CAES Installation For Wheel Tractor Scraper{7604} Caterpillar

Wheel Tractor-Scraper:

621G (S/N: ANG1-UP; ALP1-UP)

623G (S/N: AWB1-UP; ARW1-UP)

627G (S/N: AXF1-UP)

631G (S/N: AXZ1-UP)

637G (S/N: AYN1-UP)

Introduction

This document outlines the process for the installation of the Computer Aided Earthmoving System on a Wheel Tractor Scraper (WTS). The installation process for the WTS will require some welding, hole cutting, high voltage electrical wiring and the use of a variety of power tools. The time required to complete the installation process will vary with each application. If the installation involves more than one scraper you can expect the overall time required to perform each machine installation to decrease as the experience of the installation crew increases. A minimum of ten hours should be budgeted for the first scraper and somewhere between eight and ten hours for subsequent machines, depending on the organization and support of the electricians, maintenance personnel, metal fabricators and welders.

Illustration 1	g00986594
CAESultra system components. (1) L1/L2 GPS Antenna. (2) MS840 or MS740 GPS Receiver and Power Supply. (3) Operating System with Color Touch Screen Display (Navigator is shown). (4) TC900 or TC900B Radio.

Illustration 2	g01014932
CAES Machine Arrangement

CAES for the Wheel Tractor Scraper class of machine is composed of the following 2 major systems groupings:

1. 167-8901 CAES Arrangement (Display, GPS Receiver)
   • Monitor Display Gp

   • 194-8020 Communication Receiver Gp

   • 194-8015 Satellite Antenna As

   • 5S-7349 Bolt

   • 9X-6165 Washer

   • Vibration Isolator Mounting Gp

   • CAES Software Gp

   • Wiring Diagram

2. 167-8636 CAES Installation Ar
   • 167-8932 Cable

   • 167-8804 Cable

   • 225-5360 Machine Wiring Gp

   • Antenna Mounting Gp

   • Radio Mounting Gp

   • Receiver Mounting Gp

   • Display Mounting Gp

   • Display Mounting Gp

General Preparation

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

In addition to the normal safety precautions taken in the day to day operation of heavy machinery, the following preliminary steps are recommended:

1. Move the machine to a smooth, level location, preferably in a shady location.

2. Move away from other working machines and personnel.

3. Lower the bowl to the ground.

4. Stop the engine.

5. Engage the machine brake.

6. Position wheel chocks.

7. Power down the scraper.

8. Maintain custody of machine keys, when applicable.

Tools

GPS Antenna Installation

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Illustration 3	g00992380
(1) GPS Antenna Mounting Location Behind The Bowl Of a 623F WTS.

1. Chose the location for GPS antenna.

   Note: The GPS antenna should be mounted on the machine with an unobstructed view of the sky. The recommended mounting location for the antenna that is attached to the four-foot antenna mast, is the rear end of the machine behind the bowl, close to rear axle and on or near the machine's center line. The chosen site should not impede refueling or other normal machine functions. Also, the chosen mounting site should be rigid enough to avoid excess vibration and sheet metal flexing. An additional consideration that often dictates placement is the actual coaxial cable length.

   Note: It is recommended that the antenna coaxial cable be routed and semi-permanently secured prior to the fabrication and subsequent mounting process to avoid unnecessary rework.

   Note: In the case of the Wheel Tractor Scraper machine application, the GPS antenna coaxial cable routes from the GPS receiver, through a hole with a minimum diameter of 3.5 cm (1.375 inch) that is cut toward the back of the cab or through an existing cable pass-through near the back of the cab. The cable should trace the other hydraulic cables from the back of the tractor along side the bowl to the rear end of the machine.

2. Attach the GPS Antenna to the mounting bracket with the four bolts, washers and shock mount grommets that are provided in the GPS Antenna Mounting Kit.

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Illustration 4	g00992397
(2) GPS Antenna And Mast In Place On a 623F WTS

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Illustration 5	g00992402
GPS Antenna Mast Mounted On a 620 Elevating Wheel Tractor Scraper.

3. Chose the mounting site for the antenna mast.

   Note: If the selected site is between the solid frame beams on sheet metal alone, additional support may be required. The antenna mast should not impede refueling or other normal machine functions. Also, the chosen mounting site should be rigid enough to avoid excess vibration and sheet metal flexing. An additional important consideration that often dictates placement is the actual coaxial cable length.

   Note: It is recommended that the 24.4 m (80 ft.) or 30.5 m (100 ft.) cable should be routed and semi-permanently secured prior to the fabrication and subsequent mounting process in order to avoid unnecessary rework.

4. Use the eight 5/8-11 bolts provided to attach the 1.2 m (4 ft.) medium GPS antenna mast directly to the flat plate on the back deck of the machine, or at the top of a fabricated pedestal. Tighten the eight nuts to Standard Caterpillar Specification.

   Note: Welding the mast to the machine is not recommended or approved.

   Note: It is recommended that the coax connector should be oriented toward the rear of the machine to lessen the chance of damage caused by wind, blowing precipitation, dust, and dirt.

5. Attach either end of the coaxial cable to the GPS antenna or the GPS receiver. Thread-lock is not used in either application.

6. Sub-assemble the Shock Mount Kit to the GPS antenna mast. Mount the GPS antenna to shock mount grommets and tighten to Caterpillar specification.

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Illustration 6	g00992404
Coaxial cable troth tacked to the left side of the bowl on a 623F WTS.

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Illustration 7	g00992418
Close up view of the cable trough fabricated from 2 inch angle iron stock.

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Illustration 8	g00992430
The exposed coaxial cable was sheathed with rubber tubing.

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Illustration 9	g00992433
Protective cable troth routes along the back deck up to the GPS antenna mast. The exposed coaxial cable is sheathed wherever exposed to prolong cable life.

7. Following the antenna mounting and cable routing procedures, sheath all exposed coaxial cable that may come in contact with hard, sharp or course surfaces during operation in order to avoid damage and premature wear.

GPS Receiver Installation

Note: There are several acceptable mounting locations for the GPS Receiver on the wheel tractor scraper. It is recommended that the four following criteria be satisfied prior to the selection of a mounting site for the receiver:

• The chosen site should support the overall dimensions of the unit and the provided bracket (301 mm (11.85 inch) wide X 320 mm (12.6 inch) tall).

• The chosen site should work with the standard and unaltered lengths of the main wiring harness 167-8701 , the 80 feet GPS coaxial cable, and the TC900B radio cable.

• The chosen site should provide adequate accessibility.

• The unit should not interfere with normal and safe machine functioning.

Illustration 10	g00992567
GPS Receiver Mounting Bracket (1) Mounting locations for boss (2) 3/8 inch hole (3) Boss (4) GPS mounting bracket

Illustration 11	g00992571
GPS Receiver and Bracket profile (1) SHOCK MOUNTING GROUP (2) MOUNT (3) SPACER (4) WASHER (5) BOLT (1/4-20) (6) BRACKET ASSY (GPS 740) (7) NUT (1/4-20) (8) WASHER (9) BOLT (1/4-20)

The mounting location illustrated in this manual is inside the cab, just forward and to the right of the operator seat.

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Illustration 12	g00992712
GPS Receiver Bracket mounted in front and to the right of the operator's seat on a 623F WTS.

Note: Also refer to 13

1. Mark the bolt pattern for the receiver mount using the Receiver Mounting Bracket as a template.

2. Score and remove padding, lining or insulation.

3. Attach the four weld bosses to the mounting bracket prior tack-welding in order to ensure accurate placement. Then, permanently weld the bosses to the brackets.

4. Drill four 3/8 inch holes on the marked places.

5. Fasten the GPS bracket to the machine with the four 1/4 -20 bolts and washers.

   Note: Tighten the bolts to Caterpillar standard torque specifications.

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Illustration 13	g00992718
GPS Receiver mounted to the bracket. Note the space to the right of the component for cable and harness routing.

6. Assemble the receiver to the mounting bracket with the Shock Mount Kit.

   Note: The receiver should be oriented with the fins in a vertical position in order to properly fit within the mounting bracket.

   Note: Tighten the 1/4 - 20 bolts to Caterpillar standard torque specifications.

Battery Backup Instillation

The backup battery supplies the Computer Aided Earthmoving System with power for a short period of time in the event of an abrupt and unanticipated lose of machine power. The battery stores power for approximately five minutes in order to provide the operator enough time to safely shut CAES down.

Unless an extension harness is fabricated to connect the battery box wires to the main power harness, the battery box must be located within a foot of the mounting location of the GPS Receiver. Mount the battery box to existing machine substructure or use weld bosses. Do not weld or modify the battery box.

Illustration 14	g00992797
Battery box located next to the GPS Receiver on a 623F WTS

Display Module Installation

It is recommended that the CAES display be positioned within the cab of the scraper in a way that will provide the operator with a clear view of the screen without obstructing the operator's normal field of vision. Placement of the display in many applications is the front upper right corners or lower right corners of the machine cab. In this case, the operator's vision remains unobstructed, and the display is positioned in a way to provide easy reference of work progress and accessibility to the four function keys on the display. Site and operator preference prevails on placement of the display.

The U-shaped bracket provides approximately 20 degrees of screen tilt, which can be used to avoid direct sunlight or bright glare.

Illustration 15	g01016023
CAES display mounting group

Illustration 16	g00993449
Display bracket mounted at the top of the instrument cluster of a 623F WTS

Illustration 17	g00993462
Front view of mounted display bracket

Illustration 18	g00993467
Main harness routing hole through the instrument console

Illustration 19	g00993470
Profile of dash bracket, U-shaped display bracket and the shock mount grommets.

Illustration 20	g00993472

Radio Installation

Note: The radio must be programmed as a rover before installation. Use Commset software to program the radio. Commset software is located on one of the two System CDs and is part of the Trimble Utilities.

Radio Programming Procedure

1. Connect Service Cable to the TC900B and Service Laptop.

   Note: As extension an adopter can be connected between the service cable and the TC900B cable. The TC900B cable must be disconnected at the GPS receiver and reconnected to the other end of the Gender changer. A standard straight-through serial cable can be used to extend the 9-pin connector on the TC900B Service Cable.

2. Connect the service cable to the power source. Refer to the Service Kit Instruction Manual for cabling and power instructions.

3. Start Commset on the Service Tool (Laptop).

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Illustration 21	g00992143

4. Click on "Connect". Wait until connection is established.

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Illustration 22	g00990710

5. Click on "Details" and document the serial number and firmware version. Use the last two digits of the serial number as the MAC address for the radio and click on the "Rover" button. Accept the defaults of 38400 baud and no parity for both ports.

6. Click on the "Set" button to save the setting. Once the setting has been saved, the software will automatically disconnect.

7. Reconnect and verify the setting.

8. Click on "Clone" and save a file with the name of the radio location (i.e.: "Wheel Tractor Scraper 60").

9. Click on "Exit" to terminate the program.

TC900B Radio Installation Procedure

Illustration 23	g00993199
Radio Mount Group

Illustration 24	g00993207
TC900B radio in standard bracket assembly mounted to a modified radio plate. Radio plate was cut, painted and bolted to right side of a 623F WTS.

Illustration 25	g00993213
Radio mounted by using weld bosses.

Note: To minimize interference and maximize reception, the TC900B radio should be mounted at least 3 feet away from the GPS antenna or any other transmitting radio or antenna on the machine, and the radio antenna should have 360 degrees of visibility.

1. Attach the TC900B radio to the mounting bracket by using the stainless steel socket-head screws.

2. Use the remaining stainless steel socket head screw to attach the lower support bracket to the bottom of the radio.

3. Bolt the lower support bracket to the mounting bracket.

4. Mount the assembled radio assembly with the remaining screws and washers from the Shock Mount Kit.

5. Connect the 0 dB antenna tip to the radio.

6. Connect the straight end of the radio cable to the radio.

7. Route the cable down the ROPS post to the GPS receiver location.

Main Harness Installation

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Illustration 26	g00993696
Main harness connected to GPS receiver

1. Connect the main harness to the GPS receiver.

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Illustration 27	g00993694
Main harness routed through floor plate

2. Route the main harness through the floor plate.

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Illustration 28	g00993697
Main harness securely clamped

3. Secure the main harness by utilizing clamps or cable ties.

Illustration 29	g00993684

The 20 inch main harness that connects the GPS Receiver to the CAES display unit has two distinct ends. The round DT pin cannon plug, which comes pre-attached to the main harness, connects to the GPS receiver. The square 70 pin AMP connector, which connects the main harness to the back of the CAES display, is shipped unattached to the main harness to better facilitate main harness routing. Each wire within the main harness is clearly marked for proper insertion into the back of the connector.

Insert the pin end of each numbered wire into the correlating hole on the back of the connector. Seat each pin securely into the back of the connector. The pin will click when the pin is properly seated. Attach the wires of the main harness to the back of the connector from the center outward. To remove a pin from the back of the connector, slide the red DT pin removal tool over the wire to be removed. Push the tool to the bottom of the pinhole while gently pulling on the wire.

Illustration 30	g00993670
Electrical schematic for power harness and fuse installation.

Refer to electrical schematic above and make the electrical connections.

1. Route the RED (+ 24 volt) wire to one side of the fuse holder.

2. Supply +24 VDC from the Main Solenoid to the other side of the fuse holder.

3. Route the PINK (switched 24 VDC) wire to second fuse holder.

4. Supply switched +24 VDC from the key switch to the other side of the second fuse holder.

5. Route the BLACK (Negative/Ground) wire to a suitable ground lug on the machine.

Note: If the Run-Relay is not easily accessible, the key switch may be used as a substitute connection point.

Setting Machine ID for CD1040

1. Before applying power to the CAES System for the first time, turn the key switch to OFF position.

2. Check the voltage between pin A (+) and B (-), the result should be 24 volt.

3. Check the voltage between pin B (-) and C, the result should be 0 volt.

4. Turn the key switch to ON position.

5. Check the voltage between pin B (-) and C, the result should be 24 volt.

6. Turn the key switch to OFF position.

7. Connect the three pin DT connector from the power harness to the mating CAES main harness power connector.

8. Turn the key switch to ON position.

   Note: The display unit should light up and run through the Power On Self Test (POST). After completing the POST, the Display Unit should start booting the Operating System and then Scan Disk (BLUE SCREEN) will run to check the condition of the hard drive.

9. When the Microsoft SCANDISK starts (hint: BLUE SCREEN), press and hold the top two buttons of the display unit until the screen display shows "STANDBY MODE".

10. Release the top two buttons.

    Note: Do not press ENTER to continue! By pressing ENTER, the system will return to boot-up process.

11. Press the "⇒" key.

    Note: The display should now be at the "ON-LINE EDIT APPLICATION" screen. This screen is used to change the machine ID number.

12. Follow the instructions on the bottom of the screen to set the machine ID.

    Note: Do not press ENTER until you see the correct ID on display.

The list below is part of a worksheet that may be utilized prior to the first use of the new system. We recommend that the form is completed and filed in a retrievable location. If computer data is lost, the hard copy will provide a quick and easy means of reference in the process of recovery.

Machine ID Worksheet

Machine ID Number____________________

Machine Name____________________

Display Serial Number____________________

Machine Dimensions____________________

Radio Serial Number____________________

Application (Grade, Ore, OrePlus, Compaction)____________________

Grade Tolerance - Provided by Mine____________________

Machine Dimensions

Illustration 31	g00993128
Critical machine dimensions

One of the final steps in completing the installation is to measure the machine/GPS offsets referenced to the machines specific dimensions. The GPS Z measurement should be taken between the bottom of the GPS antenna ground plane and the bottom of the tires. Use the above sample METSmanager screen shot as a reference guide and template to record the various measurements.