Assembling and Mounting the Non-Metallic Object Detection Sensor Enclosure Group {7010} Caterpillar

Machine Control and Guidance Products

CAT DETECT (S/N: DTK1-UP)

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

Motor Grader

16M Series 3 (S/N: N9Y1-UP)

18M Series 3 (S/N: N9A1-UP)

Vibratory Soil Compactor

CP44 (S/N: M4P1-UP)

Wheel Dozer

834K (S/N: TW41-UP; L4Y1-UP; LWY1-UP; TWY1-UP)

844K (S/N: M4R1-UP; K4Y1-UP)

854K (S/N: KK31-UP; RM31-UP; KK61-UP; RM61-UP)

Wheel Loader

986K (S/N: MH81-UP; NL81-UP; SWH1-UP)

988K (S/N: T8E1-UP; L8X1-UP; LWX1-UP; TWX1-UP)

988K XE (S/N: E8X1-UP; EWX1-UP)

990K (S/N: DJK1-UP; A9P1-UP; K9X1-UP)

992K (S/N: KK21-UP; RM21-UP; KK41-UP; RM51-UP)

993K (S/N: Z4D1-UP; Z8D1-UP; Z4Z1-UP; Z8Z1-UP)

994K (S/N: MM91-UP; MRK1-UP; SMX1-UP)

Introduction

This Special Instruction provides the Assembling and Mounting the Non-Metallic Object Detection Sensor Enclosure Group on certain Cat^® Products.

The 492-3090 Object Detection Box Gp can be used in various applications as a factory installed Object Detection Sensor Enclosure, Retrofit Enclosure, or as an Upgrade Enclosure.

The 492-3090 Object Detection Box Gp is designed with for use with the C5 Object Detection Sensor, but other C series sensors can be installed.

Refer to Table 6 for additional sensor part numbers.

Note: All Sensors on a communications bus must be the same part number to prevent system faults.

Important Safety Information

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

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Personal injury or death can result from sudden machine movement. Sudden movement of the machine can cause injury to persons on or near the machine. Prevent possible injury by performing the procedure that follows before working on the machine. Move the machine to a smooth and level location that is away from working machines and personnel. Ground all implements. Engage the parking brake. Stop the engine. Move the hydraulic control levers to all positions to release the pressure in the hydraulic system. To avoid accidental engine starting, turn the battery disconnect switch to the OFF position. Remove the key for the battery disconnect switch. Use a secure padlock in order to lock the battery compartment access door. Place a "Do Not Operate" tag at the Start/Stop switch location to inform personnel that the equipment is being worked on.

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Improper operation of an access platform could result in injury or death. Operators must carry out their duties properly and follow all instructions and guidelines given for the machine and access platform.

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Be sure all personnel are clear of the equipment while the equipment is being lowered. Failure to stay clear of the equipment while the equipment is being lowered may result in personal injury.

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

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Failure to use an approved access system during installation and removal of components could result in slipping and falling which could result in personal injury or death. To prevent injury or death, use an approved access system to reach the appropriate mounting locations of the components. Do not climb on the machine. Maintain three-points of contact and/or use a safety harness.

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Identify the object and the location of the object before you move the machine. Failure to identify the object and the location of the object prior to moving the machine can result in product damage, personal injury, or death.

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Personal injury or death could result without observing the following information: Environmental conditions, installation, and topographical factors can affect the proper operation of the object detection system. The following information must be considered.

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Personal injury or death can occur from heavy components falling during removal or installation. Properly support the component with a suitable lifting device during removal or installation.

Note: Caterpillar recommends that each customer conducts a risk assessment for remote control operation and establish layers of protection in and around the area of the remote controlled machine and establish safe job site procedures. Examples may include personnel training, warning signs, and barricades.

Note: Prior to operation of the machine read the Operation and Maintenance Manual.

Mounting and Dismounting

• Only mount the machine and dismount the machine at locations that have steps and/or handholds.

• Inspect the steps and the handholds before mounting and dismounting. Clean the steps and the handholds, if necessary. Repair the steps and the handholds, if necessary.

Illustration 1	g00037367

• Face the machine when you are mounting and dismounting.

• Maintain a three-point contact with the steps and the handholds. Three-point contact is maintained when two feet and one hand are in contact or one foot and two hands are in contact.

• Never get on a moving machine or off a moving machine.

• Never jump off the machine.

• Do not try to climb on the machine or climb off the machine when you are carrying tools or supplies. Use a hand line to pull equipment up to the operators platform.

• Do not use any of the controls as handholds as you are climbing into the machine or exiting the machine .

Protective Equipment

When working around the machine, wear the appropriate personal protective equipment (PPE) that is required by the specific job function, job site, federal agencies, employer, and job site conditions the job is being performed at. PPE may include but not be limited to the following items:

• Protective headgear

• Protective eyewear

• Protective footwear

In particular, wear protective eyewear when a hammer or sledge hammer is used.

When welding, wear the appropriate PPE that is required by the specific job function, job site, federal agencies, employer, and job site conditions the job is being performed at. PPE for welding may include but not be limited to the following items:

• Protective headgear

• Protective and darkening eyewear

• Protective footwear

• Protective body safety equipment

Do not wear loose clothing or jewelry that can catch on parts of the machine.

Required Tools

Illustration 2	g06203645
441-3703 Protractor

Illustration 3	g06203647
437-4620 Protractor

Illustration 4	g06203649
533-1164 Angle Bracket

Required Parts

Illustration 5	g06202963
492-3090 Object Detection Box Gp

Illustration 6	g06202926
498-1252 Bracket As

Illustration 7	g06202914
498-1255 Bracket As

Illustration 8	g06202958
6 mm (0.23 inch) and 8 mm (0.31 inch) compression limiters shipped with the Bracket As.

Contents of 492-3090 Object Detection Box Gp

Contents of 492-3089 Object Detection Enclosure Gp

Assembling and Mounting the Non-Metallic Object Detection Sensor Enclosure Group

Enclosure Assembly Instructions

Note: Mark installation with a paint pen or other indication to allow for movement checks during scheduled PMs. See additional information later in this manual.

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Illustration 9	g06203030
Exploded view of 492-3090 Object Detection Box Gp. (1) 490-8846 Screw (2) 204-6101 Hard Washer (3) 491-7209 Front Housing (4) 464-7684 Object Detection Sensor Gp (5) 491-7212 Retainer (6) 492-3226 Seal (7) 491-7211 Rear Housing (8) 9V-2818 Grommet (9) 492-3249 Mount

Note: The 515-4722 Film is not pictured

Note: The compression tape between the 491-7212 Retainer and the 464-7684 Object Detection Sensor Gp is installed during the manufacturing of the 491-7212 Retainer and should not be removed.

1. Mount the 464-7684 Object Detection Sensor Gp (4) to the 491-7209 Front Housing (3) using the 491-7212 Retainer (5), two 490-8846 Screws (1), and two 204-6101 Hard Washers (2).

2. Apply the 492-3249 Mount to the front housing using a 490-8846 Screw (1) and a 204-6101 Hard Washer (2). Torque the 490-8846 Screw (1) to 3 N·m (2.2 lb ft).

3. Secure the Sensor Harness to the 491-7209 Front Housing (3) using a 3S-2093 Cable Strap. Trim the excess end of the 3S-2093 Cable Strap down smooth as not to create any sharp edges.

4. Apply the 492-3226 Seal (6) to the 491-7211 Rear Housing (7).
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   Illustration 10	g06208195

   Note: Note the orientation of the radar. The white plastic face will be facing outward and the Radar identification label will be downward with the harness to the left routed down.

5. Assemble the 491-7209 Front Housing (3) and 491-7211 Rear Housing (7), route the harness through the hole in the 491-7211 Rear Housing (7).

6. Secure the 491-7209 Front Housing (3) to the 491-7211 Rear Housing (7) using six 490-8846 Screws (1) and six 204-6101 Hard Washers (2). Torque the 490-8846 Screws (1) to 5 N·m (3.6 lb ft).

Installation Procedure

Note: Note the direction of sensor view of the bracket for proper adjustments. Housing front cover should face the bracket protrusion for vertical mounting. For Horizontal Mounting the front cover will face towards the flush edge of the bracket.

Vertical

Typically the Vertical installation arrangement is used on the rear of Wheel Loaders.

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Illustration 11	g06206131
498-1252 Bracket As (10) Pivot hole (11) Adjustment slot (12) Direction of sensor view

1. Install the 492-3090 Object Detection Box Gp into the 498-1252 Bracket As with the face of the 492-3090 Object Detection Box Gp towards the protruded end.
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   Illustration 12	g06206135
   492-3090 Object Detection Box Gp in the 498-1252 Bracket As.

2. Align the 6 mm (0.23 inch) holes of the housing with the pivot slot and adjustment grove of the 498-1252 Bracket As. The face of the 492-3090 Object Detection Box Gp will be on the brackets side with the adjustment slot and protrusion.

3. Apply two 8T-4138 Bolts and two 9X-2038 Washers through the pivot hole.

4. Apply two 8T-4138 Bolts and two 9X-2038 Washers through the two 6 mm (0.23 inch) compression limiters and into the adjustment slot.

5. Fasten the 498-1252 Bracket As to the mounting position using the hardware provided with the machine. Tighten to 55 N·m (40.5 lb ft).

6. Adjust to the appropriate angle for the machine application and tighten the four 8T-4138 Bolts to 14 N·m (10.3 lb ft).

   Note: Use the 533-1164 Angle Bracket with the 437-4620 Protractor to set the proper angle.

7. Secure the harness tail of the 492-3090 Object Detection Box Gp to the bottom of the housing using a 7K-1181 Cable Strap.

Horizontal

Typically the Horizontal installation arrangement is used on the side of truck systems and the front of some trucks.

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Illustration 13	g06202940
498-1252 Bracket As (10) Pivot hole (11) Adjustment slot (12) Direction of sensor view

1. Install the 492-3090 Object Detection Box Gp into the 498-1252 Bracket As with the face of the 492-3090 Object Detection Box Gp towards the flush end.
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   Illustration 14	g06206138
   492-3090 Object Detection Box Gp in the 498-1252 Bracket As.

2. Align the 6 mm (0.23 inch) holes of the housing with the pivot slot and adjustment grove of the 498-1252 Bracket As. The face of the 492-3090 Object Detection Box Gp will be on the brackets side with the flush end.

3. Apply two 8T-4138 Bolts and two 9X-2038 Washers through the pivot hole.

4. Apply two 8T-4138 Bolts and two 9X-2038 Washers through the two 6 mm (0.23 inch) compression limiters and into the adjustment slot.

5. Fasten the 498-1252 Bracket As to the mounting position using the hardware provided with the machine. Tighten to 55 N·m (40.5 lb ft).

6. Adjust to the appropriate angle for the machine application and tighten the four 8T-4138 Bolts to 14 N·m (10.3 lb ft).

   Note: Use the 533-1164 Angle Bracket with the 437-4620 Protractor to set the proper angle.

7. Secure the harness tail of the 492-3090 Object Detection Box Gp to the bottom of the housing using a 7K-1181 Cable Strap.

Horizontal with Swivel

Typically the Horizontal with Swivel installation arrangement is used on front and rear of truck systems and the rear of Motor Grader systems.

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Illustration 15	g06202940
498-1255 Bracket As (10) Pivot hole (11) Adjustment slot (12) Direction of sensor view

1. Install the 492-3090 Object Detection Box Gp into the 498-1255 Bracket As with the face of the 492-3090 Object Detection Box Gp towards the flush end.
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   Illustration 16	g06206141
   492-3090 Object Detection Box Gp in the 498-1255 Bracket As.

2. Align the 6 mm (0.23 inch) holes of the housing with the pivot slot and adjustment grove of the 498-1255 Bracket As. The face of the 492-3090 Object Detection Box Gp will be on the brackets side with the flush end.

3. Apply two 8T-4138 Bolts and two 9X-2038 Washers through the pivot hole.

4. Apply two 8T-4138 Bolts and two 9X-2038 Washers through the two 6 mm (0.23 inch) compression limiters and into the adjustment slot.

5. Fasten the 498-1255 Bracket As to the mounting position using the hardware provided with the machine and the two 8 mm (0.31 inch) compression limiters provided with the bracket. Tighten to 55 N·m (40.5 lb ft).

6. Adjust to the appropriate angle for the machine application and tighten the four 8T-4138 Bolts to 14 N·m (10.3 lb ft).

   Note: Use the 533-1164 Angle Bracket with the 437-4620 Protractor to set the proper angle.

7. Secure the harness tail of the 492-3090 Object Detection Box Gp to the bottom of the housing using a 7K-1181 Cable Strap.

Optional Sealing of Grommet

The sensor harness passes through the enclosure using a split grommet. This grommet does not provide a 100 percent seal and will allow for ingress of water and dust. The ingress of water and dust is not an issue for most applications. If frequent submersion in water or operation in extreme dust is a concern, the grommet area should be sealed with a silicon-based sealer.

Sensor Enclosure Adjustments

Visual alignment

Illustration 17	g06206152
Side view of the 498-1252 Bracket As or 498-1255 Bracket As (13) Major mark (14) Minor mark

The side of the bracket has major marks (13) and minor marks (14) formed into the bracket material during manufacturing. The major marks (13) indicate 15 degree increments. The minor marks (13) indicate 5 degree increments. These marks are for the installers reference, an angle finder should be used to verify the adjustment.

Setting the Angle and Azimuth

Azimuth Adjustment Procedure

Illustration 18	g06203042
441-3703 Protractor being used to adjust an object detection sensor.

1. Loosen the four azimuth adjustment bolts on the brackets for the object detection sensors.

   1. Parallel line to the machine centerline.

   2. Parallel line to the rear of the enclosure.

   3. Azimuth measurement OUT from azimuth table.

   4. Perpendicular line to the machine centerline.

2. Use a 441-3703 Protractor to set the proper azimuth angle or adjust the angle to fine-tune the system. Refer to the angles listed in Testing and Adjusting, UENR1274, Object Detection Sensor - Adjust.

   Note: The front and rear radar enclosures will be measured from a reference perpendicular to the machine centerline running front to back. The side radars will be measured from a reference parallel to the platform mounting. A measurement indicating an IN azimuth angle will point from the mounting location inward. A measurement indicating an OUT azimuth angle will point from the mounting location outward.

3. Carefully tighten the four azimuth adjustment bolts on the brackets for the object detection sensors.

4. Check the angle again to verify that the bracket is set to the proper angle.

5. Tighten the bolts.

6. Check the angle again to verify that the bracket is set to the proper angle.

7. Proceed to the "Elevation Adjustment Procedure" section.

Elevation Adjustment Procedure

Illustration 19	g06202931
437-4620 Protractor being used with a 533-1164 Angle Bracket to level an object detection sensor.

Note: Markings on the brackets are to be used as reference only. Always make fine adjustments with the 437-4620 Protractor.

1. Loosen the four adjustment bolts on the bracket for the object detection sensor.

2. Use a 437-4620 Protractor to set the proper elevation angle or adjust the angle to fine-tune the system.

   Note: With the machine parked on a level surface the angle will be measured from the horizon to the top of the enclosure. Refer to the angles listed in Testing and Adjusting, UENR1274, Object Detection Sensor - Adjust.

3. Carefully tighten the four azimuth adjustment bolts on the brackets for the object detection sensors.

4. Check the angle again to verify that the bracket is set to the proper angle.

5. Tighten the bolts.

6. Check the angle again to verify that the bracket is set to the proper angle.

7. If needed perform the procedure that is located in Testing and Adjusting, UENR1274, Object Detection Sensor - Calibration.

Marking the Adjustments

Illustration 20	g06203032
Bracket marked after the installation and adjustment is completed.

After the installation and adjustment is completed, mark the location of the side bolts and washers on the bracket. The mark will allow for quick visual inspection of the system for proper adjustment at maintenance intervals.

Expected Results After Adjustment

After the angles and azimuths have been adjusted, and no objects are present in the coverage areas, the system shall produce no visual indicators or audible alarms when the system is active with no faults. If the system produces false detections, utilize the "Status" page in Cat Electronic Technician (Cat ET). Check which radar is falsely detecting objects and the distance at which the faults are detected.

1. Verify that the coverage areas are clear of objects.

2. Verify that no part of the machine is in the detection area. (For example, grease lines or third-party attachments.)

   Note: Due to variance in machine configurations, adjusting the radar azimuth angles in or out as Much as 5 degrees may be necessary. If this adjustment is done to avoid false detections, use the calibration procedure to verify that the system is functioning properly and providing adequate coverage. Any change from the documented angles will change the coverage area.

3. Verify that the internal enclosure seal is not obstructing the radars viewing angle.

   Note: Remove, adjust, or replace the cover if the internal enclosure seal is obstructing the view.

1. Verify that the coverage areas are clear of objects.

2. Verify that the sensor is not detecting the ground.

   Note: Due to variance in machine height, adjusting the radar angle upward as much as 5 degrees may be necessary. If this adjustment is done to avoid false ground detections, use the calibration procedure to verify that the system is functioning properly and providing adequate coverage.

   Note: Any change from the documented angles will change the coverage area.

Torque Reference

Sensor Part Number Reference

Illustration 21	g06236174
(15) C4 sensor (16) C5 sensor (17) C6 sensor

Note: The sensor harness indicates the series. For series with multiple part numbers. refer to the connector key or part number tag.