Installation of G610 Hardware for Cat® Terrain v6.0 for Excavators {7490} Caterpillar

Excavator

All

Machine Control and Guidance Products

TERRAIN GRADING (S/N: TFE1-UP)

TERRAIN LOADING (S/N: TFL1-UP)

TERRAIN OFFICE (S/N: TER1-UP)

Introduction

This Special Instruction provides information for installing the following Cat^® Terrain v6.0 for grading and loading hardware components on the listed excavators:

• 389-0324 Terrain Installation Gp

• 389-0345 Electronics Gp

The installation requires welding, cutting holes, using electrical tools, and using mechanical tools.

The installation includes the following procedures:

• Receiver installation

• Angle sensor installations

• Pressure switch installation

• Machine radio installation

• Display module installation

• Battery backup installation

• Harness installations

• Optional alarm installation

• Calibration and measure-up procedures

After a technician has completed the first installation process, future installations will require less time to complete.

Operation and Maintenance Manual

The operation of Terrain for grading and loading on-board software is covered in the Operation and Maintenance Manual, M0078762, "Cat^® Terrain v6.0 for Grading and Loading". Refer to this manual for more information.

Open the 392-9004 USB Memory Module containing the Terrain operational files and documentation.

Print the Operation and Maintenance Manual of the desired language and secure the manual in the cab of the machine.

Safety Section

Work safely. Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools to perform these functions properly.

Safety precautions and warnings are provided in this instruction and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. Therefore, the warnings in this publication and the warnings that are on the product are not all inclusive.

When a tool, procedure, work method, or operating technique that Caterpillar does not recommend is used, ensure that you and others are safe during use. Also, ensure that the product will not be damaged or made unsafe by the operation, lubrication, maintenance, or repair procedures that are used.

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

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Electrocution Hazard! Keep the machine and attachments a safe distance from electrical power. Stay clear 3 m (10 ft) plus twice the line insulator length. Read and understand the instructions and warnings in the Operation and Maintenance Manual. Failure to follow the instructions and warnings will cause serious injury or death

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Machine swings. Stay back. Crushing hazard could cause serious injury or death.

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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 sudden machine movement. Sudden movement of the machine can cause injury to persons on or near the machine. Prevent possible injury by performing the procedure that follows before working on the machine. Move the machine to a smooth horizontal location. Move away from working machines and personnel and lower the implement to the ground. Permit only one operator on the machine. Keep all other personnel away from machine or in view of the operator. Engage the parking brake. Stop the engine. Move the hydraulic control levers to all positions to release the pressure in the hydraulic system.

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Personal injury or death can result from fumes, gases and ultraviolet rays from the weld arc. Welding can cause fumes, burn skin and produce ultraviolet rays. Keep your head out of the fumes. Use ventilation, exhaust at the arc, or both, to keep fumes and gases from your breathing area. Wear eye, ear and body protection before working. 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 cause death. Read and understand the manufacturer's instructions and your employer's safety practices. Do not touch live electrical parts. See "American National Standard Z49.1, Safety in Welding and Cutting" published by the American Welding Society. American Welding Society 2501 N.W. 7th Street Miami, Florida 33125 See "OSHA Safety and Health Standards, 29 CFR 1910", available from U.S. Department of Labor. U.S. Department of Labor Washington, D.C. 20210

Illustration 1	g00037860

Use steps and handholds whenever mounting the machine. Use steps and handholds whenever dismounting the machine. Before mounting the machine, clean the step and the handholds. Inspect the step and handholds. Make all necessary repairs.

Face the machine whenever mounting the machine and whenever dismounting the machine. Maintain a three-point contact with the step and with handholds.

Note: Three-point contact can be both feet and one hand. Three-point contact can also be a single foot and two hands.

Do not mount a moving machine. Do not dismount a moving machine. Never jump off the machine. Do not try to mount the machine when carrying tools or supplies. Do not try to dismount the machine when carrying tools or supplies. Use a hand line to pull equipment onto the platform. Do not use any controls as handholds when entering the cab or when exiting the cab.

General Preparation

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

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

1. Move the machine to a suitable location that is smooth, level, and out of direct sunlight.

2. Move away from other working machines and personnel.

3. Lower the bucket to the ground.

4. Stop the engine.

5. Engage the machine brake.

6. When possible, maintain ownership of the keys for the machine.

Required Tools

The tools that are listed in Table 1 are required to install the Terrain components for excavators. The list contains the recommended Caterpillar service tools. The list also contains tools for general use that do not have a specified part number.

Table 1

Part Number	Description
1U-7230	Hand Tool Group (Screwdrivers)
1U-9369	Measuring Tape
8T-9293	Torque Wrench (1/2 inch Drive)
9S-1748	Socket Wrench Set (1/2 Inch Drive)
9S-3263	Thread Lock Compound
194-3584	Socket Wrench Set (Torx screw)
199-6156	Socket Wrench Set (1/2 Inch Drive)
389-0331	Tool Group (Terrain Service Kit)
291-1414	CAES Tool Gp
Not specified	Drill Bit Set
Not specified	Hole Punch Set
Not specified	Fish Tape
Not specified	Cable Ties/Clips
Not specified	Tap Set

Required Parts

The 389-0345 Electronics Gp contains two receivers, a display module, and a USB memory module. The USB memory module contains files for the monitor operating software, system documentation, and a schematic diagram of the system.

Table 2

Contents of the 389-0345 Electronics Gp
Part Number	Part Name	Notes
450-6213	Satellite Receiver	MS992 Receiver (dual)
392-9004	USB Memory Module	Contains operational files and documentation
439-4341	Display Module	G610 display module with loaded operating system

The 389-0324 Terrain Installation Ar contains the items listed in Table 3 used during installation of the Terrain hardware. Tables 4 through 8 describe the contents of the kits.

Table 3

Contents of 389-0324 Terrain Installation Ar
QTY	Part Number	Part Name	Notes
1	167-8604	Monitor Mounting Gp	For G610 display module
2	291-5398	Receiver Mounting Gp	For receiver
1	333-2850	Sensor Wiring Gp
1	389-0332	Monitor Mounting Gp
1	389-0338	Machine Wiring Gp	Machine

Table 4

Contents of 167-8604 Monitor Mounting Gp
QTY	Part Number	Part Name	Notes
4	0S-0509	Bolt	3/8-16
1	147-3417	Mount	Ceiling or dash mount
4	3Y-7829	Boss	Weld, 3/8-16
4	5M-2894	Hard Washer
4	8X-7422	Boss	Weld, 3/8-16

Table 5

Contents of 291-5398 Receiver Mounting Gp (two kits)
QTY	Part Number	Part Name	Notes
4	5D-0353	Locking Bolt
4	6V-8801	Nut
4	8M-2770	Clip
4	8T-4121	Hard Washer
4	8T-4195	Bolt
8	8T-4896	Hard Washer
8	8T-5360	Hard Washer
8	8T-9380	Bolt
1	147-3449	Plate	Antenna
1	156-8045	Plate	CAES
1	289-9630	Plate	CAES

Table 6

Contents of 333-2850 Sensor Wiring Gp
QTY	Part Number	Part Name	Notes
1	292-0306	Sensor Wiring Gp	CAES
1	292-0308	Sensor Wiring Gp	CAES

Table 7

Contents of 389-0332 Monitor Mounting Gp
QTY	Part Number	Part Name	Notes
4	4M-5282	Bolt	1/4-20 Display module bracket to dash bracket
6	7K-1181	Cable Strap
8	8C-5607	Isolation Mount
4	8C-5608	Spacer
4	8T-4205	Hard Washer
4	8T-9364	Bolt	1/4-20
4	9X-6165	Washer	Display module bracket to dash bracket
2	130-5300	Clip
1	383-3032	Bracket

Table 8

Contents of 389-0338 Machine Wiring Gp (Terrain)
QTY	Part Number	Part Name	Notes
4	2L-8067	Terminal
4	2L-8071	Terminal
4	2L-8079	Terminal
2	3S-8665	Clip	Harness
3	5P-6264	Grommet
30	8M-2773	Clip
4	8T-0325	Bolt	M5 For battery
4	8T-0328	Hard Washer	For battery
1	167-8703	Wire As	Power supply
1	167-8984	Battery
1	265-8147	Harness	Fuse
1	278-7396	Wire As
1	285-6655	Harness As	Chassis
2	285-6657	Wiring Harness	Receiver jumper
2	292-1120	Mounting Block	For Battery
1	311-8690	Harness As	Receiver extension
	389-0333	Cable As	Ethernet
1	392-9004	Memory Module	USB Flash Drive
1	457-2067	Wiring Harness	Terrain Main Front
1	457-2068	Wiring Harness	Terrain Main Rear
1	462-1914	Wiring Harness	HEX crossover for second receiver
1	472-0145	Chassis Harness As	Use to extend the length of the 457-2068 Rear Harness As
1	514-0267	Plug As

Satellite Receiver Mast Parts

Use the parts in Table 9 to fabricate a mast for the receiver. These parts are not included in the 389-0320 Terrain Installation Ar.

Table 9

GPS Receiver Mast Parts (Not included in the 389-0345 Electronics Gp)
QTY	Part Number	Part Name	Description
1	8T-2647 (1)	Tube	Receiver mounting
4	147-3448 (1)	Gusset	Receiver mounting
		Angle Iron (2 in)	Harness protection

(1)	Refer to Special Instruction, REHS1729, "CAES Receiver Mast Fabrication"

Optional Parts

The optional items in Table 10 may also be required during the installation. These parts are not provided in the 389-0324 Terrain Installation Ar.

Table 10

Optional Parts Needed for Terrain Installation (Not included in the 389-0345 Electronics Gp)
Part Number	Part Name	Notes
3E-5239	Relay	Used for Reverse Auto-Calibration option
4C-4200	Paint	CAT Yellow
7K-1181	Cable Strap	Straps for securing harness
7T-1099	Link	Weld links for harness routing
141-5830	Silicone Sealant	RTV for grommets
167-8709	Alarm	Annunciator
205-4285	Electrical Converter	24V/12V converter for use with TC900B radios
285-6653	Radio Harness	Extension harness for radio or receiver

Audible Alarm

The display must have an audible alarm installed when a site uses Proximity Awareness (Detect). The alarm is optional for other sites.

Table 11 lists the parts contained in the alarm installation kit.

Table 11

435-4719 Alarm Gp Basic (Terrain)
Part Number	Part Name	Notes
441-8287	Harness As	Connects to audible alarm and 383-3027 Wiring Harness (main front)
444-5691	Alarm As	Audible CAN alarm

Hydraulic Pressure Sensor Group

The 375-6126 Pressure Sensor, also called a dig sensor, is sold separately or as part of the high accuracy dipper positioning system and replaces all previous dig sensors. The new sensors are more reliable and improve accuracy of both the dig count and the material identification.

The pressure sensors, which are included in the 527-8048 Pressure Sensor Gp, are used on hydraulic excavators that are running the G610 display module, a dual antenna positioning system, and have full body and linkage sensors.

Table 12

527-8048 Pressure Sensor Gp
Qty	Part Number	Description
25	3S-2093	Cable Strap
2	375-6126	Pressure Sensor
1	392-9004	Module (Memory, USB)
2	451-8738	Mounting Block
1	527-8045	Sensor Harness
1	527-8046	Sensor Harness
1	459-1754	Interface Module (CAN DATA LINK)
1	459-8166	Housing Bracket
1	459-8167	Cover
2	7X-2535	Bolt (Hex head, M6X1)
8	8T-4171	Bolt (Hex head, M6X1)
10	8T-4224	Hard Washer

System Overview

The primary Terrain dual antenna hardware components for excavators include two receivers, various sensors, and a display module.

Illustration 2	g03739576
Primary Cat® Terrain components for dual receiver machines (1) G610 display module (6) Satellite receiver (21) 243-4108 Sensor Harness As (one for each AS450/AS460 in kit) (29) Pitch and roll angle sensor (30) Boom angle sensor (31) Stick angle sensor (32) Bucket angle sensor

Note: GNSS receivers shown are MS992. MS975 receivers ship with the kit.

Illustration 3	g03863847
(5) Data radio (sold separately) (6) ( 7) Receiver (22) Pressure switches (29) Machine body pitch and roll sensor (30) Boom angle sensor (31) Stick angle sensor (32-A) Bucket angle sensor (32-B) Alternate location for bucket angle sensor

Illustration 2 shows the primary components and Illustration 3 shows the side view of an excavator listing the locations of the components.

Illustration 4	g06234675
Dual antenna Terrain hardware architecture

Illustration 4 shows the connections between the cables, harnesses, and the Terrain components that are described within this instruction.

Reference: For a complete wiring schematic of Terrain, refer to Schematic, UENR5471, "Terrain On-Board Electrical System" on SISweb and the Terrain G610 System Diagram in the "02 System Documentation\System Diagrams\v6.0" folder on the USB memory module.

Summary of Welding and Potential Welding by Sections

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NOTICE
Welding on the machine or jump starting the machine can damage the electronics in the display or the battery backup unit (BBU). To avoid damaging the electronics or BBU, disconnect the BBU from the power supply before welding or jump starting. If welding, reconnect the BBU to the power supply once welding is finished. If jump starting, reconnect the BBU to the power supply once the machine starts and the jumpers have been disconnected.

Table 13

Welding	Section
Yes	Receiver installation
Possible	Machine radio installation
Possible	Main rear harness assembly installation
Possible	Display module installation
Possible	Main front harness assembly installation
No	Optional buzzer installation
Yes	Battery backup installation
No	Power supply wiring and fuse installation

Installation Procedures

Installing the Receivers

Note: This installation procedure requires welding.

Note: Ensure that the harnesses are routed and restrained in a manner that does not create a trip hazard.

The terms receiver, GPS or GNSS receiver, satellite receiver, and positioning module are synonymous. This manual uses the terms receiver and satellite receiver.

Table 14

Installation Parts List for 450-6213 Satellite Receiver
QTY	Part #	Part Name	Notes
2			The site must build suitable masts for the receivers.
8	8T-4121	Hard Washer (Receiver)	M10 Washer for receiver
8	8T-4195	Bolt	M10 Bolt for receiver
16	8T-9380	Bolt	7/16-14 Bolts to attach masts to machine
16	8T-5360	Hard Washer	7/16-14 Washers to attach masts to machine
2	147-3449	Plate	Utilized to build masts for the receivers
2	156-8045	Plate	On machine base plate that must be welded to machine and is used to attach receiver masts to machine
2	285-6657	Wiring Harness	Receiver harness (jumper) (optional)
2	450-6213	Satellite Receiver	MS992 receiver
2	513-7972	Plate As	Adapter plate for MS975 receiver

To install the GNSS receivers, complete these steps:

1. Disconnect the battery backup unit (BBU) from the power supply before commencing any welding.

   Failure to follow this instruction may result in damage to the display or to the BBU.

2. Attach the 156-8045 Plate to the counterbalance that is on the machine.

   1. Park the machine on a level surface with the bucket on the ground.

   2. Check that the mounting plates are level in the front, back, left, and right. These checks ensure that the masts will be mounted vertically.

      Reference: Refer to Special Instruction, REHS1729, "CAES Receiver Mast Fabrication" for instructions that detail the construction of two 4 ft masts for the two receivers.

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      Illustration 5	g03453358
      156-8045 Plate mounted to machine with receiver mast mounted to plate

   3. Determine the mounting location on the machine for the plates.

      Consider the following requirements when choosing the location:

      • Position the plates as near to the sides of the counterbalance as possible.

      • Make sure that the receivers will not extend past the sides of the counterbalance. If the receivers extend too far, the receivers may get damaged.

      • Position the plates so that the receivers will avoid possible overhead obstructions.

      • Position the plates so that the receivers are high enough to receive clear signals from the satellites.

      • Do not position the plates so the receivers are so high the machine cannot enter a height-restricted area such as the shop.

      • Do not position the two receivers in the same line fore and aft (y axis).

      Note: There is no requirement to attach the plates to the highest point of the counterbalance.

3. Weld the plates securely to the counterbalance to minimize movement and vibration.

4. Attach the GNSS receivers to the 513-7972 Adapter plates. Use four 8T-4195 Bolts and four 8T-4121 Hard Washers for each plate.

5. Attach the receiver masts to the plates. Use the 8T-9380 Bolts (7/16-14) and the 8T-5360 Washers.
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   Illustration 6	g03453359
   Receivers mounted to masts

6. Attach a receiver to each of the masts. Use four 8T-4195 Bolts and four 8T-4121 Hard Washers.

   Mount the receivers to allow the operator easy visibility of the LEDs when outside of the cab. The location may be determined by site preference.

7. The 285-6657 Wiring Harness may be installed now. Refer to the section entitled "Installing the Terrain Harnesses" in this manual for detailed instructions.

Installing the Angle Sensors

Terrain uses an angle sensor to determine the pitch and the roll of the single antenna excavator, and the pitch of the dual antenna excavator. The system also uses three angle sensors to determine the tilt positions of the boom, stick, and bucket relative to the machine centerline.

Table 15

Position and Angle Sensors Parts List
Part Number	Part Name	Notes
4C-4198	Paint	Optional Caterpillar Medium Gloss Black: Used to paint welded areas
4C-4200	Paint	Optional Caterpillar High Gloss Yellow: Used to paint welded areas
333-2850	Sensor Wiring	Sensor installation group with mounting hardware

Terrain uses the following sensors:

AS450C - Used to measure the angle of the boom, stick, and bucket

AS460C - Used to measure the pitch of the machine body

Refer to Table 16 for the reference document for your application.

Table 16

Reference Document for Various Applications
Application	Reference
CAESultra v4.0 and later machine	Special Instruction, REHS4456, "Installation of the Pitch and Roll Angle Sensor for CAESultra"
Terrain v4.5 and later machine	Special Instruction, REHS7229, "Installation of the Pitch and Roll Angle Sensor for Cat® Terrain"
Programming the angle sensors	Systems Operation, UENR2509, "Cat® Terrain for Grading and Loading", "As-Built Surfaces"

The feedback from these four sensors provides the following:

• Accurate representation on the display module of the boom, stick, and bucket positions relative to the ground

• Precise bucket positioning for material recognition and As-Built Surface swathing

Illustration 7	g03453360
AS450 Angle Sensor

All the sensors have the same physical appearance as the sensor that is shown in Illustration 7. The only difference is that the 312-0755 Angle Sensor has a decal on the sensor that indicates the pitch and roll of the sensor.

The basic installation procedure for the sensors is as follows:

1. Park the machine on firm, level ground.

2. Disconnect the battery backup unit (BBU) from the power supply.

3. Determine the mounting location for the sensors.

4. Temporarily route the sensor harnesses to ensure that the harnesses can be connected at the proposed locations.

   Reference: Refer to the section entitled "Installing the Terrain Harnesses" in this manual for additional information.

5. Weld bosses to the machine for the intended locations of the sensors.

6. Mount the bracket assemblies to the weld bosses.

7. Connect the sensors to the harness assemblies.
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   Illustration 8	g01805993
   Cutaway view of a typical sensor (46) 8T-4171 Bolt (M6), 5P-4115 Hard Washer (47) 322-0222 Cover (48) 322-0221 Bracket (49) 312-0754 Angle Sensor (AS450C) or 312-0755 Angle Sensor (AS460C) (50) 5C-7261 Nut (M8) and 8T-4224 Hard Washer (51) 8T-4136 Bolt and 8T-4121 Hard Washer (52) 9R-2060 Boss

8. Install the 322-0222 Covers on the brackets.

Installing the Pitch Angle Sensor

Note: This procedure requires welding.

The 312-0755 Angle Sensor is used to measure the pitch of the machine. The sensor can also be used to measure roll for a single antenna excavator. For the dual antenna excavator, Terrain calculates roll using position from the antenna. Check the label on the sensor before installation.

Consider the following requirements when choosing the location for the sensor:

• Select a central, level mounting location that is square to the machine.

• Select a location that protects the sensor from damage.

• Orient the 322-0221 Bracket for the angle sensor so that the harness points towards the rear of the machine.

• Select a solid mounting location so that the only measurement is the machine body pitch and roll.

• Select a mounting location that is clear of the boom movement.

• Select a mounting location that the 521-3654 Sensor Harness can reach from the display module.

To install the pitch angle sensor, complete these steps:

1. Park the machine on firm, level ground.

2. Disconnect the battery backup unit (BBU) from the power supply before commencing any welding.

   Failure to follow this instruction may result in damage to the display or to the BBU.

3. Verify the label on the sensor.

4. Bolt the 9R-2060 Bosses to the 322-0221 Bracket by using 8T-4136 Bolts (M10) and 8T-4121 Hard Washers. Use the sensor bracket and bosses as a template to locate the welding points for the bosses.

5. Tack weld the bosses to the body.

6. Remove the 322-0221 Bracket and finish welding the bosses to the machine.

7. Once the welding has cooled, paint the bosses to prevent the bosses from rusting.

8. Once the paint has dried, bolt the 322-0221 Bracket to the machine using 8T-4136 Bolts (M10) and 8T-4121 Hard Washers.

9. Torque the bolts to 25 ± 6 N·m (18.4 ± 4.4 lb ft).
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   Illustration 9	g03453361
   Installed 312-0755 Angle Sensor for pitch and roll

10. Bolt the 312-0755 Angle Sensor to the 322-0221 Bracket using the 5C-7261 Nuts (M8) and the 8T-4224 Hard Washers.

11. Torque the nuts to 25 ± 6 N·m (18.4 ± 4.4 lb ft).

Installing the Boom Angle Sensor

Note: This procedure requires welding.

The 312-0754 Angle Sensor is used to measure the tilt of the boom.

To install the boom angle sensor, complete these steps:

1. Place the machine on firm, level ground.

2. Disconnect the battery backup unit (BBU) from the power supply before commencing any welding.

   Failure to follow this instruction may result in damage to the display or to the BBU.

3. Verify the label on the sensor.

4. Select a location on the boom for the 322-0221 Bracket.

   Consider the following requirements when choosing the location for the sensor before welding the bracket:

   • Ensure that the mounting bracket is parallel to the centerline of the boom. The boom may require a welded spacer so that the mounting bracket is parallel to the centerline of the boom.

   • Ensure that the face of the mounting bracket is vertical when the bracket is mounted.

   • Ensure that the mounting bracket is free from obstructions throughout the full boom movement.

   • Ensure that the cables can be attached to the angle sensor.

   • Ensure that the cables are protected from damage throughout the full boom movement.

5. Bolt the 9R-2060 Bosses to the 322-0221 Bracket. Use 8T-4136 Bolts (M10) and 8T-4121 Hard Washers. Use the sensor bracket and bosses as a template to locate the welding points for the bosses.

6. Position the 322-0221 Bracket adhering to the notes above from Step 4. The orientation of the sensor cable will be compensated for when the calibration procedure is performed.

7. Tack weld the bosses to the boom ensuring the following:

   • Never weld across the boom or the stick of the machine.

   • Always weld in a lengthwise direction.

   • Never weld within 75 mm (3 inch) of an existing weld.

8. Remove the 322-0221 Bracket and finish welding the bosses to the boom.

9. Once the welding has cooled, paint the bosses to prevent the bosses from rusting.

10. Once the paint has dried, bolt the 322-0221 Bracket to the machine using 8T-4136 Bolts (M10) and 8T-4121 Hard Washers.

11. Torque the bolts to 25 ± 6 N·m (18.4 ± 4.4 lb ft).
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    Illustration 10	g03453362
    312-0754 Angle Sensor installed on the boom

12. Bolt the 312-0754 Angle Sensor to the 322-0221 Bracket using the 5C-7261 Nuts (M8) and the 8T-4224 Hard Washers.

13. Torque the nuts to 25 ± 6 N·m (18.4 ± 4.4 lb ft).

Installing the Stick Angle Sensor

Note: This procedure requires welding.

The 312-0754 Angle Sensor is used to measure the tilt of the stick.

To install the stick angle sensor, complete these steps:

1. Place the machine on firm, level ground.

2. Disconnect the battery backup unit (BBU) from the power supply before commencing any welding.

   Failure to follow this instruction may result in damage to the display or to the BBU.

3. Verify the label on the sensor.

4. Select a location on the stick for the 322-0221 Bracket.

   Consider the following requirements when choosing the location for the sensor before welding the bracket:

   • Ensure that the mounting bracket is parallel to the centerline of the stick. The stick may require a welded spacer so that the mounting bracket is parallel to the centerline of the stick.

   • Ensure that the face of the mounting bracket is vertical when the bracket is mounted.

   • Ensure that the mounting bracket is free from any obstruction throughout the full stick movement.

   • Ensure that the cables can easily attach to the tilt sensor and that the cables are protected from damage throughout the full stick movement.

5. Bolt the 9R-2060 Bosses to the 322-0221 Bracket. Use 8T-4136 Bolts (M10) and 8T-4121 Hard Washers. Use the sensor bracket and bosses as a template to locate the boss welding points.

6. Position the 322-0221 Bracket adhering to the notes above from Step 4. The orientation of the sensor cable will be compensated for when the calibration procedure is performed.

7. Tack weld the bosses to the stick ensuring the following:

   • Never weld across the boom or the stick of the machine.

   • Always weld in a lengthwise direction.

   • Never weld within 75 mm (3 inch) of an existing weld.

8. Remove the 322-0221 Bracket and finish welding the bosses to the stick.

9. Once the welding has cooled, paint the bosses to prevent the bosses from rusting.

10. Once the paint has dried, bolt the 322-0221 Bracket to the machine using 8T-4136 Bolts (M10) and 8T-4121 Hard Washers.

11. Torque the bolts to 25 ± 6 N·m (18.4 ± 4.4 lb ft).
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    Illustration 11	g03453363
    The 312-0754 Angle Sensor installed on the stick

12. Bolt the 312-0754 Angle Sensor to the 322-0221 Bracket using the 5C-7261 Nuts (M8) and the 8T-4224 Hard Washers.

13. Torque the nuts to 25 ± 6 N·m (18.4 ± 4.4 lb ft).

Installing the Bucket Angle Sensor

Note: This procedure requires welding.

The 312-0754 Angle Sensor is used to measure the tilt of the bucket.

To install the bucket angle sensor, complete these steps:

1. Place the machine on firm, level ground.

2. Disconnect the battery backup unit (BBU) from the power supply before commencing any welding.

   Failure to follow this instruction may result in damage to the display or to the BBU.

3. Verify the label on the sensor.

4. Select a location on either the bucket or the bucket linkage for the 322-0221 Bracket. The bucket linkage is the linkage that is at the end of the bucket ram and the stick.

   Consider the following requirements when choosing the location for the sensor before welding the bracket:

   • Ensure that the face of the mounting bracket is vertical when the bracket is mounted.

   • Ensure that the bucket linkage or the bucket can move throughout the full movement without damage to the mounting bracket or the cables.

   • Mount the sensor on the bucket link with the connector towards the stick link pin.

   • Find a protected location on the back side of the bucket if the sensor is mounted on the bucket.

5. Bolt the 9R-2060 Bosses to the 322-0221 Bracket. Use 8T-4136 Bolts (M10) and 8T-4121 Hard Washers. Use the sensor bracket and bosses as a template to locate the boss welding points.

6. Position the 322-0221 Bracket adhering to the notes above from Step 4.

7. Tack weld the bosses to the bucket or to the bucket linkage ensuring the following:

   • Always weld in a lengthwise direction.

   • Never weld within 75 mm (3 inch) of an existing weld.

8. Remove the 322-0221 Bracket and finish welding the bosses to the boom.

9. Once the welding has cooled, paint the bosses to prevent the bosses from rusting.

10. Once the paint has dried, bolt the 322-0221 Bracket to the machine. Use 8T-4136 Bolts (M10) and 8T-4121 Hard Washers.

11. Torque the bolts to 25 ± 6 N·m (18.4 ± 4.4 lb ft).
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    Illustration 12	g03453364
    The 312-0754 Angle Sensor installed on the bucket

12. Bolt the 312-0754 Angle Sensor to the 322-0221 Bracket using the 5C-7261 Nuts (M8) and the 8T-4224 Hard Washers.

13. Torque the nuts to 25 ± 6 N·m (18.4 ± 4.4 lb ft).

Note: Provide extra protection for the angle sensor. Ensure that the device movement does not inhibit machine movement and that there is adequate movement for the cables around the linkages.

Installing the Pressure Sensor

The 375-6126 Pressure Sensor, also called a dig sensor, is sold separately or as part of the high accuracy dipper positioning system. The sensor replaced all previous dig sensors. The sensor is reliable and improves the accuracy of both the dig count and the material identification.

The pressure sensors, which are included in the 527-8048 Pressure Sensor Gp, are used on excavators that are running the G610 display module, a dual antenna positioning system, and have full body and linkage sensors. The pressure sensor triggers a signal when the hydraulic system is loaded to a predefined pressure, indicating that the machine is digging.

Note: The pressure sensors must be installed on the high-pressure side of the hydraulic circuit.

The pressure sensor is affected by the following:

• The hardness or softness of the material being dug: Softer material means that the system can be run at lower dig pressure.

• The size of the hydraulic working pressure of the excavator: Lower working pressure means that the system can be run at lower dig pressure.

The sensor is supported by a robust, semi-automated, on-board process that is completed from inside the cab with the machine powered on. The process allows the installer or operator to alter the pressure at which the software shows that the machine is digging, based on the environment in which the machine is working.

Note: Typically, the sensors do not require manual calibration.

Glossary of Terms

Table 17

Term	Description
Pressure Sensor	An electronic transducer installed in a hydraulic circuit to determine the pressure in the circuit.
States	Devices connected to the on-board software (sensors, ECM, receivers and so on) send information to the software about the status of the device. The status can be complex and is not limited to "ON" and "OFF". The information in these messages is called the "states".
"Dig" state	The state "Dig" is one of a set of descriptions for the Dig State, an option in the Digital window. The dig state value describes whether the machine is in a "Dig", "Idle", or "Dump" state. The Dig State is also used internally by the on-board software for certain features. A dig state is triggered when both hydraulic lines show high pressure.
"Deactuate" state	When the pressure in the sensor is below 15% of the pressure required (trigger point) for more than 300 ms, then the sensor sends out a "deactuate" state message.
Peak Pressure	Maximum pressure in the hydraulic line as recorded by the sensor in one cycle. Operators load the dipper in various ways, producing different peak pressures.
Trigger Point	The value (in bar) at which the dig point is determined, either by operator calibration or automatic calibration.
Debounce time	A value must meet or exceed the target value for this length of time to be considered in an ON or OFF state. Default = 300ms

System Operation

The 375-6126 Pressure Sensors are installed in both the stick and dipper hydraulic lines. The pressure sensors provide analog outputs to the 459-1754 CAN Interface Module. The module reads the sensor values and provides these values to the on-board software.

Illustration 13	g03772216
Dig states: Dig (green), Dump (blue), and Idle (yellow)

The on-board software uses trigger points and the pressure sensor output to determine the dig state of the bucket, shown in the Digital Window item Dig State (DS) as shown in Illustration 13.

The on-board software reads the pressure sensor channels and compares each value to the user-set or automatic set trigger points. If the trigger points are met, or exceeded, on both channels for a set time (Dig Debounce Durations), then the on-board software recognizes this combination as the "Dig" dig state. When one of the pressure values falls below its trigger point for the specified time, the software removes the "Dig" dig state .

For more information refer to "Dig Sensors for Stick and Dipper" in the MCU Help file.

Manuals

The Operation and Maintenance Manual, M0078762, "Cat^® Terrain for Grading and Loading" has been updated to describe the process to alter the pressure at which the software shows that the machine is digging.

The MCU Help file describes the following settings that are used in the install process:

Dig Debounce Durations

• Actuate Dipper

• Actuate Stick

• Deactuate Dipper

• Deactuate Stick

The settings apply to dual antenna excavators using the high accuracy dipper position system.

Note: To revert to using the previous dig sensor prior to v 5.2, enable the "Use Dig Switch" setting to enable use of the legacy dig switch.

Installing the Pressure Sensor Components

Illustration 14	g03762976
527-8048 Pressure Sensor Gp components (1) 459-1754 Interface Module As (CAN Data Link) (2) 459-8167 Cover (3) 8T-4171 Bolt (4) 8T-4224 Hard Washer (5) 3S-2093 Cable Strap (6) 392-9004 Module (Memory, USB) (7) 375-6126 Pressure Sensor (8) 7X-2535 Bolt (9) 451-8738 Mounting Block (10) 459-8166 Housing Bracket (11) 527-8046 Sensor Harness As (12) 527-8045 Sensor Harness As

The CAN interface module (1) interfaces to pressure sensors (7) that are installed on the head end of the hydraulic lines to read the following:

Stick - Reads "stick in"

Bucket - Reads "bucket curl"

Note: The bucket configuration for a hydraulic excavator is opposite that of the hydraulic front shovel.

The module mounts to a housing bracket (10) and is mounted on top of an existing inclination sensor bracket.

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NOTICE
Welding on the machine or jump starting the machine can damage the electronics in the display or the battery backup unit (BBU). To avoid damaging the electronics or BBU, disconnect the BBU from the power supply before welding or jump starting. If welding, reconnect the BBU to the power supply once welding is finished. If jump starting, reconnect the BBU to the power supply once the machine starts and the jumpers have been disconnected.

To install the system components of the 527-8048 Pressure Sensor Group, complete these steps:

1. Remove all stored energy in the machine.

2. Install the 459-8166 Mounting Bracket to the top of the pitch/roll sensor bracket.

   Refer to Illustration 14 and use the following hardware:

   • Two 451-8738 Mounting Blocks (9)

   • Four 8T-4171 Bolts (3)

   • Four 8T-4224 Hard Washers (4)

   If mounting the CAN Interface module to the Pitch/Roll sensor consider the following when choosing a location:

   • The sensor harness is installed in line with the existing inclination sensor harness.

   • Ensure that the chosen location allows you to reach both the hydraulic manifold and the inclination sensor harness.

   • Select a position where the body of the module will be protected from damage.
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   Illustration 15	g03708681
   CAN interface module (13) Mounting holes

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   Illustration 16	g03763017
   Mounting bracket and CAN interface module installed on top of pitch/roll sensor bracket.

3. Mount the 459-1754 CAN Interface Module to the mounting bracket through the mounting holes (13) using two 7X-2535 Bolts and two 8T-4224 Hard Washers.
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   Illustration 17	g03749606
   Installed pressure sensors (7)

4. Install the 375-6126 Pressure Sensors (7) into a two-circuit hydraulic manifold that connects to the head ends of the supply lines for the stick and bucket.

5. Install the 527-8045 Pressure Sensor Harness.
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   Illustration 18	g03762998
   527-8045 Pressure Sensor Harness (7) Pressure sensors (14) "S2" (15) "S3" (16) "P1"

   1. Insert the 4-pin plugs "S2" (14) and "S3" (15) of the 527-8045 Pressure Sensor Harness into the receptacles of the pressure sensors (7).

   2. Using the supplied parts from the attached plastic bag, wire receptacle "P1" (16) as follows:

      Ground - 205-BK(Black)

      Switched power - A116-YL(Yellow)

      Analog 1 - K472-OR(Orange)

      Analog 2 - K473-BR(Brown)

      Note: "P1" can be cut in the field to fit and then the connector can be installed.

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   Illustration 19	g03763016
   527-8046 Pressure Sensor Harness. (17) "P1" (18) "S3" (19) "S2" (20) "S4"

6. Install the 527-8046 Pressure Sensor Harness.

   1. Install the pressure sensor harness to the existing inclination sensor harness.

      Note: The pressure sensor harness uses receptacle "P1" (17) and plug "S2" (19) to tee into the inclination sensor harness at any existing connection in the harness.

   2. Connect plug "S3" (18) to the integrated 12-pin connector on the CAN interface module.

   3. Connect the 4-pin plug "S4" (20) to receptacle "P1" of the 527-8045 Pressure Sensor Harness that was wired in Step 5.a.
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   Illustration 20	g03761459
   Secured pressure sensor harnesses

7. Secure the harnesses properly using weld links and cable straps.

   Ensure the following:

   • Route and secure the harnesses so that the harnesses do not obstruct the service panels or cause a tripping hazard.

   • Protect the harnesses from mechanical damage.

   • Protect the harnesses when the harnesses pass over or through any sharp metal edges.

   • Avoid locations that are near a source of heat.

8. Refer to Illustration 14 and use the following hardware to attach the 459-8167 Cover (2) to the 459-8166 Mounting Bracket:

   • Four 8T-4171 Bolts (3)

   • Four 8T-4224 Hard Washers (4)

Configuring the Pressure Sensors

1. If your machine is using legacy dig switches (no longer available), then enable the "Machine" > "Switches" > "Use Dig Switch" setting.

   This setting overrides the presence of the "Dig Debounce Durations" settings and is required when using the "old" dig selection method. Complete this step either now or after calibrating the front linkage.

   Note: Complete this procedure either now or else after calibrating the front linkage.

2. Install the dig sensor hardware for a stick and a bucket hydraulic pressure sensor.

3. Obtain a v6.0 security key.

4. Open the MCU and enter the new security key and the following settings:

   • "Machine" > "Security"

   • "Machine" > "Sensors" > "Dig Debounce Durations" > "Actuate Dipper / Deactuate Dipper". Default = 300ms.

   • "Machine" > "Sensors" > "Dig Debounce Durations" > "Actuate Stick / Deactuate Stick". Default = 300ms.

   Refer to MCU Help, "Dig Debounce Durations (ms)" for detailed information about these settings.

5. Send the new mach_cfg.txt file to the G610 display module and restart the on-board software.

Automatic Trigger Points (Recommended)

To use automatic (default) trigger points, complete these steps:

1. Power up the machine after installing the new Terrain software, then start the on-board software on the G610 display module.

2. The default trigger pressure for the first dig is 75 bar. (1 bar is equivalent to 100 kPa (14.5 psi).)

3. The default pressure for the second dig is 50% of the maximum pressure for the first dig.

4. The default pressure for any consecutive dig is 50% of the maximum pressure for the previous dig.

Manually Setting the Trigger Points

Note: Using the manual process to set the trigger points requires the use of the 444-5691 Alarm As.

Menu - Opens the main menu

To manually set both trigger points simultaneously, complete these steps:

1. Power up the machine after installing the new Terrain software, then start the on-board software on the G610 display module.
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   Illustration 21	g03709514
   "Calibrate Dig Sensors" dialog

2. In the main menu, select "Ore Control" > "Calibrate Dig Sensors".

   This menu item has no toolbar button. The "Calibrate Dig Sensors" dialog appears.

3. Complete one dig cycle.

   When both sensors are next in the “actuate” state an audible signal sounds.

   Note: When both sensors are in the actuate state, the software assumes that the machine is digging.

4. Observe the relationship between the audible signal and dipper digging. Perform one normal dig within 15 seconds of starting recording.

   During this time the on-board software records data of pressure (in bar) for stick and bucket sensors in the DiagMsgLog file. The default for the first dig is 75 bar.

   Note: 1 bar is equivalent to 100 kPa (14.5 psi).

5. Complete a second dig cycle.

   The default for the second dig cycle is 50% of the maximum pressure of the first dig.

6. Use the "Calibrate Dig Sensors" dialog to increment the sensitivity of the sensor to digging. Refer to Illustration 21.

   The Increment (up arrow) and Decrement (down arrow) buttons used in this dialog increase and decrease the trigger point by 5 bar.

   • If the audible signal lasts longer than the time period the dipper appears to be digging, then decrease the dig sensitivity.

   • If the audible signal does not last as long as the time period the dipper appears to be digging, then increase the sensitivity.

7. Close the dialog box.

8. In the main menu deselect the "Ore Control" > "Calibrate Dig Sensor" option.

   The audible signal will not sound.

9. Select "OK".

   The on-board software stores the new values.

10. Set up the Dig State (DS) option in a Digital window.

11. Set up the Stick Pressure (StP) and Bucket Pressure (BuP) option in a Digital window.

    StP and BuP are the current values for the pressure of the stick and bucket sensors. The values update continuously.

Reverting to Automatic Trigger Points

To revert from manually set trigger points to automatic trigger points, in the main menu select "Ore Control" > Reset to Default Calibration.

When the pressure sensor value is 300ms (default), the pressure sensor value must be above the current trigger point for more than 300ms before the pressure sensor state changes from "deactuate" to "actuate". When the dig sensor values drop below the trigger point by more than 15% of peak pressure for more than 300ms (default), the pressure sensor state changes from "actuate" to "deactuate".

The software records peak pressure and trigger point values in the DML for each dipper load. The audible dig state sound is not affected by the "Machine" > "Alarms" or the "Detect" > "Alarms" settings in the MCU.

Operator Instructions: Setting the Trigger Point

Menu - Opens the main menu

To reset the trigger point at any time, complete these steps:

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Illustration 22	g03709514
"Calibrate Dig Sensors" dialog

1. In the main menu, select "Ore Control" > "Calibrate Dig Sensors".

   The "Calibrate Dig Sensors" dialog appears.

2. Complete one dig.

   When both sensors are digging, an audible signal sounds. The default pressure for the first dig is 75 bar.

   Note: 1 bar is equivalent to 100 kPa (14.5 psi).

3. Observe the relationship between audible signal and dipper digging.

4. Complete a second dig.

   The default pressure for the second dig is 50% of the maximum pressure of the first dig.

5. Use the "Calibrate Dig Sensors" dialog to increment the sensitivity of the sensor to digging. Refer to Illustration 22.

   The Increment (up arrow) and Decrement (down arrow) buttons used for this calibration increase and decrease the trigger point by 5 bar.

   • If the audible signal lasts longer than the time period the dipper appears to be digging, then decrease the dig sensitivity.

   • If the audible signal does not last as long as the time period the dipper appears to be digging, then increase the sensitivity.

6. Close the dialog box.

7. In the main menu deselect the "Ore Control" > "Calibrate Dig Sensor" option. The audible signal will not sound.

The on-board software records all dig cycles completed while the "Calibrate Dig Sensors" dialog is open as production dipper loads.

The audible dig state sound is not affected by the Mute Alarms settings.

Installing the Machine Radio

A machine radio is not supplied with Terrain. The customer must supply the machine radio. Use the 389-0333 Cable As to connect the third-party radio to the main front harness.

To install a machine radio, complete these steps:

1. If welding is required, disconnect the battery backup unit (BBU) from the power supply before commencing any welding.

   Failure to follow this instruction may result in damage to the display or to the BBU.

2. Determine the mounting procedure for the radio.

   Suggested mounting procedures include:

   • Utilize the existing light brackets (if equipped).

   • Weld bosses to the machine and use a radio mounting bracket.

   • Mount the radio inside the cab and mount an external antenna outside the cab.

3. Determine the mounting location on the machine for the radio.

   Consider the following requirements when choosing the location:

   • Mount the radio at least 3 ft from the satellite receiver or any other transmitting radio or antenna on the machine. This location maximizes reception of the radio.

   • Ensure that the radio antenna has 360 degrees of visibility.

4. Install the machine radio in the desired location.
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   Illustration 23	g03474679
   389-0333 Cable As (Radio) (A) "P2" to Ethernet of customer supplied radio for power (B) "P1" to main rear harness

5. Connect the standard RJ-45 Ethernet connector "P2" (A) to the customer-supplied radio.

   The connector can also be used to supply power to the radio. Refer to the section entitled "Using Power Over Ethernet" in this manual.

6. Connect the 12-pin (key D) connector "P1" (B) of the 389-0333 Cable As to the main rear harness.

Using Power Over Ethernet

Power over Ethernet (PoE) technology describes a system that safely passes both electrical power and data on the same Ethernet cable.

On the 383-3028 Rear Harness As, move the following two wires from Connector "P4" into Pin 1 and 2 of Connector "P3".

• Power: 1-BU(Blue)

• Ground: 2-BK(Black)

Note: The 514-0267 Plug As allows a third-party radio harness to connect into the POE circuit of the 389-0333 Cable As (Ethernet) connector P2.

Installing the Display Module

Note: Welding may be required during this installation.

Table 18

Parts List for Installation of Display
Part Number	Part Name	Notes
167-8604	Monitor Mounting Gp	Parts and brackets for mounting display to dash or to ceiling
389-0322	Terrain Installation Gp	U-bracket with mounting hardware
439-4341	Display Module	G610 display module with loaded operating system

To install the display module on the machine, complete these steps:

1. If welding is required, disconnect the battery backup unit (BBU) from the power supply before commencing any welding.

   Failure to follow this instruction may result in damage to the display or to the BBU.

2. Position the display within the cab of the machine.

   Consider the following requirements when choosing the location:

   • Place the display within 1.2 m (4 ft) of the eyes of the operator.

   • Choose a location that does not block the operator from seeing risk areas around the machine.

   • Locate the display near the plane that the operator normally views during operations that benefit most from the use of the Terrain system. Ideally, locate the display no more than 30 degrees from this viewing angle.

   • Locate the display where the operator can easily see both the work in progress and the information on the display.

   • Ensure that there is easy access to the touch screen from the normal sitting position of the operator

3. Verify that the location for the display does not result in any of the following:

   • Blocking the view of safety films within the cab

   • Preventing the operator from safely entering or exiting the cab

   • Preventing the operator from seeing the view from the mirrors or the direct view out of the cab

   • Causing discomfort to the resting position of the arms or legs

   • Impeding the use of any operator controls within the cab

   • Exposing the display to excessive glare from direct sunlight

   Note: The display is mounted on a u-shaped bracket that can be tilted approximately 20 degrees to minimize glare from direct sunlight.

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   Illustration 24	g03453368
   (1A) 383-3032 Bracket (1B) 147-3417 Mount (1C) Site fabricated display module mount pedestal

4. Determine the mounting procedure for the display. Sites can use the ceiling/dash adapter or can fabricate one of the following:

   • Custom adapter

   • Mounting pedestal using the bracket assembly as a template to mark the bolt pattern
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   Illustration 25	g01310403
   The exploded view of 150-1893 Vibration Isolator Mounting Group is shown. (1) 439-4341 Display Module (34) 389-3032 Bracket (35) 8T-4205 Hard Washer (36) 8T-9364 Bolt (1/4-20) (39) 8C-5607 Isolation Mount (40) 8C-5608 Spacer (41) 9X-6165 Washer (42) 4M-5282 Bolt (1/4-20)

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   Illustration 26	g01273003
   167-8604 Monitor Mounting Group (A) 147-3417 Mount (B) 0S-0509 Bolt (3/8-16) (C) 5M-2894 Hard Washer

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   Illustration 27	g03453369
   Isolation mounts installed to 389-3032 Bracket

5. Assemble the eight isolation mounts (39) and the four spacers (40) to the u-shaped 383-3032 Bracket using four washers (41) and four bolts (42).

   Refer to Illustration 25 for a detailed view of the shock mount detail when attaching the display module to the 383-3032 Bracket. Refer to Illustration 26 if using the ceiling/dash adapter.

6. Tighten the bolts to Caterpillar standard torque specifications.
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   Illustration 28	g03453370

7. Mount the display module.

   The display module in Illustration 28 is mounted in the front upper right corner of the cab using a site fabricated ceiling bracket.

   Depending on the machine and the location of the display module, the installation may require customizing by modifying the ceiling/dash adapter mount.

8. Remove the 126-1774 Connector Cover from the 70-pin connector of the main front harness.

   Note: The connector cover is removed because this cover limits the ability to adjust the angle of the display.

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   Illustration 29	g03455990
   G610 harness installation (2) G610 Display (2a) P1 (70-pin) of 383-3027 Harness As (2b) (not used) (2c) P3 of 383-3027 Harness As to USB port (2d) P2 of 383-3027 Harness As to power port

9. Install the main front harness connectors to the display (2).

   Reference: Refer to the section entitled "Installing the Main Front and Main Rear Harnesses" in this manual for the correct procedure in routing the main front harness.

   1. Connect the P1 70-pin connector (2a) to the display.

   2. Connect the gray P1 (key A) 12-pin connector (2c) to the USB port (middle).

      Note: The top 12-pin connector port (2b) is not used.

   3. Connect the black P2 (key B) 12-pin connector (2d) to the power port (bottom).
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   Illustration 30	g03453371
   383-3027 Wiring Harness installed on bracket (9) 383-3027 Wiring Harness (main front) (34) 389-3032 Bracket (46) 130-5300 Clips (47) Receptacle

10. Secure the connection for the service cable.

    The 389-0322 Monitor Mounting Group also contains a 130-5300 Clip. Referring to Illustration 30, use this clip to secure the service connection for the serial cable. Choose a location that is convenient to service personnel but does not obstruct the view of the operator. Choose the location that is best for the site.

Installing the Battery Backup

Note: This procedure may require welding.

Illustration 31	g03453372
Mounted 167-8984 Battery Gp (backup)

The battery backup supplies the on-board software with temporary power. Power is supplied for a short time in the event of an abrupt, unplanned loss of power to the machine.

The battery backup stores power for approximately 5 minutes. This delay provides enough time for the operator to shut down the on-board software safely.

To install the battery backup, complete these steps:

1. If welding is required, disconnect the battery backup unit (BBU) from the power supply.

   Failure to follow this instruction may result in damage to the display or to the BBU.

2. Consider the following requirements when choosing the location:

   • Do not place the battery backup in any location that prevents normal, safe functioning of the machine.

   • Provide sufficient area to coil the standard, unaltered length of the 383-3027 Harness As (main front) to prevent a trip hazard

   • Ensure that the power supply lead from the front main harness can reach the battery backup.

   • Choose an area that accommodates the overall dimensions of two 292-1120 Mounting Blocks while attached to the battery backup.

   • Ensure adequate accessibility to the battery.
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   Illustration 32	g01817855
   Exploded view of mounting for battery backup (3) 167-8984 Battery Gp (backup) (3C) 8T-0325 Bolts (M5) (3D) 8T-0328 Hard Washers (3E) 292-1120 Mounting Blocks

3. Bolt the two mounting blocks (3E) to the battery backup (3) using the bolts (3C) and the hard washers (3D).

4. Score and remove padding, lining, or insulation material. Remove enough material to allow room to weld the mounting blocks.

5. Use the mounting blocks as a template to locate the welding points for the blocks. Outline the outside edges of the mounting blocks.

6. Remove the mounting blocks from the battery backup.

7. Tack weld the mounting blocks in the marked locations.

8. Verify that the flange holes of the battery line up with the tapped holes in the mounting blocks.

9. Permanently weld the mounting blocks.

10. Once the welding has cooled, paint the bosses to prevent the bosses from rusting.

11. Once the paint has dried, bolt the battery backup to the machine using the bolts (3C) and the hard washers (3D).

12. Tighten the bolts to Caterpillar standard torque specifications.

If this installation is new and is using a TC900C/CR900 radio, then the installation is complete. If the harnesses and MS990 receiver are being updated using a currently installed TC900B radio, then continue with this installation.

If the machine has a currently installed TC900B radio, complete these steps:

Note: This procedure may require welding.

1. If welding is required, disconnect the battery backup unit (BBU) from the power supply.

   Failure to follow this instruction may result in damage to the display or to the BBU.

2. Locate a 205-4285 Power Converter (12V/24V Inverter) near the battery.

3. To ensure accurate placement of the converter, attach the two 5 mm bosses to the converter and tack weld the bosses in place.

4. Remove the converter from the bosses and finish welding the bosses to the machine.

5. Once the welding has cooled, paint the bosses to prevent the bosses from rusting.

6. Once the paint has dried, bolt the converter to the bosses.

7. Tighten the bolts to Caterpillar standard torque specifications.

Installing the Fuse Harness

Illustration 33	g03469418
265-8147 Harness As (fuse harness)

The 265-8147 Harness As is a three wire in-line connection that protects the Terrain hardware components. The fuse harness can be mounted on either side of the battery. The design of the connectors ensures a correct connection to the mating connector.

To install the fuse harness, complete these steps:

1. Choose a location for the harness on the machine that allows the fuses to be easily replaced.
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   Illustration 34	g03469217
   Fuse harness connected at location (B) between main front harness and battery backup (1) From power supply wire (Loc A) Connection between power supply wire and battery backup (2) Battery backup (3) 265-8147 Harness As (4) From main front harness (Loc B) Connection between main front harness and battery backup

2. Choose one of the following locations to install the fuse harness:

   Location A (Loc A) - Between the power supply wire (1) and the battery backup (2)

   Location B (Loc B) - Between the main front harness (4) and the battery backup (2)

3. Connect the fuse harness.

   1. Connect one end of the fuse harness to the mating connector of the desired location, either power (A) or main front harness (B).

   2. Connect the opposite end of the fuse harness to the mating connector on the battery backup.

Installing the Power Supply Wire and Fuses

The 167-8703 Wire As (power supply) is provided with the 389-0333 Machine Wiring Gp. The power supply wire connects to the 167-8984 Battery Gp (battery backup) and to the machine power supply. The power and the key switched power are connected through a 10 amp fuse.

To install the power supply wire and fuses, complete these steps:

1. Turn the key start switch to the OFF position.
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   Illustration 35	g01268941
   Electrical schematic for installing power harness and fuses

2. Referring to Illustration 35, route the 167-8703 Wire from the 167-8984 Battery to the Run relay.

   The two fuses that are shown can be supplied by utilizing the 265-8147 Harness As.

   Note: If the Run relay is not easily accessible, use the key start switch as a substitute connection point.

3. For the following steps, use a 2L-8067 Terminal, a 2L-8071 Terminal, or a 2L-8079 Terminal:

   These terminals are included in the 389-0333 Machine Wiring Gp.

   1. Connect the RD "+24 volt" wire to the supply side of the Run relay.

   2. Connect the PK "Switched +24 volt" wire to the switched side of the Run relay.

   3. Connect the BK "Ground" wire to a ground lug.

4. Confirm that there is a 10 amp fuse in each of the 265-8147 Fuse Holders.

Installing the Terrain Harnesses

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NOTICE
Harness installations may require welding. If welding is required, disconnect the battery backup unit (BBU) from the power supply. Failure to follow this instruction may result in damage to the display or to the BBU.

Consider the following points when installing the harnesses:

• Route and restrain harnesses in a manner that does not create a trip hazard.

• Do not extend either the serial cables or the CAN cables. If any cable is not of sufficient length, contact your Caterpillar Technical Communicator for detailed instructions as to how to proceed with the installation.

• Do not cut off any part of any harness unless instructed to do so. Bundle, tie wrap, and store any extra harness in a convenient place.

• The harnesses are marked with tape at the location of the last splice. If the harness is cut, do not cut the harness shorter than the tape. If the harness is cut shorter than the tape, then the spliced wires could be cut.

During the installations, refer to Illustration 4 in the "System Overview" section of this manual for a basic overview of the components and harnesses that are to be installed.

This section describes the installation of the harnesses listed in Table 19.

Table 19

Harnesses for Dual Receiver Installation
Part Number	Part Name	Notes
167-8703	Wire	System power
243-4108	Sensor Harness	3 ft
521-3655	Sensor Harness
521-3654	Sensor Harness
278-7396	Wire	Non-TC900B radio
285-6655	Chassis Harness	System, 75 ft
462-1914	Wiring Harness	HEX crossover harness for second receiver
285-6657	Wiring Harness	For MS992 receiver, 2 each
311-8690	Harness As	HEX extension harness
383-3027	Wiring Harness	Main front
383-3028	Wiring Harness	Main rear

Installing the Main Front and Main Rear Harnesses

Table 20

Part Number	Part Name	Notes
167-8984	Battery	Battery backup
285-6655	Harness As	System chassis
383-3027	Wiring Harness	Main front
383-3028	Wiring Harness	Main rear
439-4341	Display Module	G610 display module with loaded operating system

To install the main front and main rear harness, complete these steps while referring to Table 20:

1. The main front harness connects between the display module, power at the battery, and the main rear harness.

2. From the monitor, route the main front harness to the location of the battery and connect the 3-pin connector. The connectors on both the battery and the main front harness are matched.

3. Route the 12-pin connector on the main front harness to the location under the cab where the main rear harness is to be installed.

4. Connect the 12-pin connector on the main front harness to the 12-pin connector on the main rear harness.

5. The main rear harness connects between the main front harness, the radio harness, the battery (if required), and the chassis harness.

6. Locate the 12-pin connector on the main rear harness in a location that provides easy connection to the chassis harness. Choose a location that provides easy access for connecting the 285-6649 Harness As. This harness is used for performing the Terrain sensor and receiver calibration.
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   Illustration 36	g03453373
   Front harness securely clamped

7. Secure the main rear harness. Use 3S-8665 Clips, 8M-2773 Clips, or 7K-1181 Cable Straps.

Installing the Auxiliary Harness

The auxiliary harness, which is the 6-pin DT plug "P9" on the 383-3027 Wiring Harness, is used to connect the pressure switches and the various system sensors.

Table 21

Table for Wires for Auxiliary Harness
Wire Color	Signal	From P9 Pin	To
BU	SW +24	1	P3 pin 10
BU	DIG 6	2	P1 pin 68
YL	CAN2 HI	3	P3 pin 6
GN	CAN 2 LO	4	P3 pin 5
PU	DIG 5	5	P1 pin 67
BK	- BAT	6	P3 pin 12

The auxiliary harness connects to one of the following:

• 521-3654 Sensor Harness As for pitch sensor

• 381-8746 Sensor Harness As (part of the 420-5877 Pressure Switch Kit

• New harness that is part of the 451-8741 Pressure Sensor Gp

Connect the 6-pin DT receptacle of the 381-8746 Sensor Harness As (part of 420-5877 Pressure Switch Kit) to the 6-pin DT plug "P9" on the 383-3027 Front Harness As.

Installing the Chassis Harness and the Receiver Harnesses

Table 22

Part Number	Part Name	Notes
285-6655	Chassis Harness	System harness (75 ft)
462-1914	Wiring Harness	HEX crossover harness (second receiver)
285-6657	Wiring Harness	For MS992 receiver (2 each)
383-3028	Rear Harness As	Main rear
311-8690	Control Harness	HEX extension harness

Table 23

285-6657 Receiver Harness Installation Parts List
QTY	Part Number	Part Name	Notes
8	5D-0353	Locking Bolt	3/18-16 Bolts for clips to secure harness
8	6V-8801	Nut	3/18-16 nuts for clips
8	8M-2770	Clip	Used to clip harness down. The harness is connected between the main rear harness and the rear of the machine where the receivers are located. Also, use these instructions to connect the second receiver chassis harness and the two receiver harnesses.
16	8T-4896	Hard Washer	3/18-16 washers for clips

To install and connect the receiver chassis harness and the receiver harnesses, complete these steps while referring to Tables 21,22, and23.

Permanently mount the receiver harnesses in a safe position that protects the harnesses from mechanical damage.

1. Route the harnesses.

   Consider the following points when routing the harnesses:

   • Route the harnesses and secure the harnesses so that no service panels are obstructed.

   • Protect the harnesses when passing over or through any sharp metal edges.

   • Avoid locations that are near a source of heat.

2. Connect one receiver harness to the left receiver.

   Fasten the harness near the connector to reduce strain on the connector. Fasten the harness down the mast. Use the included clips, bolts, washers, and nuts.

   Note: Fasten the 12-pin connector in an area that is secure, yet still accessible.

   Note: Left and right are defined from behind the machine and looking forward toward the cab.

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   Illustration 37	g03453375
   Receiver harness routing down the mast of the receiver

3. Connect the second receiver harness to the right receiver. Fasten the harness near the connector to reduce the strain on the connector. Fasten the harness by routing the harness down the mast.

4. Connect the second receiver harness to the right receiver harness. Route this harness over to the left receiver.

   Note: On large machines, the 311-8690 Harness As (receiver extension) may be needed.

5. Connect the chassis harness to the 12-pin connector on the left receiver harness. Connect the 8-pin connector to the second receiver harness or to the control harness, if required.

6. Route the chassis harness from the rear of the machine to the location in the cab of the main rear harness. Any extra harness can be stored in the body of the machine near this harness.

7. Secure the harness with clips and cable ties.

8. Connect the chassis harness to the 12-pin connector of the main rear harness.

9. Create a coil for any excess harness. Use cable ties to secure the harness.

10. Check that all connectors are tight.

Installing the Sensor Harnesses

Table 24

QTY	Part Number	Part Name	Notes
4	102-8805	Receptacle Kit
1	134-2540	Receptacle	CAN terminator
4	243-4108	Sensor Harness As
1	276-4084	Harness As
2	521-3655	Sensor Harness	16 M, one bare end
2	521-3654	Sensor Harness	8 M, one bare end
3	312-0754	Angle Sensor	Boom, stick, bucket
1	312-0755	Angle Sensor	Pitch and roll

Table 25

Pin Number	Signal Name	Wire Reference 521-3655 Harness	Wire Color 243-4108 Harness
1 (1)	+ Battery	BR-105	RD
2	Spare	BU-A741	BU
3	CAN HI	GN-F711	GN
4	CAN LO	GY-F712	WH
5	Spare	PU-A742	BR
6 (1)	Ground	BK-229	BK

(1)	Use larger green-striped socket

Note: If a 389-0331 Tool Group (service kit) is available, utilize the 291-1502 Harness As with the 291-1386 Harness As (Hex Sensor) to program the 312-0754 Angle Sensor as boom, stick, and bucket sensors before mounting on the machine. If not done, then once the sensors are installed, each of the sensors will need to be disconnected and programmed one sensor at a time.

For information on programming the locations of the arm sensors, refer to the section entitled "Replacing a Sensor (if needed)" in this manual.

Reference: For information on the 389-0331 Tool Group (service kit), Special Instruction, REHS7225, "Cat^® Terrain Service Kit".

Use the following steps to connect the angle sensors from the main harness:

Table 24, Table 25, and Illustration 38.

Illustration 38	g03190877
Angle sensor wiring diagram (A) Harnesses with bare ends (B) Body pitch and roll sensor and harnesses on the body (C) Boom sensor and harnesses on the boom (D) Stick sensor and harnesses on the stick (E) Bucket sensor, harness, and CAN terminator on the bucket or nearby on the stick (23) 276-4084 Wiring Harness (system harness adapter) (24) 521-3654 Sensor Harness (HEX) (8 m) (one bare end) (25) 521-3655 Sensor Harness(HEX) (16 m) (one bare end) (26) 521-3655 Sensor Harness (HEX) (16 m) (one bare end (27) 521-3654 Sensor Harness (HEX) (8 m) (one bare end) (28) 243-4108 Sensor Harness (short) (29) 312-0755 Angle Sensor (AS460C pitch and roll) (30) 312-0754 Angle Sensor (AS450 boom) (31) 312-0754 Angle Sensor (AS450C stick) (32) 312-0754 Angle Sensor (AS450C bucket) (33) 134-2540 Receptacle

Consider the following points when routing the harnesses:

• Utilize the routing of the hydraulic lines to route the harnesses correctly. This action will ensure that enough harness is available throughout all machine movements.

• Make sure that the harness is protected from mechanical damage.

• Route the harness so that the harness does not prevent access to any service panels.

• If the harness passes over or through any sharp metal edges, protect the harness at those locations.

• Secure the harness. Use cable ties.

• Secure the harness near each connector to reduce strain on the connector.

• Avoid locations that are near a source of heat.

Due to the location of the Y splits on the angle sensor harnesses and the need to shorten and install ends on the harnesses, use the following sequence to install the harnesses:

• Bucket sensor to the stick sensor

• Stick sensor to the boom sensor

• Boom sensor to the body pitch and roll sensor

• Body pitch and roll sensor back to the main harness

Note: This sequence may be altered as required by the site or the specific installation.

1. Connect the short sensor harness to the bucket sensor.

2. Route the short sensor harness to an 8 m sensor harness. This harness will route toward the stick sensor. Use care to route the harness away from any potential pinch points. Secure the harness to the machine. Use tie straps.

   Note: The connection between the 8 m harness and the short harness may be either on the bucket or on the stick, as required.

3. Install the adapter harness and the CAN terminator on the other Y-end of the 8 m harness. Secure the harness to the machine.

4. Route and attach the 8 m harness over the machine linkage. The harness will route from the bucket sensor location back to the stick sensor. Follow the hose routing. Use as much of the machine as possible to protect the harness. Use the clips and the tie straps to secure the harness.

5. Connect another short sensor harness to the stick sensor and route the harness. Ensure that the 8 m harness from the bucket sensor and a 16 m harness that will route to the boom sensor can be connected.

6. Ensure that the 16 m harness can connect to the short harness to the stick sensor and the 8 m harness to the bucket sensor.

7. Cut the 8 m harness for the bucket sensor to an appropriate length at the bare end. Use a receptacle kit to attach a connector to the bare end of the harness.

8. Install a piece of 125-7876 Heat Shrink Tube over the end of the cut braiding. This action ensures that the braiding does not fray.

9. Attach the wires to the connector pins as specified in Table 25.

   Note: In the receptacle kit, use the pins with a green stripe for the red and black wires. Use the remaining pins for the remaining wires.

10. Connect the 8 m and 16 m harnesses together. Ensure that the short harness to the stick sensor is connected.

11. Route the 16 m sensor harness. Attach the harness over the machine linkage. Route the harness from the stick sensor location back to the boom sensor. Follow the hose routing and use as much of the machine as possible to protect the harness. Use the clips and the plastic straps to secure the harness.

12. Connect another short harness to the boom sensor. Route the harness to ensure that the 16 m harness from the stick sensor and a new 16 m harness that will route toward the body sensor can be connected.

13. Ensure that the 16 m harness that leads to the body can connect with both the short harness to the boom sensor and the 16 m harness that goes to the stick sensor and the bucket sensor.

14. Cut the 16 m harness for the stick sensor and the bucket sensor to an appropriate length at the bare end. Use a receptacle kit to attach a connector to the bare end of the harness.

15. Install a piece of 125-7876 Heat Shrink Tube over the end of the cut braiding to prevent the braiding from fraying.

16. Attach the wires to the connector pins as specified in Table 25.

    Note: In the receptacle kit, use the pins with a green stripe for the red and black wires. Use the remaining pins for the remaining wires.

17. Connect the two 16 m harnesses together. Ensure that the short harness to the boom sensor is connected.

18. Attach the 16 m sensor harness. Route the harness over the machine linkage from the boom sensor location to the body pitch and roll sensor. Follow the hose routing and use as much of the machine as possible to protect the harness. Use the clips and the plastic straps to secure the harness.

19. Connect another short harness to the body pitch and roll sensor. Ensure that the location of the harness allows the 16 m harness from the boom sensor and an 8 m harness that will route toward the system wiring harness can be connected.

20. Ensure that the 8 m harness that leads to the system wiring harness can connect with both the short harness to the body sensor and the 16 m harness that goes to the boom, stick, and bucket sensors.

21. Cut the 16 m harness for the boom, stick, and bucket sensors to an appropriate length at the bare end. Use a receptacle kit to attach a connector to the bare end of the harness.

22. Install a piece of 125-7876 Heat Shrink Tube over the end of the cut braiding to prevent the braiding from fraying.

23. Attach the wires to the connector pins as specified in Table 25.

    Note: In the receptacle kit, use the pins with a green stripe for the red and black wires. Use the remaining pins for the remaining wires.

24. Connect the 8 m harness and the 16 m harnesses together. Ensure that the short harness to the body sensor is connected.

25. Attach the 8 m sensor harness. Route the harness over the machine from the body sensor location back to the system wiring harness. Follow the hose routing and use as much of the machine as possible to protect the harness. Use the clips and the plastic straps to secure the harness.

26. At the system wiring harness, ensure that the 8 m harness that leads to the angle sensors is in a location that the 8 m harness can be cut to length and can be connected to the system wiring harness.

27. Cut the 8 m harness for the angle sensors to an appropriate length at the bare end. Use a receptacle kit to attach a connector to the bare end of the harness.

28. Install a piece of 125-7876 Heat Shrink Tube over the end of the cut braiding to prevent the braiding from fraying.

29. Attach the wires to the connector pins as specified in Table 25.

    Note: In the receptacle kit, use the pins with a green stripe for the red and black wires. Use the remaining pins for the remaining wires.

30. Connect the system wiring harness and the 8 m harnesses together.

31. Verify that all the connectors are tight and that all the harnesses are secured.

Installing the Optional Alarm

Menu - Opens the main menu

To install the optional alarm, complete these steps:

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Illustration 39	g03789844
Alarm components (50) 383-3027 Harness As (main front) connector "P11" (51) 411-8287 Harness As connector "S1" (52) CAN connector with terminating resistor (53) 444-5691 Alarm (54) 411-8287 Harness As (alarm) connector "P2" (55) Magnetic mounts (1 on all four corners)

1. Select a metallic location within the cab to mount the alarm.

   The location must provide ready access to connector "P11" (50) of the main front wiring harness.

2. Clean and smooth the area on which the magnetic mounts (55) of the alarm (53) will attach.

3. Attach the alarm to the clean surface.

4. Connect the alarm to the main front harness as follows:

   1. Connect the alarm harness connector "P2" (54) to the alarm.

   2. Connect the alarm harness connector "S1" (51) to the main front harness connector "P11" (50).

      Note: The CAN connector (52) comes pre-installed with a terminating resistor.

5. Verify the operation of the alarm using one of the following methods:

   Startup - Start the on-board software and listen for a short audible sound.

   Buzzer Test - Open the main menu and select "Diagnostics" > "Buzzer Test" and listen for a short audible sound.

   Notify the office if either of the following conditions exist:

   • The alarm is connected, but no audible sound is heard.

   • The alarm volume is either too loud or too quiet.

6. In the MCU, set up Machine > Alarms.

7. In the MCU, set up Detect > Alarms to allow the operator to mute, acknowledge, or filter audible alarms.

General Procedures

Performing the Initial Power Checks

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NOTICE
Prior to performing this test, ensure that the machine is not locked out/ tagged out. If so, then all voltages will read 0 V. Ensure that extra precautions are taken to alert personnel that you are working on the machine with live voltages. Lockout/ tagout the machine when this check is complete, as needed.

To verify the power connections, complete these steps:

1. Remove any lockout/ tagout device.

2. Turn the key start switch to the OFF position.

3. On the power cable from the key start switch, check for 24 V between pin A, (+) battery power and pin B, (-) battery power.

   Note: The pinouts are embossed on the underside of the molded plug.

4. Check for 0 V between pin B and pin C, (+) switched power.

5. Turn the key start switch to the ON position.

   Note: Do not turn the key all the way to the START position.

6. Check for 24 V between pin B and pin C.

7. After power has been verified, connect the 3-pin connector of the 167-8703 Wire to the 3-pin connector of the 265-8147 Fuse Harness that is located near the 167-8984 Battery.

8. Lockout/ tagout the machine, as required.

Entering Reference Data

Enter the following information for future reference:

Machine ID Number____________________

Machine Name____________________

Display Serial Number____________________

Radio Serial Number____________________

Application (Grade or Ore) ____________________

Grade Tolerance (provided by site)____________________

Setting Up the Display Language

There are two ways to select the language that appears on the display module:

• The office selects the language file by sending a file activate of the specific language file from the office to the machine.

• The operator selects the language file through the "Select Language File" dialog.

Menu - Opens the main menu

To use the "Select Language File" dialog to set a new language on the display, complete these steps:

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Illustration 40	g03747546
"Select Language File" dialog

1. From the main menu, select "System" > "Select" > "Select Language File".

   The "Select Language File" dialog appears.

   By default, the following languages are listed in the "Select Language File" dialog:

   • English (default)

   • French

   • Spanish

   • Swedish

   • Portuguese

   • Russian

   • Mongolian

2. Select the language that will be used on the display module.

   For example, to use the Spanish language, select "6.0 Spanish".

3. Select "OK".

   Note: When the operator shuts down the on-board software, the software saves the selected language.

Reference: For information on advanced tasks such as editing the "Set Language File" dialog, installing a new language in the MCU, and using resource files and language identifiers, refer to Systems Operation, M0080062, "Language Support".

Set Up Procedures

Setting Up the Sensors on the Bench

Caterpillar recommends setting up the sensors before fitting the sensors to the Boom, Stick, and Bucket.

On the bench, connect one sensor at a time. Set up the mach_cfg.txt file to use sensors, enable the Calibration menu, and change the sensor type. Once each sensor is set up, clearly label the sensor to avoid accidentally installing the sensor in the wrong position.

Sensors can be placed in various locations on the machine or programmed as replacements for other sensors.

General Information

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NOTICE
Enter correct details. Any errors transfer directly into the finished as-built surface file. All measurements are in meters.

The system components must be calibrated after installation and before operation. The calibration information is used for various purposes including the following:

• Positioning the bucket

• Calculating current elevation

• Calculating coverage

• Identifying material

• Drawing the machine on the display

Note: The calibrations that are in this section assume that all system hardware components have been installed.

The completed calibration process provides the following information to the software:

• Relative position of the slave receiver to the master receiver

• Relative position of the master receiver to the center of the boom pivot

• Relative position of the slave receiver to the center of the boom pivot

• Alignment of the machine relative to the two receivers

• Machine body pitch sensor offset angle

• Boom, stick, and bucket tilt sensor offset angles

• Boom, stick, and bucket dimensions

• Machine body dimensions

• Boom pivot height above the ground

Configuring the Machine Configuration File

Enter the type of sensors expected by the machine configuration file as follows:

1. Open the MCU.

2. Select the machine name.

3. In "Machine" > "Machine Dimensions", enter the required dimensions.
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   Illustration 41	g03864054

4. In "Calibration File Name", enter the correct name for the calibration file. The default name is "calibration.txt".

5. For a dual antenna machine, the "Use AS7 Sensor" setting appears. This setting lets the system instruct a programmable sensor to behave as an AS7 sensor (before v5).

6. Select "File".

7. In the menu bar, select "File" > "Send to Cat MineStar System".

8. If setting the system up to use Body, Avoidance and Path regions around the machine, complete a system measure-up procedure in Fleet office software.

   The Body, Avoidance, and Path regions around the machine running Terrain software are drawn using values stored in the office software and not the dimensions stored in the Terrain software. Users should make sure that both sets of dimensions match so that inconsistencies do not arise in other functions of the system that use dimensions.

9. Select "Send to MineStar".

10. Restart the on-board software.

To use an AS450 sensor to measure inclination on a boom, stick or bucket, refer to the section entitled "Changing the Sensor Type" in this manual.

Enabling the Calibration Menu

Menu - Opens the main menu

Enable the Calibration menu item in the on-board software as follows:

1. Open the master configuration file "master.txt" in the on-board software on the display module.

2. Configure the following:

   $ Calibration Menu =1

3. Save the "master.txt" file.

4. Restart the on-board software.

   The "Calibration" menu can now be opened from the main menu.

   Note: If a calibration file cannot be found, then the system automatically enables the "Calibration" menu. If this setting is not set in the "master.txt" file, then the "Calibration" menu is disabled after a calibration file has been written.

Changing the Sensor Type

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NOTICE
Ensure that only one sensor is connected to the harness during this procedure. Failure to connect only one sensor at a time could render the sensors unusable.

Menu - Opens the main menu

To select the location of the sensor, complete these steps:

1. Within the on-board software, open the main menu.
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   Illustration 42	g06181059
   "Change Sensor Type" dialog

2. Select "Calibration" > "Set Sensors IDs"

   The "Change Sensor Type" dialog opens.

To use an AS450 sensor to measure the inclination on a boom, stick, or bucket:

1. Touch the appropriate radio button.

2. When the correct selection is shown, touch the "Set" button.

3. Touch "Done".

   The "Change Sensor Type" dialog closes.

4. In the main menu, select "Diagnostics" > "Sensor" to confirm that the correct sensor appears and the related data is displayed to the right-hand side of the selection.

To use an AS460 sensor to measure pitch and roll on the body of a machine:

1. Open "Diagnostics" > "Sensors".

   Note: Do not open the "Calibration" > "Set Sensor Ids" window because the machine configuration file settings will overwrite the "Set Sensor Ids" settings.

2. Verify that the data for both pitch and roll displays.

Calibrating the Sensors on the Machine

Once the sensors have been attached to the machine, calibrate the sensors using the following procedures:

• Calibrating a new sensor

• Calibrating the body sensor

Calibrating a New Sensor

To calibrate a new sensor, complete these steps:

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Illustration 43	g06197042
"Choose Sensor Type" dialog

1. In the on-board software, open "Calibration" > "Sensor Calibration."

   The "Choose Sensor Type" dialog opens.

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   Illustration 44	g06185092
   "Calibrate Sensor" dialog for a boom sensor

2. Select the type of sensor to calibrate, then select "Done".

   • Boom

   • Stick

   • Linkage (dog-bone)

   • Bucket

   The "Calibrate Sensor" dialog opens for the selected type.

3. Select "Edit" to enter the height difference for the selected sensor.

   Enter a positive value for the following instances:

   • Stick pin higher than boom pin

   • Bucket, dog-bone link pin (H) higher than bucket pin (G)

   • Dog-bone to cylinder pin (F) higher than dog-bone to stick pin (D)

   • Bucket to dog-bone pin (H) higher than bucket pin (G)

   For all other instances, enter a negative value.

4. Select the side, "Left"or "Right", on which the sensor is mounted, as viewed from the cab.

5. Select Done.

   The software calculates the angle of the sensor and this number appears in "Implement Angle".

   Note: If required, "Implement Angle" can be edited.

6. Check that the position of the bucket tip center is within an acceptable range.

   Note: For buckets with different length teeth, the reported position is on the line between the outer teeth, not the inner teeth.

Calibrating the Body Sensor

This section describes calibrating the center of rotation (COR) of the existing or new body sensor to provide information about pitch, roll, and the position of the COR.

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Illustration 45	g06185109
"Rotation" dialog

1. In the on-board software, open "Calibration" > "COR Calibration".

   The "Rotation" dialog opens.

2. Press "Start", then rotate slowly horizontally until the software calculates all the items and the box turns green.

   Note: The rotation will require more than 180 degrees.

   1. Select "Done" after the software calculates the COR to stop at this point.

   2. Select "Done" after the software completes all three calculations.

   3. Select "Cancel" to exit without saving the calculations.

Replacing a Sensor (if needed)

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NOTICE
Ensure that only one sensor is connected to the harness during the configuration. Failure to connect only one sensor at a time could render the sensors unusable.

Before the arm sensors can be used, specify the segment of the arm to which each sensor is mounted. Only one arm sensor at a time can be connected to the system harness during the configuration procedure.

Once all the arm sensors have been configured, each 243-4108 Sensor Harness As can be reconnected for the boom, the stick, and the bucket. The 322-0222 Covers can then be installed on the sensors by using 8T-4171 Bolts (M6) and 5P-4115 Hard Washers.

Setting up the UTS

Previously, a water level tube was used during the calibration and measure-up. The instructions in this manual use the SCS900 Data Collector v3.x and a Universal Total Station (UTS) This method is faster, more accurate, and can be done by a single person even in medium winds.

The equipment needed for these procedures includes the following:

Measurement instrument - The Site Positioning System SPS930 is the recommended instrument to use. Any of the following instruments can also be used: SPS730, SPS700, SPS610, Automatic Total System (ATS), and 5600.

Extra supplies - Cleaner (degreaser), clean rags, black marker pen, reflective tape, magnetic targets and punch (optional), and two steel rulers

The following procedures are completed during the machine calibration:

• Marking all points on the machine and setting up the Total Station instrument for measuring

• Starting a new Site and Work Order

• Set up and orient the UTS

• Editing the excavator points with the measured values

Marking All Points and Setting Up for Measurement

Prior to beginning this procedure, ensure that the machine is level side to side. All the points must be measured on the centerline of the machine or on a line that is parallel to the centerline.

Note: The measurements obtained are only as accurate as the positions of the targets. Centering the targets on the specified locations is critical to obtaining accurate measurements.

To mark all points and set up for measurement, complete these steps:

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Illustration 46	g06183582
Control and Measurement points (A) Boom pin middle (B) Stick pin (D) Dog-bone, stick pin (F) Dog-bone, cylinder pin (G) Bucket pin (H) Bucket, dog-bone link pin (J) Bucket tooth, edge (Q) Bucket rear (Ant) Antenna (TUBP) Track under boom pin

1. Establish the following seven measurement points shown in Illustration 46 at the specified locations on the machine:

   A - Boom pin middle

   B - Stick pin

   D - Dog-bone, stick pin

   F - Dog-bone, cylinder pin

   G - Bucket pin

   H - Bucket, dog-bone line pin

   J - Bucket tooth, edge

   Note: If the bucket tooth (J) is loose, wedge the tooth to prevent movement during the measure-up.

2. Clean all the established points using a cleaner (degreaser) and clean rags.
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   Illustration 47	g03740515
   Graphical steps for creating accurate cross pattern on reflective tape for boom pin

3. Create and label targets using reflective tape.

   1. Determine and mark the horizontal centerline for the target (1-5).

   2. Determine and mark the vertical centerline for the target (6-9).

   3. Apply a piece of reflective tape, transfer your marked lines to the tape, and label the point so that the label can be seen through the instrument (10-12).

      Note: If reflective tape is not available, use duct tape or electrical tape. With this method, use DR (Direct Reflex) measuring mode rather than Standing measuring mode. DR mode does not use the prism and is less accurate than using reflective tape.

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   Illustration 48	g03740517
   Graphical steps for applying magnetic EDM targets

4. Alternatively, use magnetic EDM targets (not supplied).

   Note: If magnetic EDM targets are used, use a 1/4 inch transfer punch or fabricate your own tool (as shown) to center the targets.

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   Illustration 49	g03740573
   Position of bucket square

5. Position the hex bucket.

   • Rest the bucket on the ground to prevent movement of the bucket.

   • Ensure that the Dog-bone Link (D-F) is square to the bucket.

6. Set up the instrument.

   If working on a large machine, set up the UTS on the same side as the operator to have continuous line of sight with the operator.

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   Illustration 50	g03740611
   Placement of instrument at least 5 m from machine

   1. Initially, place the instrument at least 5 m (16.4 ft) away from the machine, aligned halfway between the extents of the boom, stick, and bucket.

      Note: It is not always possible to set the instrument halfway between the extents, due to machine size and shape which can restrict visibility to the pins, especially the Boom Pin target. Set up the instrument in a position that allows the best line of sight to all required points.

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      Illustration 51	g03740686
      Maintaining a minimum sight angle of less than 30 degrees

   2. Verify that all points can be observed through the UTS and that the two angles from Normal (perpendicular to machine) are less than 30 degrees.

   3. Continue moving the instrument back until the boom pin target and all other targets are visible to the instrument.

      Note: The boom pin target (A) is the most difficult target to see. Refer to Illustration 46.

Starting a New Site and Work Order

This section describes using the Trimble SCS900 software, v3.x, on a Trimble TSC3 data controller to measure the position of various points.

To start a new site and work order, complete these steps:

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Illustration 52	g03740762
"Open Site" dialog

1. Start the SCS900 software on the Trimble data controller or UTS that is being used for the calibration procedure.

   Once started, the system opens the "Open Site" dialog.

2. Select "New Site..." from the "Site:" drop-down box (1), then select the "OK" button (2).

   The "New Site" dialog opens for input.

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   Illustration 53	g03740761
   Entering the site name in the "New Site" dialog

3. Enter a new site name in the Site field (3) of the dialog. Complete all other fields, then select the "Next" button (4).

   Note: Choose a name that is easily recognizable such as the site or the company name.

   The "Site Creation Options" dialog opens. The fields in the dialog are blank.

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   Illustration 54	g06184535
   "Site Creation Options" dialog

4. Enter any required data, then select the "Finish" button (5).

   The "Open Site" dialog opens again with the "Site" field populated with the site name entered in Step 3. A "Work Order" field appears on the dialog.

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   Illustration 55	g03740774
   "Open Site" dialog with new "Work Order" field (6) displayed

5. Select "New work order..." from the "Work Order" drop-down box (6), then select the "OK" button (7).

   The "New Work Order" dialog opens with a blank "Work Order" field (8).

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   Illustration 56	g03740777
   "New Work Order" dialog

6. Enter a new work order name in this field, then select the "Finish" (9) button.

   Note: Enter a new work order name that is easily recognizable, such as the machine name.

   The "Open Site" dialog opens again. The new "Work Order" information is populated in the field and a new "Design" field (10) appears.

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   Illustration 57	g03740789
   "Open Site" dialog with new "Design" field

7. If required, add a design from the "Design" drop-down box (11), then select the "Accept" button (12).
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   Illustration 58	g03740793

8. Select the "Cancel" button (13) if the "Receiver Setup" page opens.

Once the new site and a work order are created, a "Home: <site name>" menu page is available with more functions.

Setting Up and Orienting the UTS

Use the exiting site control points to calibrate the machine. If there are no existing site control points, use temporary control points in an arbitrary coordinate system.

To input the coordinates of the control points, either use a control point file or else complete these steps:

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Illustration 59	g03796901

1. Select the "Total Station" menu (14) from the new "Home: <site name>" menu.

   The "Setup" submenu page opens.

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   Illustration 60	g03741109

2. Select the "Enter / Edit Control Points" submenu (15).

   After selecting the "Enter / Edit Control Points" submenu, the "Point Manager" dialog opens.

3. Set up and orient the UTS over the control point that will be used for the instrument.

   Assume that the point is to be named "Inst1".

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   Illustration 61	g06184544
   "Point Manager" dialog

   1. Select the "Add" button (16) on the dialog and enter the coordinates and details of the "Inst1" control point.

   2. Orient the UTS over another control point that will be used for reference, select "Add", and enter coordinates for this new point.

      Assume that the point is to be named "Ref".

      Note: At a minimum set up an instrument and a reference control point. More control points can be added, as required.

4. Populate the control points on the main instrument screen.

   1. After all control points have been added, select "Close" on the "Point Manager" dialog.

      The dialog closes and the main instrument screen returns.

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      Illustration 62	g03741126
      Main instrument screen showing location of Home Page icon

   2. Select the Home Page icon (22) to open the "Home: <site name>" menu of the instrument.
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      Illustration 63	g03796901
      "Home: <site name>" menu

   3. In the "Home:" menu, select the "Total Station" menu (14).

      The "Setup" submenu page opens.

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      Illustration 64	g03741129

   4. Select the "Station Setup" submenu (24).

      The "Total Station Setup" dialog opens.

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      Illustration 65	g06184551
      "Total Station Setup" dialog

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      Illustration 66	g03741131

   5. Select the "Set up on a known control point" radio button, then select the "Accept" (25) button.

      The main instrument screen returns and a blank "Instrument Point" field (26) is displayed in the header.

   6. Select the Plan Options icon (27) on the main instrument screen. Refer to Illustration 66.

      The "Plan Options" dialog opens.

   7. Verify or select the following options on the "Measure" tab of the "Plan Options" dialog:

      • "Point names"

      • "Control points"

      • "Measured surface"

      • "Setout points"

      • "Measured feature"

      • "Coverage grid"

      • "Elevation" radio button
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      Illustration 67	g06184568
      "Measure" tab of "Plan Options" dialog

   8. Enter the value "10.000 m" in the "Grid Size" field (28), then select the "Accept" (29) button. Refer to Illustration 67.

      The main instrument screen returns and is populated with the control points that were entered previously.

5. Set the position of the UTS instrument.
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   Illustration 68	g03741178
   Main instrument screen showing the instrument and reference control points.

   1. Select the "Inst1" control point (30).

      Note: When the control points that were previously entered are selected, the icon that is tied to the point updates with a blue circle to indicate that the point has been selected.

      The "Instrument Point" field populates with the selected control point.

   2. Select the "Accept" button (31). Refer to Illustration 68.

      The "Enter Instrument Height" dialog opens.

6. Enter the vertical height of the instrument.
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   Illustration 69	g03741180
   "Enter Instrument Height" dialog

   1. Enter the height of the instrument in the "Instrument vertical height:" field.

   2. In the "Measurement method:" drop-down, select "Vertical height".
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      Illustration 70	g03741183
      "Known Station Setup" dialog

   3. Select the "Accept" button (32). Refer to Illustration 70.

      The "Known Station Setup" dialog opens.

7. Set up the second point for reference.

   1. Select the "Add Point" (33) button in the "Known Station Setup" dialog.

      The main instrument screen returns and a "Point name:" field is displayed in the header.

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      Illustration 71	g03741184

   2. Select the "Ref" point (34) on the main instrument screen.

      The UTS is now set up within the coordinate system and is ready for orientation.

8. Orient the UTS.
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   Illustration 72	g03741402
   Main instrument screen with control point selected

   1. Carefully point the instrument at the reference control point ("ref").

      The "Take Measurement" dialog opens.

   2. Select the "Select" button (35) on the main instrument screen.
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      Illustration 73	g03741186
      "Take Measurement" dialog

   3. Verify that the distance between the two control points ( "Inst1" and "Ref") is correct. If not, then modify the setup data.

   4. Select "Measure" (36) in the "Take Measurements" dialog.
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      Illustration 74	g03741188
      "Known Station Setup" dialog

   5. Select "Accept" (38) on the "Known Station Setup" dialog.

      The "Known Station Setup" dialog opens with the control point name checked. A green circle with a white check mark (37) appears in the header with a message notifying that the “Setup error is in tolerance.”

      Note: If the set up errors are outside of tolerance (too large), recheck the set up data and measure again.

The UTS is now set up, oriented to the coordinate system, and ready to use.

Setting Up the Machine and the UTS

Machine Requirements

The following measures must be observed during the calibration procedures:

• Park the machine on flat ground. Pitch and roll must be zero.

• The machine must be able to rotate through 180 degrees without the tracks moving.

• Continue to run the machine engine throughout the calibration procedure.

• Extend the boom, stick, and bucket as far out as possible.

• Face the bucket to the ground for excavators.

• Place the bucket teeth further away from the machine than the bucket pin.

UTS Requirements

• The UTS must be set up on a control point that is precisely positioned in the coordinate system of the site.

• All required points on the machine must be visible to the UTS.

Using the UTS

The Universal Total Station (UTS) is used for the following:

• Measuring all control points to establish the coordinates of the points

• Exporting the measured calibration data as a CSV file

Best Practices for Antenna Measurements

The GNSS antenna locations, "AntL"and"AntR", are crucial to the system operating well. This section describes the best way to measure these locations.

• "AntL" and "AntR" are the location of the phase center of the left and right GNSS antenna.

• Find details of the phase center either on the antenna housing or from the manufacturer.

• If the UTS cannot "see" the phase center, remove the antenna and replace with a prism or another target used by surveyors. Measure the prism or target, and incorporate the offset to the phase center into the "AntL" and "AntR".

• Measure carefully. Terrain checks these measurements against the GNSS position from the satellites and reports an error if the difference is more than 2cm in any direction.

• If using an arbitrary coordinate system, the difference will be larger than 2cm. Discuss with the site surveyor the ramifications for the system once the system is working on the coordinate system of the site.

• Leave "AntL" and "AntR" blank and the system will use the GNSS positions from the antenna. Understand the consequences before leaving these values blank.

When measuring BT (bucket tooth, center) and J (bucket tooth, edge):

• Use a measuring tape to find the exact center.

• Mark the points with chalk/paint first

• If the UTS cannot "see" the target, use a prism and pole. Verify that the pole is vertical.

• Accurate measurement of BT is critical. The line between BT and the boom pin center defines the vertical plane for the entire calibration.

When measuring boom pin center:

• Use a prism and a pole.

• Add the radius of the pin to the pole height so that the point measured lies on the central axis of the pin.

• If the boom pin center is inaccessible, measure to each end of the pin along the centerline: "AL" for left end, and "AR" for right end. Enter "AL" and "AR" into the CSV file and Terrain automatically calculates the boom pin center.

The stick pin (B) and the bucket/dog-bone link pin (H) can be measured on the left-hand or on the right-hand side of the arm. The software shifts the position onto the BT-A vertical plane.

Measuring All Control Points

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NOTICE
The physical setup and location of the Total Station instrument is critical for the remainder of this process. Ensure that all targets are visible from the chosen location, the instrument is on stable ground, and the instrument is properly leveled directly over the survey point.

This section explains the process for measuring all control points on the excavator to establish the coordinates of the points.

To measure the points, complete these steps:

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Illustration 75	g03806285

1. From the main screen, select the "Measuring Mode" icon (41)

   The "Total Station" dialog opens.

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   Illustration 76	g06184589
   "Total Station" dialog

2. Select DR for direct measurement to the linkage points or the acrylic targets of the machine.

3. If measuring to a prism, select "Standing".
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   Illustration 77	g06184601

4. From the Total Station dialog, select "DR Target".

   The "DR Target Settings" dialog opens.

5. Set the "Target height:" to "0" for direct measurements to the linkage points or acrylic targets of the machine. If using a prism, set the correct target height.
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   Illustration 78	g03806539

6. Carefully point the UTS at each point that is to be measured. When the cross hairs of the UTS are precisely centered on the point, use the "Measure" button (86) to measure the point.

   The "Measure Control Point" dialog opens.

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   Illustration 79	g06184652
   "Measure Control Point" dialog showing stick pin point named as "B"

7. Correctly name the point after each measurement, then select the "Accept" button on the "Measure Control Point" dialog to save the named point.

8. Repeat naming for all required points listed below:

   A - Boom pin center

   AL - Boom pin left

   AR - Boom pin right

   B - Stick pin

   D - Dog-bone, stick pin

   F - Dog-bone, cylinder pin

   G - Bucket pin

   H - Bucket, dog-bone link pin

   J - Bucket tooth, edge (for drawing the plan view icon)

   BT - Bucket tooth, center

   Q - Bucket rear (for scaling the profile icon)

   AntL - Antenna left

   AntR - Antenna right

   COR - Center of rotation (for PR2 messages only; not used to calibrate the machine)

   TUBP - Track under boom pin (at ground level; used to determine the boom pin height when mapping at the tracks)

Exporting Measured Data as a CSV File

To export the measured machine calibration data as a CSV file, complete these steps:

1. On the main measure window, select the Home Page icon to open the "Home: <site name>" menu.
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   Illustration 80	g06184622

2. Select "Import / Export" from the menu.

   The "Import / Export" submenu page opens.

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   Illustration 81	g06184627

3. Select "Measured Data".

   The "Export Measured Data" dialog opens.

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   Illustration 82	g06184640

4. Select the following from the pull-down menus:

   "Export type:" - "CSV file"

   "Coordinate order:" - "P, E, N, Elev, D"

   "File location" - Export to "Device". If USB drive is connected, export to "Memory Card (\Hard Disk\)".

The CSV file is now ready for import into the Terrain on-board software. The software will then complete the calibration calculations.

Using the Linkage Calibration Wizard

Note: The receivers can remain connected during this task.

Use the Linkage Calibration wizard to enter data into the calibration file, then the system will calculate the required values that are needed by the system to function accurately. Enter the numbers as positive values, even if the measurements are to the left of the center of the boom pin.

Note: In the past, negative (rather than positive) values were entered for measurements to the left of the center of the boom pin (as seen from the cab).

After the system calculates these values, the system enters values and measurements into the "Calibration Summary" dialog. The values are stored on-board in the calibration.txt file. If needed, modify the values in the "Calibration Summary" dialog at any stage after completing the linkage

Ensure the following before beginning the Wizard:

• The machine is still parked where the measurements were taken.

• CSV files (measurements) or old calibration files are stored in the root directory of the G610 display.

• Verify that the power light is illuminated.

• Locate the phase center of the receiver.

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Illustration 83	g06184944
"Connect Devices" dialog

1. In the main menu, touch "Calibration" > "Calibration Wizard".

   The "Connect Devices" dialog opens. If any AS4xx sensors are not connected, this dialog remains open. Select "Cancel" to exit and start again at another time, or leave this dialog open while devices are connected into the system.

   When all devices are connected, this dialog closes quickly and the "Choose Method" dialog opens.

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   Illustration 84	g06184949
   "Choose Method" dialog

2. From the "Choose Method" dialog, select one of the following methods to enter data into the system.

   • "Enter data manually"

   • "Load from CSV"

   • "Upgrade from old calibration file"

Entering Data Manually

Note: Make a copy of your existing calibration.txt file from "D:\caes\config" before starting this work.

Use this section if data has been written down during the measure-up process.

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Illustration 85	g06187579
"Finding GNSS Positions" dialog

1. Touch "Enter data manually".

   The "Finding GNSS Positions" dialog opens within about 60 seconds. During this period the following occurs:

   • The system places the receiver into Static mode.

   • The "No GPS" Position Status icon appears on the lower Status bar.

   • Other machines will see this machine with a large machine buffer (Detect Strategy)

   • When the system calculates the positions, the "Measurements" dialog, which can be edited fully, opens showing "East", "North", and "Elevation" columns.
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   Illustration 86	g06187593
   GNSS "Warning" dialog for poor accuracy

2. In the following circumstances, touch "Skip" to continue without finding the current position of the GNSS receivers:

   • There are no visible satellites.

   • There no GNSS corrections.

   • The current position has poor accuracy.

   The "Warning" dialog indicating poor accuracy appears.

3. Select one of the following on the "Warning" dialog:

   No - Exit the calibration procedure.

   Yes - The system uses whatever position is available or uses "0" (zero) if there is no position available.

   The system calculates the GNSS receiver positions and opens the "Measurements" dialog which can be edited fully.

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   Illustration 87	g06184974
   "Measurements" dialog

4. Select one of the following on the "Measurements" dialog.

   Back - Return to the previous screen.

   Cancel - Exit the calibration procedure without saving any data.

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   Illustration 88	g06184981
   "Edit" item "X" dialog

5. Click a row to edit the following position data using the "Edit" item "X" dialog.

   • "Easting"

   • "Northing"

   • "Elevation"

   Note: Touching one of the "Edit" buttons opens a numerical keyboard.

6. After each position value is entered, touch "OK" to return to the "Measurements" dialog.

7. When all data has been entered in the "Measurements" dialog, touch "Next".

   The Calibration Summary screen opens.

   Note: The system initially stores data, either entered manually or from the CSV file, in the backup file "caes\config\LastCalibrationData.csv".

Loading Data from the CSV File

Note: Make a copy of your existing calibration.txt file from "D:\caes\config" before starting this work.

Use this section if a CSV file was created and stored in the root directory of the G610 display by one of the following methods:

• The machine was measured with a UTS, which output the data to a CSV file.

• Data was entered into a spreadsheet, such as Microsoft Excel, and was exported to a CSV file.

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Illustration 89	g06184991
Example of CSV file listing

1. Touch "Load from CSV".

   A list appears showing any CSV files in the root directories of the following folders:

   • D: drive on the G610 display

   • C: drive on a PC or portable PC

   • External drive, such as a USB memory module, attached to the G610 display
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   Illustration 90	g06187579
   "Finding GNSS Positions" dialog

2. Touch a CSV file name.

   The "Finding GNSS Positions" dialog opens within about 60 seconds. During this period the following occurs:

   • The system places the receiver into Static mode.

   • The "No GPS" Position Status icon appears on the lower Status bar.

   • Other machines will see this machine with a large machine buffer (Detect Strategy)

   • When the system calculates the positions, the "Measurements" dialog, which can be edited fully, opens showing "East", "North", and "Elevation" columns.
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   Illustration 91	g06187593
   GNSS "Warning" dialog for poor accuracy

3. In the following circumstances, touch "Skip" to continue without finding the current position of the GNSS receivers:

   • There are no visible satellites.

   • There no GNSS corrections.

   • The current position has poor accuracy.

   The "Warning" dialog indicating poor accuracy appears.

4. Select one of the following on the "Warning" dialog:

   No - Exit the calibration procedure.

   Yes - The system uses whatever position is available or uses "0" (zero) if there is no position available.

   The system calculates the GNSS receiver positions and opens the "Measurements" dialog which can be edited fully.

5. Once the system has found GNSS receiver positions, one of the following occurs:
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   Illustration 92	g06185008
   "Info" dialog

   1. If the positions in the CSV differ from the positions calculated by the GNSS receiver by more than 2cm, then the "Info" dialog opens showing the difference between the CSV data and the current GNSS receiver data.

      Use knowledge of the local situation to select one of the following:

      "Use CSV" - Use the data from the CSV file that was created during measure-up.

      "Use GNSS" - Use data from the GNSS receiver in "Static" mode.

      "Cancel" - Return to the "Choose Method" dialog and find a more accurate GNSS position.

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      Illustration 93	g06185012
      "Measurements" dialog showing populated position data

   2. If positions from the CSV and the current GNSS receiver are within 2cm of each other, the "Measurements" dialog opens.

      Note: In the "Measurements" dialog, the "AntL" and "AntR" position data comes from either the CSV file or the GNSS receivers. All other data comes from the CSV file.

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   Illustration 94	g06184981
   "Edit" item "X" dialog

6. Click a row in the "Measurements" dialog to edit the following position data using the "Edit" item "X" dialog.

   • "Easting"

   • "Northing"

   • "Elevation"

   Note: Touching an "Edit" button opens a numerical keyboard.

7. After each position value is entered, touch "OK" to return to the "Measurements" dialog.
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   Illustration 95	g06185021
   "Sensor Mounting" dialog

8. When all data has been entered in the "Measurements" dialog, touch "Next".

   The "Sensor Mounting" dialog opens.

9. Touch on which side the sensors are located, and then touch "Next"

   Note: "Right" refers to the right-hand side looking from the cab along the boom.

10. Touch Next.

    The "Calibration Summary" dialog opens.

    Note: The system initially stores data, either entered manually or from the CSV file, in the backup file "CAES\config\LastCalibrationData.csv".

Using an Existing Calibration File

Note: Make a copy of your existing calibration.txt file from "D:\caes\config" before starting this work.

Use this section if the machine has not been measured in the current position and there is an existing Terrain calibration file. This two-step procedure is completed after upgrading to "Terrain" v6.0. The machine must be in high accuracy. During this procedure the machine will rotate 180 degrees.

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Illustration 96	g06231946

1. From the main menu, select "Calibration" > "Linkage Calibration Wizard".

   Note: The Wizard will not be available unless the master.txt file contains the "$ Calibration =1" key.

   The "Choose Method" dialog opens.

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   Illustration 97	g06184949
   "Choose Method" dialog

2. Touch "Upgrade from old calibration file" on the "Choose Method" dialog.

   The "Rotation" dialog appears.

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   Illustration 98	g06231965

3. Touch "Start" on the "Rotation" dialog, then slowly rotate through 180 degrees.

   The dialog contains a list of items that are calculated during the rotation. The progress box transitions from a red color to a yellow color as the calibration begins. As the machine is rotated, each item is calculated and a check mark appears to the left of the item. Once all items are calculated, the progress box turns to a green color.

4. Select "Done" after the progress box turns to a green color.

   The "Calibration Summary" dialog appears.

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   Illustration 99	g06231971
   "Calibration Summary" dialog

5. Confirm the values on the "Calibration Summary" dialog, edit the values as needed, then touch "OK" to complete the calibration.
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   Illustration 100	g06231988
   Incorrectly scaled machine icon

6. Look at the machine icon in the profile view. If the icon is not scaled properly, complete the COR calibration.

   1. In the main menu, select "Calibration" > "COR Calibration" to open the "Rotation" dialog.

   2. Complete Steps 3 through 5 above.

Calibration Summary Table

Table 26 describes the items in the summary dialog:

Table 26

Calibration Summary
Item	Fields (from the left)	Description
Arm Measurements- Boom - Stick - Bucket	Width (meters)	Data calculated by the system, for the width, length and height of the boom, stick and bucket.- Width = perpendicular to the machine - Length = pin to pin along centerline - Height = pin to ground The system uses width and height to draw the machine icon on the display, and uses length for important calculations.
	Length (meters)
	Height (meters)
Body Measurements- Master GNSS - Slave GNSS - COR Offset - Machine	Offset from boom pin (East)	The offset of the GNSS receiver and the COR from the boom pin, as calculated by the system in X, Y, and Z values.
	Offset from boom pin (North)
	Offset from boom pin (Elevation)	Length and width calculated by the system. The system uses length and width of the machine to draw the machine icon on the display. Use these two fields as a quick check that your measurements are correct.
	Machine length and width (meters)
Body Sensor	Roll angle (degrees)	The roll and pitch angle offset of the body sensor, calculated by the system assuming the machine is parked on flat ground.Note: Use a UTS or spirit level to calculate these values when parked on ground that is not flat.
	Pitch angle (degrees)
Sensor Placement- Boom Sensor - Stick Sensor - Bucket Sensor	Side of machine (Left, Right)	Side of the machine. as seen from the cab.
	Sensor on linkage	Ticked if there Is a sensor on the linkage. Note: Mount on linkage, not on bucket
Sensor Offsets- Boom - Stick - Bucket	Offset angle (degrees)	The offset angle of the sensor, calculated by the system from an imaginary line drawn pin to pin along the centerline: Boom A-B; Stick B-G; Bucket G-J.
Linkage- DG - GH - FH - DF - DGB Angle - HGJ Angle	Distance (meters)	The distances and angles the software calculated, with the lengths, or straight sides of the angle, calculated pin to pin along the centerline.
	Angle (degrees)

Modifying the Calibration Values

Use the "Calibration Summary" dialog to review all values.

To open the "Calibration Summary" dialog, complete these steps:

1. Enter "$ Calibration Menu" in the master.txt file.

   The "Calibration" > "Calibration Summary" item appears in the main menu of the on-board software.

2. Select "Calibration" > "Linkage Calibration Summary" and enter data into any of the fields in the "Calibration Summary" dialog.

3. Touch one of the following:

   "Cancel" - Start the wizard again at the "Choose Method" dialog. All edited data will be lost.

   "OK" - Store the data in the calibration file.

Validating the Calibration

At minimum, verify that the position of the center bucket tooth is within acceptable limits of the "Blade Center" item in the Positions diagnostic window.

Note: The "calibration.bak" file is the second copy of the most recent "calibration.txt" file, not the backup copy of the original or existing "calibration.txt" file of the machine. Make a copy of the existing "calibration.txt" file from "D:\caes\config" before starting this work.

To validate the calibration, complete these steps:

1. Mark a location on the ground.

2. Have a surveyor record "Northing", "Easting", and "Elevation" of the point.

3. Move the center of the bucket to the surveyed point.

4. If the bucket has no center tooth, split the difference between center teeth.

   Note: The teeth may not be touching ground.

5. Compare the survey point to the on-board readings.

Calibration Settings (pre v6.0)

Prior to Terrain v6.0, calibration values were written as settings in the calibration.txt file and edited using the calibration wizard. From v 6.0 onwards, the values are stored as app settings and cannot be edited by hand.

The following settings were written to the calibration file:

AntX 0 - Specifies the horizontal distance in the X axis from the master antenna to the center of the boom pivot

AntY 0 - Specifies the horizontal distance in the Y axis from the master antenna to the center of the boom pivot

AntZ 0 - Specifies the horizontal distance in the Y axis from the master antenna to the center of the boom pivot

AntX 1 - Specifies the horizontal distance in the X axis from the slave antenna to the center of the boom pivot

AntY 1 - Specifies the horizontal distance in the Y axis from the slave antenna to the center of the boom pivot

AntZ 1 - Specifies the vertical distance from the slave antenna to the center of the boom pivot

Boom Sensor Left - Specifies the side of the boom to which the boom sensor is mounted

Boom Sensor Offset - Specifies the offset angle that is applied to the raw boom angle

Bucket Sensor Left - Specifies side of the bucket to which the bucket sensor is mounted

Bucket Sensor Offset - Specifies the offset angle that is applied to the raw bucket angle

Excavator Boom Height - Specifies the boom height of the machine

Excavator Boom Length - Specifies the boom length of the machine

Excavator Boom Width - Specifies the boom width of the machine

Excavator Boom Pin Height - Specifies the height of the center of the boom pin above the machine track on the ground

Excavator Bucket Height - Specifies the bucket height of the machine

Excavator Bucket Length - Specifies the bucket length of the machine

Excavator Bucket Pins Length - Specifies the distance between the pins of the bucket.

Excavator Bucket Pins To Tip Angle - Specifies the angle formed between the bucket tip and the pins of the bucket.

Excavator Bucket Width - Specifies the bucket width

Excavator Bucket Sensor On Link - Specifies that the sensor for the bucket is installed on the bucket link

Excavator Cylinder To Bucket Length - Specifies the length of the cylinder to bucket link

Excavator Machine Length - Specifies the length of the body of the machine

Excavator Machine Width - Specifies the width of the body of the machine

Excavator Stick Height - Specifies the stick height of the machine

Excavator Stick Length - Specifies the stick length of the machine

Excavator Stick Link To Bucket Length - Specifies the distance from the center of the bucket link pivot on the stick to center of the bucket pivot

Excavator Stick To Cylinder Link Length - Specifies the distance from the center of the bucket link pivot on the stick to the center of the cylinder link

Excavator Stick To Link Angle - Specifies the angle between the dog-bone (pin to pin) and the stick (pin to pin)

Excavator Stick Width - Specifies the stick width of the machine

Pitch Sensor Offset - Specifies the offset angle that is applied to the raw machine pitch angle

Roll Sensor Offset - Specifies the offset angle that is applied to the raw roll angle

Stick Sensor Left - Specifies side of the stick to which the stick sensor is mounted

Stick Sensor Offset - Specifies the offset angle that is applied to the raw stick angle

Measurements Worksheet

Illustration 101	g06185066
Measurements worksheet

Illustration 102	g06189254
Hydraulic excavator - side and top views