Procedure to Install Machine Automation System on R1600H Load Haul Dump Machines {7000, 7600}
- Load Haul Dump
- R1600H (S/N: 9SD186-UP)
Introduction
This special instruction covers the procedure to install Machine Automation System (MAS) on R1600H (S/N: 9SD186-UP) 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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| NOTICE |
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Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. |
Reference Section
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.
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| Parts Required for R1600H (S/N: 9SD186-UP) with ROPS | ||
|---|---|---|
| Qty | Part Number | Description |
| 4 | Cotter Pin | |
| |
Nonslip Tread | |
| 1 | Access Cover As | |
| 1 | Cover As | |
| 1 | OR |
Camera and Mounting Gp (Front 78º)
OR Camera and Mounting Gp (Front 115º) |
| 1 | Communication Radio Gp | |
| 1 | Onboard Installation Ar (ROPS) | |
| 1 | Cover As | |
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| Parts Required for R1600H (S/N: 9SD186-UP) with FOPS | ||
|---|---|---|
| Qty | Part Number | Description |
| 4 | Cotter Pin | |
| |
Nonslip Tread | |
| 1 | Access Cover As | |
| 1 | Cover As | |
| 1 | OR |
Camera and Mounting Gp (Front 78º)
OR Camera and Mounting Gp (Front 115º) |
| 1 | Communication Radio Gp | |
| 1 | Onboard Installation Ar (FOPS) | |
| 1 | Cover As | |
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.
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| 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 |
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| 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 |
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| 12 | Electrical | Check that 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) | ||
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| Non-Standard Customer Additions | ||
|---|---|---|
| Ref No | Description | Comments |
Machine Preparation
- Move the machine to a hard level surface away from operating machines and away from personnel.
- Engage the parking brake. Place wheel blocks in front of the wheels and behind the wheels.
- Stop the engine.
- De-grease and pressure clean machine.
- Raise lift arms and install locking pins.
- Install the steering frame lock. Refer to Disassembly and Assembly, "Steering Frame Lock - Remove and Install".
- 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.
- Remove radiator cover and deck cover group.
- Remove cabin pressurizer and covers.
- Remove upper cab lighting.
- Remove the fire extinguisher and the fire extinguisher mounting bracket (if fitted).
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
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| Parts for 338-6691 Sensor Mounting Gp(1) | ||
|---|---|---|
| Qty | Part Number | Description |
| 1 | Cotter Pin | |
| 3 | Bolt | |
| 1 | Grommet | |
| 2 | Nut | |
| 3 | Bolt | |
| 6 | Hard Washer | |
| 1 | Coupling | |
| 1 | Rotary Sensor | |
| 1 | Spacer | |
| 1 | Stud | |
| 1 | Plate | |
| 1 | Plate | |
| 1 | Rod As | |
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| (1) | These parts are part of |
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| Parts for 366-3987 Plate and Film Gp(1) | ||
|---|---|---|
| Qty | Part Number | Description |
| 4 | Drive Screw | |
| 1 | Film Warning (Crush Hazard) | |
| 1 | Identification Plate (Year of Manufacture) | |
| 1 | Film Identification (Beacon, Horn) | |
| 1 | Serial Number Plate | |
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| (1) | These parts are part of |
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| Parts for 366-3992 Camera Wiring Gp(1) | ||
|---|---|---|
| Qty | Part Number | Description |
| 5 | Clip | |
| 5 | Cable Strap | |
| 2 | Clip | |
| 1 | Cable As | |
| 1 | Cable As | |
| 3 | Connection Assembly | |
| 1 | Protective Cap | |
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| (1) | These parts are part of |
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| Parts for 366-4011 Camera and Mounting Gp (ROPS) Rear(1) | ||
|---|---|---|
| Qty | Part Number | Description |
| 2 | Bolt | |
| 1 | Bolt | |
| 1 | Clip | |
| 1 | Hard Washer | |
| 2 | Washer | |
| 1 | Connection Assembly | |
| 1 | Camera Gp | |
| 1 | Plate | |
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| (1) | These parts are part of |
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| Parts for 366-4013 Camera and Mounting Gp (Front 78º) | ||
|---|---|---|
| Qty | Part Number | Description |
| 4 | Cable Strap | |
| 3 | Bolt | |
| 4 | Bolt | |
| 4 | Hard Washer | |
| 3 | Washer | |
| 1 | Connection Assembly | |
| 1 | Camera Gp 78º | |
| 1 | Plate | |
| 1 | Mount As | |
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| Parts for 366-7696 Communication Radio Gp | ||
|---|---|---|
| Qty | Part Number | Description |
| 1 | Communication Radio Gp | |
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| Parts for 370-2413 Communication Wiring Gp(1) | ||
|---|---|---|
| Qty | Part Number | Description |
| 6 | Spacer | |
| 3 | Cable Strap | |
| 1 | Clip | |
| 2 | Bolt | |
| 2 | Bolt | |
| 3 | Clip | |
| 6 | Nut | |
| 9 | Cable Strap | |
| 4 | Bolt | |
| 14 | Hard Washer | |
| 10 | Clip | |
| 1 | Cable | |
| 1 | Cap | |
| 1 | Cable | |
| 1 | Cable As | |
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| (1) | These parts are part of |
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| Parts for 370-2414 Radio Mounting Gp(1) | ||
|---|---|---|
| Qty | Part Number | Description |
| 2 | Bolt | |
| 4 | Bolt | |
| 2 | Bolt | |
| 6 | Hard Washer | |
| 4 | Bolt | |
| 8 | Isolation Mount | |
| 4 | Hard Washer | |
| 2 | Washer | |
| 1 | Clip | |
| 1 | Mount As | |
| 1 | Plate | |
| 4 | Spacer | |
| 1 | Cover | |
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| (1) | These parts are part of |
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| Parts for 370-2489 Rotary Switch Gp(1) | ||
|---|---|---|
| Qty | Part Number | Description |
| 1 | Rotary Switch Gp | |
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| (1) | These parts are part of |
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| Parts for 370-2545 Electrical Converter Gp(1) | ||
|---|---|---|
| Qty | Part Number | Description |
| 8 | Bolt | |
| 8 | Hard Washer | |
| 5 | Bolt | |
| 5 | Hard Washer | |
| 2 | Electrical Converter | |
| 1 | Mount As | |
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| (1) | These parts are part of |
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| Parts for 370-2593 Circuit Breaker Gp(1) | ||
|---|---|---|
| Qty | Part Number | Description |
| 2 | Cable Strap | |
| 4 | Bolt | |
| 2 | Bolt | |
| 4 | Hard Washer | |
| 2 | Hard Washer | |
| 4 | Bolt | |
| 1 | Circuit Breaker Panel Gp | |
| 1 | Plate | |
| 1 | Cover | |
| 1 | Cable As | |
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| (1) | These parts are part of |
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| Parts for 379-9821 LADAR Sensor and Mounting Gp (ROPS) Front(1) | ||
|---|---|---|
| Qty | Part Number | Description |
| 1 | Nut | |
| 4 | Bolt | |
| 6 | Hard Washer | |
| 4 | Hard Washer | |
| 2 | Bolt | |
| 2 | Nut | |
| 4 | Bolt | |
| 2 | Bolt | |
| 1 | Bolt | |
| 4 | Bolt | |
| 8 | Isolation Mount | |
| 4 | Spacer | |
| 4 | Hard Washer | |
| 1 | Washer | |
| 4 | Lockwasher | |
| 1 | Mount As | |
| 1 | Sensor Mount As | |
| 1 | Sensor | |
| 1 | Sensor Mount As | |
| 1 | Sensor Mount As | |
| 1 | Protective Cover | |
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| (1) | These parts are part of |
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| Parts for 379-9822 LADAR Sensor and Mounting Gp (ROPS) Rear(1) | ||
|---|---|---|
| Qty | Part Number | Description |
| 1 | Nut | |
| 4 | Bolt | |
| 6 | Hard Washer | |
| 4 | Hard Washer | |
| 2 | Bolt | |
| 2 | Nut | |
| 4 | Bolt | |
| 2 | Bolt | |
| 1 | Bolt | |
| 8 | Isolation Mount | |
| 4 | Spacer | |
| 4 | Hard Washer | |
| 1 | Washer | |
| 4 | Lockwasher | |
| 4 | Bolt | |
| 1 | Mount As | |
| 1 | Sensor | |
| 1 | Mount As | |
| 1 | Sensor Mount As | |
| 1 | Sensor Mount As | |
| 1 | Protective Cover | |
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| (1) | These parts are part of |
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| Parts for 379-9911 LADAR Sensor and Mounting Gp (FOPS) Front(1) | ||
|---|---|---|
| Qty | Part Number | Description |
| 1 | Nut | |
| 4 | Bolt | |
| 4 | Hard Washer | |
| 4 | Bolt | |
| 4 | Bolt | |
| 4 | Bolt | |
| 4 | Hard Washer | |
| 1 | Bolt | |
| 8 | Isolation Mount | |
| 4 | Spacer | |
| 4 | Hard Washer | |
| 1 | Washer | |
| 4 | Lockwasher | |
| 1 | Mount As | |
| 1 | Sensor | |
| 1 | Sensor Mount As | |
| 1 | Sensor Mount As | |
| 1 | Sensor Mount As | |
| 1 | Protective Cover | |
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| (1) | These parts are part of |
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| Parts for 379-9939 Camera and Mounting Gp (FOPS) Rear(1) | ||
|---|---|---|
| Qty | Part Number | Description |
| 2 | Bolt | |
| 2 | Washer | |
| 1 | Clip | |
| 1 | Connection Assembly | |
| 1 | Camera Gp | |
| 1 | Plate | |
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| (1) | These parts are part of |
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| Parts for 379-9940 LADAR Sensor and Mounting Gp (FOPS) Rear(1) | ||
|---|---|---|
| Qty | Part Number | Description |
| 4 | Bolt | |
| 4 | Hard Washer | |
| 4 | Hard Washer | |
| 1 | Bolt | |
| 1 | Nut | |
| 1 | Nut | |
| 4 | Bolt | |
| 2 | Bolt | |
| 4 | Bolt | |
| 1 | Bolt | |
| 8 | Isolation Mount | |
| 4 | Spacer | |
| 4 | Hard Washer | |
| 1 | Washer | |
| 4 | Lockwasher | |
| 1 | Mount As | |
| 1 | Sensor | |
| 1 | Sensor Mount As | |
| 1 | Sensor Mount As | |
| 1 | Sensor Mount As | |
| 1 | Protective Cover | |
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| (1) | These parts are part of |
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| Parts for 380-0044 Sensor Wiring Gp(1) | ||
|---|---|---|
| Qty | Part Number | Description |
| 2 | Clip | |
| 2 | Cable As | |
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| (1) | These parts are part of |
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| Parts for 423-8805 Camera Gp (Front 115º) | ||
|---|---|---|
| Qty | Part Number | Description |
| 4 | Cable Strap | |
| 3 | Bolt | |
| 4 | Bolt | |
| 4 | Hard Washer | |
| 3 | Washer | |
| 1 | Connection Assembly | |
| 1 | Camera Gp 115º | |
| 1 | Plate | |
| 1 | Mount As | |
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| Parts for 433-6827 Radio Wiring Gp(1) | ||
|---|---|---|
| Qty | Part Number | Description |
| 2 | Nut | |
| 6 | Strap | |
| 2 | Bolt | |
| 2 | Hard Washer | |
| 2 | Bolt | |
| 4 | Hard Washer | |
| 1 | Cable As | |
| 1 | Cable As | |
| 2 | Electronic Filter | |
| 2 | Cable As | |
| 1 | Plate | |
| 2 | Cable As | |
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| (1) | These parts are part of |
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| Parts for 435-1510 Computer Mounting Gp(1) | ||
|---|---|---|
| Qty | Part Number | Description |
| 4 | Hard Washer | |
| 4 | Bolt | |
| 1 | Mount As | |
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| (1) | These parts are part of |
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| Parts for 436-0204 Warning Lighting Gp(1) | ||
|---|---|---|
| Qty | Part Number | Description |
| 4 | Bolt | |
| 1 | Bolt | |
| 1 | Nut | |
| 6 | Bolt | |
| 6 | Hard Washer | |
| 2 | Clip | |
| 6 | Nut | |
| 6 | Screw | |
| 1 | Lighting | |
| 1 | Lighting | |
| 2 | Shield | |
| 1 | Plate | |
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| (1) | These parts are part of |
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| Parts for 439-4823 Camera Wiring Gp Front(1) | ||
|---|---|---|
| Qty | Part Number | Description |
| 2 | Locknut | |
| 2 | Cable Strap | |
| 1 | Nut | |
| 1 | Bolt | |
| 2 | Hard Washer | |
| 2 | Hard Washer | |
| 2 | Bolt | |
| 2 | Clip | |
| 1 | Connection Assembly | |
| 1 | Cable As | |
| 1 | Plate | |
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| (1) | These parts are part of |
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| Parts for 439-4824 Communication Wiring Gp (FOPS)(1) | ||
|---|---|---|
| Qty | Part Number | Description |
| 2 | Spacer | |
| 7 | Cable Strap | |
| 3 | Clip | |
| 2 | Bolt | |
| 9 | Cable Strap | |
| 2 | Bolt | |
| 4 | Hard Washer | |
| 6 | Clip | |
| 1 | Cable | |
| 1 | Cap | |
| 1 | Cable | |
| 1 | Cable As | |
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| (1) | These parts are part of |
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| Parts for 439-4825 Camera Wiring Gp (FOPS)(1) | ||
|---|---|---|
| Qty | Part Number | Description |
| 5 | Clip | |
| 5 | Cable Strap | |
| 1 | Clip | |
| 1 | Cable As | |
| 3 | Connection Assembly | |
| 1 | Protective Cap | |
| 1 | Cable As | |
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| (1) | These parts are part of |
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| Parts for 443-3785 Communication Wiring Gp(1) | ||
|---|---|---|
| Qty | Part Number | Description |
| 1 | Spacer | |
| 2 | Washer | |
| 1 | Bolt | |
| 2 | Bolt | |
| 1 | Hard Washer | |
| 1 | Clip | |
| 1 | Grommet | |
| 5 | Bolt | |
| 4 | Strap | |
| 1 | Clip | |
| 1 | Clip | |
| 1 | Nut | |
| 1 | Clip | |
| 1 | Bolt | |
| 9 | Hard Washer | |
| 1 | Clip | |
| 2 | Screw | |
| 1 | Clip | |
| 5 | Clip | |
| 1 | Clip | |
| 1 | Clip | |
| 1 | Chassis Harness As | |
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| (1) | These parts are part of |
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| Parts for 443-3786 Communication Wiring Gp(1) | ||
|---|---|---|
| Qty | Part Number | Description |
| 4 | Cable Strap | |
| 1 | Spacer | |
| 2 | Bolt | |
| 3 | Hard Washer | |
| 2 | Clip | |
| 2 | Clip | |
| 1 | Grommet | |
| 1 | Grommet | |
| 1 | Nut | |
| 1 | Bolt | |
| 1 | Grommet | |
| 1 | Hard Washer | |
| 2 | Hard Washer | |
| 2 | Bolt | |
| 1 | Clip | |
| 1 | Clip | |
| 1 | Connection Assembly | |
| 2 | Protective Cap | |
| 1 | Plate | |
| 4 | Cable As | |
| 1 | Cable As | |
| 3 | Cable As | |
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| (1) | These parts are part of |
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| Parts for 450-0680 Communication Wiring Gp(1) | ||
|---|---|---|
| Qty | Part Number | Description |
| 3 | Clip | |
| 2 | Bolt | |
| 2 | Nut | |
| 2 | Hard Washer | |
| 2 | Cable Strap | |
| 3 | Bolt | |
| 1 | Angle | |
| 5 | Hard Washer | |
| 2 | Clip | |
| 2 | Adapter | |
| 1 | Cable As | |
| 1 | Cable As | |
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| (1) | These parts are part of |
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| Parts for 450-2751 Electronic Control and Mounting Gp(1) | ||
|---|---|---|
| Qty | Part Number | Description |
| 1 | Electronic Control Mounting Gp | |
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| (1) | These parts are part of |
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| Parts for 425-4816 Electronic Control Mounting Gp(1) | ||
|---|---|---|
| Qty | Part Number | Description |
| 4 | Bolt | |
| 4 | Washer | |
| 4 | Locknut | |
| 4 | Spring Washer | |
| 4 | Mount | |
| 4 | Control | |
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| (1) | These parts are part of |
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| Parts for 459-8791 Antenna and Mounting Gp(1) | ||
|---|---|---|
| Qty | Part Number | Description |
| 4 | Bolt | |
| 4 | Hard Washer | |
| 6 | Washer | |
| 6 | Screw | |
| 2 | Antenna | |
| 2 | Seal Pad | |
| 2 | Mount As | |
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| (1) | These parts are part of |
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| Parts for 460-1568 Sensor Wiring Gp(1) | ||
|---|---|---|
| Qty | Part Number | Description |
| 1 | Grommet | |
| 1 | Sensor Harness As | |
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| (1) | These parts are part of |
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| Parts for 489-0362 Interface Module Gp(1) | ||
|---|---|---|
| Qty | Part Number | Description |
| 1 | Plug As | |
| 1 | Interface Box As | |
| 2 | Cable | |
| 1 | Cable As | |
| 1 | Interface Module Gp | |
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| (1) | These parts are part of |
MAS Preassembly
Refer to machine-specific parts manual for parts assembly.
Assemble Front Camera and Mounting
- Assemble 366-4013 Camera and Mounting Gp (Front 78º) , or 423-8805 Camera and Mounting Gp (Front 115º), using items (1) through (4). Refer to Illustration 1.
- 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)
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| Illustration 1 | g03834739 |
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(1) (2) (3) (4) | |
Assemble Warning Lights
- Assemble items (2) through (13) to 459-6794 Cover As (1). Refer to Illustration 2.
- 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)
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| Illustration 2 | g03844735 |
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(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) | |
Assemble Rear LADAR Sensors FOPS
- Assemble items (2) through (21) to 379-9941 Sensor Mount As (1). Refer to Illustration 3.
- 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)
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| Illustration 3 | g03844196 |
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(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14) (15) (16) (17) (18) (19) (20) (21) | |
Assemble Rear LADAR Sensors ROPS
- Assemble items (2) through (21) to 379-9905 Mount As (1). Refer to Illustration 4.
- 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)
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| Illustration 4 | g03844240 |
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(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14) (15) (16) (17) (18) (19) (20) (21) | |
Assemble Rear Camera and Mounting ROPS
- Assemble items (2) through (9) to 379-9905 Mount As (1). Refer to Illustration 5.
- 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)
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| Illustration 5 | g03844756 |
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(1) (2) (3) (4) (5) (6) (7) (8) (9) | |
Assemble Rear Camera and Mounting FOPS
- Assemble items (2) through (7) to 379-9941 Sensor Mount As (1). Refer to Illustration 6.
- 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)
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| Illustration 6 | g03844777 |
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(1) (2) (3) (4) (5) (6) (7) | |
Adjust Rear LADAR Angle
- Adjust rear LADAR angle so that the mounting bracket slots align.
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| Illustration 7 | g03835812 |
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LADAR Mounting Bracket Slot | |
Align Rear Camera
- Align rear camera. Ensure that text behind lens glass is correctly orientated and horizontal.
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| Illustration 8 | g03834718 |
Assemble Front LADAR Sensors FOPS
- Assemble items (2) through (19) to 379-9913 Sensor Mount As (1). Refer to Illustration 9.
- 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)
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| Illustration 9 | g03844782 |
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(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14) (15) (16) (17) (18) (19) | |
Assemble Front LADAR Sensors ROPS
- Assemble items (2) through (21) to 379-9816 Sensor Mount As (1). Refer to Illustration 10.
- 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)
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| Illustration 10 | g03845292 |
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(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14) (15) (16) (17) (18) (19) (20) (21) | |
Adjust Front LADAR Angle
- Adjust front LADAR angle so that the mounting bracket slots align.
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| Illustration 11 | g03835812 |
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LADAR Mounting Bracket Slot | |
Assemble Radio Wiring
- Assemble items (2) through (28) to 361-8470 Mount As (1). Refer to Illustration 12 and Illustration 13.
- 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
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| Illustration 12 | g03859619 |
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(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) | |
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| Illustration 13 | g06008314 |
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(1) (14) (15) (16) (17) (18) (19) (20) (21) (22) (23) (24) (25) (26) (27) (28) | |
Assemble Rotary Sensor and Wiring
- Assemble items (1) through (4), to 338-6518 Plate (5). Refer to Illustration 14.
- 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
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| Illustration 14 | g03851047 |
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(1) (2) (3) (4) (5) | |
Assemble Electrical Converters
- Assemble items (2) through (5) to 370-2549 Mount As (1). Refer to Illustration 15.
- Apply Bostik Never-Seez Marine Grade to all bolt threads prior to installation
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| Illustration 15 | g03843763 |
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(1) (2) (3) (4) (5) | |
Assemble Electronic Control Mounting
- Install eight items (2) through (4) (resilient mounts), to 370-2549 Mount As (1), where highlighted. Refer to Illustration 16 and Illustration 17.
- Do not grip rubber section of mount with tooling when tightening
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| Illustration 16 | g03861439 |
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(1) (2) (3) (4) | |
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| Illustration 17 | g03861443 |
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
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| Illustration 18 | g03841023 |
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(1) | |
Install 292-0358 Rotary Switch Gp (1). Refer to Illustration 18.
- 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
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| Illustration 19 | g03848643 |
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(1) (2) (3) (4) (5) (6) (7) | |
Install items (1) through (7) to radiator housing. Refer to Illustration 19.
- 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
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| Illustration 20 | g03849379 |
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(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) | |
Install items (1) through (12) to rear frame and radiator housing. Refer to Illustration 20.
- 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
20 ± 4 N·m (15 ± 3 lb ft)
Install Radio Mounting
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| Illustration 21 | g03865337 |
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Exploded View of Radio Mount | |
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| Illustration 22 | g06008316 |
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(1) (2) (3) (4) (5) "N" Type connector (6) Ethernet cable (7) Power connection | |
Install Radio Mount using items (1) through (4). Refer to Illustration 21 and Illustration 22.
- 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
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| Illustration 23 | g03835184 |
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(1) (2) Red light (3) Amber light | |
Install 459-6794 Cover As (1). Refer to Illustration 23.
- 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
- Install 366-4013 Camera and Mounting Gp (Front 78º), or 423-8805 Camera and Mounting Gp (Front 115º) on front frame with items (1) through (6). Refer to Illustration 24.
- Apply Bostik Never-Seez Marine Grade to all bolt threads prior to installation
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Illustration 25 g03847271 - Align front camera (1). Refer to Illustration 25.
- Ensure that text behind the camera lens glass is correctly orientated and horizontal
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| Illustration 24 | g06013334 |
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(1) (2) (3) (4) (5) (6) | |
Install Articulation Sensor Mounting
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| Illustration 26 | g03861845 |
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(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) | |
- Install items (1) through (10). Refer to Illustration 26.
- 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)
- Install Grommet (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 27 g03851800 460-1568 Sensor Wiring Gp
(11)392-8092 Plate
(12)6H-4006 Grommet
(13)326-7031 Sensor Harness As - Install 460-1568 Sensor Wiring Gp. Refer to Illustration 27.
- Apply Lanotec Type A Grease to all connectors prior to installation
- Install Grommet (12) to Plate (11)
- Install Plate (11) using existing hardware
- Pass Harness (13) through Grommet (12)
- Install Harness (13) to Rotary Sensor (10)
Install Front Camera Wiring
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| Illustration 28 | g03849390 |
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| |
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| Illustration 29 | g03850160 |
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(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) | |
Install items (1) through (13) on front frame. Refer to Illustration 28 and Illustration 29.
- 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
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| Illustration 30 | g03841036 |
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(1) (2) (3) | |
- 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 30.
- Apply Bostik Never-Seez Marine Grade to all bolt threads prior to installation
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Illustration 31 g06008846 450-2751 Electronic Control and Mounting Gp
(4)425-4816 Electronic Control Mounting GpShow/hide table
Illustration 32 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 - Install items (5) through (8) of 425-4816 Electronic Control Mounting Gp to resilient mount assemblies (9) that were installed previously. Refer to Illustration 31 and Illustration 32.
Install Automation Interface Control Module
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| Illustration 33 | g06009438 |
|
(1) | |
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| Illustration 34 | g06009437 |
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(2) (3) (4) (5) (6) Resilient Mount | |
- Install items (2) through (5) of 437-0385 Interface Module Gp to resilient mount assemblies (6) that were installed previously. Refer to Illustration 33 and Illustration 34.
- 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
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| Illustration 35 | g03851805 |
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(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) | |
Install items (1) through (10). 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 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
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| Illustration 36 | g06016731 |
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(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14) (15) (16) (17) Existing bolt (18) Existing washer (19) Existing bolt (20) Existing washer (21) (22) (23) (24) (25) (26) (27) | |
- Remove existing items (17) to (20). Retain for installation purposes.
- Install items (2) through (27).
- Install Clip (5) with items (17) and (18) that were removed previously.
- Install earth terminals with items (19) and (20) that were removed previously.
Refer to Illustration 36.
- 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
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| Illustration 37 | g03835977 |
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| |
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
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| Illustration 38 | g03860901 |
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(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14) (15) (16) (17) (18) (19) (20) (21) (22) (23) (24) (25) (26) (27) (28) (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 | |
- Install items (2) through (28).
- Connect item (3) to port (36).
- Connect item (22) to port (35).
- Connect item (23) to port (33).
- Connect item (24) to port (31).
- Connect item (25) to port (34).
- Connect item (26) to port (32).
- Connect item (27) to port (29).
- Connect item (28) to port (37).
Refer to Illustration 38.
- 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
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| Illustration 39 | g03835983 |
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Typical Example Front LADAR Gp | |
- Install front LADAR Gp on machine. Refer to “Assemble Front LADAR Sensors” in this publication.
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Illustration 40 g03835984 Typical Example of Rear LADAR Gp - Install rear LADAR Gp on machine. Refer to “Assemble Rear LADAR Sensors” in this publication.
Install Communication Wiring and Camera Wiring ROPS
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| Illustration 41 | g06016680 |
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(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) Onboard Radio (12) Rear LADAR (13) Front LADAR (14) (15) (16) (17) (18) | |
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| Illustration 42 | g06012538 |
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(4) (19) (20) (21) (22) (23) (24) (25) (26) | |
Install items (1) through (26). Refer to illustrations 41 and 42.
- 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
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| Illustration 43 | g06016700 |
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(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) Onboard Radio (12) Rear LADAR (13) Front LADAR (14) (15) | |
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| Illustration 44 | g06012548 |
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(6) (16) (17) (18) (19) (20) (21) (22) (23) | |
Install items (1) through (23). 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 (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
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| Illustration 45 | g06012897 |
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Location of Cab Lighting on LADAR mounts (Rear) (1) | |
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| Illustration 46 | g06139344 |
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Location of Cab Lighting on LADAR mounts (Front) (1) (2) | |
- Install cab lights. Refer to Illustration 45 and Illustration 46.
- 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 47 g03840478 Wiring Location for Rear Cab Lights Show/hide table
Illustration 48 g03838180 Wiring Location for Front Cab Lights - Connect wiring to front and rear cab lights. Refer to Illustration 47 and Illustration 48.
- 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 ROPS
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| Illustration 49 | g03843236 |
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(1) (2) | |
- Install 379-9909 Cable As (1) and 5P-9085 Clip (2). Refer to Illustration 49.
- Apply Lanotec Type A Grease to all connectors prior to installation
Install Sensor Wiring FOPS
- Install 379-9909 Cable As (1). Refer to Illustration 50.
- Apply Lanotec Type A Grease to all connectors prior to installation
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| Illustration 50 | g03860204 |
|
(1) | |
Install
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| Illustration 51 | g03836565 |
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Film on Circuit Breaker Cover (1) | |
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| Illustration 52 | g03835988 |
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Film on Dash Panel (2) (A) (B) | |
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| Illustration 53 | g03835989 |
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Serial Number Plate on Front Left Side of Hitch (3) (C) (D) | |
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| Illustration 54 | g06024922 |
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Installation of Serial Number Plate (3) (4) | |
- Install items (1) through (4) of 366-3987 Plate and Film Gp. Refer to Illustration 51, Illustration52, Illustration 53, and Illustration 54.
Parts for Deck Covers
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| Parts for Deck Covers | ||
|---|---|---|
| Qty | Part No | Description |
| 4 | Cotter Pin | |
| |
Nonslip Tread | |
| 50 |
Tape Reflective (Black/Yellow)(1) | |
| 1 | Access Cover As | |
| 1 | Cover As | |
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| (1) | This part is part of |
Install Deck Covers
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| Illustration 55 | g06143227 |
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Locations of Deck Covers (1) (2) (3) (4) (5) (6) (7) | |
- Remove existing items (1) through (5). Retain items (1) through (4) for installation purposes.
- Install existing items (1) through (3) to new locations on machine deck.
- Install items (6) and (7), using existing pins (4) and new cotter pins (5).
Refer to Illustration 55.
Install Nonslip Tread
- Install 5P-5895 Nonslip Tread (1). Refer to Illustration 56.
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| Illustration 56 | g06143228 |
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Locations of Nonslip Tread (1) (A) (B) (C) (D) (E) (F) | |
Install Reflective Tape
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| Illustration 57 | g06016712 |
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Locations of Reflective Tape (1) | |
- Install 178-4946 Tape (1). Refer to Illustration 57.
Install Parts That Were Removed
- Install the remaining deck covers.
- Install the fire extinguisher.
- Install the cabin pressurizer and 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 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
- Perform the automation system preparation for troubleshooting procedure before entering the operations area. Refer to Troubleshooting, Testing, and Adjusting, "Automation System Preparation for Troubleshooting".
- Insert the battery disconnect switch key and move the battery disconnect switch to the ON position.
- Turn the key start switch to the ON position.
- Move the remote control switch to the ON position.
- Move the autonomous control enable switch to the AUTO position. The machine is now in autonomous mode.
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Illustration 58 g03839828 Typical Example of "Cat Networking Devices Manager" Window
(1) "Cat Networking Devices Manager" window - On the Service Laptop, open "Cat Networking Devices Manager" window (1).
- The radio to be configured will appear initially as an "Off-board" radio (default factory configuration).
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Illustration 59 g03837589 Typical Example of "On-board" Tab
(2) "On-board" tab - 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 60 g03837590 Typical Example of "Essential Configuration" Window
(3) "Essential Configuration" tab
(4) Role "On-board"
(5) Location "Machine ID" or "Site Identifier" - Select "Essential Configuration" menu (3).
- In the "Essential Configuration" window, change the following parameters.
- (4) Role "On-board"
- (5) Location "Machine ID" or "Site Identifier"
- 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
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| Required Tools | |||
|---|---|---|---|
| Tool | Part Number | Description | Qty |
| A | Tool | 1 | |
| B | Screwdriver | 1 | |
| C | Service Kit | 1 | |
| D | Cable As | 1 | |
| E | Cable As | 1 | |
| F | Adapter Kit | 1 | |
| G | Cable As | 1 | |
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| 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. | ||
- 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)
- 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
Show/hide tableTable 40 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"
- 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"
- 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"
- 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"
- 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"
- 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.
- 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 61 g03839276 "Welcome to SOPAS" - If window "Welcome to SOPAS" appears, close window (1).
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Illustration 62 g03839277 "SOPAS Engineering Tool" - Select "Project" menu (2) and then "New Project" (3).
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Illustration 63 g03839278 "Connection Wizard" - Click "Communication" menu (4) and select "Connection Wizard" (5).
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Illustration 64 g03839279 "Connection Wizard" / "Show all Connected Devices" - Select "Show all connected devices", then click "Next" button (6).
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Illustration 65 g03839280 "Interface Selection" - Ensure that the Internet Protocol (IP) box (7) is checked and select "Next" button (8).
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Illustration 66 g03839281 "Performing Auto IP Scan" - "Performing Auto IP scan" icon (9) will appear on the screen. The connected devices will appear after the scan.
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Illustration 67 g03839282 Default "IP Address" Settings - 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 68 g03839283 "Change IP Configuration" - 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.
- 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
- Procedure
- Place machine in operations area.
- Move battery disconnect switch to the ON position.
- Move the key switch to the ON position.
- Move Remote Control switch to the ON position.
- Move Automation Control Enable switch to the AUTO position.
- Record the serial number of the Automation ECM fitted to the machine.
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Illustration 69 g03837619 "Software Manager" - Open "Software Manager".
- Click the "Scan Now" button on the "Software Manager" window.
- Observe the "IP Address" of the Automation ECM which matches the recorded serial number.
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Illustration 70 g03837620 "Device Information" / "Install Package" - Right-click the "IP Address" in the "Device Information" field and select "Install Package".
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Illustration 71 g03837621 "Flash" File Window - Use file selection window to select the "Flash" file.
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Illustration 72 g03837623 "Install" Window - Confirm details on the "Install" window and click "Yes".
- When package installation is complete, right-click the "IP Address" in the "Device Information" field and select "Reboot".
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Illustration 73 g03837625 Automation ECM "IP Address" Window - 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
- Move battery disconnect switch to the ON position.
- Ensure that the Autonomous Control Enable switch is in the MANUAL position.
- Connect Cat ET and note "Active" and/or "Logged" codes.
- Rectify any "Active" codes and clear any "Logged" codes.
- 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
- Turn off engine.
- Connect Cat ET and note "Active" and/or "Logged" codes.
- Rectify any "Active" and/or "Logged" codes.
- Turn the Autonomous Control Enable switch to the AUTO position.
- Check that the Amber and Red warning lights function for 5 seconds.
- 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 41 Description Power Train ECM Logged Codes 590-9 681-5 1610-5 1925-5 1927-5 1927-3 1928-3 Show/hide tableTable 42 Description CAT Monitoring System Logged Code 248-2 - Proceed to machine Command for Underground system commissioning.
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