CAES Installation For Wheel Loader{7604} Caterpillar

Wheel Loader:

992 (S/N: 25K1-UP)

992C (S/N: 42X1-UP; 49Z1-UP)

992D (S/N: 7MJ1-UP)

992G (S/N: 7HR1-UP)

994 (S/N: 9YF1-UP)

994D (S/N: 3TZ1-UP)

Introduction

This procedure describes the process for installing Computer Aided Earth-moving Equipment on wheel loaders. The installation will require welding, hole cutting, electrical and mechanical tools. After a technician has completed the first installation process, future installations should require between six to eight hours.

The installation process can be broken down into the following nine sections:

• GPS Antenna Installation

• GPS Receiver Installation

• Display Module Installation

• Wireless Machine Radio Programming and Installation

• Main Harness Installation

• Power Harness / Fuse Installation

• Battery Box Installation

• Setting Machine ID

• Dimension Measurements

The following major groups are included in the CAES System for the Wheel Loader:

• CAES System Arrangement

• Wiring Gp.

• Mounting Gp. (Antenna L1/L2 GPS)

• Mounting Gp. (GPS Receiver)

• Mounting Gp. (Machine Radio)

• Mounting Gp. (Display)

• Mounting Gp. (Dash)

• Plate Gp. (CAES Serial Number ID)

General Preparation

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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 bucket 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.

Tools

• Wrench set

• Drill Bit Set

• Electricians Hole Punch Set

• Fish Tape

• Cable ties/Clips

• Tap set

CAES Components

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

Illustration 2	g01014932
CAES machine arrangement

GPS Antenna Installation

Procedure

The antenna must be mounted on the machine so the antenna has an unobstructed view of the sky. The recommended mounting location for the GPS Antenna is the top of the cab. The least obtrusive location in the case of the 992G is in place of the front lifting eye.

Note: Tag and store the lifting eye for future use.

1. Remove the lifting eye and center the antenna bracket over the 5/8 hole.

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Illustration 3	g00992161
GPS Antenna Mounting Hardware

2. Attach the GPS Antenna Mounting Bracket to the top of the cab using a 5/8 bolt screwed directly into the threaded lifting eyehole, or fabricate a threaded-boss threaded bolt combination.

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Illustration 4	g00989200

3. Sub-assemble the Shock Mount Kit to the GPS Antenna Mounting Bracket.

Note: Using the existing threaded lifting eyehole will eliminate the need to weld or drill & tap the machine in order to mount the GPS antenna.

4. Mount the antenna bracket to the top of the cab by-way using the existing threaded lifting eyehole.

5. Tighten all mounting bolts to standard specifications.

Illustration 5	g00992193
The recommended mounting site for the GPS antenna

Attach Antenna to the Mounting Bracket

Illustration 6	g00992230

1. Attach the GPS Antenna to the Mounting Bracket with the four bolts, washers and shock mount grommets provided with the GPS Antenna Mounting Kit.

   Note: Orient the coax connectors to the rear of the machine.

2. Attach either end of the coax cable to the connector on the GPS Antenna.

3. Route the cable down the ROPS post and toward the mounting location of the GPS Receiver.

GPS Receiver Installation

There are several acceptable mounting location for the GPS Receiver within the cab of the machine. The three locations depicted in this manual were selected using the three following criteria:

• The chosen site provides the installers with a location that will support the overall dimensions of the unit

• The chosen site provides adequate accessibility

• The unit is located out of the way of normal operator and machine functioning

The preferred mounting locations depicted in this manual are as follows:

Illustration 7	g00992255
GPS Receiver mounted on the right side of the operators seat

Illustration 8	g00992259
GPS Receiver mounted on the inside of the cab storage bin

Illustration 9	g00992264
GPS Receiver mounted on the left rear vertical pillar behind the operators seat

1. Use the receiver mounting bracket as a template in order to mark and then drill the bolt pattern for the receiver mount in the buddy seat housing.

   Note: The receiver must be oriented so that the fins are vertical when installed.

2. Install the receiver mounting bracket using the four supplied washers, nuts, and bolts.

3. Sub-assemble the shock mount kit to the GPS receiver.

4. Attach the GPS receiver to the mounting bracket with the remaining bolts and washers from the shock mount kit.

5. Ensure all bolts are tighten to standard torque specifications.

Illustration 10	g00992282

Battery Box Installation

Illustration 11	g00992251
Battery box mounted on the back side of the GPS receiver.

Unless an extension cable is made up, the battery box must be located very close to the same mounting location as the GPS Receiver. In the photo above, the battery box is mounted to the backside of the receiver mounting bracket.

Display Module Installation

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

Illustration 12	g00992843
CAES display mounting group (1) BRACKET ASSY. (DISPLAY U-SHAPED) (2) BOLT (1/4-20) (3) WASHER (4) SHOCK MOUNTING GROUP (5) MOUNT (6) SPACER (7) WASHER (8) BOLT (1/4-20)

Illustration 13	g00994865
Ceiling/Dash adapter

Illustration 14	g00994857
Typical display mounting location. Mounted to the center of the ceiling using 1 inch weld bosses.

Illustration 15	g00994862
Optional mounting location. Mounted in front upper right corner of the cab using site fabricated ceiling bracket.

In a standard installation, the harness with 70-pin connector routes under the floorboard, through the instrument dash, through a hole in the top right corner of the dash, and to the display unit. If the 70-pin connector is not shipped unattached to the main harness, then it will be necessary to remove the 70-pin connector and reroute the harness through the hole in the top of the dash.

Note: Mark the individual wires before removing them from harness.

Route the harness. Reconnect all wires.

Note: See ""Main Harness Installation" "

Radio Installation

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

Radio Programming Procedure

1. Connect Service Cable to the TC-900B and service laptop.

   Note: As extension a Gender changer can be connected between the service cable and the TC-900B cable. The TC-900B cable must be disconnected at the GPS Receiver and reconnected to the other end of the Gender changer. A standard straight-through serial cable can be used to extend the 9-pin connector on the TC-900B Service Cable.

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

3. Start Commset on the service laptop.

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Illustration 16	g00992143

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

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Illustration 17	g00990710

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

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

7. Reconnect and verify the setting.

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

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

TC 900B Radio Installation Procedure

Illustration 18	g00993199
Radio Mount Group

Note: To minimize interference and maximize reception the TC 900B radio should be mounted at least 3 feet away from the GPS antenna or any other transmitting radio or antenna on the machine, and the radio antenna should have 360 degrees of visibility.

Note: It is recommended to use the existing threaded holes for backup light brackets in the right rear of the cab to install the TC 900B radio. An alternate mounting location is the right side of the cab to wrapper plate. In this case, the weld bosses are used. Refer to the photos below.

Illustration 19	g00995064
TC 900B mounted on right rear of the cab

Illustration 20	g00995066
TC 900B mounted to the right side of the cab

1. Attach the TC 900B radio to the mounting bracket using the stainless steel socket-head screws.

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

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

4. Sub-assemble the Shock Mount Kit to the mounting bracket.

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

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

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

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

Main Harness Installation

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Illustration 21	g00993696
Main harness connected to GPS receiver

1. Connect the main harness to the GPS receiver.

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Illustration 22	g00993694
Main harness routed through floor plate

2. Route the main harness through the floor plate.

3. Rout the harness through the inside of the front instrument console. The exit can be on the top right side of the console.

4. Connect the harness to the Display Unit.

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Illustration 23	g00993697
Main harness securely clamped

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

Illustration 24	g00993684

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

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

Illustration 25	g00993670
Electrical schematic for power harness and fuse installation.

Refer to electrical schematic above and make the electrical connections.

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

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

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

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

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

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

Setting Machine ID

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

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

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

4. Turn the key switch to ON position.

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

6. Turn the key switch to OFF position.

7. Connect the three pin DT connector from the power harness to the matting CAES Main Harness power connector.

8. Turn the key switch to ON position.

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

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

10. Release the top two buttons.

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

11. Press the "⇒" key.

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

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

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

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

Machine ID Worksheet

Machine ID Number____________________

Machine Name____________________

Display Serial Number____________________

Machine Dimensions____________________

Radio Serial Number____________________

Application (Grade, Ore, OrePlus, Compaction)____________________

Grade Tolerance - Provided by Mine____________________

Machine Dimensions

Illustration 26	g00995093

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