Installation Procedure for the Cat® Detect Object Detection and Vision Systems for Quarry, Off-Highway and Mining Truck Applications {7610, 7620} Caterpillar

Machine Control & Guidance Products

CATDETECT-OBJECTDETEC (S/N: DTJ1-UP)

CATDETECT-VISIONONLY (S/N: DTL1-UP)

Introduction

Do not perform any procedure in this Special Instruction until you have read the information and you understand the information.

This Special Instruction covers the installation of the Object Detection and Vision System on Quarry, Off-Highway, and Mining Truck applications. This system is to be installed on machines that meet certain requirements and are not currently covered by the Object Detection retrofit systems available. These machines are listed in the machine and "DETECTOBJ" price list.

These kits are to be used on Quarry, Off-Highway, or Mining Trucks of the 70-400 ton classes.

This system can be configured to have 2, 4, or 8 Object Detection sensors on the machine. The system can be configured to have 2 or 4 cameras on the machine. The number of sensors will be determined by the size of the machine and mounting location availability. A Caterpillar technology representative or dealer support should be consulted prior to beginning an installation project.

Important Safety Information

Use only proper tools and observe all precautions that pertain to the use of those tools. Failure to follow these procedures can result in personal injury. The following procedures should also be observed.

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 any tool, procedure, work method, or operating technique you use that is not recommended by Caterpillar is safe.

Ensure that the product will not be damaged or the product will not be made unsafe by the operation, lubrication, maintenance, or repair procedures used.

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Personal injury or death can result from improper assembly procedures. Do not attempt any assembly until you have read and understand the assembly instructions.

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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.

Weld Specifications and Qualifications

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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

Note: Personal breathing protection should be worn by the personnel that are welding. Personal breathing protection will prevent fumes from entering the lungs of the person that is welding. Use a 1U-8088 Type H Respirator Gp for breathing protection.

Welders must be qualified for fillet welding and groove welding. The welder must be qualified in different welding angles. The welders should be qualified in the use of the welding processes that follow: Shielded Metal Arc Welding (SMAW), Flux Cored Arc Welding (FCAW) and Gas Metal Arc Welding (GMAW). Refer to ISO 9606 or "American National Standards Institute (ANSI)/American Welding Society (AWS) Specification D1.1, or Specification D14.3" for information that regards the qualifications for the processes that follow: SMAW process, FCAW process, and GMAW process. The welders must have used the process at some time within the last 6 months. The welders must complete the process of certification if the welders have not used the welding processes for 6 months.

The power source should be able to supply 500 A or more with DC current for the welding operation. The power source should be able to gouge metal with 500 A.

Use the direct current electrode positive (DC reverse polarity).

The welding wire must be shielded with CO₂ gas or Argon/CO₂ 80/20 gas.

All repair welds should be done in a controlled environment. Controlled environments prevent the rapid cooldown after the repair. Controlled environments would be inside a repair shop.

All welds should be done in the horizontal position to make a smooth surface finish.

If the vertical position must be used in the welding procedure, the operation should be performed in the "vertical up" direction, instead of the "vertical down" direction.

Recommended European weld consumables: SAF Oerlikon Carbofil SG3, ESAB OK Autrod 12.64, Pittini Pitarc G9, or Thyssen® Union k56

If only manual welding is possible, use ESAB OK 48.00 with a rod diameter of 3.25 mm (0.128 inch) or the equivalent AWS A5.1 E7018 or EN ISO 2560-A E 42 4 B 42 H5.

If welding quenched steel or tempered steel, the recommendation is to use specific filler metal with higher mechanical properties and lower hydrogen levels such as flux cored wire with AWS A5.20 Class E70T-5 specification. If something other than an AWS A5.20 Class E70T-5 Electrode is used, preheat to 200° C (392° F) and maintain interpass temperature at 150° C (302° F).

Mask all parts prior to gouging.

Proper Welding Procedure on Machines and Engines with Electronic Controls

Proper precautions are necessary to prevent damage to electronic controls. When you weld on a machine with electronic controls, use the steps that follow:

1. Turn off the engine. Put the key start switch in the OFF position.

2. If the machine has a battery disconnect switch, open the switch. If the machine does not have a battery disconnect switch, disconnect the negative battery cable at the battery.

3. Connect the ground cable for the welder directly to the actual machine component that will be welded. Attach the clamp for the ground cable as close as possible to the area that is being welded. This connection will reduce the chance of damage from welding current to the components that follow: bearings, hydraulic components, and electrical components.

   Note: Do NOT use electrical components as a ground point for the welder. Do NOT use ground points for electronic components as a ground point for the welder.

4. Protect the wiring harnesses from the weld splatter.

Preparing the Metal for Welding

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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.

All grease, water, paint, rust, dirt, and scale must be removed before welding. Any of these materials will discharge gas which will cause porosity in the weld deposit. Water and rust will cause hydrogen embrittlement. Hydrogen embrittlement causes cracks in the weld deposit.

Note: Identify the material to be welded. Some bumpers are cast and cannot be welded. Alternate mounting methods may have to be used in this scenario.

Installation Kits

Installation Kits are listed in the "DETECTOBJ" price list. Refer to this list for additional ordering information. Installation of this system will require the following components:

Display Mounting - Can be a RAM mount or pedestal. Provides mounting and hardware for the display.

Cab Kit - Contains the display, display harnessing, hardware, and components used to complete the cab portion of the installation.

Note: The display is not shipped with software installed. Software is available on SIS Web. The software is installed using 425-6889 Cable As and 479-4193 Wiring Cable Assembly available from the service kit 457-9179 Object Detection Kit. These parts are also available separately through parts distribution channels.

Vision Kit - Contains the camera, camera mounting, rear lamp, and camera cables. Vision kits for 2 and 4 camera applications are available.

Object Detection Kit - Contains the Object Detection sensors, sensor mounting, sensor harnessing, power converter, and associated hardware needed to complete installation on the machine. Sensor kits are available for 2, 4, and 8 sensor applications.

The following are some configuration examples:

• 150 ton to 400 ton class machines will use 8 Object Detection sensors and 4 cameras

• 70 ton to 150 ton class machines will use 2 or 4 sensors with 2 or 4 cameras.

Parts Tables

This section lists the kits and the components of these kits. The last table contains accessory parts that may need to be ordered if they are not already available.

Installation Requirements

Machine Requirements

The system requires a regulated power supply with a nominal voltage of 24 volts DC and must sustain a maximum load of 20 amps. Switched and unswitched inputs are required as well as a machine ground that is common with the chassis ground.

The system requires a 24 volt DC input for machine motion in forward and reverse. Connections will be made to these points with the systems cab harness.

The system requires a 24 volt DC input for machine body position if a dump body is installed. Connections will be made to these points with the systems cab harness.

Note: Additional electrical connectors and wiring may be required to complete the machine interface connections.

Component Location Selection

Ensure the guidelines listed in the following section are properly observed for selecting mounting locations, mounting the components, and routing harnessing and cables.

Determining the Mounting Locations

Harnesses and cables will interconnect all the components and interface with the machine. Harnesses and camera cables will be routed through the cab and to the rear of the machine. Follow harness routing guidelines and trace existing harnessing routes.

Note: Ensure that the components are located in areas that allow the cab harness to be routed and connected to all components and machine interfaces.

The following components must be mounted in the cab:

Display and display mounting - The display performs system processing, displays video from the camera, displays detection information, produces audible alarms in certain situations, and mounting ensures that the display is visible to the operator without interfering in machine operation. Additional considerations for display mounting can be found in the following section. The display will be installed in the machine cab on the RAM and bracket or pedestal option.

Power Converter - Converts power from 24 volts DC to 12 volts DC for sensor power. The power converter is installed in the machine cab near the machines electrical system center.

Relays - The relays are for main power, lamp, and switched inputs. The relays are installed in the machine cab near the machines electrical system center.

Circuit Breaker - System power circuit breaker is mounted on the circuit breaker panel or the provided plate.

The following components must be mounted on the machine:

Camera - The camera provides a video signal to the system display. The cameras must be mounted in an area clear of obstructions. Ensure that the area provides a view of the rear of the machine as reference and an adequate view of the systems desired coverage area to the rear of the machine.

Note: 4-camera systems will have a front, right-hand, rear, and left-hand camera.

Note: 2-camera systems will have a front and rear camera.

Rear and Side Lamps - Provides illumination for the camera when operating in conditions with reduced ambient lighting. The rear lamp should be mounted to the rear of the machine near the camera. Only mount the lamp if approved for locale use. Some regulations may prevent mounting of additional lamps on the rear of machines. Side lamps will be used on 4-camera systems to illuminate the right and left-hand camera coverage area.

Object Detection Sensors - Provides detection information to the display. The sensors must be mounted in an area that provides a clear area in the sensors field of view and does not interfere with access to the machine.

Note: 8-sensor systems will have two front sensors (left and right), one right-hand, one-left hand sensor, and four rear seasons (left, right, upper, and lower).

Note: 4-sensor systems will have one front sensor, one right-hand sensor, one left-hand sensor, and one rear sensor.

Note: 2-sensor systems will have one front sensors and one rear sensor.

Mounting Location Selection for the Display

The monitor display group must be mounted in a location that will not interfere with the existing equipment in the cab. If necessary, relocate the existing equipment.

Note: The monitor display group must not interfere with any movement of the operator.

Ensure that the monitor display group does not cause any of the listed conditions:

• Interfere with the direct view of the operator or the view in the mirror of the operator.

• Interfere with the ability to enter the cab or exit the cab from the seat of the operator or the buddy seat

• Expose the operator or the person in the buddy seat to potential of additional injury from impact during machine collisions or rollovers.

• Interfere with the operation of the machine controls. The machine controls include the following components: the gear selector, the retarder, and the steering wheel.

• Interfere with operator comfort. Operator comfort includes the rest positions for the arm and the leg.

• Block or cover up any warning films.

Preparation for Installation

This section outlines the following information:

• Custom brackets needed for installation

• Inspecting the machine and component mounting locations

• Special tools and resources required for the installation

• Grounding practices for the ECM

Custom brackets needed for installation on some machines

Some machines require additional brackets or custom component mounting depending on third party equipment installs and customer requirements.

Thorough evaluation of the machine should be done prior to install. The purpose of this evaluation is to identify all component mounting locations. The evaluation also identifies any risk associated with component mounting such as access to other components, interference with electrical systems, and interference with machine harness and cabling.

Inspecting the machine

Perform an inspection of the machine to identify the best mounting location for each component. Verify that the selected location will meet the following conditions:

• The installation will not interfere with the ability of the operator to view from the cab.

• The installation will not block any mirrors.

• The components will not block the entry or the exit of the operator.

• The components will not interfere with the operation of other equipment

• The cables will not extend beyond the electrical specifications

Guidelines for routing the harnesses

Use the following guidelines when routing harnesses:

• Route the harnesses in a manner that does not create a trip hazard.

• Properly restrain the harnesses.

• Protect the harnesses from mechanical damage.

• Ensure that the cable routing does not prevent access to any service panels.

• Protect the cables from sharp metal edges.

• Secure the cables near each connector in order to reduce strain on the connector.

• Ensure that the cables will not be exposed to excessive heat.

Tools, parts, and resources required for installation

Ensure that the following list of tools, parts, and resources are available prior to installation:

Note: The welder is required for the installation of the mounting blocks and brackets for the camera and Object Detection sensors. The welder may be required for the display bracket mounting.

Note: The service kit 457-9179 Object Detection Kit is recommended for any technicians who perform installation or servicing of this system.

Grounding practices

Note: The system has ground terminals that connect to the chassis ground of the machine. This ground strap will ground the system and components.

The equipment is grounded for the following purposes:

• Safety of personnel

• Safety of equipment through protection against lightning strikes

• Signals that are free of noise.

• Improved equipment operation

• Reduction of emitted noise

• Continuity of service

Installation Procedure

Camera and Lamp Installation

Refer to the steps in the following sections for the camera and lamp mounting procedures:

1. Collect the necessary parts from the vision kit. Refer to Table 8.
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   Table 8

   Parts Used for Camera and Lamp Installation
   Quantity	Part Number	Part Name
   1	268-9063	Bracket As
   1	8T-4185	Bolt
   1	8T-4121	Hard Washer
   1	8M-2772	Clip
   1	122-5855	Spacer
   1	7Y-8169	Grommet
   3	8T-4136	Bolt
   3	8T-4121	Hard Washer
   1	336-6684	Camera Gp
   1	426-5380	Flood Lamp Gp

2. Ensure that the machine key switch and main battery disconnect are in the off position.

Front camera mounting

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Illustration 1	g06087440
(1) 51 mm (2.0 inch) (2) 63.5 mm (2.5 inch)

1. At the mounting location for the front camera, weld the 255-8274 Plate. Alternatively, drill 4 x 13.8 mm (0.54 inch) holes spaced 63.5 mm (2.5 inch) by 51 mm (2.0 inch). Refer to Illustration 1. Ensure proper orientation of the drilled holes.
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   Illustration 2	g06089932
   (3) Hardware to secure camera to bracket (4) Camera group hardware (5) Hardware to secure upper bracket to lower bracket (6) Additional lower bracket hardware (7) Lower bracket hardware (8) Clip ladder hardware

2. Assemble the front camera mounting assembly as seen in Illustration 2. Refer to Table 9.
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   Table 9

   Front Camera Mounting Assembly Hardware
   Quantity	Part Number	Part Name
   Hardware to Secure Camera to Bracket (3)
   3	8T-6466	Bolt
   3	8T-4121	Hard Washer
   3	8T-4133	Nut
   1	312-4475	Bracket
   Camera Group Hardware (4)
   1	305-3748	Plate As
   1	336-6684	Camera Gp
   Hardware to Secure Upper Bracket to Lower Bracket (5)
   4	8T-4136	Bolt
   8	7X-7729	Washer
   4	8T-4133	Nut
   Additional Lower Bracket Hardware (6) (1)
   4	7X-7729	Washer
   4	8T-4133	Nut
   Lower Bracket Hardware (7)
   4	8T-4195	Bolt
   4	7X-7729	Washer
   1	348-8145	Bracket
   Clip Ladder Hardware (8)
   1	4P-7581	Clip
   1	8T-4136	Bolt
   2	8T-4121	Hard Washer
   1	8T-4133	Nut

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   (1)	Use this hardware only if the bracket will be bolted on front of the platform and not the weld plate.

3. Assemble the 336-6684 Camera Gp. Mount the assembly to the 312-4475 Bracket.
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   Illustration 3	g06087450
   Front camera mounting example

4. Bolt the front camera mounting assembly to the weld plate or the four holes previously drilled. Refer to Illustration 3.

Rear camera mounting

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Illustration 4	g06090042
(9) 336-6684 Camera Gp (10) 7X-7729 Washer (11) 8T-4195 Bolt (12) 348-9537 Plate As

1. Assemble the camera to the 348-9537 Plate As. Refer to Illustration 4.

2. If the Object Detection sensors are installed, this assembly will be mounted to the sensor mounting brackets. If no sensors are installed, drill two 13.5 mm (0.532 inch) holes spaced 50 mm (2.0 inch) apart.

3. To mount the lamp assembly, drill a single 13.5 mm (0.532 inch) hole on the side of the camera bracket or another bracket on the rear of the machine.

4. Mount the lamp to the hole using the nut and washers provided with the lamp.

5. Adjust the lamp towards the camera viewing area. Adjust the lamp to face downwards and just beyond the rear of the machine.

6. Tighten the mounting bolt to 55 ± 10 N·m (41 ± 7.4 lb ft). Tighten the angle adjustment bolt to 27 ± 8 N·m (20 ± 6 lb ft).

Left and right camera mounting (4 camera systems only)

Illustration 5	g06090100
(13) Camera group hardware (14) Hardware to secure camera plate (15) Plate (16) Hardware to secure lamp (17) Lamp group hardware (18) Hardware to secure bracket

1. At the left and right-hand camera mounting locations, do either of the following:

   • Weld the 255-8274 Plate

   • Drill four 13.8 mm (0.54 inch) holes. Space the holes 63.5 mm (2.5 inch) by 51 mm (2.0 inch). Refer to Illustration 1. Ensure proper orientation.

2. Assemble the left and right-hand camera mounting assemblies.

3. Mount the lamp to the hole using the nut and washers provided with the lamp.

4. Adjust the lamp towards the camera viewing area. Adjust the lamp downwards and just beyond the rear of the machine.

5. Tighten the mounting bolt to 55 ± 10 N·m (41 ± 7.4 lb ft). Tighten the angle adjustment bolt to 27 ± 8 N·m (20 ± 6 lb ft).

6. Assemble the 336-6684 Camera Gp. Mount the 336-6684 Camera Gp to the 305-3747 Plate As.

7. Mount the camera mounting assembly to the 255-8274 Plate or the four holes previously drilled.

Object Detection Sensor Mounting (Radar Systems Only)

This section covers the mounting procedure for the Object Detection sensors. Repeat the procedure if multiple sensors will be installed.

Installation hardware

Refer to Table 11 for the required parts needed from the Object Detection Sensor kit.

Front object detection sensors

1. Mark a weld location for the 8X-6110 Block at the mounting location for the front sensor.

2. Remove all paint and dirt from the marked location and 8X-6110 Block. Apply a 6 mm (0.24 inch) fillet weld around the perimeter of the block. Ensure that the area has cooled after welding before applying a protective layer of paint. The protective layer of paint prevents corrosion. Refer to Table 6 for paint recommendations.
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   Illustration 6	g06090140
   (19) Top of bumper (20) Two 8X-6110 Blocks

3. Assemble the front radar structure. Mount the front radar structure to the 8X-6110 Block. Refer to Illustration 6.

Side object detection sensors

Illustration 7	g06090440
Side Object Detection Sensors (21) 8T-4186 Bolt, 7X-7729 Washer, 6V-7744 Locknut (22) 452-1420 Object Detection Box Gp (23) 458-2204 Bracket As, 380-4489 Plate (24) 380-6932 Bracket, 9X-8256 Washer, 5C-9553 Bolt (25) 379-8128 Sensor Mounting Gp (26) 8T-4136 Bolt, 7X-7729 Washer (27) 8T-4183 Bolt, 198-4778 Hard Washer

1. Weld the 348-8762 Plate As at the mounting location for the left and right-hand Object Detection sensors.
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   Illustration 8	g06090655
   (28) 372-9143 Plate (29) 452-1420 Object Detection Box Gp (30) 326-9055 Film (NO STEP) (31) 8T-4189 Bolt, 5P-4116 Hard Washer (32) 378-6997 Bracket As, 8T-4196 Bolt, 7X-7729 Washer, 265-9596 Hard Washer

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   Illustration 9	g06090659
   (33) 8T-4196 Bolt, 265-9596 Hard Washer (34) 380-4489 Plate

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   Illustration 10	g06090666
   (35) 8T-4195 Bolt, 7X-7729 Washer (36) 8T-4183 Bolt, 198-4778 Hard Washer (37) 378-7007 Plate As

2. Assemble the left and right-hand Object Detection Mounting assemblies using the proper hardware. Refer to Illustrations 8,9, and 10.

3. Mount the assembly to the 348-8762 Plate As.

Rear object detection sensor

Illustration 11	g06090671
Example of rear object detection sensor mounting location

Illustration 12	g06090676
Example of mounted rear object detection sensor

The rear of trucks varies greatly by manufacturer. The rear mounting structure provided in this kit may need modifications to allow mounting one rear of each unique application. Unique brackets may need to be fabricated for other types of mounting applications.

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Illustration 13	g06090692
(38) 8T-4648 Bolt, 198-4778 Hard Washer, 6V-7687 Locknut (39) 092-5524 Bolt, 265-9596 Hard Washer, 6V-7687 Locknut

1. Install the 419-5055 Clamp halves to the axle housing using the proper hardware. Refer to Illustration 13.

2. Torque the top 8T-4648 Bolts (38) to 100 N·m (73.8 lb ft). Torque the bottom 092-5524 Bolts (39) to 50 N·m (36.9 lb ft).
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   Illustration 14	g06090700
   (40) 8T-4195 Bolt, 8T-4121 Hard Washer (41) 419-5054 Bracket As (42) 419-5053 Bracket As (43) 389-7028 Plate As (44) 8T-4182 Bolt, 8T-4121 Hard Washer (45) Rear view of assembled brackets

3. Attach 389-7028 Plate As (43) to 419-5053 Bracket As (42) and 419-5054 Bracket As (41). Refer to Illustration 14 for the proper hardware.

4. Weld the assembled bracket from Step 3 to the axle clamps installed in Step 1. Ensure that the front face of the bracket is perpendicular to the ground.

5. Perform a mock fit up of the anti-rotational brackets to determine the correct location of the two 422-2398 Blocks.

6. After determining the proper location, prepare the welding area. Weld the two 422-2398 Blocks to the frame.
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   Illustration 15	g06090706
   (46) 8T-4648 Bolt, 198-4778 Hard Washer, 6V-7687 Locknut (47) 8T-4195 Bolt, 7X-7729 Washer (48) 419-5054 Bracket As (49) 422-2398 Block (50) 8T-4195 Bolt, 7X-7729 Washer (51) 419-6048 Bracket As (52) 8T-4186 Bolt, 7X-7729 Washer (53) 419-5056 Bracket As (54) 092-5524 Bolt, 265-9596 Hard Washer, 6V-7687 Locknut (55) 419-5053 Bracket As (56) 419-5055 Clamp

7. Bolt the brackets together using the proper hardware. Refer to Illustration 15.

Radar Mounting

Mounting the rear-upper radars

Note: The following procedure is for one upper radar. Use the same procedure for the second radar.

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Illustration 16	g06090717
(57) 380-4489 Plate (58) 8T-4196 Bolt, 7X-7729 Washer, 265-9596 Hard Washer (59) 458-2206 Bracket As (60) 8T-4186 Bolt, 7X-7729 Washer

1. Assemble the rear radar assemblies. Attach the 452-1420 Object Detection Box Gp to the 458-2204 Bracket As. Use four 8T-4136 Bolts, two 7X-7729 Washers, and one 380-4489 Plate. Refer to Illustration 16.
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   Illustration 17	g06090721
   (61) 348-8765 Clamp Bracket (62) 8T-4186 Bolt, 7X-7729 Washers, 6V-7744 Locknut (63) 452-1420 Object Detection Box Gp

2. Attach the assembled box group and bracket assembly to the 348-8765 Clamp Bracket. Use four 8T-4186 Bolts, eight 7X-7729 Washers, and four 6V-7744 Locknuts.

3. Mount the upper radar assemblies to the rear bracket on the back of the truck. Use two 8T-4186 Bolts and two 7X-7729 Washers for each assembly.

Mounting the rear-lower radars

Note: The following procedure is for one lower radar. Use the same procedure for the second radar.

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Illustration 18	g06091075
(64) 458-2204 Bracket As (65) 8T-4136 Bolt, 7X-7729 Washer, 380-4489 Plate (66) 8T-4186 Bolt, 7X-7729 Washer

1. Assemble the rear radar assemblies. Attach the 452-1420 Object Detection Box Gp to the 458-2204 Bracket As. Use four 8T-4136 Bolts, two 7X-7729 Washers, and one 380-4489 Plate. Refer to Illustration 18.
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   Illustration 19	g06090721
   (61) 348-8765 Clamp Bracket (62) 8T-4186 Bolt, 7X-7729 Washers, 6V-7744 Locknut (63) 452-1420 Object Detection Box Gp

2. Attach the assembled box group and bracket assembly to the 348-8765 Clamp Bracket. Use four 8T-4186 Bolts, eight 7X-7729 Washers, and four 6V-7744 Locknuts. Refer to Illustration 19.

3. Mount the lower radar assemblies to the rear bracket on the back of the truck. Use two 8T-4186 Bolts and two 7X-7729 Washers.

Illustration 20	g06090710

Illustration 21	g06090711

Note: Depending on the application, there is a possibility that the rear axle clamps in the provided kits may not be applicable. Refer to Illustration 20 and Illustration 21 for other examples to mount rear radars. Ensure that the chosen method of installation provides adequate radar support for vibration and conditions in the field.

Display Mounting Installation and Mounting the Display

Use the following procedures to install the display mounting and to mount the display.

Note: There are two options for display mounting. Follow the instructions for the kit that was ordered.

Collect one of the following mounting kits:

• 451-3759 Display Mounting Kit (RAM)

• 462-2978 Display Mounting Kit (PEDESTAL)

Mounting the RAM-style display mount

1. Determine if the machine has a base capable of supporting the RAM mount footprint.

   Note: Mounting for a RAM base may already exist.

   1. If the RAM base footprint already exists, use the area for mounting the RAM coupler. Attach the 329-2680 Base to the footprint. Use four 8T-4753 Screws if the location contains M5x.08 threads. If this location accepts another thread size, use the fastening hardware intended to be used at this location of the machine model.

   2. Use the following steps if the RAM base footprint does not already exist but there is an area for mounting the base.

      1. Paint the bracket to protect from corrosion.
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         Illustration 22	g06090740
         (67) 38.1 mm (1.50 inch) (68) 110 mm (4.33 inch) (69) 30.2 mm (1.19 inch)

      2. Drill four 8 mm (0.31 inch) holes in the mounting area. Drill the holes in a 30.2 mm (1.19 inch) by 38.1 mm (1.50 inch) pattern. Refer to Illustration 22.

      3. Attach the 329-2680 Base to the 329-2682 Bracket As using the four holes. Use four 8T-4753 Screws.

   3. If the RAM base does not exist and there is no area for mounting the base, use one of the following procedures:

      • Drill mounting holes and bolt the mounting

      • Weld the mounting plate

      1. To bolt the mount, first paint the bracket to protect from corrosion. Drill two 10.5 mm (0.41 inch) holes in the mounting area. Space the holes 110 mm (4.33 inch) apart as seen in Illustration 22.

         Attach the 329-2682 Bracket As to the mounting area through the two holes. Use two 8T-4189 Bolts, four 5C-7261 Nuts, and four 8T-4224 Hard Washers.

         Attach the 329-2680 Base to the 329-2682 Bracket As. Use four 8T-4753 Screws.

      2. To weld the mounting plate, first clean the area to be welded. Remove any paint or grease.

         Weld the 329-2682 Bracket As to the mounting location. Use 4 mm (0.16 inch) x 3 mm (0.12 inch) fillet welds. Each fillet weld is 20 mm (0.79 inch) long.

         Attach the 329-2680 Base to the 329-2682 Bracket As. Use four 8T-4753 Screws.

2. Assemble the remainder of the RAM clamp and bases. Use the 329-2679 Clamp and the second 329-2680 Base.

3. Attach the 450-0297 Bracket As to the 329-2680 Base. Use four 8T-4753 Screws.
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   Illustration 23	g06090764
   Display and display mounting assembly (70) 450-0297 Bracket As (71) 329-2680 Base (72) 329-2679 Clamp (73) 329-2682 Bracket As (74) 8T-4189 Bolt, 5C-7261 Nut, 8T-4224 Hard Washer

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   Illustration 24	g06090769
   Rear view of display mounting assembly (70) 450-0297 Bracket As (71) 329-2680 Base (72) 329-2679 Clamp (75) 6V-5683 Bolt, 114-6658 Washer (76) 8T-4753 Screw

4. Attach 459-2220 Electronic Control Gp to the 450-0297 Bracket As. Use four 6V-5683 Boltsand four 114-6658 Washers.

Mounting the pedestal-style display mount

Illustration 25	g06090771
(77) 348-2163 Pedestal As (78) 5S-7379 Bolt, 8T-4896 Hard Washer (79) 167-8748 Plate

Illustration 26	g06090779
(80) 444-7077 Plate (81) 6V-5683 Bolt, 114-6658 Washer (82) 9X-2042 Screw, 5P-4116 Hard Washer (83) 352-4694 Bracket (84) 9B-7237 Bolt, 8T-4896 Hard Washer (85) 132-5789 Clip

1. Clear a 152 mm (5.98 inch) by 152 mm (5.98 inch) area for the 167-8748 Plate at the mounting location. Remove paint and grease.

2. Clear the area and weld the 167-8748 Plate using 6 mm (0.2 inch) fillet welds. Use at least two 25 mm (0.98 inch) long fillet welds per side.

3. After the weld has cooled, paint the 167-8748 Plate to prevent corrosion.

4. Assemble the pedestal-style display mount. Refer to Illustration 25 and Illustration 26.

   1. Bolt the 348-2163 Pedestal As to the 167-8748 Plate. Use four 5S-7379 Bolts and four 8T-4896 Hard Washers.

   2. Place the 352-4694 Bracket into the clamp on the top of the 348-2163 Pedestal As.

   3. Install the 132-5789 Clip to the clamp. Tighten the clamp using one 9B-7237 Bolt and one 8T-4896 Hard Washer.

   4. Mount the 444-7077 Plate to the 352-4694 Bracket. Use four 9X-2042 Screws and four 5P-4116 Hard Washers.

   5. Mount the 459-2220 Electronic Control Gp to the 444-7077 Plate. Use four 6V-5683 Bolts and four 114-6658 Washers.

Mounting the Power Converter (Radar Systems Only), Relays, and Circuit Breakers

Use the following procedures when mounting the electrical components. Ensure that the components installed are in a locations such that the 495-2266 Cab Harness As can connect to all components.

Obtain the following parts from the cab kit.

Obtain the following parts from the converter kit located in the object detection kit:

1. Use the following procedure if an area is available to mount the 490-5042 Bracket.

   1. Mark the location of the mounting holes for the bracket. The hole pattern is 140 mm (5.5 inch) by 470 mm (19 inch).

   2. Drill four 13 mm (0.51 inch) holes at the marked locations.

   3. Mount the 490-5042 Bracket. Use four 8T-4137 Bolts, eight 8T-4121 Hard Washers, four optional 9R-2613 Weld Boss, Spacer M10/25, and four 344-5675 Nuts to secure the bracket through the drilled holes.

   4. Mount the 6T-3644 Circuit Breaker As to the 490-5042 Bracket. Use two 9X-8486 Screws and two 4B-4863 Washers.

   5. Mount the two 3E-5239 Relay As to the 490-5042 Bracket. Use two 5C-9553 Bolts, two 9X-8267 Washers, and two 6V-8225 Nuts to secure the circuit breaker.

   6. Mount the three 231-3930 Relay As to the 490-5042 Bracket. Use three 5C-9553 Bolts, three 9X-8267 Washers, and three 6V-8225 Nuts.

   7. If installing Object Detection sensors, mount the 443-6362 Power Converter to the 490-5042 Bracket. Use four 9X-2045 Screws, four 9X-8267 Washers, and four 6V-8225 Nuts to secure the converter to the bracket.

Electrical component mounting bracket

Illustration 27	g06090787
(86) 443-6362 Power Converter (87) 7X-2533 Bolts, 6V-8225 Nuts, 7X-2533 Bolts (88) 5C-9553 Bolts, 9X-8267 Washers, 6V-8225 Nuts (89) 6T-3644 Circuit Breaker As (90) 9X-8486 Screws, 4B-4863 Washers (91) 5C-9553 Bolts, 9X-8267 Washers, 6V-8225 Nuts (92) 8T-4137 Bolts, 8T-4121 Hard Washers, Spacer M10/25, 344-5675 Nuts (93) 490-5042 Bracket (94) 3E-5239 Relay As (95) 231-3930 Relay As

Use the following procedure to mount the components in the electronic compartment.

1. Mark the location of the mounting holes for each component. Refer to Illustration 27 for the proper layout of the circuit breaker and the power converter.
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   Illustration 28	g06090789
   (96) 40 mm (1.57 inch) (97) 5 mm (0.2 inch) (98) 12 mm (0.5 inch)

2. Drill two 5 mm (0.2 inch) holes and one 12 mm (0.5 inch) hole for the circuit breaker. Refer to Illustration 28.

3. Drill five 8 mm (0.31 inch) holes for mounting the relays.
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   Illustration 29	g06090791
   (99) 101.6 mm (4 inch) (100) 130.7 mm (5.1 inch)

4. Drill four 8 mm (0.31 inch) holes to mount the power converter. Refer to Illustration 29.

5. Mount the 6T-3644 Circuit Breaker As through the holes drilled in Step 2. Use two 9X-8486 Screws and two 4B-4863 Washers to secure the circuit breaker.

6. Mount the two 3E-5239 Relay As through the holes drilled in Step 3. Use two 5C-9553 Bolts, two 9X-8267 Washers, and two 6V-8225 Nuts to secure the relays.

7. Mount the three 231-3930 Relay As through the holes drilled in Step 3. Use three 5C-9553 Bolts, three 9X-8267 Washers, and three 6V-8225 Nuts to secure the relays.

8. If installing Object Detection sensors, mount the 443-6362 Power Converter through the holes drilled in Step 4. Use four 9X-2045 Bolts, four 9X-8267 Washers, and four 6V-8225 Nuts to secure the power converter.

Machine Power and Interface Connections

Use the power and cab harnesses to connect to the following:

• Unswitched power

• Switched power

• Ground

• Machine forward

• Machine reverse

• Machine body up (if available)

Obtain the following parts from the cab kit:

• 494-4251 Power Harness As

• 495-2266 Cab Harness As

1. Identify the unswitched power source for the system.

2. Install the terminal end of the 494-4251 Power Harness As to a power lug of the power source.

3. Identify the switched power source for the system.

4. Connect the key switch power lead terminal of the 495-2266 Cab Harness As, labeled "Key Switch", to the key switched power source of the machine.

5. Identify a machine grounding lug. Connect the harness ground terminals, labeled "Ground", to these lugs.

6. Identify a 24-VDC circuit that is only powered when the machine is in forward gear.

7. Connect the "Gear FWD Machine Interface" terminal to this connection.

   Note: If a splice must be made, use the 207-3814 Wire As listed in the accessory tables. Terminate in Deutsch connectors.

8. Identify a 24-VDC circuit that is only powered when the machine is in reverse gear.

9. Connect the "Gear REV Machine Interface" terminal to this connection.

   Note: If a splice must be made, use the 207-3814 Wire As listed in the accessory tables. Terminate in Deutsch connectors.

10. Use the following procedure for machines with dump bodies.

    1. Identify a 24-VDC circuit that is only powered when the dump body of the machine is in the up position.

    2. Connect the "Body Up Machine Interface" terminal to this connection.

       Note: If a splice must be made, use the 207-3814 Wire As listed in the accessory tables. Terminate in Deutsch connectors.

Converting Harness for Switch to Ground Applications

Illustration 30	g06091753
(101) Relay connection (to be removed) (102) Relay connection (103) Ground wires (there are two) (104) Reverse Gear Machine Interface

1. Find the appropriate signal wires (forward, reverse, and body position) to the display. In the following example, Y985 is the wire for the reverse signal.

2. Identify the relays with the signal wires found in Step 1. Cut off the relay.

3. Tape every wire back except for the signal wire (Y985) and the machine interface wire. In this example the machine interface wire is 594. Ensure that all unused grounds are properly secured.

4. Attach the signal wire from the display (Y985) directly to the machine interface wire (594).

Routing the Harness and Camera Cable

Route the harness and camera cable after all components have been installed and once machine connections have been made. Drill a bulk head hole so that the bulk head connector of the chassis harness and the cab harness can be mounted. Drill a hole for the camera harness.

Obtain the following parts:

Bulkhead connections for the camera and sensor harness

1. Drill a 41.5 mm (1.63 inch) hole and a 50 mm (1.97 inch) hole into the area of the machine that will contain the bulkhead connectors.

2. Install the 456-8330 Cable As in the 50 mm (1.97 inch) hole.

   Note: The connector end with the pins should be in the interior of the cab.

3. Install the bulkhead connector of the 494-3952 Chassis Harness As in the 41.5 mm (1.63 inch) hole.

Camera cables

1. Select the appropriate lengths of the cable assemblies to connect the camera to the bulkhead connector. Ensure that each end is securely fastened. Wrap the connection in electrical tape to prevent loosening.

2. Make the connection to the camera.

3. Route the cables from the camera to the bulkhead connector.

4. Make the bulkhead connection.

5. Coil any excess cable at the two end connections. Ensure that the coils maintain a radius of at least 150 mm (6 inch) to prevent cable damage.

6. Secure the cable every 400 mm (16 inch). Use the 7K-1181 Cable Strap (15.5-IN) to secure the cable.

7. Connect the 494-4251 Power Harness As to the video connector of the display.

8. Route the harness to the interior side of the bulkhead connector.

9. Coil excess cable at the bulkhead end. Ensure that the coils maintain a radius of at least 150 mm (6 inch) to prevent cable damage.

10. Connect to the bulkhead connector.

11. Secure the cable every 400 mm (16 inch). Use the 7K-1181 Cable Strap (15.5-IN) to secure the cable.

Sensor and chassis harness

1. Locate the 494-3954 Sensor Harness As, 494-3952 Chassis Harness As, and 494-3953 Lighting Harness As.

   Note: The 494-3953 Lighting Harness As is only used when adding additional length to the rear of the system.

2. Connect the 494-3954 Sensor Harness As to the Object Detection sensors installed at the rear of the machine. Make the following connections:

   1. For one-sensor systems, connect the "Left Radar" harness lead to the left sensor.

   2. For two-sensor systems, ensure the following connections:

      • Connect the "Left Radar" harness lead to the left sensor.

      • Connect the "Right Radar" harness lead to the right sensor.

   3. For three-sensor systems, ensure the following connections:

      • Connect the "Left Radar" harness lead to the left sensor.

      • Connect the "Center Radar" harness lead to the center sensor.

      • Connect the "Right Radar" harness lead to the right sensor.

3. Route the opposite end of the harness back towards the machine. Use existing harness routes and follow harness routing guidelines.

4. Connect to the Deutsch connection end 494-3952 Chassis Harness As. If additional length is needed, connect the 494-3953 Lighting Harness As.

5. Connect the bulkhead end of the 494-3952 Chassis Harness As to the bulkhead connector.

6. Route the end labeled "Lamp" to the camera lamp.

7. Secure the unused ends of the sensor harness with the 7K-1181 Cable Strap (15.5-IN).

8. Secure the harnesses every 400 mm (16 inch). Use the 7K-1181 Cable Strap (15.5-IN) to secure the cable.

Cab harnesses connections

1. Connect the "Power"lead to the power receptacle of the display.

2. Connect the "CDL"lead to the CDL receptacle of the display.

3. Connect the "Ethernet 1"lead to the Ethernet 1 receptacle of the display.

4. Connect the "Ethernet 2"lead to the Ethernet 2 receptacle of the display.

5. Connect the "Power Converter"lead to the installed power converter.

6. Connect the "FWD Gear", "REV Gear", and "Body" leads to the installed 231-3930 Relay As.

7. Connect the "Main Power" and "Lamp" leads to the installed 3E-5239 Relay As.

8. Connect the power connection of the 494-4251 Power Harness As to the 495-2266 Cab Harness As.

9. Secure the harnesses every 400 mm (16 inch). Use the 7K-1181 Cable Strap (15.5-IN) to secure the cable.

10. With the main disconnect of the machine on, turn the machine key switch to the "on" position. The display powers up to the software installation screen.

Software Installation

Refer to Special Instruction, REHS7353, "Procedure for Installing Object Detection Software on Monitor Display Group" for software installation instructions. The latest software versions are available on SIS Web. Search Service Magazines for Object Detection software releases under serial numbers (S/N: DTL) and (S/N: DTJ).

Note: The display is not shipped with software installed. Software is available on SIS Web. Install the software using the 425-6889 Cable As and 479-4193 Wiring Cable Assembly. These cables are available in the 457-9179 Object Detection Kit. These parts are also available separately through parts distribution channels.

Generic Object Detection for Trucks Equipment ID Configuration and Recommended Filter Settings

After the Object Detection software is flashed onto the display, use the Cat^® Electronic Technician (Cat ET) Service Tool to enter the appropriate equipment ID for the application. Refer to Table 16 for the correct IDs.

Note: The filter settings in the table are a good starting point but require adjusting depending on the application.