Procedure to Install GRADE System Upgrade Components Supported by Software on Certain Next Gen Excavators {7220} Caterpillar

Excavator

320 (S/N: BR61-UP; ZBN1-UP; YBP1-UP; HEX1-UP)

323 (S/N: BR91-UP; DWF1-UP; YBL1-UP; RAZ1-UP)

330 (S/N: KEL1-UP; PFN1-UP; LHW1-UP)

336 (S/N: SP91-UP; JHD1-UP; TPK1-UP; FEL1-UP; YBN1-UP; DKS1-UP; GDY1-UP)

340 (S/N: TYH1-UP; WDN1-UP)

Introduction

This Special Instruction contains the procedure to install GRADE System upgrade components for the machines listed above. The following are the Grade System upgrade components supported by the machine software:

• Laser Catcher

• Tilt Bucket Sensor

• Heading Sensor

• Tiltrotator Sensor

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

Safety

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Do not operate or work on this product unless you have read and understood the instruction and warnings in the relevant Operation and Maintenance Manuals and relevant service literature. Failure to follow the instructions or heed the warnings could result in injury or death. Proper care is your responsibility.

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Failure to follow all safety guidelines prescribed in this document and by governing authorities and regulatory agencies may result in severe injury or death of personnel or machine damage.

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Personal injury or death can result from improper maintenance procedures. To avoid injury or death, follow the procedures exactly as stated below.

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Climbing equipment may be required to access this service point. Refer to the Operation and Maintenance Manual, "Mounting and Dismounting" topic for safety information.

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Before servicing/performing maintenance on the machine, electrical power must be physically disconnected; battery plugs must be disconnected from the batteries, or the trailing cable must be unplugged, and warning tags and padlocks shall be applied by a certified electrician. Certified electricians shall perform or direct any electrical work, including any energized testing, repair work in controllers, motors, or other approved compartments, and shall insure that all compartments are properly closed and inspected prior to re-energization. All applicable lock out and tag out procedures must be followed.

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Personal injury can result from flame cutting or welding on painted areas. The effect of gasses from burned paint is a hazard to the person doing the cutting or welding. Do not flame cut or weld on painted areas.

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Protect yourself and others; read and understand this warning. Fumes and gases can be dangerous to your health. Ultraviolet rays from the weld arc can injure eyes and burn skin. Electric shock can kill. Read and understand the manufacturer's instruction and your employer's safety practices. Keep your head out of the fumes. Use ventilation, exhaust at the arc, or both, to keep fumes and gases from your breathing zone and the general area. Wear correct eye, ear and body protection. Do not touch live electric parts. Refer to the American National Standard Z49.1, "Safety in Welding and Cutting" published by the American Welding Society, 2501 N.W. 7th Street, Miami, Florida 33125: OSHA Safety and Health Standards, 29 CFR 1910, available from U.S. Dept. of Labor, Washington D.C. 20210.

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

Illustration 1	g03840524

• Face the machine when you are mounting and dismounting.

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

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

• Never jump off the machine.

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

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

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

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

Machine Preparation

Follow the below procedure to prepare the machine for installation.

1. Park the machine on a hard level surface.

2. Apply parking brake.

3. Turn the engine key to the OFF position.

4. Isolate the electrical system by turning the battery disconnect switch to the OFF position.
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   Illustration 2	g00104545

5. Attach a "Do Not Operate" warning tag or a similar warning tag to the start switch or to the controls before you service the equipment. These warning tags are available from your Caterpillar dealer.

Required Parts

The required parts listed below are available from SITECH/Trimble.

Note: Caterpillar does not supply these required parts listed below.

Required Parts for Laser Catcher Upgrade

The SITECH/Trimble part number required for the installation of laser catcher are listed in tables below.

Required Parts for Tilt Bucket Sensor Upgrade

The SITECH/Trimble part number required for the installation of tilt bucket sensor are listed in tables below.

The minimum software version required to support Tilt Sensor configurations is Prod4.0. The software part numbers for prod4.0 are listed in Table 6.

Required Parts for Heading Sensor Upgrade

The SITECH/Trimble part number required for the installation of heading sensor are listed in tables below.

The minimum software version required to support Tilt Sensor configurations is Prod5.0. The software part numbers for Prod5.0 are listed in Table 6:

Laser Catcher Upgrade for GRADE System

The 320/323 Next Generation Excavators do not have a laser catcher option from the factory. A laser catcher can be ordered from SITECH.

Required Parts

Hardware Installation of LC450 Laser Catcher

Illustration 3	g06308411
Laser catcher

Laser catcher functionality is supported on 2D Basic, 2D Advanced, and 3D GRADE machine options although the parts are not supplied from the factory. Refer to Table 11 and 12 for the required SITECH./Trimble part numbers.

Illustration 4	g06308412
Laser catcher mounted on the machine (1) Laser catcher

The laser catcher is bolted to the mounting plate that is fixed to the two bosses and auxiliary hydraulic attachment block already supplied on the stick linkage of a 2D Basic, 2D Advanced, or 3D GRADE configuration. Follow the procedure below to install the laser catcher:

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Illustration 5	g06308450
Mounting the 151505-00 Mounting Plate (Trimble part number) (2) 151505-00 Mounting Plate (Trimble part number) (3) Washer (4) Bolt

1. Mount plate to the laser receiver plate to the two round bosses and the auxiliary hydraulic attachment block. Secure 151505-00 Mounting Plate (2) (Trimble part number) to the stick linkage using washer (3) and bolts (4) included in the kit.
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   Illustration 6	g06308452
   Mounting the 369-1562 Laser Receiver As (1) ( 1) Laser catcher (5) Washer (6) Bolt

2. Attach 369-1562 Laser Receiver As (1) to the plate using four washers (5) and four bolts (6) supplied. For typical installations, on the left side of the stick linkage where the mounting points are supplied, install the connector to face downward. Installing the connector to face downward makes the laser receiver window to be angled slightly forward making for better line-of-site to the rotating reference site laser.

3. Connect the laser receiver (LC450) using the 150408-002 Cable and 150416-020 Cable supplied (Trimble part number ). Connect the two cables together as one harness, alone would not be long enough to reach the indented mounting location from the connector to the stick linkage.
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   Illustration 7	g06308453
   Wiring diagram for 150408-002 Cable

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   Illustration 8	g06308454
   Wiring diagram for 150416-020 Cable

4. Connect the four-pin deutsch plug from 150416-020 Cable to the GT-C4 connector near the stick IMU sensor. Connect the four-pin deutsch plug from 150408-002 Cable to the 150416-020 Cable and then to the laser catcher. Use a splitter if a tilt GS520 sensor is used for a tilt bucket.
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   Table 13

   Connector Pinout 176-2946 Connector Plug As
   Pin	Wire	Function
   1	159	24V Power
   2	Y787	High CAN
   3	Y788	Low CAN
   4	235	Ground

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   Illustration 9	g06308456
   Laser catcher harness connected to machine expansion connector on the stick linkage

5. The harnessing can be secured under the mounting plate using the chain links attached to the stick linkage.
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   Table 14

   Connector Pinout 369-1562 Laser Receiver As
   Pin	Function
   A	+Battery
   B	Select A
   C	CAN High
   D	CAN Low
   E	Select B
   F	Ground

Configuration and Measurements for LC450 Laser Catcher

Follow the procedure below to configure the LC450 laser catcher:

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Illustration 10	g06308458

1. Navigate to the operating mode menu and configure the laser catcher to "Installed". When the laser catcher option is set to "Installed" in the operating mode menu, the laser catcher dimension option will appear beneath the laser catcher option. The dimensions for the laser catcher position can be configured in the laser catcher dimension option.
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   Illustration 11	g06309365

2. Select the "Laser Catcher Dimension" option to enter the dimensions of the laser catcher location on the stick linkage.
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   Illustration 12	g06308460

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   Illustration 13	g06308462

3. Enter the length B-L. Length B-L is the straight-line distance (parallel to the linkage centerline) from the joint between the stick linkage and boom linkage to the cross hairs on the laser catcher receiver window. Length B-L will only be a negative value if the laser receiver position is above the stick pin connection to the boom linkage when the stick is vertical. The laser receiver position above the stick linkage is not a standard laser receiver position and the supplied mounting bosses. Do not position the laser catcher in this area.
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   Illustration 14	g06308463

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   Illustration 15	g06308464

4. Enter the length L-M for the shortest distance between the cross hairs on the laser catcher receiver window to the line between the two end pins on the stick linkage. A string line can be used to allow easier reference of the line between the B and G pins on the stick linkage. Reference to Illustration for positive and negative directions.
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   Illustration 16	g06308465

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5. Enter the side by side offset by measuring the distance between the stick centerline and the bracket surface where the laser catcher rests. This dimension can be important while operating the system on a side slope, when accepting a laser strike from the rotating site laser.

6. The laser catcher is ready to function, once the laser catcher is connected and these dimensions are configured properly.

Tilt Bucket Sensor Upgrade for GRADE System

Required Parts

The SITECH/Trimble part number required for the installation of tilt bucket sensor are listed in tables below.

Hardware Installation of GS520 Inertial Measuring Unit (IMU) Tilt Bucket Sensor

The GRADE System on a 320/323 Next Generation Excavators can integrate with an attached GS520 Inertial Measuring Unit (IMU). This will provide guidance for tilting work tool in any of the three available GRADE configurations. The guidance for tilt buckets can be viewed in the machine monitor on 2D Basic configurations. In the 2D Advanced or 3D configuration of the GRADE System the guidance can be viewed using the TD520 GRADE display.

Illustration 18	g06308467
GS520 Inertial Measuring Unit (IMU) tilt sensor

The GS520 IMU tilt sensor is a six degree of freedom sensors with three sensed axes of rotation and three sensed directions of acceleration. The 160115-508 Kit GS520 IMU tilt sensor and the mounting kit are available separately. Refer to Table 20 and 21 for the required SITECH./Trimble part numbers.

Illustration 19	g06308475
955-2010 FRU – Sensor Module, GS520

• 955-2010 FRU – Sensor Module, GS520. GS520 is intended as the tilt sensing IMU for Next Generation 320Excavators.

Illustration 20	g06308469
150426-030 Hydraulic Hose Armor 3 m (9.8 ft) with 150425-40 Sensor Cable 4 m (13.1 ft) assembled.

• 150426-030 Hydraulic Hose Armor 3 m (9.8 ft)

• 150425-40 Sensor Cable 4 m (13.1 ft) with four-pin deutche to M12 connector

Illustration 21	g06308474
144020-30 Bracket GS5XX (Weld On)

• 144020-30 Bracket GS5XX (Weld On)

Illustration 22	g06308470
144030-30 Bracket - Cover GS5XX

• 144030-30 Bracket - Cover GS5XX

Follow the procedure below to install the tilt bucket sensor:

1. Mount the 144020-30 Bracket GS5XX to the tilting mechanism so that the GS520 IMU has the proper orientation to sense the tilting motion of the work tool.

   The GRADE System can support a variety of mounting orientations but it must be oriented so that one of the sensing acceleration axis and rotational axis is aligned with the rotational axis of the tilting mechanism. The first release of the GRADE System is limited to supporting mounting orientations when the bolting face of the GS520 IMU is vertical when the tilt axis is horizontal with the connector facing the left or right side of the tilt bucket.

   Prod 5.0 software supports all mounting orientations of the GS520 sensor provided one of the sensor faces is aligned with the rotation axis.

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   Illustration 23	g06308476
   Example mounting of the 955-2010 FRU – Sensor Module, GS520

2. 955-2010 FRU – Sensor Module mounted on the machine
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   Illustration 24	g06308477
   Wiring diagram for 150426-030 Hydraulic Hose Armor 3 m (9.8 ft)

3. Route the 150426-030 Hydraulic Hose Armor 3 m (9.8 ft) with 150425-40 Sensor Cable 4 m (13.1 ft) assembled from the sensor on the bucket to the connector on the stick linkage. The kit includes a variety of hardware to secure the cable. The cable assembly should be routed so that the tilting mechanism has full range of motion.
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   Table 17

   Connector Pinout 176-2946 Connector Plug As
   Pin	Wire	Function
   1	159	24V Power
   2	Y787	High CAN
   3	Y788	Low CAN
   4	235	Ground

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   Table 18

   GS520 IMU Sensor Connector Pinout
   Pin	Signal
   1	NC
   2	Power
   3	Ground
   4	CAN High
   5	CAN Low

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   Illustration 25	g06308456
   Tilt bucket sensor harness connected to machine expansion connector on the stick linkage

4. Connect the four-pin deutsch plug from 150425-40 Sensor Cable 4 m (13.1 ft) to the GT-C4 connector near the stick IMU sensor. A splitter may be used if a laser receiver is used in addition to the tilt bucket.

Configuration and Measurements for GS520 Tilt Bucket Sensor

The GRADE System must be configured prior to identify the GS520 IMU tilt sensor that is connected.

The minimum software version required to support tilt sensor configurations is Prod4.0. The software part numbers for prod4.0 are listed in Table 6.

Follow the below procedure to configure the tilt bucket sensor:

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Illustration 26	g06308479

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Illustration 27	g06308478

1. Navigate to "Apps > Setting > Machine Setting > Grade > Operating Mode > Tilt Bucket Sensor" and set the tilt bucket sensor option to "Installed". Read and acknowledge the warning.

   Note: The camera images will not be shown on the monitor in this mode. Be aware of the machines surroundings.

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   Illustration 28	g06308480

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   Illustration 29	g06308481

2. Navigate to "Apps > Bucket/Work Tool Setting" and select the work tool to configure with the GS520 IMU tilt sensor settings for guidance. The work tool must be selected as indicated by the round dot in the circle. The name and other settings may be changed to match the indented work tool.
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   Illustration 30	g06308482

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   Illustration 31	g06308483

3. To change the tool name, select "Tool #XX Name" and an interface for entering a new name will appear.
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   Illustration 32	g06308484

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   Illustration 33	g06308485

4. Using the touchscreen keyboard, enter the desired work tool name.

   Note: Cursor will not be available, use the backspace key to modify a name.

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   Illustration 34	g06308486

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   Illustration 35	g06308487

5. If the tool type shows "Bucket" instead of "Tilt Bucket", then the tool type must be changed in order for the GS520 IMU sensor to be configured to use with the work tool. The tool type can only be viewed in this screen. To change the tool type, the parameter must be modified by navigating "Tool #XX Program > Basic Settings" and entering the service password "9992".
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   Illustration 36	g06308488

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   Illustration 37	g06308489

6. The tool type can be changed to the desired "Tilt Bucket" setting in the basic setting menu of the tool program. The "Tilt Bucket" setting that supports the GS520 IMU sensor and hydraulic tilting function.

   Note: There may be other hydraulic settings that need to be configured for the hydraulic function of the tilting mechanism.

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   Illustration 38	g06308491

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   Illustration 39	g06308492

7. Once the desired work tool is selected as well as the desired tool name and tool type are configured, the "Bucket Measure-Up" option will guide the configuration of all dimensions and angles for a tilting work tool. The "Tool #XX Dimension" will list and allow editing of all the parameters resulting from the "Bucket Measure-Up" process but will not provide the guided interface.
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   Illustration 40	g06308493

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   Illustration 41	g06308494

8. Select "Bucket Measure-Up" to complete the guided process for entering work tool dimensions. When making changes in the Bucket Measure-Up, incorrect work tool selection, or dimensions will adversely affect the accuracy and function of the GRADE System and other guidance features. Read and acknowledge the warning. Read and acknowledged the safety setup conditions prior to proceeding.
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   Illustration 42	g06308495

9. Place the machine in an open area where the front linkage can be moved to various positions for recording dimensions and angles of the work tool. Ensure that the GS520 tilt bucket sensor is installed and connected to the bucket. The process will not fail at this stage if the GS520 tilt sensor is not recognized. This may be helpful to verify if there is any active diagnostic codes against the sensor.
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   Illustration 43	g06308496

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   Illustration 44	g06308498

10. Set the nominal position of the bucket. High accuracy with a level is not required. The sufficient position would be the bucket with the teeth directed back towards the cab and the bucket cutting edge relatively flat.
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    Illustration 45	g06308499

11. There may be cases where the standard bucket dimensions have already been entered for a tilting work tool and the GS520 IMU tilt sensor is now being added. If the standard non-tilting bucket dimensions have already been added and the GS520 IMU tilt sensor is being added, then use the "Skip" button to go directly to the GS520 IMU-related steps. In cases when no dimensions have been entered for this work tool, press the "OK" button to proceed with the entire work tool guided measure-up process.
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    Illustration 46	g06308538

12. Measure the distance between points G and H and enter the value in the screen.

    Note: The dimensions of any quick coupler or quick hitch are included the bucket dimensions. For machines with quick couplers, the bucket measurement to point G is measured to the pin between the stick linkage and quick coupler linkage. Similarly for machines with quick couplers, the bucket measurement to point H is to the pin between the power linkage and the quick coupler. The points where the bucket attaches to the quick coupler are ignored. Length G-H is a critical for accuracy and should be measured to the nearest 1.00 mm (0.039 inch).

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    Illustration 47	g06308542

13. Use the "Help" option to display an image of the point locations, if unfamiliar with the measurement points on the bucket option. The "Help" option can be selected by using the jog dial or tapping the touch screen. The "Help" option is available in all screens and can be selected to show an illustration or other context help that will assist in completing the instructions.
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    Illustration 48	g06308540

14. A measured dimension must be entered for each listed length. The length must be measured on the physical bucket and entered by tapping the value box to bring up the entry screen. Jog dial can also be used to select the value.
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    Illustration 49	g06308547

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    Illustration 50	g06308561

15. Measure and enter the distance from point G to point J. Refer to Step 14 for instruction to enter the length dimension. Press "OK" to continue. Length G-J is critical for accuracy and should be measured to the nearest 1.00 mm (0.039 inch).
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    Illustration 51	g06308563

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    Illustration 52	g06308564

16. Measure and enter the distance from point G to point Q. Refer to Step 14 for instruction to enter the length dimension. Press "OK" to continue. Length G-Q does not require as high accuracy measurement as some of the dimensions.

    Note: Point Q is on the heel of the bucket. Point Q is not used for guidance but for the "E-Fence" features. Point Q can be selected based on the discretion of the user as the point that has the potential to be the highest point of the machine in certain linkage positions.

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    Illustration 53	g06308565

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    Illustration 54	g06308569

17. Measure and enter the distance from point J to point Q. Refer to Step 14 for instruction to enter the length dimension. Press "OK" to continue. Length J-Q does not require as high accuracy measurement as some of the dimensions.

    Note: Point Q is located on the heel of the bucket. Point Q is not used for guidance but for the "E-Fence" features. Point Q can be selected based on the discretion of the user as the point that has the potential to be the highest point of the machine in certain linkage positions.

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    Illustration 55	g06308571

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    Illustration 56	g06308578

18. Measure and enter the width of the bucket. Refer to Step 14 for instruction to enter the length dimension. Press "OK" to continue. The width may impact the accuracy of the system when using the left or right focus point to determine position and elevation with a tilt bucket.

    The "Help" screen shows the width of the work tool. The width dimension is important for accuracy if the exact location of the left and right focus points on the bucket are utilized for cut/fill guidance or for registering points in a 3D design file.

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    Illustration 57	g06308586

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    Illustration 58	g06308591

19. Align point G vertical with point J. Suspend a plumb bob from point G and curl the bucket until point J, which is directly below point G. A long bubble level can also be used to align the bucket position, which will be advantageous in windy conditions. Once the bucket is positioned correctly, press the "OK" button to continue. Aligning point G to point J correctly is critical for accuracy.

    Note: If a quick coupler is used on the linkage, point G is the pin connection between the stick linkage and the quick coupler linkage. In such cases the plumb bob should be held from this point.

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    Illustration 59	g06308594

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    Illustration 60	g06308598

20. Measure and enter the length ST-K offset distance from the tilt sensor center point (point ST) to the tilt axis of rotation (point K). This measurement should be parallel to the bucket cutting edge. The tilt sensor center point (point ST) is indicated by an indent on the top face of the GS520 IMU tilt sensor. High accuracy measurement is not required and measurement within 5.00 mm (0.197 inch) is sufficient.
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    Illustration 61	g06308600

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    Illustration 62	g06308602

21. Measure and enter the length ST-MT perpendicular distance from the line between point G and point J. Point MT is the intersection of a horizontal line from point ST over to the vertical line between point G and point J. The tilt sensor center point (point ST) is indicated by an indent on the top face of the GS520 IMU tilt sensor. High accuracy measurement is not required and measurement within 5.00 mm (0.197 inch) is sufficient.
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    Illustration 63	g06308604

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    Illustration 64	g06308606

22. Measure and enter the vertical length J-MT. Length J-MT is the distance from the intersection point (point MG) of a horizontal line from the GS520 sensor center point and the vertical line between point G and point J to the bucket cutting edge (point J). The tilt sensor center point (point ST) is indicated by an indent on the top face of the GS520 IMU tilt sensor. High accuracy measurement is not required and measurement within 5.00 mm (0.197 inch) is sufficient.
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    Illustration 65	g06308610

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    Illustration 66	g06308611

23. Attach a magnetic bubble level to the floor of the bucket and curl the bucket or hang a plumb bob over the back of the bucket until the floor is vertical. Once the bucket is positioned correctly, press the "OK" button to continue.

    Note: Positioning the bucket with the floor vertical will capture the angle of the bucket for future wear compensation.

    Note: A plumb bob may be utilized to ensure that the bucket cutting edge/floor is vertical in this step instead of a bubble level.

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    Illustration 67	g06308613

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    Illustration 68	g06308616

24. Define an initial length of the bucket teeth or cutting edge. This dimension is utilized for the "Tooth Wear Compensation" feature. When measuring length J-J1, point J1 is located at the discretion of the user. Refer to Step 14 for instruction to enter the length dimension. Press "OK" to continue.

    Note: The user should select a measurement location that is not likely to be affected by bucket wear. For example, measuring the cutting edge to the tip of a tooth is not advised because the cutting edge can also wear over time.

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    Illustration 69	g06308905

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    Illustration 70	g06308907

25. Level the tilting axis using the bucket curl function. Once the bucket is positioned correctly, press the "OK" button to continue. Care should be taken when leveling the axis to calibrate the GS520 IMU tilt sensor accurately. The end of the tilting axis pin may provide a good surface for leveling the bucket axis. Select a parallel surface, if a surface other than the tilt axis is selected for leveling the tilt axis.
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    Illustration 71	g06308909

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    Illustration 72	g06308910

26. Level the bucket cutting edge using the tilt function. Once the bucket is positioned correctly, press the "OK" button to continue. Take care when leveling the cutting edge to calibrate the GS520 IMU tilt sensor accurately. A long level can be helpful in measuring across multiple bucket teeth or a longer cutting edge.
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    Illustration 73	g06308913

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    Illustration 74	g06308915

27. Measure and enter the distance between the tilting axis (point K) and the cutting edge. If the tilt axis is level, the vertical length J-K is the perpendicular/vertical distance between the tilt axis and point J on the bucket cutting edge. Refer to Step 14 for instruction to enter the length dimension. Vertical length J-K is a critical for accuracy and should be measured to the nearest 1.00 mm (0.039 inch).
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    Illustration 75	g06308916

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    Illustration 76	g06308917

28. Tilt the bucket to raise the left bucket focus point until the bucket tilt reaches the end of its stroke. Hold the thumbwheel to keep the bucket tilt function activated raising the left tip until the procedure continues.

    Note: The "Help" button illustrates the left bucket tip being raised by the tilt function.

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    Illustration 77	g06308919

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    Illustration 78	g06308920

29. If the bucket was positioned correctly, then press the "OK" button to complete the calibration. Press the "Back" button to exit the procedure.

30. The tilting axis will now show a tilting icon in the machine monitor. The cut/fill guidance value will be shown to the focus point of the bucket.

Heading Sensor Upgrade for GRADE System

The GRADE System on a 320/323 Next Generation Excavators can integrate with an attached HS410 heading sensor.

The HS410 heading sensor provides directional information for the 2D Basic, 2D Advanced, or 3D GRADE system. Directional information is useful when working with 2D Basic or 2D Advanced GRADE machine configuration on a jobsite that includes target slopes and rotating the machine to accomplish the grading tasks.

The heading sensor is a magnetic compass and accuracy can be influenced by large nearby iron objects moving in relation to the device. The heading sensor is installed on top of a mast that moves the sensing element from the iron of the machine and influences of the machine on the directional accuracy.

Note: The height of the heading sensor may cause problems with transportation.

The parts for installing the heading sensor are available from SITECH dealers. The harnesses and connection points are different depending on whether the machine is a 2D Basic or 2D Advanced/3D machine configuration.

Required Parts

The SITECH/Trimble part number required for the installation of heading sensor are listed in tables below.

Hardware Installation of HS410 Heading Sensor

Illustration 79	g06355202
807-4050 HS410 Heading Sensor device for both 2D Basic and 2D Advanced/3D configurations

Mount the heading sensor on the far back of the machine away from the front linkage as possible. Weld the base plate included with the sensor onto the counterweight.

Illustration 80	g06355203
Mounting location for HS410 heading sensor

• Place the mounting plate near the center rear edge of the counterweight. This will clear the access plate for the counterweight and provide more rigidity to the bracket mounting, although the plate may overhang the edge a small amount.

Note: The mounting location and hardware can be modified to accommodate specific applications or requirements as long as the impact on sensor accuracy and function are not disturbed.

Illustration 81	g06355207
150776-01 Harness, 150758-01 In-Line Terminating Resistor , 150408-002 Heading Sensor Add-on Harness for 2D Basic Next Gen Excavator configurations.

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Illustration 82	g06355208
C-C48 connector used as the connection point for 2D basic configurations

1. Connect the 150776-01 harness to the C-C48 connector on 2D Basic configured machines. This connector is on the right, outside of the cab under the boom pin.
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   Illustration 83	g06355209
   150408-002 Heading sensor add-on harness for 2D advanced/3D Next Gen Excavator configurations

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   Illustration 84	g06355210
   GP-C19 connector used as the connection point for 2D advanced/3D configurations

2. Connect the 150408-002 harness to the GP-C19 connector on 2D Advanced or 3D configured machines. This connector is installed near the base of the radiator in coiled loop.

Configuration and Measurements for HS410 Heading Sensor

The GRADE System must be configured prior to identify the HS410 heading sensor that is connected.

The minimum software version required to support heading sensor configuration is Prod5.0. The software part numbers for Prod5.0 are listed in Table 6:

Follow the below procedure to configure the heading sensor:

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Illustration 85	g06355325

1. Navigate to "Apps > Settings > Machine Settings > Grade > Operating Mode" through the machine monitor. Set the heading sensor option to "Installed".

   As long as the heading sensor is electronically connected, no abnormal update rate diagnostic code will appear in the active diagnostic screen.

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   Illustration 86	g06355327

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   Illustration 87	g06355362

2. The heading sensor once connected and set to installed, must be calibrated for its position on the machine. Navigate to the "Apps > Settings > Service > Calibrations" and select heading sensor, to start the heading sensor.

   The system identifies that the heading sensor is connected before providing the warning.

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   Illustration 88	g06355363

3. Read and acknowledge the warning related to completing this calibration on the machine.
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   Illustration 89	g06355365

4. Swing the upper chassis 180 degrees and press "OK" to proceed.
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   Illustration 90	g06355367

5. The system will record data at this position.
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   Illustration 91	g06355369

6. Rotate the upper chassis at a constant speed for multiple rotation until the monitor proceeds to the next step.
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   Illustration 92	g06355371

7. The monitor will proceed when sufficient data is collected.
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   Illustration 93	g06355373

8. Align the upper chassis with the track and undercarriage. The alignment can be with the machine facing forwards or backwards on the tracks.
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   Illustration 94	g06355375

9. Without using the swing function, rotate the machine to a heading angle of 0 degrees by tracking the machine.
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   Illustration 95	g06355377

10. When the machine comes to rest with a heading angle close enough to zero, the "OK" button will be enabled. Press the "OK" button to proceed.
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    Illustration 96	g06355380

11. Use the linkage to lift the tracks off the ground until the required pitch angle is met.
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    Illustration 97	g06355381

12. When the required pitch is met, the "OK" button will be enabled. Press the "OK" button to proceed.
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    Illustration 98	g06355385

13. When the calibration is successfully completed, the heading sensor is fully configured and ready to work.

Tiltrotator Sensor Upgrade for GRADE System

The GRADE System supports guidance to the worktool cutting edge on supported tiltrotators enabled with a GS520 tilt sensor and rotation/indexator sensor from the tiltrotator manufacturer.

The installation and configuration of GS520 tilt sensor for a tiltrotator is same as the GS520 tilt sensor. The GS520 tilt sensor available mounting locations may have some differences, as most tiltrotators include a quick coupler for removing work tools. Mounting positions are limited to locations between the quick coupler/rotation mechanism and the tilting mechanism.

The tiltrotator manufacturers have tiltrotators that can provide the messaging necessary to be used by the GRADE System to provide guidance to the worktool cutting edge. The manufactures that provide integrated sensing capability of the worktool rotation access over J1939 CAN messaging are listed below:

• Cat^® Tiltrotator

• RotoTilt

• Engcon

• Steelwrist

Prod4.0 is the minimum software required to support tiltrotator configurations. The software part numbers for Prod4.0 are listed in Table 6.

Hardware Installation of Tiltrotator Sensor

The tiltrotator hardware (both worktool attachment and rotation sensor) should be installed according to the manufactures instructions. The hardware installation instructions included in this document, are limited to the electrical connection requirements for obtaining the J1939 CAN messaging from the tiltrotator sensor to the necessary connection point on the GRADE System and installation of the GS520 tilt sensor hardware.

Tilt Rotator J1939 CAN Messaging Connection

The GRADE System has two different ways of connecting tiltrotator J1939 CAN messaging outputs to the GRADE System depending on the tiltrotator manufacturer and the Next Gen Excavator configuration.

Illustration 99	g06371277
Tilt rotator connector for Cat tiltrotator / RotoTilt J1939 CAN messaging over L854-YL(Yellow)/L855-GN(Green)J1939 CAN wires.

Illustration 100	g06371281
Location of the "C-C87" connector for Cat tiltrotator / RotoTilt tiltrotator connection to L854-YL(Yellow)/L855-GN(Green)J1939 CAN wires

For Cat tiltrotator and RotoTilt tiltrotators, the J1939 CAN messaging from the tiltrotator should be directed to the "C-C87" two-pin connector on the back wall of the cab in the battery compartment. "C-C87" connector is the second connector directly in front of the network manager. Refer to illustration100.

Illustration 101	g06371290
Tilt rotator connector for Engcon/Steelwrist J1939 CAN messaging over Y787-YL(Yellow)/Y788-GN(Green)CAN wires.

Illustration 102	g06371294
Location of the "GM-C2" connector for Engcon/Steelwrist tiltrotator connection to Y787-YL(Yellow)/Y788-GN(Green)J1939 CAN wires.

For Engcon and Steelwrist tiltrotators, the J1939 CAN messaging from the tiltrotator should be directed to the "GM-C2" eight-pin connector in the cab under the right side front paneling.

The following SITECH/Trimble parts can be used to connect an Engcon/Steelwrist tiltrotator J1939 CAN output to the "GM-C2" eight-pin connector on the machine.

Configuration and Measurements for Tiltrotator

The configuration and measurements are necessary in the GRADE System for functioning guidance. The configuration and measurements for a tiltrotator are similar to the configuration and measurements of a tilt bucket, with a few minor differences. The following are the tiltrotator specific instructions that are different from the tilt bucket configuration and measurement:

If a supported tiltrotator sensor J1939 CAN output is connected as described in the Section "Tilt Rotator J1939 CAN Messaging Connection", proceed with configuring the GRADE System. Follow the below procedure to configure the GRADE System:

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Illustration 103	g06371307

1. Navigate to "Menu > Settings > Machine Settings > Grade > Operating Mode". Set the tilt sensor and the tiltrotator sensor to "Installed".

   Note: Steps 2 through 3a will be available only for 2D Advanced or 3D GRADE configuration where the machine is equipped with an EC520 Controller. Skip these steps when installing Cat tiltrotator or RotoTilt on a 2D Basic GRADE configuration.

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   Illustration 104	g06371309

2. If the tiltrotator is being configured on a Next Gen 2D Advanced or 3D Excavator with an EC520 installed, log into the web interface. Navigate "Installation Assistant > Setup" and configure the attachment to include the tiltrotator model.
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   Illustration 105	g06371310

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   Illustration 106	g06371343

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   Illustration 107	g06371311

3. Square the rotation axis of the tiltrotator with the front linkage and zero the tiltrotator manufacturer sensor. Cat tiltrotator and RotoTilt tiltrotators are zeroed through a process from the manufacture, either with a specific sensor power cycle sequence or by entering a code in the controller. Through this process no offset is applied in the machine monitor or the web interface as shown in Illustration 105.

   Steelwrist and Engcon tiltrotators are not zeroed by the manufacturer and instead an offset is applied in the EC520 controller. To measure and save this offset, follow the procedure below:

   1. Square the work tool.

   2. Navigate to "Configure > Attachments" in the web interface.

   3. Open "Edit" interface. Refer to Illustration 106.

   4. Press the measure button in the popup interface. Refer to Illustration 107.
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   Illustration 108	g06371312

4. With the tiltrotator connected and configured, the GRADE System should no longer show a diagnostic code for the tiltrotator sensor.

5. Select a "Bucket/Work Tool Setting" and configure as a "Tiltrotator". If the selected work tool is not "Tool Type > Tiltrotator", then navigate to "Tool Programming > Basic Settings > Tool Type" and configure.

6. Proceed with the configuration of the worktool similar to tilt bucket, using the bucket measure-up process.
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   Illustration 109	g06371907

7. The additional step related to the tiltrotator is to enter the dimension to the rotation axis from the "G" pin with the rotation axis vertical. The "Help" interface will provide an image to aid in understanding the requested measurement.

8. Complete the remaining steps of the worktool configuration.

9. The GRADE system will now provide guidance to the cutting edge of the tiltrotator.

   To confirm functionality and communication of the tiltrotator sensor with a 2D Basic configuration, rotate the axis and verify that the Length "A-J" changes with the worktool rotation.

   To confirm functionality and communication of the tiltrotator sensor with a 2D Advanced or 3D configuration, rotate the axis and verify that the rotation of the image in the TD520 GRADE display matches the physical worktool.