Installation of the AccuGrade® GPS Electronic Components For Version 6.1{7220} Caterpillar

Track-Type Tractor:

D8T (S/N: KPZ1-UP; J8B1-UP)

D9T (S/N: RJS1-UP)

Introduction

ReferenceOperation and Maintenance Manual, SEBU8002, "AccuGrade^® GPS"

Note: This Special Instruction provides information for the installation of the 255-2430 GPS Electronic Kit , the 241-7920 Display Mounting Kit and the 259-4746 Radio Mounting Kit .

Operation and Maintenance Manual

Locate the Operation and Maintenance Manual, SMRU8002, "Muti-lanuage CD". Print the Operation and Maintenance Manual of the desired language and secure the manual in the cab of the machine.

The operation of the AccuGrade GPS System is covered in the Operation and Maintenance Manual, SEBU8002, "AccuGrade^® GPS". Refer to this manual for more information.

Important Safety Information

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 in order 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. If a tool, a procedure, a work method or operating technique that is not specifically recommended by Caterpillar is used, you must ensure that it is safe for you and for other people to use. You should ensure that the product will not be damaged or the product will not be made unsafe by the operation, lubrication, maintenance or the repair procedures that are used.

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Accidental engine starting can cause injury or death to personnel working on the equipment. To avoid accidental engine starting, disconnect the battery cable from the negative (−) battery terminal. Completely tape all metal surfaces of the disconnected battery cable end in order to prevent contact with other metal surfaces which could activate the engine electrical system. Place a Do Not Operate tag at the Start/Stop switch location to inform personnel that the equipment is being worked on.

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Personal injury or death can result from improper lifting or blocking. When a hoist or jack is used to lift any part or component, stand clear of the area. Be sure the hoist or jack has the correct capacity to lift a component. Install blocks or stands before performance of any work under a heavy component. Approximate weights of the components are shown. Clean all surfaces where parts are to be installed.

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Once the system is placed in automatic mode, blade movement may occur. Ensure that all personnel are clear of the blade before you place the system in automatic mode. Personal injury or death from crushing could occur.

Required Tools

The following tools will be required in order to install the AccuGrade System. The list below contains the recommended Caterpillar service tools.

Note: All the tools that are listed in Table 1 are to be provided by the dealership. Some of the tools must be obtained from sources other than Caterpillar.

Table 1

Part Number	Description
9S-1748	Wrench Set (Socket) (1/2 Inch Drive)
199-6156	Metric Wrench Set (Socket) (1/2 Inch Drive )
194-3584	Wrench Set (Socket) (Torx screw)
1U-7230	Hand Tool Group (Screwdrivers)
8T-9293	Torque Wrench (1/2 inch Drive)
9S-3263	Thread Lock Compound
266-2916	Measure Up Tool
1U-9367	Metric Tape Measure
	Level (Minimum 4 foot)
	Plum Bob (Minimum 16 oz.)
	Framing Square or Carpenter Square (Minimum 2 foot)

Parts List

Table 2

Contents of the 255-2430 GPS Electronic Kit
Quantity	Part Number	Description
2	248-1500	Mast (GPS)
1	265-5762	Display Assembly
1	204-6606	Mounting Kit
2	254-9136	Cables (Coiled)
1	255-0939	Case (Plastic)
1	255-0940	Case (Plastic)
1	226-9170	Angle Sensor
2	252-8744	Warning Film (Blade)
1	254-9951	Coiled Cable
2	244-1717	Receiver (GPS)
2	252-9628	Bracket Kit (Quick Release)
3	244-1720	Light Bar
4	4B-4863	Washer
4	8T-2659	Self-Locking Nut
2	151-6283	Bolt
8	8T-4223	Hard Washer
8	8T-4648	Bolt
6	9X-1046	Truss Head Screw
2	9X-8256	Washer
1	226-6115	Compact Flash
1	194-8031	Compact Flash Adapter
Contents of the 241-7920 Display Mounting Kit  (1)
Quantity	Part Number	Description
4	179-4324	Locknut
1	247-4151	Plate Assembly
1	247-4152	Plate Assembly
1	252-5110	Cover
2	252-5111	Gasket
1	252-5112	Base Assembly
4	198-9706	Truss Head Screw M5X0.8
4	204-6102	Hard Washer
4	4B-4274	Washer
2	4B-4863	Washer
2	8T-2659	Self Locking Nut M4X0.7
4	8T-4121	Hard Washer
4	8T-4137	Bolt M10X1.5
2	9X-1046	Truss Head Screw M4X0.7
Contents of the 259-4746 Radio Mounting Group
Quantity	Part Number	Description
6	8C-5607	Mount
3	8C-5608	Spacer
1	140-7480	Mounting Bracket
1	167-8610	Bracket As.
2	5S-7349	1/4 - 20 Bolt
2	8T-4205	Hard Washer
3	9X-2480	M6 X1 Bolt
3	9X-6165	Washer
6	167-8999	Cap Screw

( 1 )

The mounting kit for the Display is located behind the operator seat.

Installation of the GPS Masts to the Blade

Note: Make sure that the mast and the mounting bracket are free from dirt.

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Illustration 1	g01149328

1. Position one of the 248-1500 Masts (3) onto the left hand mounting bracket (1) .

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Illustration 2	g01111390

2. Mount the mast (3) so that the bracket for the cable strain relief (2) points towards the right hand side of the machine in respect to the operator seat. Refer to Illustration 2.

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Illustration 3	g01110022

3. Secure the 248-1500 Mast (3) to the mounting plate (1) with the four 8T-4648 Bolts and 8T-4223 Washers (4). Torque the 8T-4648 Bolts to 305 N·m (225 lb ft).

4. Repeat Steps 1 through 3 in order to install one of the 248-1500 Masts onto the right hand mounting plate.

Installation of the GPS Receivers

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In order to prevent personal injury during installation and removal of the GPS receivers, use an approved access system in order to reach the mounting locations of the GPS receivers at the top of the masts. Do not climb on the blade.

Illustration 4	g01126902
Typical illustration of an approved access system

Illustration 5	g01114189
Bottom of the GPS Receiver (5) GPS Receiver (6) Bracket (Quick Release) (7) Thumb wheel (8) Bolts

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NOTICE
If the quick-release bracket 252-9628 Bracket-Kit (6) has been removed from the 244-1717 GPS Receivers (5), the bolts (8) must be torqued to 41 N·m (30 lb ft) when installed.

Note: Make sure that the top of the mast and mounting bracket are free of dirt.

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Illustration 6	g01149331

1. Slide the 244-1717 GPS Receiver (5) with the quick release bracket 252-9628 Bracket Kit (6) onto the top of the 248-1500 Mast (3). Orient the receiver so that the LED's will be visible from the cab of the machine.

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NOTICE
You must fully insert the GPS Mast (3) into the quick-release bracket (6) on the GPS Receiver (5). Otherwise, the blade tip to antenna measurements will not be correct, resulting in wrong elevation guidance and construction.

2. Firmly hand tighten the thumb wheel (7) located on the quick release bracket 252-9628 Bracket Kit in order to secure the 244-1717 GPS Receiver .

   Note: If you remove the 244-1717 GPS Receiver assembly from the machine, put the assembly in the 255-0939 Plastic Foamed Lined Case for protection.

Installation of the Warning Film

Illustration 7	g01069921
The warning label 252-8744 Film that is placed on the mast

Place a 252-8744 Film on the 248-1500 Masts . While you are standing between the machine and the blade, place the 252-8744 Film on the rear of the mast at eye level.

Connecting the Coiled Cables

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In order to prevent personal injury during installation and removal of the GPS receivers, use an approved access system in order to reach the mounting locations of the GPS receivers at the top of the masts. Do not climb on the blade.

Illustration 8	g01126902
Typical illustration of an approved access system

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Illustration 9	g01114226

1. Connect the ninety degree connector of one of the 254-9136 Coiled Cables to the connector (14) on the left hand 244-1717 GPS Receiver .

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   NOTICE
   It is essential that the left mast and the right mast are connected to the respective left and right harness connectors. This will ensure proper blade movement.

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   Illustration 10	g01089596
   (15) Left hand connector box (16) Left hand connector for the coiled cable on the left GPS Receiver

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   Illustration 11	g01090111
   (17) Quick disconnect style connector on the coiled cable for the left hand GPS Receiver.

   1. The other end of the coiled cable is the quick disconnect style (17). Connect the cable by pushing the connector (17) onto the connector (16) on the left hand connector box (15). The connector (17) for the left hand GPS Receiver is marked with an "L".

2. Connect the ninety degree connector of one of the 254-9136 Coiled Cables to the connector (14) on the right hand 244-1717 GPS Receiver .
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   Illustration 12	g01149344
   (15) Right hand connector box (16) Right hand connector for the coiled cable on the left GPS Receiver

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   Illustration 13	g01115088
   (17) Quick disconnect style connector on the coiled cable for the right hand GPS Receiver.

   1. The other end of the coiled cable is the quick disconnect style (22). Connect the cable by pushing the connector (22) onto the connector (21) on the right hand connector box (20). The connector (21) for the right hand GPS Receiver is marked with an "R".

Installation of the Angle Sensor to the Blade

Illustration 14	g01158714
Proper orientation of the Angle sensor as mounted within the angle sensor bracket.

The AccuGrade System uses the 226-9170 Angle Sensor in order to determine the pitch of the machine's blade.

The angle sensor is used in manual operation to determine the pitch of the blade. The angle sensor is also used for valve calibration. For AccuGrade Systems running Version 6.1 firmware, the angle sensor is optional. However, if the machine is not parallel to the design, the cut/fill information will not be as accurate.

Note: When cable is received the ninety degree connector will be in the 12 o'clock position.

Note: Do not attach the 226-9170 Angle Sensor to the mounting plate until Step 3.

1. Connect the ninety degree connector of the 254-9951 Coiled Cable to the connector (11) on the 226-9170 Angle Sensor (9) .
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   Illustration 15	g01150777
   The angle sensor bracket is not shown. Refer to Illustration 14. (9) 226-9170 Angle Sensor (11) Angle Sensor Connector (12) Angle Sensor Harness Connector (13) Jam Nut

   1. Tighten the connector (12) .

   2. Loosen the Jam nut (13) in order to rotate the ninety degree connector to the proper orientation. Do not rotate the connector more than 100 degrees.

   3. Tighten the jam nut (13) in order to lock down the orientation of the ninety degree connector.

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Illustration 16	g01148673
The angle sensor bracket is not shown. Refer to Illustration 14. (1) Mounting Plate (3) Mast (9) 226-9170 Angle Sensor (10) 151-6283 Hex Head Bolts (11) Angle Sensor Connector (12) Angle Sensor Harness Connector (13) Jam Nut

2. Locate the 226-9170 Angle Sensor (9) on the mounting plate (1) on the left hand side of the blade. The sensor will be located behind the 248-1500 Mast (3). Locate the angle sensor so that the connector (11) is parallel to the blade and perpendicular to the machine.

3. Attach the 226-9170 Angle Sensor to the mounting plate (1) with two 151-6283 Hex Head Bolts (10) .

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Illustration 17	g01114428
(19) Quick disconnect style connector on the coiled cable for the angle sensor.

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Illustration 18	g01114430
(15) Left hand connector box (18) Left hand connector for the coiled cable on the angle sensor

4. The other end of the coiled cable is the quick disconnect style (19). Connect the cable by pushing the connector (19) onto the connector (18) on the left hand connector box (15). The connector (18) for the angle sensor is marked with a "T".

Installation of the GPS Display

Table 3

Contents of the 241-7920 Display Mounting Kit  (1)
Quantity	Part Number	Description
4	179-4324	Locknut
1	247-4151	Plate Assembly
1	247-4152	Plate Assembly
1	252-5110	Cover
2	252-5111	Gasket
1	252-5112	Base Assembly
4	198-9706	Truss Head Screw M5X0.8
4	204-6102	Hard Washer
4	4B-4274	Washer
2	4B-4863	Washer
2	8T-2659	Self Locking Nut M4X0.7
4	8T-4121	Hard Washer
4	8T-4137	Bolt M10X1.5
2	9X-1046	Truss Head Screw M4X0.7

( 1 )

The mounting kit for the Display is located behind the operator seat.

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Illustration 19	g01091180

1. Remove the six T40 Torx bolts (23) from the instrument panel of the machine.

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Illustration 20	g01089601

2. Pull the instrument panel away from the mounting bracket in order to access the rear of the storage compartment. Refer to Illustration 20.

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Illustration 21	g01110167

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Illustration 22	g01140141

3. Remove the four 4mm hex head screws and washers (24) from the storage compartment.

4. Remove the storage compartment (25) .

   Locate the harness connector (26) for the Display. Before the right hand bracket is installed, position the harness connector. Refer to Illustration 22.

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Illustration 23	g01089688

5. Install the left hand 247-4152 Bracket (28) with two 8T-4137 16mm Bolts and 4T-4121 Washers (27) .

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Illustration 24	g01089682

6. Install the right hand 247-4151 Bracket (29) with two 8T-4137 16mm Bolts and 4T-4121 Washers (27) .

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Illustration 25	g01110577
(30) Connector on the back of the Display

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Illustration 26	g01149360

7. Position the 265-5762 Display (31) in order to connect the connector (26), that is located on the harness (33) for the Display, to the connector (30) that is located on the back of the Display.

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Illustration 27	g01139627
Typical assembly of the shock mount (34) Shock Mount (35) Washer (36) Number 8 Hex Head Screw

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Illustration 28	g01149363

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Illustration 29	g01139654

8. Install the 265-5762 Display (31) to the brackets from Step 6 with four number 8 hex bolts (36), four washers (35), and eight shock mounts (34) that are included with the 204-6606 Mounting Kit .

   Note: Apply thread compound, which is included in the 204-6606 Mounting Kit , to the threads of the bolts.

Installation of the Cover Panel

Illustration 30	g01089943
(37) 252-5110 Cover Panel

Illustration 31	g01090097
Rear view of instrument panel

Install the 252-5110 Cover Panel (37) onto the front of the instrument panel with four 198-9706 Truss Head Screws M5X0.8 , four 4B-4274 Washer and four 179-4324 Locknuts (38) .

Installation of the Light Bars

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Illustration 32	g01114487

1. Remove the foam insert (23) from the top of the instrument panel in order to access the harness connectors for the left light bar, the right light bar and the top light bar.

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Illustration 33	g01114500

2. Locate the light bar harness (40) .

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Illustration 34	g01114507

3. Position the instrument panel in order to allow the right harness connector and the left harness connector for the 244-1720 Light Bars to be guided through the openings in the instrument panel. Refer to Illustration 34.

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Illustration 35	g01149054
(41) Instrument Panel (42) 204-6102 Washer (43) 9X-1046 Truss Head Screw , 4B-4863 Washer , 8T-2659 Self - Locking Nut (44) 244-1720 Light Bar

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Illustration 36	g01149025

4. Install one of the 244-1720 Light Bars (44) onto the left hand side of the instrument panel with two 9X-1046 Truss Head Screws , two 4B-4863 Washers , two 8T-2659 Self - Locking Nuts (43) and two 204-6102 Washer (42) .

   Note: Install the two 204-6102 Washers (42) between the light bar and the instrument panel. Refer to Illustration 35 and Illustration 36.

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Illustration 37	g01149410

5. Install the 241-7290 Grommet into the openings in the side of the instrument panel where the light bar cable was routed.

   Refer to Illustration 37.

6. Repeat Step 4 and Step 5 in order to install one of the 244-1720 Light Bars (44) on the right hand side of the instrument panel.

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Illustration 38	g01089920

7. Mount the 252-5112 Light Bar Mounting Plate (45) to the top of the instrument panel (41) with two 9X-1046 Truss Head Screws , two 4B-4863 Washers , two 8T-2659 Self - Locking Nuts (43) .

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Illustration 39	g01149141

8. Mount one of the 244-1720 Light Bars (44) onto the 252-5112 Light Bar Mounting Plate (45) that was installed in Step 7, with two 9X-1046 Truss Head Screws .

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Illustration 40	g01090102

9. Connect the left harness connector to the connector on the left 244-1720 Light Bar .

10. Connect the right harness connector to the connector on the right 244-1720 Light Bar .

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Illustration 41	g01089953

11. Connect the harness connector to the connector on the top 244-1720 Light Bar . Install the foam insert that was removed in Step 1.

    Note: It may be necessary to adjust the foam insert in order to allow the harness to fit properly.

Reinstall the Instrument Panel

Illustration 42	g01090127

1. Reposition the instrument panel onto the mounting bracket.

2. Install the six T40 Torx bolts (10) that were removed from the instrument panel in Step 1 (Installation of the GPS Display).

Installation of the Radio

Table 4

Contents of the 255-2425 Radio Kit (TC900C)
Quantity	Part Number	Description
6	167-8999	Cap Screw
1	255-2424	Radio Gp

Illustration 43	g01149419
Radio installed onto the radio mounting bracket. (51) 255-2424 Radio Gp (52) 167-8610 Bracket As (53) 140-7480 Mounting Bracket (54) 5S-7349 Bolt (55) 8T-4205 Hard Washer (56) 167-8999 Cap Screw

1. Install the 255-2424 Radio Gp (51) onto the 167-8610 Bracket As (52). Refer to Illustration 43.

2. Secure the antenna end of the 255-2424 Radio Gp (51) to the 167-8610 Bracket As (52) with four 167-8999 Cap Screws (56) .

3. Secure the 140-7480 Mounting Bracket (53) to the connector end of the 255-2424 Radio Gp (51) with two 167-8999 Cap Screws (56) .

4. Secure the 140-7480 Mounting Bracket (53) to the 167-8610 Bracket As (52) with two 5S-7349 Bolts (54) and two 8T-4205 Hard Washers (55) .

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Illustration 44	g01149429
Radio attached to the E-Rops with shock mounting hardware. (57) 9X-2480 M6 Bolt (58) 9X-6165 Washer (59) 8C-5608 Spacer (60) 8C-5607 Isolation Mount

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Illustration 45	g01149434
Radio shock mounting hardware

5. Secure the radio assembly to the machine with three 9X-2480 M6 Bolt (57), three 9X-6165 Washer (58), three 8C-5608 Spacer (59) and three 8C-5607 Isolation Mount (60). Tighten the bolts to a torque of 20 N·m (15 lb ft).

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Illustration 46	g01139749

1. Locate the harness for the radio. Connect the harness to the connector that is located on the bottom of the radio.

Display Operation

Illustration 47	g01149439
(70) LCD screen (71) Soft keys (72) Hard keys (73) Escape key (74 ) Next key (75) Power key (76) "Zoom In" key (77) Arrow keys (78) "Zoom Out" key (79) OK key (80) Menu key (81) Slot for data card

The AccuGrade GPS Display is a computer that runs the software for the AccuGrade System.

The Display is used in order to operate the AccuGrade System. The Display has a color LCD screen in order to show information and a keypad for entering information.

Power key

The Power key turns the Display on and off:

In order to turn on the Display, ensure that the ignition switch is in the ON position then press the Power key.

In order to turn off the Display, press and hold the Power key for several seconds, until the Display shuts down. This delay reduces the risk of inadvertently shutting off the power. You can turn off the AccuGrade System from any screen or from any dialog.

Soft Keys

Soft keys are graphical "keys" that appear at the bottom of the screen. In order to activate the displayed function, press the hard key directly below the soft key.

Press the "Menu" key in order to change the available options for the soft key.

The soft key functions relate to particular screens or dialogs. The soft key functions are only available when these screens or dialogs are accessed. For example, "New Level" only appears on the "Design Selection" screen, as that function relates only to that screen.

If a soft key has no function in a screen or the soft key has no function in a dialog, the soft key is blank.

The text on a soft key can show one of the following details:

• A description of the soft key function. (For example, "Zoom Machine" enlarges the view in order to show the machine.)

• The file or the setting that has been selected

The text changes when you press the soft key in order to select options. The top line of this soft key ends with a colon and the bottom line shows the current option or setting. For example, the soft keys "Blade: Left" and "Blade: Right" show the side of the blade that has focus. The current focus (Left or Right) shows on the bottom line of the soft key.

Some soft keys will appear in more than one dialog. The function of the soft key is the same function.

Hard Keys

The hard keys are the six physical keys that are located immediately below the LCD screen. Hard keys are used in order to operate the function that is shown on the soft key directly above the hard key.

Arrow keys

Use the arrow keys to perform the following actions:

• move within menus and lists.

• enter text or numbers into data entry fields in dialogs.

• pan the "Plan View", pan the "Cross Section View", or pan the "Profile View"

Navigating within menus and lists

In order to choose an item from a menu or a list, complete the following steps:

1. Press the up arrow or the down arrow in order to highlight the desired option.

2. Press the OK key.

Entering data

In text and number fields in any of the dialogs, complete the following actions:

• Press the up arrow or the down arrow in order to scroll through the available characters.

• Press the left arrow or the right arrow in order to move between characters.

Display brightness

The brightness of the Display can be adjusted.

In order to increase the brightness of the Display, hold down the Menu key and press "+".

In order to decrease the brightness of the Display, hold down the Menu key and press the minus sign "-".

Working with Dialogs

The "system setup", "alignment selection", "horizontal offset" selection, "vertical offset" selection, "design selection", and the "Setup Menu - Configuration" option screens are called dialogs. Use dialogs in order to enter data. Use the dialogs in order for the AccuGrade System to be set up according to your requirements. The selected field in a dialog is identified by the blue background color.

Press the arrow keys on the Display in order to enter data:

The up arrow steps through the upper case letters (A through Z) the numbers (0 through 9), the decimal point ".", the negative sign "–", the positive sign "+", a space, and back to "A".

Note: Available values will depend on the type of field that is selected. For example, the only values that are available for number fields are 0 through 9, the decimal point ".", "–", and "+".

The down arrow steps through the same character set, but in reverse.

When you change a character in a field, the up arrow and the down arrow start stepping from the existing character.

The right arrow steps to the next character to the right. In fields that allow spaces, press the right arrow twice in order to insert a space.

The left arrow is used in order to move back one character to the left. This deletes the character in the space to the left.

Dialogs may contain any of the following items:

Text fields - Use the text fields in order to enter your own information. For example, when you set up the name of your level surface design or sloping surface design, use the arrow keys in order to enter this data.

Number fields - Use the number fields in order to enter required values. For example, when you set up the vertical and horizontal offset, use the arrow keys in order to enter values into these fields.

List boxes - List options or possible selections. Use the arrow keys in order to select the listed item.

Warnings

An error such as the loss of GPS data will cause inaccurate guidance. When an error occurs, a warning message flashes on the screen. Light bar guidance and automatic control are not provided under these conditions. For more information, Refer to Operation and Maintenance Manual, SEBU8082, "Flashing Warning Messages". Illustration 48 is an example of a warning message.

The "No GPS Receiver Data" warning appears when a machine needs to be moved.

Illustration 48	g01104216

Hourglass

When the system performs an operation that takes more than a few seconds, an hourglass appears on the current screen. For example, the hourglass appears in the following situations:

• The hourglass appears in the "Plan View", the "Cross Section View", or the "Profile View", while the software updates the Display after a pan or zoom.

• The hourglass will appear in the "Select Design File" dialog while a design is being loaded from the data card.

The following dialog shows the hourglass while theAccuGrade System loads a design file:

Illustration 49	g01104252

Language Configuration

The firmware for the Display will be translated into the list of languages below.

• US English (USA)

• UK English (GBR)

• Dutch (NLD)

• Finnish (FIN)

• French (FRA)

• German (DEU)

• Spanish (ESP)

• Swedish (SWE)

• Portuguese (PRT)

• Italian (ITA)

The language translations will be available on the CD that can be found in the installation kit for the AccuGrade System.

Table 5 shows an example of the language files for the Display that are available on the CD for the AccuGrade System.

Table 5

Location of firmware files
Language	Version 6.1
UK English	AccuGrade V6.1 GBR.SG1
US English	AccuGrade V6.1 USA.SG1
Dutch	AccuGrade V6.1 NLD.SG1
Finnish	AccuGrade V6.1 FIN.SG1
French	AccuGrade V6.1 FRA.SG1
German	AccuGrade V6.1 DEU.SG1
Spanish	AccuGrade V6.1 ESP.SG1
Swedish	AccuGrade V6.1 SWE.SG1
Portuguese	AccuGrade V6.1 PRT.SG1
Italian	AccuGrade V6.1 ITA.SG1

The AccuGrade System is shipped with the factory installed US English firmware.

Use the "Display Firmware Upgrade" procedure in order to change the language.

Note: The other language files are also available on SIS Web.

Required Equipment

You need the following equipment in order to upgrade your firmware for the Display and enable the option keys.

• The Display and your machine.

• If applicable, an option keys file that is provided by your dealer using FPS

• A data card

• A PC card adapter

• An office PC with a PC card slot

Copying The Files To The Data Card

1. Use an office PC or SISweb in order to copy the appropriate AccuGrade GPS V6.1 AAA.SG1 files from the Software CD to the root folder of a data card. AAA is the language code. For example, AccuGrade GPS V6.1 USA.SG1 is version 6.1 in US English.

   Note: You can copy as many different .SG1 files to the data card as necessary. For example, the Spanish and Portuguese versions can all be copied onto the data card at the same time.

2. If required, copy the Option key<serial number>.txt file supplied by your dealer.

3. Turn off the Display.

Upgrading The Display Firmware

1. Insert the data card into the Display.

2. Press the "POWER" key in order to turn on the Display.

   Note: Do not turn off the Display until Step 5.

   The Display detects all .SG1 files and lists them on the "Select Display Software File for Upgrade" screen.

3. Use the up arrow key and the down arrow key in order to select the image file you want to upgrade to. Press the "OK" key in order to continue. Press the "ESC" key in order to cancel the upgrade procedure.

   Note: Save the machine settings before upgrading if any settings have been changed.

4. The "Update Display Software – New Version Detected" confirmation screen appears. Press the "OK" key in order to start the upgrade process. Press the "ESC" key in order to cancel the upgrade.

   Stage 1 of the firmware upgrade starts automatically. The upgrade firmware is copied into temporary memory.

   Stage 2 then starts automatically. The upgrade firmware is verified in internal memory, and the temporary memory is erased.

5. When prompted, turn off the external power to the Display.

6. Wait at least 30 seconds before you reconnect power. Then, turn on the Display.

Working With The Setup Menus

Use the "Setup Menu" dialogs in order to access the AccuGrade System setup items. The "Setup Menu" dialogs are available in Normal, Service, and Training mode. However, different dialogs and items become available for the mode you select. Service Mode provides access to all of the Configuration and Installation options. In Normal Mode, the dialogs and options are predefined and may only be changed by reverting to Service Mode. In Training Mode, menus and options relating to control devices are not displayed. Refer to Table 6 for more details.

Note: Changes to the items in the "Setup Menu" dialogs take effect as soon as you exit the Setup menu.

Note: All of the AccuGrade System setup parameters are reset to defaults whenever you load a new version of the firmware for the Display.

Perform the following steps in order to access the "Setup Menu" dialogs.

1. Press the "MENU" key until the "Setup Menu" Soft Key is displayed.

2. Press "Setup Menu" Soft Key.

The following menus are available in the Service Mode: Setup Menu - Configuration and Setup Menu - Installation.

Setup Menu - Configuration

Items in the Setup Menu – Configuration dialog include troubleshooting items as well as system variables and settings. By default, some of these items are visible in Service Mode only, while others are visible in all modes. The options are as shown in Table 6.

Table 6

This Setup Menu - Configuration Item ...	Is Available In These Modes (by default) ...	For more information, refer to, RENR8083
Blade Wear	All modes	Systems Operation, "Blade Wear"
Vertical Offset Switch Increment	Service mode	Systems Operation, "Vertical Offset Increment"
Lightbar Scales	All modes	Systems Operation, "Light Bar Scales"
Display and Lightbar Brightness Setting	All modes	Systems Operation, "Display and Light Bar Brightness (Display and Lightbar)"
Map Recording	Service mode	Systems Operation, "Map Recording"
Valve Speed	Normal and Service mode	Testing and Adjusting, "Blade Reaction Time - Adjust"
Calibrate Sensors	Service Mode	Testing and Adjusting, "Angle Sensor - Calibrate"
Avoidance Zone	Service mode	Systems Operation, "Avoidance Zone"
Text Items	Service mode	Systems Operation, "Text Items"
Plan View Rotation	Service mode	Systems Operation, "Plan View Rotation"
Beeper	Service mode	Systems Operation, "Beeper"
Save Settings	Service mode	Systems Operation, "Display Settings"
Restore Settings	All Modes	Systems Operation, "Display Settings"
GPS Receiver Configuration	All Modes	Systems Operation, "Receiver Configuration"
Diagnostics	Normal and Service mode	Troubleshooting, " Diagnostic Capabilities"

Setup Menu - Installation

Items listed under the Setup Menu - Installation dialog include items used when you install or reinstall an AccuGrade System, or to update the device firmware. In order to access the Setup Menu - Installation dialog, press the Soft Key (Installation). By default the Setup Menu - Installation dialog is only available in Service mode. However the operator configuration can be customized so that some or all of the Setup Menu - Installation dialog is available in Normal mode.

Depending on the current machine configuration, different options are available from the Setup Menu - Installation dialog. The options are shown in table 7.

Table 7

This Setup Menu item ...	in these modes (by default) ...	For more information, refer to, RENR8083
Machine Settings	Service Mode	Testing and Adjusting, "Machine Type"
Units	Service Mode	Systems Operation, "Display Units"
Machine Dimensions	Service Mode	Testing and Adjusting, "Machine Dimensions - Set"
Lightbar Connections	Service Mode	Testing and Adjusting, "Light Bar - Set"
Valve Calibration	Service Mode	Testing and Adjusting, "Bank Valve (Grade Control) - Calibrate"
Wireless Communications Support	Service Mode	Systems Operation, "Wireless Communications"
Upgrade Firmware	Service Mode	Systems Operation, "Receiver Firmware Upgrade, Display Firmware Upgrade, Angle Sensor Firmware Upgrade"
Software Support Option	Service Mode	Systems Operation, "Software Support Option"
Guidance Hours	Service Mode
Operator Configuration	Service Mode	Systems Operation, "Operator Access"
Launch RadioLink	Service Mode	Systems Operation, "Radio Utility"

Machine Settings

Configure the machine type using the "Machine Settings" dialog.

In order to access the "Machine Settings" dialog perform the following steps.

Configure A Machine

1. Start the Display in Service mode.

2. From the "Setup Menu – Configuration" dialog, press the "Installation" soft key in order to list the items under the "Setup Menu – Installation" dialog. Refer to Systems Operation, "Setup Menu" for more information on the Setup Menu.

3. Use the down arrow key or the up arrow key until "Machine Settings" is highlighted. Press the "OK" key. A dialog similar to Illustration 50 appears.

   The dialog shows a summary of the current settings.

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Illustration 50	g01149156

4. Press the "Edit Machine" soft key. A dialog similar to Illustration 54 will appear.

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Illustration 51	g01262840

5. Select "Dozer" from the list.

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Illustration 52	g01262835

6. Select the "GPS Receiver Type".

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Illustration 53	g01262843

7. Select "Blade Pitch".

   The Pitch Sensor is part of the AccuGrade System. However, the Pitch Sensor is not required for operation.

   Note: If the Pitch Sensor is not used, the accuracy of the GPS in manual mode will be affected.

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Illustration 54	g01149168

8. Press the up arrow or the down arrow in order to select the appropriate radio type.

   Select "TCXXXC". Caterpillar systems normally use the TC900C radio or the TC450C radio.

   If a 3rd party radio is selected, the data is passed over RS232. Refer to Special Instruction, REHS2425, "Customer Supplied Radios" for additional information.

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Illustration 55	g01118344

9. Press the "OK" key.

   A dialog similar to Illustration 55 will appear.

10. Scroll up or down in order to select the blade type that is needed.

11. Press the "OK" key.

    A dialog similar to Illustration 56 will appear.

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Illustration 56	g01150141

12. Press the up arrow or the down arrow in order to select the correct valve module. For "G" series Track Type Tractors, select "VM410". For all other Track Type Tractors, select "A4:M1".

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Illustration 57	g01262849

13. Select "Yes" for Lightbar.

14. Press the "OK" key.

    The summary "Machine Settings" dialog re-appears.

15. Review the selections. Press the "OK" key in order to save the settings.

    Once you have configured the new machine, the system sends updates to the GPS Receiver (if required). A dialog informs you that the GPS Receiver is being configured.

    If the changes are successful, you return to the "Setup Menu – Installation" dialog.

    If the changes are not successful, a dialog informs you that the GPS Receiver configuration was not updated. In order to solve this:

    1. Make sure the GPS Receiver is being recognized by the system. In order to do this, check the "Diagnostics" dialog.

    2. Send a GPS configuration file to the GPS Receivers by:
       • reselecting the current design (if the current design contains a coordinate system).

       • using the "GPS Receiver Configuration" item on the "Setup Menu".

16. Press the "ESC" key in order to exit the "Setup Menu – Installation" dialog. The changes take effect immediately.

17. Save the Machine Settings in the "Save Settings" dialog.

Configure The Units

Note: Caterpillar recommends setting the distance Units as Metric in order to perform machine measure up.

The "Units" menu has five dialogs which allow you to select the units to show distance, speed, grade, cross slope, and station. In each dialog the current setting is highlighted.

Perform the following steps in order to set the units.

1. Start the Display in Service Mode.

2. From the "Setup Menu - Configuration" dialog, press the "Installation" soft key in order to list the items under the "Setup Menu - Installation" dialog.

3. Use down arrow key or the up arrow key until "Units" is highlighted.

4. Press the "OK" key. By default, the "Distance Units" dialog is selected. The dialog in Illustration 58 appears.

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Illustration 58	g01023989

5. Do the following as necessary from any of the "Units" dialogs.
   • Press the "Distance" soft key in order to select the distance units.

   • Press the "Speed" soft key in order to select the speed units.

   • Press the "Grade" soft key in order to select the grade units.

   • Press the "Cross Slope" soft key in order to select the cross slope units.

   • Press the "Station Format" soft key in order to select the station (chainage) format for a road design.

   • Press the "ESC" key in order to cancel and return to the "Setup Menu - Installation" dialog.

6. When any or all of the units have been set, press the "OK" key in order to save the settings and return to the "Setup Menu - Installation" dialog. You can begin to enter details such as the machine dimensions, in those units immediately.

7. Press the "ESC" key in order to exit the "Setup Menu - Installation" dialog.

   The Units are saved in the Display Settings file.

Distance

Distance values appear on the screen in the following formats.

• Meters - as "m" (default for all Display firmware files except for US English)

• International feet - as "ft"

• US survey feet - as "FT" (default for US English Display firmware)

Perform the following steps in order to change the distance units.

1. If any other unit setup dialog is shown, press the "Distance" soft key.

2. Use the down arrow key and the up arrow key in order to choose the required distance units.

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NOTICE
The DXF file format does not contain any information on the units used (feet or meters). As all DXF drawing files are unitless, use the SiteVision Office software in order to ensure that the correct units are set.

Note: If you change your units, any currently displayed Site Map and Background Plan files are reloaded. Then the Site Map and Background Plan files are displayed in the new units.

Speed

Speed can be shown in the following formats.

• Kilometers per hour - as "km/h" (default for all Display firmware files except for US English)

• Miles per hour - "mph"

Perform the following steps in order to change the speed units.

1. Press the "Speed" soft key .

2. Use the down arrow key and the up arrow key in order to choose the required units.

Grade

Grade values can be shown in the following formats:

• Percentage - as "%"

• Ratio - as "rise: run" (default)

Perform the following steps in order to change the grade units.

1. Press the "Grade" soft key .

2. Use the down arrow key and the up arrow key in order to choose the required format.

Cross Slope

Cross slope values can be shown in the following formats:

• Percentage - as "%" (default)

• Ratio - as "rise: run"

Perform the following steps in order to change the cross slope units.

1. Press the "Cross Slope" soft key .

2. Use the down arrow key and the up arrow key in order to choose the required format.

   A positive value indicates a rising cross slope as you move away from the master alignment. A negative value indicates a falling cross slope as you move away from the master alignment.

Station Format

Station (chainage) values can be shown in the following formats:

• 1000.00 (default)

• 1+000.00

• 10+00.00

• 1/000.00

Perform the following steps in order to change the station format.

1. Press the "Station Format" soft key .

2. Use the down arrow key and the up arrow key in order to choose the required format.

3. When this has been completed and the other units are set, press the "OK" key in order to save the settings and return to the "Setup Menu - Installation" dialog.

4. Press the "ESC" key in order to exit the "Setup Menu - Installation" dialog. The changes take effect immediately.

Machine Dimensions

Illustration 59	g01113705
(A) Top of the lower housing heightabove right cutting edge bolt (B) Top of lower housing height above left cutting edge bolts (C) The distance that the receiver is back from the right bolts of the cutting edge. (D) The distance the receiver is back from left bolts of the cutting edge (E) Distance the GPS Receiver is in from right blade tip (F) Distance the GPS Receiver is in from left blade tip (G) Blade height (H) Blade width

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NOTICE
You must enter correct details. Any errors transfer directly into the finished surface.

Note: Caterpillar recommends that you use the receiver measure up tool. If the measure up tool is not available, the height measurements should be made to the top of the lower housing on the GPS Receiver. Measure both the left and the right GPS Receivers.

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NOTICE
Different offsets will be applied to the measured machine dimensions, depending on what option is selected in the "Measure height to" field. Selecting the wrong "Measure height to" option will introduce a vertical error of 73 mm (2.87 inch)

In order to make the measurements, you will need the following equipment:

• GPS Receiver measure up tool

• Straight edge

• Clamps

• Plumb bob

• Two foot steel framing square

• Carpenter's level (Minimum four foot)

• Steel tape or ruler

Note: The machine must be remeasured if the blade is replaced. The machine must be remeasured if the mast mount is bent or replaced.

The AccuGrade System uses the machine dimensions in order to calculate the position of the cutting edge of the blade from the GPS antennas.

The AccuGrade System provides guidance to the cutting edge of the blade. The AccuGrade System does not provide guidance to the forward swept corner bits. Refer to Illustration 60.

Illustration 60	g01113571
Machine measurements in Plan view (D) Horizontal distance from cutting edge bolts to front of the cutting edge (I) Horizontal distance from the cutting edge bolts back to the left GPS Receiver. (F) The distance in from the left blade tip.

Use the "Setup Menu" dialogs in order to access all of the setup options for the AccuGrade System.

Refer to Systems Operation, "Setup Menu".

Proceed with the following steps in order to measure the machine dimensions and to enter the machine dimensions into the Display.

1. Ensure that the machine is on level ground.

2. Position the blade so the blade is straight with no angle.

3. With a carpenters level, position the blade so that the top of the cutting edge is level.

   Refer to Illustration 61.

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Illustration 61	g01113603

4. Roll the blade so that the left antenna mast is vertical in the forward/back direction.

   If you cannot roll the blade in order to position the left mast in the vertical position, ensure that the blade is in the working position.

   The machine is now in a position so that the machine dimension measurements can be taken.

5. Measure the height of the GPS Receiver above the center of the mounting bolts for the cutting edge.

   1. Remove the left hand GPS Receiver from the left hand mast.
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   Illustration 62	g01113821

   2. Install the Measure Up Tool onto the left GPS mast.

   3. Rotate the measure up tool so that the tool is perpendicular to the blade. With the measure up tool in this position, you can measure the vertical distance to the bolts on the cutting edge.

      Refer to Illustration 63.

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   Illustration 63	g01113836

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   Illustration 64	g01113830

   4. With the help of a carpenters level, anchor the measuring tape onto the measure up tool and measure the distance to the middle of the bolts on the cutting edge.

      Ensure that the carpenters level is level and the tape measure is plumb before taking the measurement.

      If the measure-up tool is not level, measure the difference and add or subtract the difference to the height.

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   Illustration 65	g01121254

   5. Note this measurement on the table that is provided at the end of this manual.

6. Measure the GPS Receiver back from center of cutting edge bolts.

   1. The measure up tool will remain perpendicular to the cutting edge of the blade.

   2. Secure a plumb bob line from one of the centered notches in the measure up tool so that the plumb bob line hangs in front of the mounting bolts for the cutting edge.

      Note: Remember the distance of the notch on the measure up tool. This distance is used in Step 6.d.

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   Illustration 66	g01114091

   3. Measure the distance from the plumb bob line to the center of the bolts for the cutting edge.

   4. In order to calculate the "Antenna back from the cutting edge bolts" distance, subtract the value that was measured in Step 6.c from the distance that is shown on the measure up tool notch.

      Note: This number is a negative value if the center of the GPS antenna is in front of the center of the mounting bolts for the cutting edge.

   5. Note this measurement on the table that is provided at the end of this manual.

7. Measure the GPS Receiver to blade offsets.

   1. Rotate the measure up tool so that the measure up tool is parallel to the cutting edge of the blade. The measure up tool should extend beyond the end of the blade.
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   Illustration 67	g01113970

   2. Secure a plumb bob line from one of the centered notches in the measure up tool. The plumb bob line should hang to the ground.

      Note: Remember the distance of the notch on the measure up tool. This distance is used in Step 7.d.

   3. Measure the distance from the tip of the blade to the plumb bob line. A square and straight edges may need to be used in order to extrapolate the widest point of the blade to near the plumb bob, so the measurement can be taken parallel with the cutting edge.

   4. In order to calculate the "Antenna in from the blade tip" distance, subtract the value that was measured in Step 7.c from the distance that is shown on the measure up tool notch.

      Note: If the center of the mast is outside the blade tip, this number is a negative value.

   5. Note this measurement on the table that is provided at the end of this manual.

      This is the horizontal distance, in line with the face of the blade, from the left blade tip to the center of the GPS antenna. Refer to "F" in Illustration 59.

8. Measure the height of the right GPS Receiver above the center of the mounting bolts for the cutting edge.

   1. Remove the measure up tool from the left hand mast.

   2. Reinstall the left hand GPS Receiver onto the left hand mast.

   3. Remove the right hand GPS Receiver from the right hand mast.

   4. Install the Measure Up Tool onto the right hand mast.
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   Illustration 68	g01113821

   5. Rotate the measure up tool so that the tool is perpendicular to the blade. With the measure up tool in this position, you can measure the vertical distance to the bolts on the cutting edge.

      Refer to Illustration 69.

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   Illustration 69	g01113836

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   Illustration 70	g01113830

   6. With the help of a carpenters level, anchor the measuring tape onto the measure up tool and measure the distance to the middle of the bolts on the cutting edge.

      Ensure that the carpenters level is level and the tape measure is plumb before taking the measurement.

      If the measure-up tool is not level, measure the difference and add or subtract the difference to the height.

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   Illustration 71	g01121254

   7. Note this measurement on the table that is provided at the end of this manual.

9. Measure the GPS Receiver back from center of cutting edge bolts.

   1. The measure up tool will remain perpendicular to the cutting edge of the blade.

   2. Secure a plumb bob line from one of the centered notches in the measure up tool so that the plumb bob line hangs in front of the mounting bolts for the cutting edge.

      Note: Remember the distance of the notch on the measure up tool. This distance is used in Step 6.d.

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   Illustration 72	g01114091

   3. Measure the distance from the plumb bob line to the center of the bolts for the cutting edge.

   4. In order to calculate the "Antenna back from the cutting edge bolts" distance, subtract the value that was measured in Step 9.c from the distance that is shown on the measure up tool notch.

      Note: This number is a negative value if the center of the GPS antenna is in front of the center of the mounting bolts for the cutting edge.

   5. Note this measurement on the table that is provided at the end of this manual.

10. Measure the GPS Receiver to blade offsets.

    1. Rotate the measure up tool so that the measure up tool is parallel to the cutting edge of the blade. The measure up tool should extend beyond the end of the blade.
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    Illustration 73	g01113970

    2. Secure a plumb bob line from one of the centered notches in the measure up tool. The plumb bob line should hang to the ground.

       Note: Remember the distance of the notch on the measure up tool. This distance is used in Step 10.d.

    3. Measure the distance from the tip of the blade to the plumb bob line. A square and straight edges may need to be used in order to extrapolate the widest point of the blade to near the plumb bob, so the measurement can be taken parallel with the cutting edge.

    4. In order to calculate the "Antenna in from the blade tip" distance, subtract the value that was measured in Step 10.c from the distance that is shown on the measure up tool notch.

       Note: If the center of the mast is outside the blade tip, this number is a negative value.

    5. Note this measurement on the table that is provided at the end of this manual.

       This is the horizontal distance, in line with the face of the blade, from the left blade tip to the center of the GPS antenna. Refer to "F" in Illustration 59.

    6. Reinstall the right hand GPS Receiver onto the right hand mast.

11. Measure the blade height.
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    Illustration 74	g01114106

    1. Measure the distance from the center of the mounting bolts for cutting edge to the top of the blade.

       Refer to "G" in Illustration 59.

    2. Note this measurement on the table that is provided at the end of this manual.

       Note: The blade height measurement is used only to display the relative height of the blade when the "Cross-section View" is selected. Unlike the other measurements, the exact height of the blade is not critical to AccuGrade System operation.

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Illustration 75	g01114126

12. Measure the blade width between tips.

    Refer to "H" in Illustration 59.

    1. Note this measurement on the table that is provided at the end of this manual.

       The AccuGrade System uses the measurements from the "Blade width between tips" field and the "Antenna in from blade tip" field for verification of the system during start-up.

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Illustration 76	g01114709
(I) Horizontal distance (J) Vertical Distance (K) Height (L) Angle

13. Measure the horizontal distance of the cutting edge.

    You must enter the dimensions for the cutting edge in order to ensure that guidance is given to the cutting edge of the blade. The AccuGrade System calculates the amount of the height value for the cutting edge in the "Blade Wear" dialog that affects the horizontal and vertical components.

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    Illustration 77	g01114148

    1. Position the level in the vertical position. Rest the vertical edge of the level on the ground. Position the level against the bottom of the cutting edge. Make sure that the level is held in the vertical position.

    2. Measure the horizontal distance from the center of the mounting bolts for the cutting edge to the carpenters level.

       Refer to "I" in Illustration 76.

    3. Note this measurement on the table that is provided at the end of this manual.

14. Measure the vertical distance to the cutting edge.

    1. Rest the level on the center of the mounting bolts for the cutting edge. Make sure that the level is held in the horizontal position.
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    Illustration 78	g01114157

    2. Measure the vertical distance from the bottom edge of the carpenters level to the tip of the cutting edge.

       Refer to "J" in Illustration 76.

    3. Note this measurement on the table that is provided at the end of this manual.

15. Measuring the ripper distance

    1. Lower the rippers to the ground.

    2. Measure the horizontal distance from the cutting edge bolts to the ripper teeth.

    3. Note this measurement on the table that is provided at the end of this manual.

       Note: Always enter a distance into the "Ripper Distance" field. If the dozer does not have a ripper, then enter the distance to the back of the machine. This distance is used in order to calculate the ripper coverage position and the "Avoidance Zone" warnings.

Entering The Machine Dimensions Into The Display

Use the "Setup Menu-Installation" dialog to enter machine settings into the AccuGrade - Grade Control System.

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Illustration 79	g01256135

1. To view all options in the "Setup Menu" dialog you must start the AccuGrade - Grade Control System in "Service" mode.

   Note: Hold the "OK" button and the "ENTER" simultaneously while you turn on the Display (1) in order to start the AccuGrade - Grade Control System in "Service" mode.

   Note: Keep a copy of all machine settings because you may need to enter them again. To record the settings on each machine, use the machine record sheets provided in this section.

   Note: You must set the measurement parameters before using the system.

2. Press the Menu key until the "Setup" Menu key is shown on the Display.

   This will display the "Setup Menu".

   Refer to Illustration 80.

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Illustration 80	g01212608

3. Press the "Installation" key to access the "Installation" menu.

   Use the arrow keys to select the "Machine Dimensions" option.

4. Press the "OK" key.

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Illustration 81	g01212610

5. Select the "Mast Measurements" option with the up arrow or down arrow keys.

6. Press the "OK" key.
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   Illustration 82	g01212627

   1. Use the arrow softkey in order to navigate through the menus screens and enter the data with the arrow keys.

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Illustration 83	g01256102

7. Enter the Left Antenna dimensions.

   1. Press the arrow keys in order to select "Measure-up tool" or "Top of lower housing" within the "Measure height to" option (M) .

      Note: Caterpillar recommends that you use the receiver measure up tool. If the measure up tool is not available, the height measurements should be made to the top of the lower housing on the GPS Receiver.

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NOTICE
Different offsets will be applied to the measured machine dimensions, depending on what option is selected in the "Measure height to" field. Selecting the wrong "Measure height to" option will introduce a vertical error of 73 mm (2.90 inch)

8. Press the up arrow soft key or the down arrow soft key in order to scroll through the measurements.
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   Illustration 84	g01256116

   1. Use the Mast measurements screen in order to enter the mast and blade measurement that were recorded previously.

   2. Press the arrow soft key to move to the next page.

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Illustration 85	g01256120

9. Press the "Finish" soft key to return the Machine Dimensions menu.

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Illustration 86	g01212663

10. Use the arrow keys to select the "Machine Dimensions" option and press the "OK" key.

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Illustration 87	g01256123

11. Use the arrow keys to enter the data and the next key to navigate between options.

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Illustration 88	g01256125

12. When all the information has been entered, press the "Ripper" soft key.

    Use the arrow keys to enter the data and the next key to navigate between options.

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Illustration 89	g01256127

13. When all the information has been entered, press the "Machine Body" soft key.

    Use the arrow keys to enter the data and the next key to navigate between options.

14. When all the information has been entered, press the "OK" key to save the data and exit.

Angle Sensor Calibration

The AccuGrade System uses the Angle Sensor in order to measure blade pitch. The Angle Sensor is also used in the valve calibration process.

The calibration process sets the current pitch reading to zero. The Angle Sensor is located on the back of the blade.

Note: Before you attempt to calibrate the Angle Sensor, make sure that you park the machine on a level surface. The machine must be in the "measure-up " position.

1. Start the Display in the "Service" mode.

2. Press the "Setup Menu" Soft Key.

   Press "Configuration" in order to list the items under the "Setup Menu - Configuration" dialog.

3. Select the Pitch Sensor Calibration.

   1. Press the up arrow or down arrow until "Sensor Calibration" is highlighted. Then select "Blade Pitch Sensor".

4. Press the up arrow or the down arrow until "Pitch Sensor Calibration" is highlighted.

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Illustration 90	g01114800

5. Press "Calibrate".

   The text "Calibrating. Please wait..." appears on the Display.

   The calibration process sets the "Current pitch" field to zero.

   A dialog appears when the calibration is complete.

6. Press "OK" in order to return to the "Setup Menu" dialog.

7. Press "ESC" in order to exit the "Setup Menu" dialog.

Setting The Light Bars

The AccuGrade System has three light bars:

• Two vertical light bars for cut/fill mode

• One horizontal light bar for left and right

Each light bar can be used in any position, but the light bar must be individually set for that position. You set only one light bar at a time.

In order to set the connections for the light bar, perform the following procedure:

1. Simultaneously press the "OK" key and the "Power" key on the Display in order to access the "Configuration" mode.

2. From the "Setup Menu - Configuration" dialog, press "Installation" in order to list the items under the "Setup Menu - Installation" dialog.

3. Press the up arrow key or the down arrow key until "Lightbar Connections" is highlighted.

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Illustration 91	g01120887

4. Press the "OK" key.

   The "Lightbar Connections" dialog will be shown on the Display.

5. Connect the light bar for the required position. Disconnect all the other light bars.

6. Press "SET" for the connected light bar. A pattern of Light Emitting Diodes (LEDs) is illuminated on the connected light bar. This should match the pattern that is shown in Illustration 91. If the light bar LEDs are illuminated at the wrong end, press "INVERT".

7. Disconnect the light bar.

8. Repeat Steps 5 through 7 in order to set the next two light bars.

9. Press the "OK" key in order to save the settings and return to the "Setup Menu - Installation" dialog.

10. Press "ESC" in order to exit the "Setup Menu - Installation".

    All changes take effect immediately.

11. When all the light bars are set, reconnect all of the light bars.

Note: If the light bars are removed from the machine, each light bar must be reinstalled in the same position. Otherwise, the Light bar Connections will need to be rerun.

Radio Configuration

The RadioLink utility allows you to change the network number or the frequency channel on Data Radios. The RadioLink utility runs on the Display.

To open the Machine Radio Configuration dialog, complete the following steps:

1. Start the Display in Service Mode.

2. Select the "Installation" soft key from the "Setup" menu.

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Illustration 92	g01244461

3. Press the up arrow or the down arrow until "Launch RadioLink" is highlighted.

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Illustration 93	g01020701

4. Press the "OK" key. The utility automatically attempts to connect to the radio.

   A dialog similar to the dialog in Illustration 93 appears.

5. For TC900C Radios, use the arrow keys to select the same network (1-40) as the base station.

6. For TC450C Radios, use the arrow keys to select the same freguency as the base station.

Configuring The GPS Receiver

In order for the AccuGrade System to work properly, perform the following steps in order to send a GPS Receiver Configuration to the GPS receivers.

Note: This is not the preferred method in order to configure the GPS receiver. Caterpillar recommends that you place the appropriate configuration file in each design folder. The system automatically sends the .cfg file when the design is loaded. This option allows you to configure the GPS receiver when no design is loaded.

Note: The GPS receiver configuration file should be provided by the group that set-up the base station on the site or the group that is doing the design work.

1. Insert a data card with a GPS receiver configuration file in the root folder into the Display.

2. Simultaneously press the "OK" key and the "Power" key in order to power up the Display in the "Configuration" mode.

3. From the "Setup Menu – Configuration" dialog, press the down arrow key or the up arrow key until "GPS Receiver Configuration" is highlighted.

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Illustration 94	g01024802

4. Press the "OK" key. The "GPS Receiver Configuration" dialog appears. This is shown in illustration 94.

   All GPS receiver configuration files in the root folder of the data card are listed on the Display.

5. Press the down arrow key or the up arrow key in order to select the correct .cfg file.

6. Press the "OK" key. The AccuGrade System sends the .cfg file to the system and also provides status information. The following text shows on the dialog in illustration 94.
   • "Loading. Please wait ..."

   You then return to the "Setup Menu – Configuration" dialog.

   You must wait a few minutes while the GPS receiver gains lock.

   Make sure that you check the GPS configuration file was properly sent. In order to do this, position the left blade tip on a known point and compare the coordinates that appear on the Display with the known coordinates of the point.

Valve Calibration

The "Valve Calibration" dialog allows you to calibrate the hydraulic valves on the machine. The characteristics of the valve vary from each machine. The calibration ensures that the valves on your machine move correctly.

A valve calibration should be done when the hydraulic oil for the machine has reached normal operating temperature and the machine's engine is running at normal operating RPM.

Note: In order to perform a successful valve calibration, you must have the complete AccuGrade System installed. An operational GPS base station with high accuracy GPS data at the machine is recommended. The machine dimensions must be entered before performing a valve calibration.

Note: For machines equipped with electrohydraulic controls, you must first perform the machine's blade control lever calibrations and valve calibrations using Cat ET.

In order to perform a valve calibration, complete the following steps:

1. Start the Display in "Service" mode.

2. From the "Setup Menu - Installation" dialog, use the up arrow key or the down arrow key until "Valve Calibration" is highlighted.

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Illustration 95	g01114764

3. Press "OK".

   A dialog that is shown in Illustration 95 will appear.

   The default "Lift" is highlighted.

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Illustration 96	g01114797

4. Press "OK". The dialog that is shown in Illustration 96 appears.

   1. Park the machine on a level surface that has a clear view of the sky.

   2. Set the blade level and set the blade square to the machine.

   3. Begin to raise the blade and check that the "Current pitch" reading increases.

      If the reading does not increase, check that the Angle Sensor has been rotated correctly. Check the installation of the Angle Sensor.

      If an operational base station is used, proceed to step 9.

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Illustration 97	g01262907

5. Press "OK".

   Place a block beneath the blade and lower the blade to the bottom of the blade's range of lift. The "Current Pitch" reading decreases.

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Illustration 98	g01262908

6. Measure the distance from the left blade tip to a point on the ground that is perpendicular to the left blade tip. Mark this point for future measurements. Enter this measurement in the Blade Elevation dialog that is represented in Illustration 98.

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Illustration 99	g01262909

7. Press "OK". Raise the blade to near the maximum height. Measure the distance from the left blade tip to the same point on the ground. Enter this measurement in the Blade Elevation dialog that is represented in Illustration 99.

8. Press "OK".

   Proceed to Step 10.

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Illustration 100	g01114784

9. Raise the blade to the maximum height. Press "OK". The dialog that is shown in Illustration 100 appears.

   You are prompted to move the blade to the bottom of the blade's range of lift. The "Current pitch" reading decreases.

10. Press "OK".

    This information is used in order to calculate the angle that the blade has moved through a full range of lift with respect to the blade pivot point.

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Once the system is placed in automatic mode, blade movement may occur. Ensure that all personnel are clear of the blade before you place the system in automatic mode. Personal injury or death from crushing could occur.

11. A message appears warning you that the valve calibration will cause the blade to start moving. Press "OK" in order to continue the calibration.

    Press the "ESC" key in order to cancel the calibration.

    A message appears telling you to make sure the Auto/Manual remote switch is set to "Auto".

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Illustration 101	g01114787

12. Press "OK". The lift valve calibration will start.

    Note: Press the "Manual" button in order to stop the calibration procedure.

    A progress bar that shows the progress of the calibration appears. The lift valve calibration will take ten to twenty minutes in order to complete. The blade automatically moves up and down during the process.

    When the valve calibration is complete, a dialog appears. The dialog informs you that the lift calibration was successful.

13. Press "OK". The first "Valve Calibration" dialog reappears.

    You can now perform the valve calibration for tilt.

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Illustration 102	g01114764

14. Press the down arrow in order to select "Tilt".

15. Press "OK". The dialog that is shown in Illustration 103 appears.

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Illustration 103	g01114789

16. Unbolt the Angle Sensor. Rotate the Angle Sensor counterclockwise 90 degrees. Rebolt the Angle Sensor. This allows the Angle Sensor to measure blade tilt.

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Illustration 104	g01114765

17. Press "OK". The dialog that is shown in Illustration 104 appears.

18. Press "OK". The dialog that is shown in Illustration 105 appears.

    You are prompted to move the blade to the bottom of the blade's range of tilt. The "Current pitch" reading decreases.

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Illustration 105	g01114791

19. Press "OK".

    This information is used in order to calculate the angle the blade has moved through a full range of tilt with respect to the blade pivot point.

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Once the system is placed in automatic mode, blade movement may occur. Ensure that all personnel are clear of the blade before you place the system in automatic mode. Personal injury or death from crushing could occur.

20. A message appears warning you that the valve calibration will cause the blade to start moving. Press "OK" in order to continue the calibration.

    Press the "ESC" key in order to cancel the calibration.

    A message appears telling you to make sure the Auto/Manual remote switch is set to "Auto".

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Illustration 106	g01114792

21. Press "OK". The tilt valve calibration will start.

    Note: Press the "Manual" button in order to stop the calibration procedure.

    A progress bar that shows the progress of the calibration appears. The tilt valve calibration will take ten to twenty minutes to complete. The blade automatically tilts left and right during the process.

22. When the tilt valve calibration is complete, a dialog that is shown in Illustration 107 appears.

    This dialog prompts you to return the Angle Sensor back to the original position so that the Angle Sensor can be used to compute blade pitch.

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Illustration 107	g01114795

23. Press "OK".

    The first Valve Calibration dialog appears.

24. Press "ESC" in order to return to the "Setup Menu - Installation" dialog.

25. Press "ESC" in order to exit the "Setup Menu - Installation" dialog.

    The calibration takes effect immediately.

Pre - Delivery Checklist

Machine Dimension Checkout

In order to verify the machine dimensions, use either two known good points or use a GPS survey tool in order to compare the points.

1. Park the machine on a level surface that has a clear view of the sky.

2. Simultaneously press the "OK" key and the "Power" key in order to power up the Display in the "Configuration" mode.

3. Press the "Next" key until the second text window appears that shows Northing, Easting and Elevation.

4. Verify that the Display is set for "Blade: Left".

5. Use the GPS survey tool and go to the left hand guidance point.

   Compare the values from the GPS survey tool and the values that are shown on the Display. The values should be within a tenth.

   Note: The Display rounds off the values. The survey tool will carry out the values to more digits. If the values are not within a tenth, then proceed to ""Machine Dimension Troubleshooting" ".

6. Repeat steps 1 through 5 in order to verify the right hand side dimensions.

Function Checkout

1. Simultaneously press the "OK" key and the "Power" key in order to power up the Display in the "Configuration" mode.

2. Press the Down arrow until "Diagnostics" is highlighted.

   Note: "Diagnostics" is always the last item in the list.

3. Press the "OK" key.

   A screen appears showing all of the devices that are detected, except for the light bars and the radio.

4. Verify that all components are found and configured: MS980 left, MS980 right, AS400, A4M1, CD550A.

5. Create a level plan or select a design from the sites card. Refer to the Operation and Maintenance Manual, SEBU8002.

6. Place the system in Auto.

7. Increment and Decrement the blade using joystick.

   Verify that the blade moves up when incremented. Verify that the blade lowers when decremented.

8. Turn Park Brake On.

   Within 60 seconds after the park brake is activated, the system should start flashing the red "AUTO" symbol in the lower left hand corner of the screen.

9. If the machine checkout is OK, then proceed to ""Save Machine Settings" " otherwise proceed to ""Machine Dimension Troubleshooting" ".

Save Machine Settings

Note: This file should be stored in a safe place so that measure-up and setup will not need to be performed again in the event something happens to the Display.

1. Simultaneously press the "OK" key and the "Power" key in order to power up the Display in the "Configuration" mode.

2. Navigate to the "Setup-Menu".

3. Navigate to "Saving Settings".

4. Press the "OK" key.

5. Use the arrow keys in order to select "Machine Settings".

6. Press the "OK" key.

7. Use the arrow keys in order to name file, ie: the serial number of the machine.

8. Press the "OK" key.

9. Press and hold the Power key in order to power down the Display.

10. Remove the flash card from the Display. Load the flash card into a computer in order to save the file.

Machine Dimension Troubleshooting

1. Verify that both the Survey unit and machine are using the same GPS configuration.

2. Verify that the Survey unit is actually at the guidance point location.

3. Configure the text screen to have Northing, Easting, Elevation, Heading, and V GPS Error.

4. Identify which measurement is off:

   Move the machine so that the heading is at 0(North), 90(East), 180(South), or 270(West).

   In the example below, the machine heading is 0(North).

   • Northing - forward/backward measurement from cutting edge bolts

   • Easting - Distance in from blade tip

   • Elevation - Distance above cutting edge

   • Vertical and Horizontal Cutting edge measurements

Machine Dimensions Table

Use Table 8 in order to record the machine dimensions.

Table 8

Machine Dimensions Table
Installation Menu	Soft Key	Field	Setting/Value
Machine Dimensions	Left Antenna	"Measure height to"
		"MS980 height above bolts" (B)
		"Receiver back from cutting edge of bolts" (D)
		"Antenna in from blade tip " (F)
	Right Antenna	"Measure height to"
		"MS980 height above bolts " (A)
		"Receiver back from cutting edge of bolts " (C)
		"Antenna in from blade tip " (E)
	Blade	"Blade height " (G)
		"Blade width between tips " (H)
		"Cutting edge horizontal " (I)
		"Cutting edge vertical " (J)
	Ripper	"Ripper back from cutting edge"

Illustration 108	g01113705
(A) Top of lower housing height above the right cutting edge bolts (B) Top of lower housing height above the left cutting edge bolts (C) Distance GPS receiver back from the right cutting edge bolts (D) Distance GPS receiver back from the left cutting edge bolts (E) Distance GPS receiver in from the right blade tip (F) Distance GPS receiver in from the left blade tip (G) Blade height (H) Blade width

Illustration 109	g01114709
Machine measurements - Plan view (D) Horizontal distance from cutting edge bolts to front of the cutting edge (I) Horizontal distance from the cutting edge bolts back to the left GPS receive (F) Distance in from the left blade tip

Customer Supplied Radios

The AccuGrade System for GPS includes a radio that must be compatible with the local GPS base station radio. Caterpillar currently offers the TC900C and TC450C for the AccuGrade System. These radios require Trimble infrastructure radios for compatibility. For sites that are using non-Trimble infrastructure, Customer Supplied Radios may be connected to the AccuGrade System. However, the Customer Supplied Radio will need to be configured for use with the AccuGrade System. This document outlines the wiring issues that must be addressed in order to provide communication with the AccuGrade System. Caterpillar makes no claim to compatibility with all radios. Additionally, Caterpillar assumes no responsibility for the performance of the system integrating Customer Supplied Radios.

• 18-gauge wire is recommended for all lines. Avoid narrower gauge wire.

• Machine pinouts may vary, consult the Electrical Schematic for each machine to determine correct pinouts.

• These instructions do not address any unique power requirements that may apply to individual Customer Supplied Radios.

Power to a Customer Supplied Radio is provided through the AccuGrade harness at a nominal 24 VDC (15 amp max). Power may vary from 22 VDC to 28 VDC during radio operation. If regulated power is required by the Customer Supplied Radio, it is the responsibility of the customer to provide a power converter to the radio. Additionally, it is the responsibility of the customer to wire the power converter to the radio.

1. Locate the schematic for the connector for your Customer Supplied Radio.

   Refer to the owner's manual or the documentation from the manufacturer.

   1. Verify that 24 VDC nominal power is acceptable.

      Note: If there are any limitations on input power, find a suitable converter, this should be wired between the AccuGrade connection and the connection for the Customer Supplied Radio.

   2. Find the required power and communications pins on the radio.

      These pins may vary for each Customer Supplied Radio. The pins that are listed below are the minimum that are required:

      • + PWR

      • GRND

      • TX

      • RX

2. Locate electrical schematic for the AccuGrade System and the specific Caterpillar machine. Schematics are available at SISWeb.

   1. Find the 8-pin connector for the GPS radio.

   2. Trace back from the 8-pin connector to the 12-pin Deutsch connector.

      Note the pin number for the following connections:

      • + PWR

      • GRND

      • COM 2 TX

      • COM 2 RX

3. Wire the new cable.

   Use the pinouts that are noted in Steps 1 and 2.

Illustration 110	g01259989

Customer Supplied Radio Example

Field Conditions

• Existing AccuGrade compatible GPS base station

• Customer Supplied Radio at the GPS base station

Required

• Create a cable that connects a compatible Customer Supplied Radio to the AccuGrade System.

1. Can the Customer Supplied Radio communicate CMR data over RS-232.

   Yes - The Customer Supplied Radio is compatible with the AccuGrade System.

   No - The Customer Supplied Radio is not compatible with AccuGrade System.

2. Will the machine radio operate within 9 VDC to 32 VDC.

   Note: Verify all necessary connections can operate at machine voltages.

   Answer - By looking in the radio documentation found that radio can run on 9 VDC to 32 VDC, but in order for radio to function the DTR line needs to be tied high and it has a limitation of 25 VDC.

   Solution - Use a 240-2735 DC - DC power Converter to step the voltage down to 12 VDC.

3. Using the radio manufactures information, make all necessary connections.
   • Power

   • Ground

   • TXD

   • RXD

   • DTR

   Note: DTR is required by this example radio in order to make radio active.

4. Using the referenced pinouts for the machine harness, wire the following for the machine harness connector.
   • Power

   • Ground

   • COM2 TXD

   Note: For G-series TTT, COM2 TXD should be COM1 TXD

   • COM2 RXD

   Note: For G-series TTT, COM2 RXD should be COM1 RXD.

5. Configure the machine radio and AccuGrade System to communicate over RS232.

   ReferenceReference Systems Operation, RENR8083, "Radio Utility"

   1. Change the settings in the Customer Supplied Radio and the Display to match.

      Default Settings For The Display

      Baud rate ... 38400

      Data Bits ... 8 (Fixed setting on Display)

      Parity ... None

      Stop Bits ... 1 (Fixed setting on Display)

6. Verify that the over-the-air data/communications rate are set the same in both the base and machine radio.

   The optimal rate may vary depending on the radio. Typically the rate is between 4800 bps and 38400 bps. The same rate must be set in both the base radio and the machine radio. If the same rate is set, you may proceed. If the rates are not the same, use the radio configuration software to set both radios to the same over-the-air data/communications rate.

7. Connect the new adapter harness to the main harness and to the machine radio.

8. Apply power to the system and verify the communication to base.

   Use the Display in order to check the Left data link. Should be increasing for the integrity. If not see the Troubleshooting section.

Third Party Radio Information Checklist

Table 9

Obtain the manual from the radio manufacturer.
Verify that the radio communicates Compact Measurement Records (CMR)s over RS232. Verify that the settings can be changed to match the Display.
Review the power requirements for the radio. Review any special requirements. machine power may run to 28VDC
Validate the radio settings in order to communicate with base radio.	Radio channel
	Over-the-air data rate
Find pin out information for manufauturer's radio.
Find drawing or pin out for correct machine. Refer to ""Radio Pin-Out Tables and Schematics" " for additional information.
Create a simple schematic from the information that was collected in order to show which pin on the radio maps to the pin on machine connector.
Create the harness based from simple schematic.
Install harness on machine. Verify the power to the radio when system is turned on.
Verify that AccuGrade System is receiving CMR's from Base Station.

Troubleshooting

No Power To Radio

• Verify connections to power and ground pins

• Verify input power required for radio

• If converter has been added, ensure +PWR and Ground from AccuGrade connector are connected to converter, and that +PWR and Ground from converter are connected to radio

No Communication Through Radio

• Verify that the radio is a Data Terminal Equipment (DTE) device.

• If the radio is a Data Communications Equipment (DCE) device, modify the TX and the RX connections as shown in Illustration 111.

Illustration 111	g01260134

Note: It is critical to follow the documentation from radio manufacturer in order to ensure the proper handshake and/or other communications startup procedure is properly executed. Additionally, Customer Supplied Radios may require additional pins to be grounded or to be tied to voltage, and these will also be identified in the manufacturer's documentation.

Radio Pin-Out Tables and Schematics

D8T

Illustration 112	g01260209

Table 10

8-PIN Connector			12-PIN Deutsch Connector
Pin	Description	Wire Number	Pin
A	+ Battery	122	1
B	Ground	200	2
C	COM 2 TXD	N961	3
D	COM 2 RXD	N958	4

D9T

Illustration 113	g01260250

Table 11

8-PIN Connector			12-PIN Deutsch Connector
Pin	Description	Wire Number	Pin
A	+ Battery	122	1
B	Ground	200	2
C	COM 2 TXD	N961	3
D	COM 2 RXD	N958	4