seez Marine Grade to all bolt threads prior to installation

• Apply Lanotec Type A Grease to all connectors prior to installation

• Do not use M22 nut provided with item (16)

• Torque bolts in item (16) to 1.7 ± 0.4 N·m (15 ± 3.5 lb in)

• Connect Ethernet cables and camera cables to bulkhead at transmission

• Run cabling around cab and connect to front & rear LADAR and rear camera bulkhead

Install Cab Lighting to LADAR Mounts

Illustration 60	g06012897
Location of Cab Lighting on LADAR mounts (Rear) (1) 219-6488 Flood Lamp Gp

Illustration 61	g06139344
Location of Cab Lighting on LADAR mounts (Front) (1) 219-6488 Flood Lamp Gp (2) 9M-4136 Spacer

1. Install cab lights. Refer to Illustration 60 and Illustration 61.

   • Apply Bostik Never-Seez Marine Grade to all bolt threads prior to installation

   • Apply Lanotec Type A Grease to all connectors prior to installation
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   Illustration 62	g03840478
   Wiring Location for Rear Cab Lights

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   Illustration 63	g03838180
   Wiring Location for Front Cab Lights

2. Connect wiring to front and rear cab lights. Refer to Illustration 62 and Illustration 63.

• Apply Bostik Never-Seez Marine Grade to all bolt threads prior to installation

• Apply Lanotec Type A Grease to all connectors prior to installation

Install Sensor Wiring

Install Sensor Wiring ROPS

Illustration 64	g03843236
380-0044 Sensor Wiring Gp ROPS (1) 379-9909 Cable As (2) 5P-9085 Clip

1. Install 379-9909 Cable As (1) and 5P-9085 Clip (2). Refer to Illustration 64.

   • Apply Lanotec Type A Grease to all connectors prior to installation

Install Sensor Wiring FOPS

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Illustration 65	g03860204
380-0045 Sensor Wiring Gp FOPS (1) 379-9909 Cable As

1. Install 379-9909 Cable As (1). Refer to Illustration 65.

   • Apply Lanotec Type A Grease to all connectors prior to installation

Install 366-3987 Plate and Film Gp

Illustration 66	g03836565
Film on Circuit Breaker Cover (1) 370-2486 Film

Illustration 67	g03835988
Film on Dash Panel (2) 336-5837 Film (A) 94 ± 2 mm (3.70 ± 0.08 inch) (B) 150 ± 2 mm (5.90 ± 0.08 inch)

Illustration 68	g03835989
Serial Number Plate on Front Left Side of Hitch (3) 380-0053 Serial Number Plate (C) 30 ± 2 mm (1.18 ± 0.08 inch) (D) 105 ± 2 mm (4.13 ± 0.08 inch)

Illustration 69	g06024922
Installation of Serial Number Plate (3) 380-0053 Serial Number Plate (4) 4B-4158 Drive Screw

1. Install items (1) through (4) of 366-3987 Plate and Film Gp. Refer to Illustration 66, Illustration67, Illustration 68, and Illustration 69.

Install Deck Covers

Parts for Deck Covers

Table 49

Parts for Deck Covers(1)
Qty	Part No	Description
6	3B-4615	Cotter Pin
127 cm (50 inch)	178-4946	Tape Reflective (Black/Yellow)
4	307-1081	Nonslip Tread
4	307-1083	Nonslip Tread
1	326-6651	Access Cover As
1	338-6474	Cover As
1	370-2629	Nonslip Tread

(1)	These parts are part of 469-4093 Command Installation Ar (ROPS) and 469-4094 Command Installation Ar (FOPS) and 366-3987 Plate and Film Gp

Install Deck Covers

Illustration 70	g06013904
Locations of Deck Covers (1) 163-6224 Hinge Bracket As (2) 5S-7379 Bolt (3) 8T-4896 Hard Washer (4) 7H-2614 Pin (5) 3B-4615 Cotter Pin (6) 338-6474 Cover As (7) 370-2693 Cover As (8) 326-6651 Access Cover As

1. Remove existing items (1) through (5) for cover (6). Retain items (1) through (4) for installation purposes.

2. Install existing items (1) through (3) for cover (6) to new locations on machine deck.

3. Install items (6) through (8), using existing pins (4) and new cotter pins (5).

   Refer to Illustration 70.

Install Nonslip Tread

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Illustration 71	g06005159
Locations of Nonslip Tread (1) 307-1083 Nonslip Tread (2) 370-2629 Nonslip Tread (3) 307-1081 Nonslip Tread (A) 80 ± 3 mm (3.15 ± 0.12 inch) (B) 90 ± 3 mm (3.54 ± 0.12 inch) (C) 140 ± 3 mm (5.51 ± 0.12 inch) (D) 67 ± 3 mm (2.64 ± 0.12 inch) (E) 78 ± 3 mm (3.07 ± 0.12 inch) (F) 50 ± 3 mm (1.97 ± 0.12 inch)

1. Install items (1) through (3). Refer to Illustration 71.

Install Reflective Tape

Illustration 72	g06016712
Locations of Reflective Tape (1) 178-4946 Tape Reflective

1. Install 178-4946 Tape (1). Refer to Illustration 72.

Install Fire Extinguisher

Parts for Fire Extinguisher

Table 50

Parts for Fire Extinguisher(1)
Qty	Part No	Description
4	8T-4121	Hard Washer
4	8T-4185	Bolt
2	443-1193	Spacer

(1)	These parts are part of 469-4093 Command Installation Ar (ROPS) and 469-4094 Command Installation Ar (FOPS)

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Illustration 73	g06024066
View of Left Side of the Machine Modifications to Fire Extinguisher Bracket (1) 370-2665 Guard As (2) 8T-4185 Bolt (3) 8T-4121 Hard Washer (4) 216-9885 Bracket As (behind extinguisher) (5) 443-1193 Spacer

1. Remove and discard existing spacers, bolts, and washers for fire extinguisher bracket (if fitted).

2. Install existing 216-9885 Bracket As (4) to 370-2665 Guard As (1) with two spacers (5), four 8T-4185 Bolt (2), and four 8T-4121 Hard Washer (3).

3. Install fire extinguisher to bracket (4).

   Refer to Illustration 73.

Install Other Parts

1. Install the remaining deck covers.

2. Install the front frame covers.

3. Install the cabin pressurizer and covers.

4. Install the firewall covers.

   • Apply Bostik Never-Seez Marine Grade to all bolt threads prior to installation

   • Refer to component drawings for tightening requirements

Configure Machine Automation System

MAS Initial Configuration

MAS Radio Configure - Configuring On-board Radio

This procedure is used to configure a radio for use as a MAS radio.

Connect a computer using an Ethernet cable to either

• The Ethernet service connection on the Automation ICM

• The LAN 2 connection on the On-board Radio

1. Perform the automation system preparation for troubleshooting procedure before entering the operations area. Refer to Troubleshooting, Testing, and Adjusting, "Automation System Preparation for Troubleshooting".

2. Insert the battery disconnect switch key and move the battery disconnect switch to the ON position.

3. Turn the key start switch to the ON position.

4. Move the remote control switch to the ON position.

5. Move the autonomous control enable switch to the AUTO position. The machine is now in autonomous mode.
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   Illustration 74	g03839828
   Typical Example of "Cat Networking Devices Manager" Window (1) "Cat Networking Devices Manager" window

6. On the Service Laptop, open "Cat Networking Devices Manager" window (1).

7. The radio to be configured will appear initially as an "Off-board" radio (default factory configuration).
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   Illustration 75	g03837589
   Typical Example of "On-board" Tab (2) "On-board" tab

8. Select the radio to be configured as an "On-board" radio (2).

   Note: Do not double-click, as the Radios Configuration Webpage will open. The Radios Configuration Webpage is not accessible when the radio has the status of a "Product with limited connectivity".

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   Illustration 76	g03837590
   Typical Example of "Essential Configuration" Window (3) "Essential Configuration" tab (4) Role "On-board" (5) Location "Machine ID" or "Site Identifier"

9. Select "Essential Configuration" menu (3).

10. In the "Essential Configuration" window, change the following parameters.

    • (4) Role "On-board"

    • (5) Location "Machine ID" or "Site Identifier"

11. Select "Apply". Radio will now reboot. Configuration of On-board radio is now complete.

    Note: If a connection to the Site Server is available, an IP Address should be assigned. If not available, the IP Address will default to 0.0.0.0.

Automation ICM Flash Software

Table 51

Required Tools
Tool	Part Number	Description	Qty
A	351-1151	Tool	1
B	9U-7291	Screwdriver	1
C	351-1138	Service Kit	1
D	351-1145	Cable As	1
E	351-1146	Cable As	1
F	327-0375	Adapter Kit	1
G	351-1148	Cable As	1

Table 52

Caution PLC1 and PLC2 require different software configuration files. The configuration files are typically named:
Device	File Name	Description
Automation ICM Operating System	IFM_CR7201_V060003.H86	Common Operating System File for use on PLC1 and PLC2
Automation ICM PLC1	MAS_CR7201_PLC1_V06_1.H86	PLC1 Configuration File
Automation ICM PLC2	MAS_CR7201_PLC2_V06_1.H86	PLC2 Configuration File
When required, the Programmable Logic Control (PLC) Operating System (OS) must be updated prior to updating the configuration file.

1. Perform the automation system preparation for troubleshooting procedure before entering the operations area.

   • Refer to Troubleshooting, Testing, and Adjusting, "Automation System Preparation for Troubleshooting"

   • Move the battery disconnect switch to the OFF position

   • Move the autonomous control enable switch to the AUTO position

   • Remove Automation ICM cover using Tooling (A) and Tooling (B) from Tooling (C)

2. Program PLC 1

   • Connect Tooling (D) to Automation ICM programming port and Tooling (E)

   • Connect Tooling (E) to the technician laptop

   • Use Tooling (F) if technician laptop does not have a serial port

   • On the Technician laptop, open the "IFM Downloader" application

   • Turn the battery disconnect switch to the ON position

   • Select "Interface" menu

   • Select "RS232"

   • Set "RS232" communication port settings to the following
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   Table 53

   RS232 Communication Port Settings
   Bits per Second	57600bps
   Data Bits	8
   Parity	N
   Stop Bits	1
   Communication Port	Set to the Communication Port that is used by 327-0375 Adaptor Kit

   • Select "OK"

   • Select "Identity"

   • Communications to PLC1 are confirmed when the confirmation window appears. Select "OK"

3. Update PLC1 Operating System

   • Select "Download"

   • Browse to and select the OS software file for PLC1 and then click "Open"

   • A window will appear after approximately 30 seconds to confirm that the download was successful. Select "OK"

4. Update PLC1 Firmware File

   • Select "Download"

   • Browse to and select the configuration software file for PLC1 and then click "Open"

   • A window will appear after approximately 30 seconds to confirm that the download was successful. Select "OK"

   • Select "Verify"

   • Select the Software file for PLC1 and select "Open". Verification of the software on PLC1 with the file that was installed, will occur

   • "Verify successful" should appear if the verify process was successful. Select "OK"

   • Select "Run" to start the software on PLC1

   • "Status: Running" will appear to confirm that PLC1 is running

   • Select "OK"

5. Program PLC 2

   Note: This procedure must follow immediately after the programming of PLC1.

   • Disconnect Tooling (E) from Tooling (D)

   • Connect Tooling (G) to Tooling (D)

   • Connect Tooling (G) to the technician laptop

   • Use Tooling (F) if technician laptop does not have a serial port

   • On the technician laptop, open the "IFM Downloader" application

   • Select "Identity"

   • Communications to PLC2 are confirmed when the "Confirmation" window appears. Select "OK"

6. Update PLC 2 Operating System

   • Select "Download"

   • Browse to and select the OS file for PLC2 and then click "Open"

   • A window will appear after approximately 30 seconds to confirm that the download was successful. Select "OK"

7. Update PLC2 Firmware File

   • Select "Download"

   • Browse to and select the configuration software file for PLC2 and then click "Open"

   • A window will appear after approximately 30 seconds to confirm that the download was successful. Select "OK"

   • Select "Verify"

   • Select configuration software file or PLC2 and select "Open". This file will verify the software on PLC2 with the file that was installed

   • "Verify successful" should appear if the verify process was successful. Select "OK"

   • Select "Run" to start the software on PLC2

   • Select "Run" to start the software on PLC2

   • "Status: Running" will appear to confirm that PLC2 is running

   • Select "OK"

   • Select "Exit" to close the Download program

   • Disconnect programming cable and programming cable from Automation ICM programming port in the Automation ICM

   • Replace Automation ICM cover

   • Turn the battery disconnect switch to the OFF position

   • Wait 10 seconds before turning the battery disconnect switch to the ON position

Onboard LADAR Configure

Procedure Requirements

Computer with Sick SOPAS Engineering Tool V2 installed and connected to Command network.

1. Procedure

   • Move the battery disconnect switch to the ON position

   • Move the remote control switch to the ON position

   • Move the autonomous control enable switch to the AUTO position

   • Open the SOPAS application
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   Illustration 77	g03839276
   "Welcome to SOPAS"

2. If window "Welcome to SOPAS" appears, close window (1).
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   Illustration 78	g03839277
   "SOPAS Engineering Tool"

3. Select "Project" menu (2) and then "New Project" (3).
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   Illustration 79	g03839278
   "Connection Wizard"

4. Click "Communication" menu (4) and select "Connection Wizard" (5).
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   Illustration 80	g03839279
   "Connection Wizard" / "Show all Connected Devices"

5. Select "Show all connected devices", then click "Next" button (6).
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   Illustration 81	g03839280
   "Interface Selection"

6. Ensure that the Internet Protocol (IP) box (7) is checked and select "Next" button (8).
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   Illustration 82	g03839281
   "Performing Auto IP Scan"

7. "Performing Auto IP scan" icon (9) will appear on the screen. The connected devices will appear after the scan.
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   Illustration 83	g03839282
   Default "IP Address" Settings

8. Select check box (10) next to the device with 10.10.30.1:2111 "IP Address". 10.10.30.1:2111 "IP Address" is the default "IP Address" for a LADAR sensor. Select the "Manually" button (11) from the "Change device IP settings" frame.

   Note: Default "IP Address" settings for LADAR sensors are 10.10.30.2 (Front), 10.10.30.3 (Rear). Multiple machines operating on the same network will require the addresses to be incremental, for example, a second machine may be 10.10.30.4 (Front), 10.10.30.5 (Rear).

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   Illustration 84	g03839283
   "Change IP Configuration"

9. Enter the new "IP Address" (12) and the subnet mask "255.255.0.0" (13) and click "OK" (14). The configuration will now be sent to the LADAR Sensor.

   Note: "IP Address" selected for LADAR must be unique and within the range 10.10.30.2 - 10.10.30.254.

10. Close the SOPAS application.

Automation ECM Flash Software

Procedure Requirements

• Computer with Command for Underground Software Manager installed and connected to Command network

• MAS Automation ECM Firmware file

1. Procedure

2. Place machine in operations area.

3. Move battery disconnect switch to the ON position.

4. Move the key switch to the ON position.

5. Move Remote Control switch to the ON position.

6. Move Automation Control Enable switch to the AUTO position.

7. Record the serial number of the Automation ECM fitted to the machine.
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   Illustration 85	g03837619
   "Software Manager"

8. Open "Software Manager".

9. Click the "Scan Now" button on the "Software Manager" window.

10. Observe the "IP Address" of the Automation ECM which matches the recorded serial number.
    Show/hide table

    Illustration 86	g03837620
    "Device Information" / "Install Package"

11. Right-click the "IP Address" in the "Device Information" field and select "Install Package".
    Show/hide table

    Illustration 87	g03837621
    "Flash" File Window

12. Use file selection window to select the "Flash" file.
    Show/hide table

    Illustration 88	g03837623
    "Install" Window

13. Confirm details on the "Install" window and click "Yes".

14. When package installation is complete, right-click the "IP Address" in the "Device Information" field and select "Reboot".
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    Illustration 89	g03837625
    Automation ECM "IP Address" Window

15. Automation ECM will reboot. When Automation ECM status is again listed as "online", click the Automation ECM "IP Address". Verify version and package name in the firmware information section are correct.

MAS Pre-Commissioning Checks

1. Move battery disconnect switch to the ON position.

2. Ensure that the Autonomous Control Enable switch is in the MANUAL position.

3. Connect Cat ET and note "Active" and/or "Logged" codes.

4. Rectify any "Active" codes and clear any "Logged" codes.

5. Test the following

   • Horn functions

   • Lights functions

   • Start engine

   • Throttle

   • Park Brake releases and reapplies

   • Machine forward and reverse function works

   • Machine up-shift and downshift works

   • Machine steering

   • Implement functions Raise, Lower, Crowd, and Dump

6. Turn off engine.

7. Connect Cat ET and note "Active" and/or "Logged" codes.

8. Rectify any "Active" and/or "Logged" codes.

9. Turn the Autonomous Control Enable switch to the AUTO position.

10. Check that the Amber and Red warning lights function for 5 seconds.

11. Connect Cat ET and note "Active" and/or "Logged" codes. The following "Logged" codes are likely to be present when Command for Underground is installed. Codes other than the ones listed are not expected and should be rectified.
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    Table 54

    Description
    Power Train ECM
    Logged Codes
    590-9
    681-5
    1610-5
    1925-5
    1927-5
    1927-3
    1928-3

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    Table 55

    Description
    CAT Monitoring System
    Logged Code
    248-2

12. Proceed to machine Command for Underground system commissioning.