Installation of the AccuGrade® - Grade Control System for the Motor Graders{7220} Caterpillar

Motor Grader:

120H (S/N: ALZ200-UP; CAF1-UP)

120M (S/N: B9C1-UP; B9N1-UP; B9W1-UP)

12H (S/N: AMZ246-UP; CBK1-UP)

12M (S/N: B9F1-UP; B9R1-UP)

135H (S/N: AMX191-UP; CBC1-UP)

140H (S/N: APM186-UP; CCA1-UP)

143H (S/N: APN186-UP)

14H (S/N: ASE296-UP)

14M (S/N: B9J105-UP)

160H (S/N: ASD191-UP; CCP1-UP)

163H (S/N: ARL247-UP)

16H (S/N: ATS180-UP)

140M (S/N: B9D1-UP; B9M1-UP)

160M (S/N: B9E1-UP; B9L1-UP)

16M (S/N: B9H100-UP)

Machine Control & Guidance Products:

ACCUGRADE (S/N: LGC1-UP)

Introduction

ReferenceOperation and Maintenance Manual, SEBU8283, "AccuGrade^® Grade Control System - CD700"

This Special Instruction provides information for the installation of the Electronic components of the Single Mast and Dual Mast AccuGrade System.

The operation of the AccuGrade System is covered in the Operation and Maintenance Manual, SEBU8283, "AccuGrade^® Grade Control System - CD700". Refer to that manual for more information.

Important Safety Information

Work safely. Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools in order to perform these functions properly. Safety precautions and warnings are provided in this instruction and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in this publication and the warnings on the product are not all inclusive. If a tool, a procedure, a work method, or an operating technique that is not specifically recommended by Caterpillar is used, you must be satisfied of your safety and the safety of other people. You should also make sure that the product will not become damaged or unsafe by the operation, the lubrication, the maintenance, or repair procedures that are chosen by you.

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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 your Caterpillar dealer for replacement manuals. Proper care is your responsibility.

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Personal injury or death can result from improper assembly procedures. Do not attempt any assembly until you have read and understand the assembly instructions.

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Movement of the transmitter could cause unexpected blade movement. Death or serious injury could occur. Turn off the transmitter before you move the transmitter or before you adjust the transmitter.

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Do not operate this system unless you are fully trained on this equipment. To avoid injury, the machines park brake must be engaged prior to starting the calibration. Maintain adequate clearance from people and objects as the blade may move abruptly during automatic hydraulic valve calibration.

Required Tools

The following tools will be required in order to install the AccuGrade^® - Grade Control System (GPS/ATS). The list below contains the recommended Caterpillar service tools.

Table 1

Part Number	Description
9S-1748	Socket Wrench Set (1/2-IN DRIVE)
199-6156	Socket Wrench Set (1/2-IN DRIVE-METRIC)
194-3584	Socket Wrench Set (TORX)
1U-7230	Hand Tool Group (SCREWDRIVERS)
8T-9293	Torque Wrench (1/2-IN DRIVE)
9S-3263	Thread Lock Compound
266-2916	GPS Measuring Assembly
1U-9367	Automatic Tape Measure (1-INX26-FT)
266-2916	GPS Measuring Assembly
	Straight Edge 1219.2 mm (4 ft)
	Adjustable Square 609.6 mm (2 ft)
	Tape Measure 15.24 m (50 ft)
	Level (minimum 1.2 m (4 ft))
	Plumb Bob (minimum 0.5 kg (1.0 lb))
	Framing Square or Carpenter Square (minimum 30.5 cm (12.0 inch))

Parts List

H Series

Table 2

292-7974 Monitor Display Arrangement (CD700)
Description	Part Number	Quantity
Radio Mounting Group	167-8602	1
Monitor (LIGHT BAR)	244-1720	3
Cab Wiring Group	247-6437	1
Radio Wiring Group	254-1561	1
Monitor Display Group (CD700)	286-0134	1
Monitor Mounting Group (CD700 DISPLAY)	286-5697	1

Table 3

286-0134 Monitor Display Group (CD700)
Description	Part Number	Quantity
Bolt	7X-2619	4
Screw-Machine	8T-7852	6
Washer	9X-8256	4
Washer-Hard	096-6166	6
Adapter-Compact	194-8031	1
Monitor Display Group	244-1716	1
Memory Card Assembly (FLASH)	283-4426	1
Compact Disc	291-3845	1
Carrying Case	292-0311	1

Table 4

286-5697 Monitor Mounting Group (CD700 DISPLAY)
Description	Part Number	Quantity
Bolt	0L-1351	1
Bolt	8T-2501	2
Screw-Machine	8T-7852	6
Washer-Hard	096-6166	6
Support Assembly	286-5686	1
Mounting Bracket Group	293-4662	1

Table 5

247-6437 Cab Wiring Group
Description	Part Number	Quantity
Strap-Cable	3S-2093	7
Clip	4D-8123	1
Clip	4K-8864	1
Clip-Ladder	4P-7581	1
Washer-Hard	5P-4115	9
Clip	5P-9297	3
Clip	5P-9299	3
Washer-Hard	8T-4121	1
Bolt	8T-4137	1
Washer-Hard	8T-4205	4
Screw-Truss Head	9X-2043	1
Screw-Truss Head	9X-2044	2
Screw-Truss Head	9X-2045	4
Screw-Machine	111-4627	2
Clip	130-5300	4
Clip-Ladder	156-6175	2
Screw-Truss Hard	225-3109	6
Plate Assembly (RH)	249-3731	1
Plate Assembly (LH)	249-3733	1
Plate Assembly	249-3736	1
(Wire Assembly)	251-7591	1
Harness Assembly	299-7694	1

Table 6

255-2425 Communication Radio Group
Description	Part Number	Quantity
Communication Radio Group	255-2424	1
Bolt	167-8999	6

Table 7

167-8602 Radio Mounting Group
Description	Part Number	Quantity
Bolt	5S-7349	2
Hard Washer	8T-4205	2
Grommet	9V-2818	2
Boss	103-5672	3
Mounting Bracket	140-7480	1
Plate	149-8196	1
Vibration Isolator Mounting Group	150-1893	1
Bracket Assembly	167-8610	1
Bolt	167-8999	6

Table 8

249-8901 Radio Wiring Group
Description	Part Number	Quantity
Washer-Hard	8T-4121	1
Nut	8T-4133	6
Bolt	8T-4136	10
Clip	033-8248	8
Radio Harness Assembly	243-3247	1

Table 9

249-7788 Grade Sensor Arrangement (CROSS SLOPE A) (1)
Description	Part Number	Quantity
Power Supply Module Assembly	226-9169	1
Position Sensor Assembly	226-6146	2
Position Sensor Group (BLADE ROTATION)	244-1714	1
Bracket Kit	250-2172	1
Bolt	4M-6425	2
Hard Washer	8T-4224	4
Bolt	270-7137	1
Sensor Bracket Assembly	255-0941	1
Screw	269-3303	3
Spacer	269-3304	3
Bolt	8T-0326	1
Sensor Harness Assembly	243-3250	1
Sensor Harness Assembly	236-2356	1
Washer	9X-8256	5
Clip	4K-8302	4
Bolt	8T-4191	4
Washer-Hard	8T-4121	1
Strap-Cable	3S-2093	7
Clip	9G-9154	2
Bolt	061-6665	2
Washer	089-7960	1
Nut	160-8500	4
Clip	186-0359	1
Flat Head Screw	188-9644	4
Hard Washer	211-9032	4
Bracket	251-2383	1
Nut	5C-2890	1
Nut	8T-4244	1
Bolt	7Y-0589	1
Nut	8T-4133	6
Bolt	8T-4195	2
Hard Washer	8T-4223	1
Sleeve	8X-5489	2
Bolt	9X-2537	4

( 1 )

120H, 135H, 12H, 140H, 143H, 160H and 163H Motor Graders

Table 10

250-3027 Grade Sensor Arrangement (CROSS SLOPE B) (1)
Description	Part Number	Quantity
Power Supply Module Assembly	226-9169	1
Position Sensor Assembly	276-6146	2
Position Sensor Group (BLADE ROTATION)	244-1714	1
Bracket Kit	250-2172	1
Bolt	4M-6425	2
Hard Washer	8T-4224	4
Bolt	270-7137	1
Sensor Bracket Assembly	255-0941	1
Screw	269-3303	3
Spacer	269-3304	3
Bolt	8T-0326	1
Sensor Harness Assembly	236-2356	1
Sensor Harness Assembly	236-2356	1
Washer	9X-8256	5
Clip	4K-8302	3
Bolt	8T-4191	4
Washer-Hard	8T-4121	1
Clip	9G-9154	2
Bolt	061-6665	2
Washer	089-7960	1
Nut	160-8500	4
Clip	186-0359	1
Flat Head Screw	188-9644	4
Hard Washer	211-9032	4
Bracket	251-2383	1
Nut	5C-2890	1
Nut	8T-4244	1
Bolt	7Y-0589	1
Nut	8T-4133	6
Bolt	8T-4195	1
Hard Washer	8T-4223	1
Sleeve	8X-5489	2
Bolt	9X-2537	4

( 1 )

14H and 16H Motor Graders

Table 11

272-5450 Sonic Sensor Group (SINGLE) / 272-5451 Sonic Sensor Group (DUAL)
Description	Part Number	Quantity (1)
Carrying Case	256-6944	1
Base Assembly	248-1484	2
Sonic Sensor Assembly (ST400)	253-8330	1
Pole	248-1487	1
Bracket Assembly	248-1488	1
Coiled Cable	248-1497	1

( 1 )

The quantity will double with the 272-5451 Sonic Sensor Group (DUAL). There is only a single storage case included with the kit.

Table 12

250-1934 Sensor Mounting Group (SONIC)
Description	Part Number	Quantity
Bolt	4L-6454	3
Bolt	7X-2537	1
Hard Washer	8T-4224	2
Bolt	8T-7547	1
Bracket Assembly	245-7405	1
Clamp	245-7406	1
Bracket Assembly	245-7407	1

Table 13

292-7971 Satellite Receiver Arrangement (SINGLE GNSS, MS990) / 292-7972 Satellite Receiver Arrangement (DUAL GNSS, MS990)
Description	Part Number	Quantity (1)
Satellite Receiver Assembly (GNSS, MS990)	291-1913	1
Bracket Assembly	252-9628	1
Mounting Bracket Group	248-1503	1
Coiled Cable	254-9136	1
Film	252-8744	1
Mast Assembly	271-6373	1
Riser	248-1502	1
Plastic Case (RECEIVER)	255-0939	1

( 1 )

The quantity will double with the 292-0315 Kit (Dual GPS Sensor) . There is only a single Carrying Case included with the kit.

Table 14

249-7803 Laser Grade Control Arrangement (ADVANCED TRACKING SYSTEM) MT600
Description	Part Number	Quantity
Laser Target Assembly	244-1722	1
Case - Plastic	248-1498	1
Bracket - Adapter	252-5237	1
Film	252-8744	1
Coiled Cable	276-0764	1
Electric Mast	226-2333	1
Adapter	245-4747	1
Coiled Cable	231-0049	1
Mount	234-9970	1
Adjustable Angle Bracket	248-1503	1
Riser	248-1496	1
Bolt	9S-1362	1
Washer	3B-4512	1

Table 15

317-6526 Laser Grade Control Arrangement (ADVANCED TRACKING SYSTEM) MT900
Description	Part Number	Quantity
Laser Target Assembly	256-2907	1
Case - Plastic	244-1719	1
Film	252-8744	1
Coiled Cable	276-0764	1
Electric Mast	226-2333	1
Adapter	245-4747	1
Coiled Cable	231-0049	1
Mount	234-9970	1
Adjustable Angle Bracket	248-1503	1
Riser	248-1496	1
Bolt	9S-1362	1
Washer	3B-4512	1
Block	275-3376	1

Table 16

249-7803 Laser Grade Control Arrangement (Advanced Tracking System) MT600
Description	Part Number	Quantity
Laser Target Kit	216-0182	1
Riser	248-1496	1
Mast Assembly	226-2333	1
Coiled Cable	231-0049	1
Receiver Mounting Group	234-9970	1
Mounting Bracket Group	248-1503	1

Table 17

292-0310 Laser Receiver Arrangement (Dual)
Description	Part Number	Quantity
Plastic Case	235-4587	1
Mast Assembly	226-2333	2
Receiver Mounting Group	234-9970	2
Hard Washer	8T-4223	16
Nut	8T-4244	8
Bolt	8T-4648	8
Film	237-7552	6
Film	252-8744	2
Laser Receiver Group	253-8329	2
Coiled Cable	276-0764	2
Coiled Cable	231-0049	2
Riser	248-1496	2
Fastener	248-1503	2

Table 18

292-0301 Laser Receiver Arrangement (Single)
Description	Part Number	Quantity
Plastic Case	235-4587	1
Mast Assembly	226-2333	1
Receiver Mounting Group	234-9970	1
Hard Washer	8T-4223	8
Nut	8T-4244	4
Bolt	8T-4648	4
Film	237-7552	3
Film	252-8744	1
Laser Receiver Group	253-8329	1
Coiled Cable	276-0764	1
Coiled Cable	231-0049	1
Riser	248-1496	1
Fastener	248-1503	1

Table 19

Available Radio Kits
Part Number	Description
Communication Radio Group	255-2425
Communication Radio Group	263-5835
Communication Radio Group	267-3819
Communication Radio Group	267-3820
Communication Radio Group	267-3821
Communication Radio Group	267-3822
Communication Radio Group	267-3823
Communication Radio Group	276-1374
Communication Radio Group	278-2270

M Series

Table 20

292-7975 Monitor Display Arrangement (CD700)
Description	Part Number	Quantity
Monitor Wiring Group	253-1964	1
Monitor Display Group	286-0134	1
Monitor (LIGHT BAR)	286-9124	3

Table 21

286-0134 Monitor Display Group
Description	Part Number	Quantity
Screw	8T-0285	6
Bolt	8T-4171	4
Washer	9X-8256	4
Hard Washer	096-6166	6
Adapter	194-8031	1
Monitor Display Group	244-1716	1
Memory Card Assembly (FLASH)	283-4426	1
Compact Disc	291-3845	1
Carrying Case	292-0311	1

Table 22

253-1964 Monitor Wiring Group
Description	Part Number	Quantity
Cable Strap	7K-1181	1
Mounting Bracket	140-7480	1
Bracket Assembly	167-8610	1
Hard Washer	222-9151	2
Knob	245-8334	2
Front Chassis Harness Assembly	252-5190	1
Bracket Assembly	253-1963	1
Radio Harness Assembly	253-7461	1
Bracket Assembly	273-1719	1
Knob	273-5924	1
Plate	295-8369	1
Bracket Assembly	295-8370	1
Plate Assembly	295-8381	1
Wiring Harness	296-1067	1
Bracket Assembly	300-7909	1
Washer	114-6658	2
Hard Washer	096-6166	6
Washer	117-8929	1
Clip	130-5300	2
Bolt	204-0813	3
Screw	225-3109	4
Cotter Pin	3B-4610	2
Lockwasher	4L-7125	4
Nut	5C-7261	2
Hard Washer	5P-4116	6
Grommet	5P-6419	1
Bolt	5S-7349	2
Clevis Pin	6B-8193	2
Bolt	7X-2537	2
Isolation Mount	8C-5607	6
Spacer	8C-5608	3
Hard Washer	8T-4205	2
Hard Washer	8T-4224	4
Bolt	8T-4908	2
Bolt	8T-7852	6
Bolt	8T-9394	2
Screw	9X-2045	2
Washer	9X-6165	3
Seal	5P-7656	1.1 dm

Table 23

262-2017 Grade Sensor Arrangement (Cross Slope)
Description	Part Number	Quantity
Position Sensor Assembly	276-6146	2
Position Sensor Group	244-1714	1
Sensor Bracket Assembly	255-0941	1
Bracket Kit	250-2172	1
Bolt	9X-2537	4
Washer	9X-8256	7
Nut	5C-2890	3
Washer	089-7960	1
Bolt	8T-0326	1
Bolt	061-6665	2
Clip	186-0359	1
Bolt	8T-3844	4

Table 24

286-0133 Sonic Sensor Group (Single)
Description	Part Number	Quantity
Sonic Sensor Assembly (ST400)	253-8330	1
Pole	248-1487	1
Bracket Assembly	248-1488	1
Coiled Cable	248-1497	1
Base Assembly	248-1484	2
Carrying Case	256-6944	1
Fastener Group	258-1536	1

Table 25

286-0132 Sonic Sensor Group (Dual)
Description	Part Number	Quantity
Sonic Sensor Assembly (ST400)	253-8330	2
Pole	248-1487	2
Bracket Assembly	248-1488	2
Coiled Cable	248-1497	2
Base Assembly	248-1484	2
Carrying Case	256-6944	1
Fastener Group	258-1536	1

Table 26

292-7971 Satellite Receiver Arrangement (SINGLE GNSS, MS990) / 292-7972 Satellite Receiver Arrangement (DUAL GNSS, MS990)
Description	Part Number	Quantity (1)
Satellite Receiver Assembly (GNSS, MS990)	291-1913	1
Bracket Assembly	252-9628	1
Mounting Bracket Group	248-1503	1
Coiled Cable	254-9136	1
Film	252-8744	1
Mast Assembly	271-6373	1
Riser	248-1502	1
Plastic Case (RECEIVER)	255-0939	1

( 1 )

The quantity will double with the 292-0315 Kit (Dual GPS Sensor) . There is only a single Carrying Case included with the kit.

Table 27

249-7803 Laser Grade Control Arrangement (ADVANCED TRACKING SYSTEM) MT600
Description	Part Number	Quantity
Laser Grade Control Ar	216-0182	1
Laser Target Kit	226-2333	1
Mast Assembly	231-0049	1
Coiled Cable	234-9970	1
Receiver Mounting Gp	248-1496	1
Riser	248-1503	1

Table 28

317-6526 Laser Grade Control Arrangement (ADVANCED TRACKING SYSTEM) MT900
Description	Part Number	Quantity
Laser Target Assembly	256-2907	1
Case - Plastic	244-1719	1
Film	252-8744	1
Coiled Cable	276-0764	1
Electric Mast	226-2333	1
Adapter	245-4747	1
Coiled Cable	231-0049	1
Mount	234-9970	1
Adjustable Angle Bracket	248-1503	1
Riser	248-1496	1
Bolt	9S-1362	1
Washer	3B-4512	1
Block	275-3376	1

Table 29

292-0310 Laser Receiver Arrangement (Dual)
Description	Part Number	Quantity
Plastic Case	235-4587	1
Mast Assembly	226-2333	2
Receiver Mounting Group	234-9970	2
Hard Washer	8T-4223	16
Nut	8T-4244	8
Bolt	8T-4648	8
Film	237-7552	6
Film	252-8744	2
Laser Receiver Group	253-8329	2
Coiled Cable	276-0764	2
Coiled Cable	231-0049	2
Riser	248-1496	2
Fastener	248-1503	2

Table 30

292-0301 Laser Receiver Arrangement (Single)
Description	Part Number	Quantity
Plastic Case	235-4587	1
Mast Assembly	226-2333	1
Receiver Mounting Group	234-9970	1
Hard Washer	8T-4223	8
Nut	8T-4244	4
Bolt	8T-4648	4
Film	237-7552	3
Film	252-8744	1
Laser Receiver Group	253-8329	1
Coiled Cable	276-0764	1
Coiled Cable	231-0049	1
Riser	248-1496	1
Fastener	248-1503	1

Table 31

Radio Kit
Description	Part Number	Quantity
Radio Group		1
Bolt	167-8999	6

System Components

Illustration 1	g01435121
H Series (1) Display (2) Angle Sensor (Mainfall) (3) Angle Sensor (Blade Slope) (4) Rotation Sensor (5) GPS Receiver (6) TC900 Radio (7) Laser Sensor (8) Sonic Sensor (9) ATS

Illustration 2	g01450825
M Series (1) Display (2) Angle Sensor (Mainfall) (3) Angle Sensor (Blade Slope) (4) Rotation Sensor (5) GPS Receiver (6) TC900 Radio (7) Laser Sensor (8) Sonic Sensor (9) ATS

Display

Illustration 3	g01287477
(80) LCD (81) Soft Keys Labels (82) Hard Keys (83) Escape Key (84) Next Key (85) Power Key (86) "+" Key (87) Arrow Keys (88) "-" Key (89) "OK" Key (90) Menu Key (91) Data Card Slot

The 244-1716 Display (1) is a computer that runs the software for the AccuGrade System. The Display (1) is used in order to operate the AccuGrade System. The Display (1) has a LCD screen in order to show information and a keypad for entering information.

Angle Sensors

Illustration 4	g01184100

The 276-6146 Position Sensor Assembly (2, 3) is a highly accurate sensor that is capable of measuring up to 100 percent slopes.

In a Cross Slope system, one 276-6146 Position Sensor Assembly (2, 3) measures the actual slope of the blade, and a second 276-6146 Position Sensor Assembly (2, 3) measures the slope of the machine in the direction of travel.

Rotation Sensor

Illustration 5	g01184175

The 244-1714 Position Sensor Group (BLADE ROTATION) (4) is a device that measures the change of the angle between two pivoting members. The primary application is for measuring the rotation of the blade. That measurement is used in order to calculate the cross slope of the blade of a machine.

Sonic Sensor

Illustration 6	g01309464
(11) 253-8330 Sonic Sensor Assembly (ST400)

The Sonic Sensor Assembly (11) uses sound waves in order to determine the distance to a reference surface. References can include the following items: string line, curb and gutter. Additionally, the reference can include the previous pass. Once the device has been locked onto a reference, any change in the distance from the set point causes a correction signal to be sent to the 244-1716 Display (1) .

The Sonic Sensor (11) measures the length of time that is taken by the sound waves to travel between the transducer in the Sonic Sensor (11) and the reference surface in order to determine the elevation. Once the elevation is set, any deviations in elevation are sent to the 244-1716 Display (1). These corrections are then sent to the Implement/Valve Control ECM. Then, the Implement/Valve Control ECM sends the correction signals to the proportional control valve.

GPS Receiver

Illustration 7	g01205196
(20) 291-1913 Satellite Receiver Assembly (21) Mast (22) Thumb Wheel On Quick Release Bracket

The 291-1913 Satellite Receiver Assembly (20) is mounted on a mast over the blade tips. The AccuGrade System utilizes one or two 291-1913 Satellite Receiver Assembly (20) .

ATS Target

Illustration 8	g01435707

The 256-2907 Laser Target Group is mounted on the left side of the blade or the right side of the blade. The 256-2907 Laser Target Group has two sections:

• An LED Unit (25), which acts as the target for the tracking system

• A Prism Unit (26), which acts as a target for the off board ATS instrument.

The ATS Instrument is a robotic theodolite capable of making high precision measurements of the azimuth, altitude and distance of the 256-2907 Laser Target Group . Specially designed servomotors work with the tracking software in order to allow the ATS to track 256-2907 Laser Target Group moving at typical machine speeds. If the 256-2907 Laser Target Group is lost, then the ATS Instrument will try to predict how the 256-2907 Laser Target Group is moving, so that it can attempt to reacquire the 256-2907 Laser Target Group .

Laser Receiver

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To prevent possible personal injury during installation and removal of the laser receivers, lower the mast to the minimum height and use an approved access system to reach the mounting locations of the laser receivers at the top of the mast. Do not climb on the blade.

The AccuGrade Laser system uses one or two Laser Receivers. The Laser Receivers are 360 degree omni-directional receivers that detect the laser beam and send information about the elevation of the laser beam to the AccuGrade Display.

LR410

Show/hide table

To prevent possible personal injury during installation and removal of the laser receivers, lower the mast to the minimum height and use an approved access system to reach the mounting locations of the laser receivers at the top of the mast. Do not climb on the blade.

Each Laser Receiver is mounted on an electric mast. Illustration 9 shows the 253-8329 Laser Receiver Group .

Illustration 9	g01309169
253-8329 Laser Receiver Group (LR410)

Table 32

Features and functions of the Laser Receiver
Callout	Feature	Function
24	Photo Detectors	The detectors sense the laser beam when it hits the receiver.
25	Power and Grade LED's	The power LED will illuminate when power is applied to the Laser receiver. The LED will flash slowly if below grade is detected and flash quickly if above grade is detected.

The Power and Grade LEDs flash in the following patterns:

• Error - 2 flashes every 1.6 seconds

• On No Beam - 1 flash every 1.6 seconds

• Above Grade - 5 flashes every second

• On Grade - Solid on

• Below Grade - 2.5 flashes every second

Electric Mast (EM400C)

The AccuGrade Laser system uses one or two 226-2333 Mast Assemblies . The 226-2333 Mast Assembly is a telescopic receiver mount that is driven by an electric motor. The mast vertically raises and lowers the laser receivers in order to locate the laser beam.

Illustration 10	g01372486
Electric Mast

Refer to Table 33 shows the features and functions of the electric mast:

Table 33

Features and Functions of the Electric Mast
Feature	Function
Inner Mast Tube	Raises and lowers the laser receiver to locate the laser beam and to change an existing elevation setting
6-Socket Receiver Cable Connector	Connects the coiled cable from the laser receiver to the electric mast
10-Pin Control Cable Connector	Connects the electric mast to the main harness
Block Adapter (LR400 only)	The receiver clamp attaches the to the block adapter.

Data Radio

Illustration 11	g01457303
CR Series

The CR Series Radio allows the machine to communicate with the off board site infrastructure. This includes the GPS base station or the Automatic Total Station (ATS).

H Series Installation Procedures

Sensors

The information in this section refers to the installation of the 249-7788 Sensor Kit or the 250-3027 Sensor Kit. .

Note: These sensors are optional for Dual GPS and Dual Laser systems.

Table 34

Tools That are Needed
Quantity	Description
1	Adjustable Square ( 600 mm (2 ft))

Rotation Sensor Installation

1. Make sure that the blade is square to the machine.

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Illustration 12	g01103304

2. Remove the bolts (48) on the swivel lid.

3. Remove bolt (47) from the frame of the circle.

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Illustration 13	g01103309

4. Remove the swivel lid (49) .

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Illustration 14	g01204141
(4) 244-1714 Position Sensor Group (BLADE ROTATION) (51) 7Y-0589 Bolt (53) 4K-8302 Clip (54) 8T-4244 Nut (56) 8T-4223 Hard Washer (81) Connector of the 243-3250 Sensor Harness Assembly

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Illustration 15	g01120720

5. Replace the bolt that was taken out in Step 3 with 7Y-0589 Bolt (51). Tighten the bolt to 55.0 ± 10.0 N·m (41.0 ± 7.0 lb ft).

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Illustration 16	g01103309

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Illustration 17	g01108042

6. Remove the white and black seals from the swivel lid.

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Illustration 18	g01108045

7. Place the seals from the swivel lid onto the 255-0941 Plate (60) .

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Illustration 19	g01102028

8. Replace the existing swivel lid with the 255-0941 Sensor Bracket Assembly (60). Place the White Spacer (65) on 255-0941 Sensor Bracket Assembly (60). Refer to Illustration 19.

   Note: The White Spacer (65) is packaged with the 244-1714 Position Sensor Group (BLADE ROTATION) (4) .

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Illustration 20	g01184190

9. Install the 255-0941 Sensor Bracket Assembly (60) and face the slot (66) in the direction that is shown in Illustration 20. This will ensure that the Rotation Arm (70) is indexed at zero. Use the 061-6665 Bolts (64) in order to secure the 255-0941 Sensor Bracket Assembly (60) .

10. Install 061-6665 Bolts (64) and tighten in order to secure the 255-0941 Sensor Bracket Assembly (60) in place.

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Illustration 21	g01108055

11. Install the 244-1714 Position Sensor Group (BLADE ROTATION) (4) onto the Plate.

    Make sure that the Rotation Arm (70) is seated into the slot (66). Make sure that the connector (71) of the 244-1714 Position Sensor Group (BLADE ROTATION) (4) faces in the direction of the rear of the machine.

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Illustration 22	g01108122

12. Use the 269-3303 Screws (75) and 269-3304 Spacers (77) in order to secure the 244-1714 Position Sensor Group (BLADE ROTATION) (4) to the 255-0941 Plate (60) .

13. Tighten the 269-3303 Screws (75) and 269-3304 Spacers on the 255-0941 Sensor Bracket Assembly (60) .

    Note: The 244-1714 Position Sensor Group (BLADE ROTATION) will continue to rotate until 250-2172 Bracket Assembly (99) is installed. Refer to Illustration 25.

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Illustration 23	g01205199
(4) 244-1714 Position Sensor Group (BLADE ROTATION) (30) 9G-9154 Clip (31) 8T-4191 Bolt (32) 8T-4121 Hard Washer (33) 8X-5489 Sleeve (53) 4K-8302 Clip (54) 8T-4244 Nut (56) 8T-4223 Hard Washer (64) 061-6665 Bolt (78) 4-pin connector of the 243-3250 Sensor Harness Assembly (79) 243-3250 Sensor Harness Assembly (80) 236-2356 Sensor Harness Assembly (88) 4-pin connector of the 236-2356 Sensor Harness Assembly

14. Connect the 243-3250 Harness (79) for the 244-1714 Position Sensor Group (BLADE ROTATION) (4) to the connector (78). Refer to Illustration 23.

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Illustration 24	g01204141
(4) 244-1714 Position Sensor Group (BLADE ROTATION) (51) 7Y-0589 Bolt (53) 4K-8302 Clip (54) 8T-4224 Nut (56) 8T-4223 Hard Washer (81) Connector of the 243-3250 Sensor Harness Assembly

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Illustration 25	g01184298
250-2172 Bracket Assembly

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Illustration 26	g01184324
Part A of 250-2172 Bracket Assembly

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Illustration 27	g01145760

15. Attach part A of the 250-2172 Bracket Assembly to the 7Y-0589 Bolt (51) that was installed in Step 5. Use the 8T-4244 Nut (54) and the 8T-4223 Hard Washer (56) .

    Note: Do not tighten the nut. There is additional hardware that will be added in the ""Installation of the Blade Slope Sensor" " section.

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Illustration 28	g01184351
Part B of 250-2172 Bracket Assembly

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Illustration 29	g01145703

16. Place the 186-0359 Clip (85) around the 243-3250 Sensor Harness Assembly (79) .

17. Use the bolts and washers (58) of the 250-2172 Bracket Assembly to secure part B of the 250-2172 Bracket Assembly and the 186-0359 Clip (85) to the top of the 244-1714 Position Sensor Group (BLADE ROTATION) (4) .

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Illustration 30	g01388261

18. Install the 270-7137 Bolt (86) between part A and part B of the 250-2172 Bracket Assembly . Refer to Illustration 30.

19. Install the Connector (81) for the 243-3250 Sensor Harness Assembly to the 244-1714 Position Sensor Group (BLADE ROTATION) (4) .

20. Stop.

Installation of the Blade Slope Sensor

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Illustration 31	g01102023
(3) 276-6146 Position Sensor Assembly (89) Connector of the 236-2356 Sensor Harness Assembly

1. Install the Sensor (3) .

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Illustration 32	g01213210
(3) 276-6146 Position Sensor Assembly (31) 8T-4191 Bolt (32) 8T-4121 Hard Washer (57) 9X-2537 Bolt (82) 251-2383 Bracket (89) Connector of the 236-2356 Sensor Harness Assembly

2. Use the 9X-2537 Bolt (57) in order to secure the 276-6146 Position Sensor Assembly to the mounting plate on the rear of the circle.

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Illustration 33	g01205199
(4) 244-1714 Position Sensor Group (BLADE ROTATION) (30) 9G-9154 Clip (31) 8T-4191 Bolt (32) 8T-4121 Hard Washer (33) 8X-5489 Sleeve (53) 4K-8302 Clip (54) 8T-4244 Nut (56) 8T-4223 Hard Washer (64) 061-6665 Bolt (78) 4-pin connector of the 243-3250 Sensor Harness Assembly (79) 243-3250 Sensor Harness Assembly (80) 236-2356 Sensor Harness Assembly (88) 4-pin connector of the 236-2356 Sensor Harness Assembly

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Illustration 34	g01204169
(30) 9G-9154 Clip (31) 8T-4191 Bolt (32) 8T-4121 Washer (33) 8X-5489 Sleeve (53) 4K-8302 Clip (54) 8T-4244 Nut (56) 8T-4223 Washer

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Illustration 35	g01213212
(3) 276-6146 Position Sensor Assembly (31) 8T-4191 Bolt (32) 8T-4121 Hard Washer (57) 9X-2537 Bolt (82) 251-2383 Bracket (89) Connector of the 236-2356 Sensor Harness Assembly

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Illustration 36	g01213225

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Illustration 37	g01213231

3. Route the 236-2356 Sensor Harness Assembly through the circle as shown in Illustration 35, Illustration 36, and Illustration 37.

4. Install the 8T-4195 Bolt (141), 4K-8302 Clip (53), 8T-4121 Washer (32), and 8T-4133 Nut (143) in order to secure the 236-2356 Blade Slope Sensor Harness to the hose tray. Refer to Illustration 36 and Illustration 37.

   Note: Additional information on routing the cables through the circle can be found in the ""Diagrams" " of this manual.

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Illustration 38	g01205199
(4) 244-1714 Position Sensor Group (BLADE ROTATION) (30) 9G-9154 Clip (31) 8T-4191 Bolt (32) 8T-4121 Hard Washer (33) 8X-5489 Sleeve (53) 4K-8302 Clip (54) 8T-4244 Nut (56) 8T-4223 Hard Washer (64) 061-6665 Bolt (78) 4-pin connector of the 243-3250 Sensor Harness Assembly (79) 243-3250 Sensor Harness Assembly (80) 236-2356 Sensor Harness Assembly (88) 4-pin connector of the 236-2356 Sensor Harness Assembly

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Illustration 39	g01102023
(3) 276-6146 Position Sensor Assembly (89) Connector of the 236-2356 Sensor Harness Assembly

5. Connect the 6-pin connector (89) of the 236-2356 Sensor Harness Assembly to the connector on the 276-6146 Position Sensor Assembly (3). Connect the 4-pin connector of the 236-2356 Sensor Harness Assembly to the mating connector on the right side of the circle.

   Note: Ensure that the 4-Pin Connector (88) of the harness for the Blade Slope Sensor is routed between the base of the sensor and the cylinder below. The round 6-Pin Connector (89) will not fit through the gap.

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Illustration 40	g01213232

6. Install the 8T-4191 Bolt (31), 8T-4121 Hard Washer (32), and 4K-8302 Clip (53) in order to secure the 236-2356 Sensor Harness Assembly to the frame of the circle. Refer to Illustration 40.

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Illustration 41	g01204169
(30) 9G-9154 Clip (31) 8T-4191 Bolt (32) 8T-4121 Washer (33) 8X-5489 Sleeve (53) 4K-8302 Clip (54) 8T-4244 Nut (56) 8T-4223 Washer

7. Place the 4K-8302 Clip (53) around the 236-2356 Blade Slope Sensor Harness . Secure the 4K-8302 Clip (53) to the 7Y-0589 Bolt (51) with the 8T-4244 Nut (54) and the 8T-4223 Washer (56) .

Installation of the Power Module

Illustration 42	g01213796
(2) 276-6146 Position Sensor Assembly (57) 9X-2537 Bolt (91) 5C-2890 Nut (92) 226-9169 Power Module (148) 188-9644 Flat Head Screw (149) 211-9032 Hard Washer (150) 160-8500 Nut

Illustration 43	g01102121
(2) 276-6146 Position Sensor Assembly (92) 226-9169 Power Module

1. Remove the cover panels that are located below the cab on the left hand side and the right hand side of the machine.

2. Remove the 3 bolts that secure the bracket for the 276-6146 Position Sensor Assembly (2) and the 061-6665 Bolts .

3. Remove the Implement/Valve Control ECM from the Plate.

4. Use the 188-9644 Flat Head Screw (148), 211-9032 Washer (149) and 160-8500 Nut (150) to mount the 226-9169 Power Module (92) to the bracket.

Note: There are 2 connectors on the 226-9169 Power Module (92). Make sure that the 061-6665 Bolts (92) is oriented correctly with the symbol for the battery. Make sure that the cables will reach to the correct connector for the 226-9169 Power Module (92). The connectors on the 226-9169 Power Module (92) are designed so that the connection of the 226-9169 Power Module (92) to the system will be correct.

Note: On some models, there are hydraulic hoses that are attached to the bracket.

Mainfall Sensor Installation

Illustration 44	g01213796
(2) 276-6146 Position Sensor Assembly (57) 9X-2537 Bolt (91) 5C-2890 Nut (92) 226-9169 Power Module (148) 188-9644 Flat Head Screw (149) 211-9032 Hard Washer (150) 160-8500 Nut

Illustration 45	g01456742

Use a 9X-2537 Bolt (57) in order to secure the 276-6146 Position Sensor Assembly (2) to the threaded hole in the bracket. Use a 9X-2537 Bolt (57), 9X-8256 washer (103) and 5C-2890 Nut (91) in order to secure the 276-6146 Position Sensor Assembly (2) to the slotted hole in the bracket. Refer to Illustration 45.

The 276-6146 Position Sensor Assembly (2) must be parallel within 2.0 mm (0.08 inch) to the frame.

1. Place the straight edge of the Adjustable Square (600 mm (2 ft)) on the side of the 276-6146 Position Sensor Assembly (2) .

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Illustration 46	g01079500

2. Verify that the second straight edge of the Adjustable Square (600 mm (2 ft)) is parallel with the edge of the cab platform. Refer to Illustration 46.

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Illustration 47	g01213796
(2) 276-6146 Position Sensor Assembly (57) 9X-2537 Bolt (91) 5C-2890 Nut (92) 226-9169 Power Module (148) 188-9644 Flat Head Screw (149) 211-9032 Hard Washer (150) 160-8500 Nut

3. If the 276-6146 Position Sensor Assembly (2) is not parallel to the cab platform, then loosen the 5C-2890 Nut (91) and the 9X-2537 Bolt (57) that is to the rear of the motor grader on the sensor. Adjust the sensor until the second straight edge is parallel with the cab platform. Tighten the nut and the bolt.

   Note: The rear hole for the sensor on the mounting bracket is slotted for purposes of adjusting.

4. Once the cab platform is parallel to the second straight edge secure the 276-6146 Position Sensor Assembly (2) .

5. After the 276-6146 Position Sensor Assembly (2) has been secured, verify that the sensor is aligned correctly.

   Note: Tightening the bolts of the 276-6146 Position Sensor Assembly (2) can cause the 276-6146 Position Sensor Assembly (2) to move out of adjustment.

GPS

The information in this section describes the procedure for the installation of the 250-3028 Kit (Dual GPS) or the 249-7802 Kit (Single GPS) .

Installation of the Adjustable Angle Bracket

The 248-1503 Adjustable Angle Bracket is used in order to mount the masts for either the 291-1913 Satellite Receiver Assembly (20) or 256-2907 Laser Target Group .

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Illustration 48	g01079269
Adjustable Angle Bracket (111) 7X-0366 Bolts (112) 8T-4994 Washers (113) 7X-0343 Bolts (114) 8T-4122 Washers

1. Secure the 248-1503 Adjustable Angle Bracket to the mounting pad on the blade with 3 7X-0366 Bolts (111) and 8T-4994 Washers (112) .

2. Tighten the 7X-0366 Bolts (111) and 8T-4994 Washers (112) to 305 N·m (225 lb ft).

Installation of the Riser

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Illustration 49	g01204205

1. Set the 248-1502 Angle Riser on top of the 248-1503 Adjustable Angle Bracket .

2. Secure the 248-1502 Angle Riser to the 248-1503 Adjustable Angle Bracket with the supplied 5/8-inch bolts, washers, and lock washers.

   Refer to Illustration 49.

3. Use the supplied lock nuts in order to lock the riser bolts in place.

4. Tighten the nuts to 215 ± 40 N·m (160 ± 30 lb ft).

GPS Receiver

Note: If a 252-9628 Bracket Kit (23) has been removed from a 291-1913 Satellite Receiver Assembly (20), the bolts must be tightened to 41 N·m (30 lb ft).

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

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Illustration 50	g01205309
Bottom of the GPS receiver (20) 291-1913 Satellite Receiver Assembly (GNSS, MS990) (22) Thumb Wheel (23) 252-9628 Bracket Kit (24) Bolts

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Illustration 51	g01205316
(20) 291-1913 Satellite Receiver Assembly (GNSS, MS990) (21) 271-6373 Mast (23) 252-9628 Bracket Kit (27) Cable strain relief

1. Slide the 291-1913 Satellite Receiver Assembly (GNSS, MS990) (20) onto the top of the 271-6373 Mast (21). Orient the Receiver so that the LEDs are visible from the cab of the machine. Refer to Illustration 51.

Note: You must fully insert the GPS Mast into the bracket on the GPS Receiver. Otherwise, the blade tip to antenna measurements will not be correct, resulting in wrong elevation guidance and construction.

2. Firmly tighten the Thumb Wheel (22) on the Bracket (23) in order to secure the 291-1913 Satellite Receiver Assembly (20) .

3. Repeat Steps 1 and 2 in order to install the remaining 291-1913 Satellite Receiver Assembly (20) and bracket onto the top of the remaining 271-6373 Mast .

   Note: Store the 291-1913 Satellite Receiver Assembly (20) in the 255-0939 Plastic Foam Lined Case when you remove the 291-1913 Satellite Receiver Assembly (20) from the machine.

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Illustration 52	g01204244
271-6373 Mast mounted to the Angle Riser

4. Place the 271-6373 Mast and 291-1913 Satellite Receiver Assembly (20) on top of the 248-1502 Angle Riser .

5. Position the mast on the mounting bracket, and rotate the masts so that the cable strain relief brackets point toward the electrical quick-disconnect brackets on the knuckles.

6. Secure each mast in place with the bolt and lock washer supplied with the mast.

7. Tighten the high tensile bolt to 370 ± 50 N·m (275 ± 37 lb ft).

Installation of the Adjustable Angle Bracket

The 248-1503 Adjustable Angle Bracket is used in order to mount the masts for either the 291-1913 Satellite Receiver Assembly (20) or 256-2907 Laser Target Group .

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Illustration 53	g01079269
Adjustable Angle Bracket (111) 7X-0366 Bolts (112) 8T-4994 Washers (113) 7X-0343 Bolts (114) 8T-4122 Washers

1. Secure the 248-1503 Adjustable Angle Bracket to the mounting pad on the blade with three 7X-0366 Bolts (111) and 8T-4994 Washers (112) .

2. Tighten the 7X-0366 Bolts (111) and 8T-4994 Washers (112) to 305 N·m (225 lb ft).

Installation of the Riser

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Illustration 54	g01079311
(96) 248-1496 Vertical Mast Riser (97) 248-1503 Adjustable Angle Bracket

1. Place the 248-1496 Vertical Mast Riser on top of the 248-1503 Adjustable Angle Bracket .

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Illustration 55	g01079262
(100) 9S-1362 Bolt (101) 3B-4512 Washer

2. Use the 9S-1362 Bolt (100) and the 3B-4512 Washer (101) in order to secure the 248-1496 Vertical Mast Riser (96) to the 248-1503 Adjustable Angle Bracket (97) .

3. Tighten the 9S-1362 Bolt (100) and the 3B-4512 Washer (101) to 305 N·m (225 lb ft).

ATS

The information in this section describes the procedure for the installation of the 317-6526 Laser Grade Control Arrangement (ADVANCED TRACKING SYSTEM) .

Installation of the ATS Sensor

1. Remove the 245-4747 Adapter Block from the 226-2333 Electric Mast (120) .

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Illustration 56	g01435715

2. Install the 275-3376 Block to the 226-2333 Electric Mast (120) .

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Illustration 57	g01435707

3. Place the 256-2907 ATS Target on top of the 226-2333 Electric Mast (120) with 275-3376 Block . Tighten the 256-2907 Laser Target Group to the electric mast with the ratchet handle on the base of the 256-2907 Laser Target Group .

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Illustration 58	g01079275

4. Remove bolts (108) and the bracket (110) .

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NOTICE
The bolts that secure the U-Bracket to the Shock Mounts are not tightened to specification. Failure to perform the following procedure may result in damage to the Electric Mast or Shock Mounts.

5. Remove the two 13 mm (1/2 inch) bolts (115) that secure the U-bracket (109) to the 234-9970 Shock Mounts (105) .

6. Apply 9S-3263 Thread Lock Compound to the two 13 mm (1/2 inch) bolts (115) .

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Illustration 59	g01080139
U-Bracket of the 234-9970 Shock Mounts

7. Install the bolt of the U-Bracket (109) to the bottom of the 226-2333 Electric Mast (120) .

8. Tighten the bolt to 305 N·m (225 lb ft).

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Illustration 60	g01080146

9. Place the 226-2333 Electric Mast (120) into the 234-9970 Shock Mount (105) .

10. Reinstall the bracket that was removed in Step 4 and tighten the bolts (108) by hand.

11. Reinstall the two 13 mm (1/2 inch) bolts (115) into the U-bracket (109) and tighten the bolts to 54 N·m (40 lb ft).

12. Tighten the bolts (108) in Step 11 to 9 N·m (85 lb in).

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Illustration 61	g01213836

13. Place the following items on top of the 248-1496 Vertical Mast Riser : the Shock Mount, the Electric Mast and the ATS Target Assembly.

14. Use the 9S-1362 Bolt (100) and the 3B-4512 Washer (101) in order to mount the 234-9970 Shock Mount (105) to the 248-1496 Vertical Mast Riser (96) .

15. Tighten the 9S-1362 Bolt (100) and the 3B-4512 Washer (101) to 305 N·m (225 lb ft).

16. Connect the straight end of the 276-0764 Coiled Cable to the connector on the ATS adapter. Tighten the connector by hand.

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Illustration 62	g01435752

17. Install the right-angle end (144) of the 276-0764 Coiled Cable (LASER RECEIVER) into the base of the electric mast.

18. Connect the right angle end (154) of 231-0049 Coiled Cable (MAST) to the base of the electric mast.

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Illustration 63	g01450850

19. Connect the quick disconnect connector of the 231-0049 Coiled Cable (MAST) to the lower or upper connector of the knuckle bracket.

Laser

Installation of the LR410 Laser Receivers

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Illustration 64	g01372499
Electric Mast with LR410 Receiver (38) Inner Mast Tube

1. Place the 253-8329 Laser Receiver Group on top of the 226-2333 Electric Mast (120). Tighten the handle on the 253-8329 Laser Receiver Group .

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Illustration 65	g01079275

2. Remove bolts (108) and the bracket (110) .

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NOTICE
The bolts that secure the U-Bracket to the Shock Mounts are not tightened to specification. Failure to perform the following procedure may result in damage to the Electric Mast or Shock Mounts.

3. Remove the two 13 mm (1/2 inch) bolts (115) that secure the U-bracket (109) to the 234-9970 Shock Mounts (105) .

4. Apply 9S-3263 Thread Lock Compound to the two 13 mm (1/2 inch) bolts (115) .

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Illustration 66	g01080139
U-Bracket of the 234-9970 Shock Mounts

5. Install the bolt of the U-Bracket (109) to the bottom of the 226-2333 Electric Mast (120) .

6. Tighten the bolt to 305 N·m (225 lb ft).

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Illustration 67	g01080146

7. Place the 226-2333 Electric Mast (120) into the 234-9970 Shock Mount (105) .

8. Reinstall the bracket that was removed in Step 4 and tighten the bolts (108) by hand.

9. Reinstall the two 13 mm (1/2 inch) bolts (115) into the U-bracket (109) and tighten the bolts to 54 N·m (40 lb ft).

10. Tighten the bolts (108) in Step 11 to 9 N·m (85 lb in).

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Illustration 68	g01213836

11. Place the following items on top of the 248-1496 Vertical Mast Riser : the Shock Mount, the Electric Mast and the Laser Receiver Assembly.

12. Use the 9S-1362 Bolt (100) and the 3B-4512 Washer (101) in order to mount the 234-9970 Shock Mount (105) to the 248-1496 Vertical Mast Riser (96) .

13. Tighten the 9S-1362 Bolt (100) and the 3B-4512 Washer (101) to 305 N·m (225 lb ft).

Installation of the Warning Film

Illustration 69	g01069921
The warning label 252-8744 Film that is placed on each mast

Place a 252-8744 Film onto each 271-6373 Mast . While you are standing between the machine and the blade, place a 252-8744 Film on the rear of each mast at eye level.

Sonic Sensor

The information in this section describes the procedure for the installation of the 272-5450 Sonic Sensor Group () or the 272-5451 Sonic Sensor Group () .

Installing the 248-1484 Base Assembly for the Sonic Sensor

Illustration 70	g01213859
248-1484 Base Assembly

1. Use the 8T-8917 Bolt (125) and 5S-7385 Washer (126) in order to mount the 248-1484 Base Assembly (106) to the blade.

2. Tighten the 8T-8917 Bolt (125) to 305 N·m (225 lb ft).

Installing the Pole in The Mounting Bracket

Illustration 71	g01103285
(8) 248-1487 Pole (106) 248-1484 Base Assembly (130) Clamping bolts of the 248-1484 Base Assembly

1. Insert the short end of the 248-1487 L - Pole (8) into the 248-1484 Base Assembly (106) far enough so that the end of the longer tube is away from the end of the blade and vertical.

2. Tighten the Clamping bolts of the 248-1484 Base Assembly in order to prevent the tube from rotating in the clamp.

Install the 248-1488 Bracket Assembly onto the 248-1487 Pole

Illustration 72	g01103324
(8) 248-1487 Pole (135) 248-1488 Bracket (136) Clamping Handle of the 248-1488 Bracket

1. Slide the 248-1488 Bracket (135) onto the 248-1487 Pole (8) .

2. Tighten the clamping handle of the 248-1488 Bracket (136) by hand.

   Note: Do not overtighten the handle.

Installing the Sonic Sensor in the Mounting Bracket

Illustration 73	g01390223
(11) 253-8330 Sonic Sensor Assembly (ST400) (8) 248-1487 Pole (135) 248-1488 Bracket (140) Ratchet Handle of the 248-1488 Bracket (141) 248-1497 Coil Cable

1. Use the Ratchet Handle of the 248-1488 Bracket (140) in order to attach the Sonic Sensor Assembly (11) to the 248-1488 Bracket (135) .

2. Hand tighten the ratchet handle of the 248-1488 Bracket (140) in order to secure the Sonic Sensor Assembly (11) in place.

   Note: Do not overtighten the handle.

3. Connect one end of the 248-1497 coil cable (141) to the connector on the Sonic Sensor Assembly (11) .

4. Tighten the connector by hand.

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Illustration 74	g01450850

5. Connect the quick disconnect connector of the 248-1497 Coil Cable to the lower connector (146) or the upper connector of the knuckle bracket (145) .

   Note: The upper and lower connectors are electrically identical. Any one of the connectors may be used.

Installation Of the 245-7404 Mounting Group For Storage Of The 248-1487 Pole

Note: If the Motor Grader is configured with a front straight scarifier or a front V-type scarifier, then the storage feature for the 248-1487 Poles for the Sonic Sensor Assembly is not compatible with the Motor Grader. If this is the case the Sonic Sensor Assembly must be configured differently. Find a suitable mounting location for the Bracket Assembly for the Pole that will allow the Pole to be stored without interfering with normal machine operation.

Illustration 75	g01383318
(116) 245-7405 Bracket Assembly , 245-7406 Clamp , 2 4L-6454 Bolts and 8T-4224 Washer (117) 245-7404 Bracket , 4L-6454 Bolt , 8T-7547 Bolt and 8T-4224 Washer

Illustration 76	g01136204
(116) 245-7405 Bracket , 245-7406 Clamp , 2 4L-6454 Bolts and 8T-4224 Washer (117) 245-7404 Bracket , 4L-6454 Bolt , 8T-7547 Bolt and 8T-4224 Washer

1. Remove the 5M-3062 Bolts from the frame.

2. Attach 245-7405 Bracket (116) and 245-7407 Bracket (117) to the frame with 4L-6454 Bolts and 8T-4224 Washers .

3. Secure the 248-1487 Pole (8) in the brackets.

Repeat 1 through 3 for Dual Sonic Sensors.

Radio

If the machine is equipped with a TC radio, proceed to ""TCxxx Radio's" ".

If the machine is equipped with a CR radio, proceed to ""CRxxx Radio's" ".

TCxxx Radio's

Illustration 77	g01213416
(6) 255-2424 Radio (159) 8T-4205 Hard Washer (192) 167-8610 Bracket Assembly (193) 140-7480 Mounting Bracket (194) 5S-7349 Bolt (196) 167-8999 Cap Screw

1. Install the 255-2424 TC900 Data Radio (6) onto the 167-8610 Bracket Assembly (192). Refer to Illustration 77.

2. Secure the end of the antenna on the 255-2424 TC900 Data Radio (6) to the 167-8610 Bracket Assembly (192) with four 167-8999 Cap Screws (196) .

3. Secure the 140-7480 Mounting Bracket (193) to the connector end of the 255-2424 TC900 Data Radio (6) with two 167-8999 Cap Screws (196) .

4. Secure the 140-7480 Mounting Bracket (193) to the 167-8610 Bracket Assembly (192) with two 5S-7349 Bolts (194) and two 8T-4205 Hard Washers (159) .

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Illustration 78	g01205039
(197) 149-8196 Plate

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Illustration 79	g01205551
Radio Mounting Group (198) Bolt (199) Washer (201) Mount

5. Attach the 255-2424 TC900 Data Radio (6) with the attached Radio Mounting Group to the 149-8196 Plate (197). Refer to Illustration 78 and 79.

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Illustration 80	g01213195

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Illustration 81	g01213239

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Illustration 82	g01213369

6. Mount the 149-8196 Plate (197) with the 255-2424 TC900 Data Radio (6) to the two weld bosses located on near the top right hand corner at the rear of the cab. Secure the 149-8196 Plate (197) to the bosses with the 8T-4136 Bolts (203) and 8T-4121 Washers (32). Refer to the following Illustrations: 80, 81 and 82.

7. Remove the right hand cover group from the right side of the machine. This is located below the cab.

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Illustration 83	g01213372
Section BB Of Illustration 82

8. Locate the 12-Pin AccuGrade harness radio connector. The connector will be located under the cab towards the rear of the machine.

9. Connect the 12-Pin Connector of the 243-3247 Radio Harness to the 12-Pin AccuGrade harness radio connector.

10. Insert the grommet that is supplied with the 243-3247 Radio Harness in to the slot/hole in the right side covers group. Refer to Illustration 82.

11. Reinstall the right hand cover group.

12. Route the 243-3247 Radio Harness up the right side of the machine to the 255-2424 TC900 Data Radio (6) .

13. Secure the 243-3247 Radio Harness to the machine using the supplied hardware. Refer to illustration 82.

    Note: Leave enough slack in the harness in order to allow the connection to the 255-2424 TC900 Data Radio (6) .

14. Connect the 243-3247 Radio Harness to the 255-2424 TC900 Data Radio (6) .

CRxxx Radio's

Illustration 84	g01427847
CR Series Radio (7) 7X-2534 Bolt (8) 4L-7125 Lockwasher (9) 9X-8256 Washer (10) Antenna (11) 4M-5282 Bolt (12) 9X-6165 Washer (13) 8C-5607 Isolation Mounts (14) 8C-5608 Spacer (15) 313-9364 Spacer (16) 313-9363 Mounting Plate (RADIO)

1. Install the 8C-5608 Spacer (14) and 8C-5607 Isolation Mounts (13) in three locations on the 313-9363 Mounting Plate (RADIO) (16) .

2. Install the 9X-6165 Washer (12) and 4M-5282 Bolt (11) with thread locker in three locations on the 313-9363 Mounting Plate (RADIO) (16) .

3. Install the 9X-6165 Washer (12) on the threads of 4M-5282 Bolt (11) .

   Note: The 9X-2480 Bolts and 7X-2533 Bolts are alternate bolts that are provided if a different thread is needed for Bolt (11) .

4. Thread the bolts into the holes on the machine mounting bracket. Tighten bolts to 12.0 N·m (9.0 lb ft).

5. Install the 4L-7125 Lockwasher (8), 9X-8256 Washer (9), and 7X-2534 Bolt (7) with thread locker in four locations on the CR Series Radio.

6. Install the bolts through the 313-9364 Spacer (15) and thread into the holes on the 313-9363 Mounting Plate (RADIO) (16). Tighten the bolts to 12.0 N·m (9.0 lb ft).

7. Remove the right hand cover group from the right side of the machine. This is located below the cab.

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Illustration 85	g01213372
Section BB Of Illustration 82

8. Locate the 12-Pin AccuGrade harness radio connector. The connector will be located under the cab towards the rear of the machine.

9. Connect the 12-Pin Connector of the 243-3247 Radio Harness to the 12-Pin AccuGrade harness radio connector.

10. Insert the grommet that is supplied with the 243-3247 Radio Harness in to the slot/hole in the right side covers group. Refer to Illustration 82.

11. Reinstall the right hand cover group.

12. Route the 243-3247 Radio Harness up the right side of the machine to the CR Series Radio.

13. Secure the 243-3247 Radio Harness to the machine using the supplied hardware. Refer to illustration 82.

    Note: Leave enough slack in the harness in order to allow the connection to the CR Series Radio.

14. Connect the 243-3247 Radio Harness to the CR Series Radio.

Display

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Illustration 86	g01313551

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Illustration 87	g01433150

1. Remove the right panel (139) from the steering console by removing 6 screws.

2. Remove the black covers (138) on the 3 bolts that are indicated in Illustration 86 and Illustration 87.

3. Remove the bolts from both sides of the steering console that are located under the black covers (138) .

   Note: There is a nut and a spacer that is located behind the bolt at the front end of the steering console. The nut and the spacer will fall into the steering console if care is not taken during removal of the front bolts.

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Illustration 88	g01313494

4. Use two 8T-2501 Bolts (210) in the holes that are closest to the front of the Motor Grader in order to attach the 286-5686 Support Assembly (122) to the steering console. Additionally, use one 0L-1351 Bolt (211) in the hole that is closest to the rear of the Motor Grader in order to attach the 286-5686 Support Assembly (122) to the steering console.

5. Reinstall the black covers (138) .

6. Reinstall the side panels (139) that were removed in Step 1.

   Note: Do not tighten screws that secure the side panels. Some of the screws will be replaced in the following procedure.

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Illustration 89	g01313898

7. Attach 244-1716 Display (1) to 286-5694 Bracket Assembly (212) with six 8T-7852 Bolts and six 096-6166 Hard Washers . Tighten the bolts.

8. Attach 286-5694 Bracket Assembly (212) to 286-5686 Support Assembly (122) .

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Illustration 90	g01313990

9. Hand tighten the 292-8963 Knob (213) .

Harness

Illustration 91	g01146300
(34) AccuGrade 40-Pin Bulkhead connector

238-8810 Harness Rework Procedure

The 238-8810 Harness will need to be reworked when used with the 244-1716 Display .

Refer to the Table 35 for a list of the parts that are required.

Table 35

Rework Components
Part Number	Description
9U-7246	Connector Repair Kit
302-4499	Wire Assembly
202-5415	Receptacle

1. Remove wires T744-WH from pin 4 and pin 11 from the 40-pin connector.

2. Insert the removed wires T744-WH into pin 1 and pin 2 of the 155-2271 Connecting Plug Kit connector of the 302-4499 Wire Assembly .

3. Insert the 2 wires for the 302-4499 Wire Assembly into pin 4 and pin 11 of the 40-pin connector.

Plug in the 202-5415 Receptacle into the 155-2271 Connecting Plug Kit .

Installation of the Display Harness

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Illustration 92	g01432254

1. Connect the 40-Pin Connector (164) of the 299-7694 Cab Harness Assembly (185) to the 40-Pin Connector (34) in the forward bulkhead on the right hand side of the cab. Hand tighten the connector.

2. Place a 4K-8864 Clip (165) around the smaller branch of the 299-7694 Cab Harness Assembly (185) .

3. Use the 8T-4137 Bolt (168) and a 8T-4121 Washer (163) in order to secure the 4K-8864 Clip (165) from Step 2 and the 4P-7581 Clip (167) to the boss that is located above the 40-Pin Connector. Secure the larger branch of the 299-7694 Cab Harness Assembly (185) to the 4P-7581 Clip (167) .

4. Remove the bottom screw from forward panel of the right side of the steering console. Use the 9X-2043 Screw (36) (36) and 5P-4115 Washer (37) in order to attach the 156-6175 Clip (38) to the lowest mounting screw hole for the forward panel on the right hand side of the steering console. Use a 3S-2093 Strap (195) in order to secure the 299-7694 Cab Harness Assembly (185) to the 156-6175 Clip .

5. Route the left hand switch connectors (3-Pin and 4-Pin Connectors) of the 299-7694 Cab Harness Assembly (185) to the left side of the cab.

6. Remove the center screw from forward panel of the right side of the steering console.

7. Place a 5P-9299 Clip (174) on the switch branch of the 299-7694 Cab Harness Assembly (185) .

8. Use the 9X-2044 Screw (158) and 5P-4115 Washer (161) in order to attach the 5P-9299 Clip (174) that was installed in Step 7 and 156-6175 Clip (175) to the middle mounting screw hole in the forward panel on the right hand side of the steering console.

9. Use two 3S-2093 Straps (195) in order to secure the beeper and display branches of the 299-7694 Cab Harness Assembly (185) to the 156-6175 Clip (175) that was installed in Step 8.

10. Connect the 3-Pin Connector and the 4-Pin Connectors of the 299-7694 Cab Harness Assembly (185) to the 3-Pin Connector and the 4-Pin Connector of the remote switches on the right hand side of the steering console.

11. Remove the top screw and connector mounting hardware from the forward panel of the right side of the steering console.

12. Add a 130-5300 Clip (156) to the connector mounting hardware and secure with the screw that was removed in Step 11.

13. Place the 2-Pin Connectors in the clip installed in Step 12.

14. Connect the 3-Pin Connector of the 251-7591 Wire Assembly to the mating 3-Pin Connector on the 299-7694 Cab Harness Assembly (185). Secure the 251-7591 Wire Assembly to the 299-7694 Cab Harness Assembly (185) with the 3S-2093 Strap (195) .

15. Route the other leg of the 299-7694 Cab Harness Assembly (185) across the front of the steering console.

16. Place a 5P-9299 Clip on the 299-7694 Cab Harness Assembly (185). The clip must leave enough slack in order to allow the 3-Pin and 4-Pin switch connectors on the left hand side of the 299-7694 Cab Harness Assembly (185) in order to reach the 3-Pin Connector and the 4-Pin Connector of the remote switches.

17. Use the 9X-2045 Screw and the 5P-4115 Washer in order to attach the 5P-9299 Clip to the middle mounting screw hole for the forward panel on the left side of the steering console.

18. Connect the 3-Pin Connector and the 4-Pin Connector of the 299-7694 Cab Harness Assembly (185) to the 3-Pin Connector and the 4-Pin Connector of the remote switches on the left hand side of the steering console.

Light Bars

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Illustration 93	g01204941
(185) 299-7694 Cab Harness Assembly (200) 244-1720 Monitor (Light Bar) (201) Bracket (LH Light Bar) (202) Bracket (RH Light Bar)

1. Route the light bar connections of the 299-7694 Cab Harness Assembly (185) as shown in Illustration 93. The longer branch of the harness goes to the left hand side of the machine. The shortest branch goes to the center of the cab.

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Illustration 94	g01205003

2. Remove the Striker Assembly (182), plate and screws from the left and right hand side of the cab.

3. Install 249-3731 Bracket (RH Light Bar) (202) and 249-3733 Bracket (LH Light Bar) (201) with screws removed in Step 2.

4. Reinstall Striker Assemblies (182) removed in Step 2.

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Illustration 95	g01205008

5. Remove the Screws (183) from the top of the instrument panel.

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Illustration 96	g01204987

6. Install the 249-3736 Bracket (Center Light Bar) (184) .

   1. Place an 8T-4205 Washer (159) between the 249-3736 Bracket (Center Light Bar) (184) and the instrument panel.

   2. Secure the 249-3736 Bracket (Center Light Bar) (184) in place with a 111-4627 Screw (155) and 5P-4115 Washer (161) .

7. Install the 244-1720 Light Bars to the three light bar brackets with the 225-3109 Screws .

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Illustration 97	g01213036
(165) 4D-8123 Clip (161) 5P-4115 Washer (174) 5P-9299 Clip (176) 9X-2045 Screw (185) 299-7694 Cab Harness Assembly (217) 5P-9297 Clip

8. Connect the light bar connectors of the 299-7694 Cab Harness Assembly (185) to the light bars.

9. Secure the 299-7694 Cab Harness Assembly (185) on the right hand side of the cab. Refer to Illustration 97.

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Illustration 98	g01213064
(161) 5P-4115 Washer (176) 9X-2045 Screw (185) 299-7694 Cab Harness Assembly (217) 5P-9297 Clip

10. Secure the 299-7694 Cab Harness Assembly (185) on the left hand side of the cab. Refer to Illustration 98.

M Series Installation Procedures

Sensors

The information in this section refers to the installation of the 262-2017 Grade Sensor Arrangement .

Table 36

Tools That are Needed
Quantity	Description
1	Adjustable Square ( 600 mm (2 ft))

Rotation Sensor

1. Make sure that the blade is square to the machine.

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Illustration 99	g01388834

2. Remove the bolts (48) on the swivel lid.

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Illustration 100	g01103309

3. Remove the swivel lid (49) .

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Illustration 101	g01108042

4. Remove the white and black seals from the swivel lid.

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Illustration 102	g01108045

5. Place the seals from the swivel lid onto the 255-0941 Plate (60) .

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Illustration 103	g01102028

6. Replace the existing swivel lid with the 255-0941 Sensor Bracket Assembly (60). Place the White Spacer (65) on 255-0941 Sensor Bracket Assembly (60). Refer to Illustration 103.

   Note: The White Spacer (65) is packaged with the 244-1714 Position Sensor Group (BLADE ROTATION) (4) .

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Illustration 104	g01184190

7. Install the 255-0941 Sensor Bracket Assembly (60) and face the slot (66) in the direction that is shown in Illustration 104. This will ensure that the Rotation Arm (70) is indexed at zero. Use the 061-6665 Bolts (64) in order to secure the 255-0941 Sensor Bracket Assembly (60) .

8. Install 061-6665 Bolts (64) and tighten in order to secure the 255-0941 Sensor Bracket Assembly (60) in place.

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Illustration 105	g01108055

9. Install the 244-1714 Position Sensor Group (BLADE ROTATION) (4) onto the Plate.

   Make sure that the Rotation Arm (70) is seated into the slot (66). Make sure that the connector (71) of the 244-1714 Position Sensor Group (BLADE ROTATION) (4) faces in the direction of the rear of the machine.

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Illustration 106	g01108122

10. Use the 269-3303 Screws (75) and 269-3304 Spacers (77) in order to secure the 244-1714 Position Sensor Group (BLADE ROTATION) (4) to the 255-0941 Plate (60) .

11. Tighten the 269-3303 Screws (75) and 269-3304 Spacers on the 255-0941 Sensor Bracket Assembly (60) .

    Note: The 244-1714 Position Sensor Group (BLADE ROTATION) will continue to rotate until 250-2172 Bracket Assembly (99) is installed. Refer to Illustration 108.

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Illustration 107	g01204141
(4) 244-1714 Position Sensor Group (BLADE ROTATION) (51) Bolt (53) Clip (54) Nut (56) Washer (81) Connector of the 243-3250 Sensor Harness Assembly

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Illustration 108	g01184298
250-2172 Bracket Assembly

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Illustration 109	g01184324
Part A of 250-2172 Bracket Assembly

12. Remove the Nut (54) and Washer (56). Pull the Clip (53) off of the Bolt (51) .

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Illustration 110	g01145760

13. Attach part A of the 250-2172 Bracket Assembly to Bolt (51). Re-assemble with the following components: Clip (53), Washer (56) and Nut (54) .

    Note: Do not tighten Nut (54). There is additional hardware that will be added in the ""Installation of the Blade Slope Sensor" " section.

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Illustration 111	g01184351
Part B of 250-2172 Bracket Assembly

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Illustration 112	g01145703

14. Place the 186-0359 Clip (85) around the 243-3250 Sensor Harness Assembly (79) .

15. Use the bolts and washers (58) of the 250-2172 Bracket Assembly to secure part B of the 250-2172 Bracket Assembly and the 186-0359 Clip (85) to the top of the 244-1714 Position Sensor Group (BLADE ROTATION) (4) .

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Illustration 113	g01388261

16. Install Bolt (86) between part A and part B of the 250-2172 Bracket Assembly . Tighten Nut (54) .

    Refer to Illustration 110 and Illustration 113.

17. Install the Connector (81) for the 243-3250 Sensor Harness Assembly to the 244-1714 Position Sensor Group (BLADE ROTATION) (4) .

18. Stop.

Installation of the Blade Slope Sensor

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Illustration 114	g01383322
(3) 276-6146 Position Sensor Assembly (89) Connector (Blade Slope Sensor Harness)

1. Install the Sensor (3) .

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Illustration 115	g01383323
(57) 9X-2537 Bolt

2. Use the 9X-2537 Bolt (57) in order to secure the 276-6146 Position Sensor Assembly to the mounting plate on the rear of the circle.

3. Connect the 6-pin connector (89) of the 236-2356 Sensor Harness Assembly to the connector on the 276-6146 Position Sensor Assembly (3) .

Mainfall Sensor

Illustration 116	g01383994
(2) 276-6146 Position Sensor Assembly (57) 9X-2537 Bolt (91) 5C-2890 Nut (103) 9X-8256 washer

1. Use the 9X-2537 Bolts (57), 9X-8256 washers (103) and 5C-2890 Nuts (91) in order to secure the 276-6146 Position Sensor Assembly (2) to the bracket.

   Refer to Illustration 116.

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Illustration 117	g01384004

2. Attach the Harness Connector (196) to the Connector on the Main Fall Sensor.

GPS

The information in this section describes the procedure for the installation of the 292-0291 Satellite Receiver Group or the 292-0292 Satellite Receiver Group .

Installation of the Adjustable Angle Bracket

The 248-1503 Adjustable Angle Bracket is used in order to mount the masts for either the 291-1913 Satellite Receiver Assembly (20) or ATS Target.

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Illustration 118	g01079269
Adjustable Angle Bracket (111) 7X-0366 Bolts (112) 8T-4994 Washers (113) 7X-0343 Bolts (114) 8T-4122 Washers

1. Secure the 248-1503 Adjustable Angle Bracket to the mounting pad on the blade with 3 7X-0366 Bolts (111) and 8T-4994 Washers (112) .

2. Tighten the 7X-0366 Bolts (111) and 8T-4994 Washers (112) to 305 N·m (225 lb ft).

Installation of the Riser

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Illustration 119	g01204205

1. Set the 248-1502 Angle Riser on top of the 248-1503 Adjustable Angle Bracket .

2. Secure the 248-1502 Angle Riser to the 248-1503 Adjustable Angle Bracket with the supplied 5/8-inch bolts, washers, and lock washers.

   Refer to Illustration 119.

3. Use the supplied lock nuts in order to lock the riser bolts in place.

4. Tighten the nuts to 215 ± 40 N·m (160 ± 30 lb ft).

GPS Receiver

Note: If a 252-9628 Bracket Kit (23) has been removed from a 291-1913 Satellite Receiver Assembly (20), the bolts must be tightened to 41 N·m (30 lb ft).

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

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Illustration 120	g01205309
Bottom of the GPS receiver (20) 291-1913 Satellite Receiver Assembly (22) Thumb Wheel (23) 252-9628 Bracket Kit (24) Bolts

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Illustration 121	g01205316
(20) 291-1913 Satellite Receiver Assembly (GNSS, MS990) (21) 271-6373 Mast (23) 252-9628 Bracket Kit (27) Cable strain relief

1. Slide the 291-1913 Satellite Receiver Assembly (GNSS, MS990) (20) onto the top of the 271-6373 Mast (21). Orient the Receiver so that the LEDs are visible from the cab of the machine. Refer to Illustration 121 and Illustration 121.

Note: You must fully insert the GPS Mast into the bracket on the GPS Receiver. Otherwise, the blade tip to antenna measurements will not be correct, resulting in wrong elevation guidance and construction.

2. Firmly tighten the Thumb Wheel (22) on the Bracket (23) in order to secure the 291-1913 Satellite Receiver Assembly (20) .

3. Repeat Steps 1 and 2 in order to install the remaining 291-1913 Satellite Receiver Assembly (20) and bracket onto the top of the remaining 271-6373 Mast .

   Note: Store the 291-1913 Satellite Receiver Assembly (20) in the 255-0939 Plastic Foam Lined Case when you remove the 291-1913 Satellite Receiver Assembly (20) from the machine.

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Illustration 122	g01204244
271-6373 Mast mounted to the Angle Riser

4. Place the 271-6373 Mast and 291-1913 Satellite Receiver Assembly (20) on top of the 248-1502 Angle Riser .

5. Position the mast on the mounting bracket, and rotate the masts so that the cable strain relief brackets point toward the electrical quick-disconnect brackets on the knuckles.

6. Secure each mast in place with the bolt and lock washer supplied with the mast.

7. Tighten the high tensile bolt to 370 ± 50 N·m (275 ± 37 lb ft).

Installation of the Adjustable Angle Bracket

The 248-1503 Adjustable Angle Bracket is used in order to mount the masts for either the 291-1913 Satellite Receiver Assembly (20) or ATS Target.

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Illustration 123	g01079269
Adjustable Angle Bracket (111) 7X-0366 Bolts (112) 8T-4994 Washers (113) 7X-0343 Bolts (114) 8T-4122 Washers

1. Secure the 248-1503 Adjustable Angle Bracket to the mounting pad on the blade with three 7X-0366 Bolts (111) and 8T-4994 Washers (112) .

2. Tighten the 7X-0366 Bolts (111) and 8T-4994 Washers (112) to 305 N·m (225 lb ft).

Installation of the Riser

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Illustration 124	g01079311
(96) 248-1496 Vertical Mast Riser (97) 248-1503 Adjustable Angle Bracket

1. Place the 248-1496 Vertical Mast Riser on top of the 248-1503 Adjustable Angle Bracket .

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Illustration 125	g01079262
(100) 9S-1362 Bolt (101) 3B-4512 Washer

2. Use the 9S-1362 Bolt (100) and the 3B-4512 Washer (101) in order to secure the 248-1496 Vertical Mast Riser (96) to the 248-1503 Adjustable Angle Bracket (97) .

3. Tighten the 9S-1362 Bolt (100) and the 3B-4512 Washer (101) to 305 N·m (225 lb ft).

ATS

The information in this section describes the procedure for the installation of the 317-6526 Laser Grade Control Arrangement (ADVANCED TRACKING SYSTEM) .

Installation of the ATS Sensor

1. Remove the 245-4747 Adapter Block from the 226-2333 Electric Mast (120) .

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Illustration 126	g01435715

2. Install the 275-3376 Block to the 226-2333 Electric Mast (120) .

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Illustration 127	g01435707

3. Place the 256-2907 ATS Target on top of the 226-2333 Electric Mast (120) with 275-3376 Block . Tighten the 256-2907 Laser Target Group to the electric mast with the ratchet handle on the base of the 256-2907 Laser Target Group .

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Illustration 128	g01079275

4. Remove bolts (108) and the bracket (110) .

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NOTICE
The bolts that secure the U-Bracket to the Shock Mounts are not tightened to specification. Failure to perform the following procedure may result in damage to the Electric Mast or Shock Mounts.

5. Remove the two 13 mm (1/2 inch) bolts (115) that secure the U-bracket (109) to the 234-9970 Shock Mounts (105) .

6. Apply 9S-3263 Thread Lock Compound to the two 13 mm (1/2 inch) bolts (115) .

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Illustration 129	g01080139
U-Bracket of the 234-9970 Shock Mounts

7. Install the bolt of the U-Bracket (109) to the bottom of the 226-2333 Electric Mast (120) .

8. Tighten the bolt to 305 N·m (225 lb ft).

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Illustration 130	g01080146

9. Place the 226-2333 Electric Mast (120) into the 234-9970 Shock Mount (105) .

10. Reinstall the bracket that was removed in Step 4 and tighten the bolts (108) by hand.

11. Reinstall the two 13 mm (1/2 inch) bolts (115) into the U-bracket (109) and tighten the bolts to 54 N·m (40 lb ft).

12. Tighten the bolts (108) in Step 11 to 9 N·m (85 lb in).

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Illustration 131	g01213836

13. Place the following items on top of the 248-1496 Vertical Mast Riser : the Shock Mount, the Electric Mast and the ATS Target Assembly.

14. Use the 9S-1362 Bolt (100) and the 3B-4512 Washer (101) in order to mount the 234-9970 Shock Mount (105) to the 248-1496 Vertical Mast Riser (96) .

15. Tighten the 9S-1362 Bolt (100) and the 3B-4512 Washer (101) to 305 N·m (225 lb ft).

16. Connect the straight end of the 276-0764 Coiled Cable to the connector on the ATS adapter. Tighten the connector by hand.

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Illustration 132	g01435752

17. Install the right angle end (144) of the 276-0764 Coiled Cable (LASER RECEIVER) into the base of the electric mast.

18. Connect the right angle end (154) of 231-0049 Coiled Cable (MAST) to the base of the electric mast.

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Illustration 133	g01450850

19. Connect the quick disconnect connector of the 231-0049 Coiled Cable (MAST) to the lower connector or the upper connector of the knuckle bracket.

Laser Receiver

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Illustration 134	g01372499
Electric Mast with LR410 Receiver (38) Inner Mast Tube

1. Place the 253-8329 Laser Receiver Group on top of the 226-2333 Electric Mast (120). Tighten the ratchet handle on the 253-8329 Laser Receiver Group .

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Illustration 135	g01079275

2. Remove bolts (108) and the bracket (110) .

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NOTICE
The bolts that secure the U-Bracket to the Shock Mounts are not tightened to specification. Failure to perform the following procedure may result in damage to the Electric Mast or Shock Mounts.

3. Remove the two 13 mm (1/2 inch) bolts (115) that secure the U-bracket (109) to the 234-9970 Shock Mounts (105) .

4. Apply 9S-3263 Thread Lock Compound to the two 13 mm (1/2 inch) bolts (115) .

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Illustration 136	g01080139
U-Bracket of the 234-9970 Shock Mounts

5. Install the bolt of the U-Bracket (109) to the bottom of the 226-2333 Electric Mast (120) .

6. Tighten the bolt to 305 N·m (225 lb ft).

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Illustration 137	g01080146

7. Place the 226-2333 Electric Mast (120) into the 234-9970 Shock Mount (105) .

8. Reinstall the bracket that was removed in Step 2 and tighten the bolts (108) by hand.

9. Reinstall the two 13 mm (1/2 inch) bolts (115) into the U-bracket (109) and tighten the bolts to 54 N·m (40 lb ft).

10. Tighten the bolts (108) in Step 9 to 9 N·m (85 lb in).

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Illustration 138	g01213836

11. Place the following items on top of the 248-1496 Vertical Mast Riser : the Shock Mount, the Electric Mast and the Laser Receiver.

12. Use the 9S-1362 Bolt (100) and the 3B-4512 Washer (101) in order to mount the 234-9970 Shock Mount (105) to the 248-1496 Vertical Mast Riser (96) .

13. Tighten the 9S-1362 Bolt (100) and the 3B-4512 Washer (101) to 305 N·m (225 lb ft).

Installation of the Warning Film

Illustration 139	g01069921
The warning label 252-8744 Film that is placed on each mast

Place a 252-8744 Film onto each 271-6373 Mast . While you are standing between the machine and the blade, place a 252-8744 Film on the rear of each mast at eye level.

Sonic Sensor

The information in this section describes the procedure for the installation of the 286-0133 Sonic Sensor Group (SINGLE) or the 286-0132 Sonic Sensor Group (DUAL) .

Installing the 248-1484 Base Assembly for the Sonic Sensor

Illustration 140	g01213859
248-1484 Base Assembly

1. Use the 8T-8917 Bolt (125) and 5S-7385 Washer (126) in order to mount the 248-1484 Base Assembly (106) to the blade.

2. Tighten the 8T-8917 Bolt (125) to 305 N·m (225 lb ft).

Installing the Pole in The Mounting Bracket

Illustration 141	g01103285
(8) 248-1487 Pole (106) 248-1484 Base Assembly (130) Clamping bolts of the 248-1484 Base Assembly

1. Insert the short end of the 248-1487 L - Pole (8) into the 248-1484 Base Assembly (106) far enough so that the end of the longer tube is away from the end of the blade and vertical.

2. Tighten the Clamping bolts of the 248-1484 Base Assembly in order to prevent the tube from rotating in the clamp.

Installing the 248-1488 Bracket Assembly onto the 248-1487 Pole

Illustration 142	g01103324
(8) 248-1487 Pole (135) 248-1488 Bracket (136) Clamping Handle of the 248-1488 Bracket

1. Slide the 248-1488 Bracket (135) onto the 248-1487 Pole (8) .

2. Tighten the clamping handle of the 248-1488 Bracket (136) by hand.

   Note: Do not overtighten the handle.

Installing the Sonic Sensor in the Mounting Bracket

Illustration 143	g01390223
(11) 253-8330 Sonic Sensor Assembly (ST400) (8) 248-1487 Pole (135) 248-1488 Bracket (140) Ratchet Handle of the 248-1488 Bracket (141) 248-1497 Coil Cable

1. Use the Ratchet Handle of the 248-1488 Bracket (140) in order to attach the Sonic Sensor Assembly (11) to the 248-1488 Bracket (135) .

2. Hand tighten the ratchet handle of the 248-1488 Bracket (140) in order to secure the Sonic Sensor Assembly (11) in place.

   Note: Do not overtighten the handle.

3. Connect one end of the 248-1497 coil cable (141) to the connector on the Sonic Sensor Assembly (11) .

4. Tighten the connector by hand.

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Illustration 144	g01450850

5. Connect the quick disconnect connector of the 248-1497 Coil Cable to the lower connector (146) or the upper connector of the knuckle bracket (145) .

   Note: The upper and lower connectors are electrically identical. Any one of the connectors may be used.

Storing The 248-1487 Poles

Illustration 145	g01312018
Left side Of Motor Grader (8) 248-1487 Poles (130) 248-1484 Base Assemblies

Illustration 146	g01385522
Rear View Of Motor Grader (8) 248-1487 Poles (130) 248-1484 Base Assemblies

The location for the Pole storage brackets allow the Pole to be stored without interfering with normal machine operation. A 248-1484 Base Assembly is used to mount the 248-1487 Pole to the Motor Grader for storage.

Radio

TCxxx Radio's

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Illustration 147	g01461507

1. Install the 273-1719 Bracket As to the cab of the machine. Reuse the bolts that were removed from the cab in order to install the bracket. Refer to Illustration 147.

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Illustration 148	g01383730

2. Use two 160-8999 Bolts (180) in order to install the 140-7480 Mounting Bracket (181) to the bottom of the Radio.

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Illustration 149	g01383734

3. Use four 160-8999 Bolts in order to install the Radio to Bracket (182) .

4. Tighten the two 160-8999 Bolts (180) .

   Refer to Illustration 148.

5. Tighten the four 160-8999 Bolts (183) .

   Refer to Illustration 149.

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Illustration 150	g01383736
(185) 8C-5607 Mounts (186) 8C-5608 Spacers (187) 4M-5282 Bolts (188) 9X-6165 Washers

6. Mount the Radio to the Motor Grader. Use the components that are listed in Illustration 150.

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Illustration 151	g01385531

7. Knock out the cab plug.

   Refer to Illustration 151.

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Illustration 152	g01385537

8. Remove the radio speaker or remove the cover for the speaker.

   Note: If you are facing forward, the speaker is the right side. If you are facing toward the rear of the Motor Grader, the speaker is the left.

   Refer to Illustration 152.

9. Locate the 12-pin DT connector of the machine harness for the AccuGrade Radio in the exposed area.

10. Plug the 253-7461 Radio Harness Assembly into the machine harness.

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Illustration 153	g01385568

11. Run the harness for the radio outward through the hole in the cab.

12. Install the cab grommet in order to seal the hole.

    Refer to Illustration 153.

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Illustration 154	g01383739

13. Connect the Harness for the Radio to the Connector (190) that is located on the bottom of the Radio.

14. Reinstall the radio speaker or cover.

CRxxx Radio's

Illustration 155	g01427847
CR Series Radio (7) 7X-2534 Bolt (8) 4L-7125 Lockwasher (9) 9X-8256 Washer (10) Antenna (11) 4M-5282 Bolt (12) 9X-6165 Washer (13) 8C-5607 Isolation Mounts (14) 8C-5608 Spacer (15) 313-9364 Spacer (16) 313-9363 Mounting Plate (RADIO)

1. Install 8C-5608 Spacer (14) and 8C-5607 Isolation Mounts (13) in three locations on the 313-9363 Mounting Plate (RADIO) (16) .

2. Install 9X-6165 Washer (12) and 4M-5282 Bolt (11) with thread locker in three locations on the 313-9363 Mounting Plate (RADIO) (16) .

3. Install 9X-6165 Washer (12) on the threads of 4M-5282 Bolt (11) .

   Note: 9X-2480 Bolts and 7X-2533 Bolts are alternate bolts that are provided if a different thread is needed for Bolt (11) .

4. Thread into holes on machine mounting bracket. Tighten bolts to 12.0 N·m (9.0 lb ft).

5. Install 4L-7125 Lockwasher (8), 9X-8256 Washer (9), and 7X-2534 Bolt (7) with thread locker in four locations on the CR Series Radio.

6. Install bolts through 313-9364 Spacer (15) and thread into holes on the 313-9363 Mounting Plate (RADIO) (16). Tighten bolts to 12.0 N·m (9.0 lb ft).

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Illustration 156	g01461507

7. Install the 273-1719 Bracket As to the cab of the machine. Reuse the bolts that were removed from the cab in order to install the bracket. Refer to Illustration 156.

8. Install the 253-1963 Bracket As (189) to the 273-1719 Bracket As . Refer to Illustration 157.

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Illustration 157	g01466272

9. Mount the radio to the 273-1719 Bracket As .

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Illustration 158	g01465769

10. Knock out the cab plug.

    Refer to Illustration 158.

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Illustration 159	g01385537

11. Remove the radio speaker or remove the cover for the speaker.

    Note: If you are facing forward, the speaker is the right side. If you are facing toward the rear of the Motor Grader, the speaker is the left.

    Refer to Illustration 159.

12. Locate the 12-pin DT connector of the machine harness for the AccuGrade Radio in the exposed area.

13. Plug the 253-7461 Radio Harness Assembly into the machine harness.

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Illustration 160	g01385568

14. Run the harness for the radio outward through the hole in the cab.

15. Install the cab grommet in order to seal the hole.

    Refer to Illustration 166.

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Illustration 161	g01457308

16. Connect the Harness for the Radio to the Connector (190) that is located on the bottom of the Radio.

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Illustration 162	g01461610

17. Connect the wiring harness for the radio to the link with a cable strap. Refer to Illustration 162.

18. Reinstall the radio speaker or cover.

Display/Light Bars

Assembly Of The Display Brackets

Step 1 through Step 2 describes the procedure for the assembly of the brackets for the 244-1716 Display .

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Illustration 163	g01383744

1. Attach the 295-8370 Display Bracket (151) to the 244-1716 Display .

   Use the 6 8T-7852 Bolts (152) and the 6 096-6166 Hard Washers (153) in order to secure the 295-8370 Display Bracket (151) .

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Illustration 164	g01383749

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Illustration 165	g01383750

2. Mount the 295-8370 Display Bracket (155) to the 295-8369 Plate (159) .

   Use the following components in order to secure the brackets:

   • 164-8346 Pins (156)

   • 8T-4224 Hard Washers (157)

   • 3B-4605 Cotters (158)

   • 245-8334 Knobs (160)

   • 222-9151 Hard Washers (161)

Assembly Of The Light Bars

Step 1 through Step 2 describes the installation procedure for the 286-9124 Light Bars (162) .

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Illustration 166	g01383755

1. Attach 2 of the 286-9124 Light Bars (162) to the 295-8370 Display Bracket (155) .

   Use 2 bolts for each Light Bar in order to secure it to the Bracket.

   Refer to Illustration 166.

Note: The horizontal Light Bar will attach to the top of the instrument cluster housing.

2. Remove the bolts that secure the instrument cluster housing.

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Illustration 167	g01383804

3. Locate the Harness Connector (175) in order to connect the horizontal Light Bar.

4. Connect the Light Bar connector to the Harness.

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Illustration 168	g01383805

5. Install the instrument cluster housing.

   Make sure that the cable for the Light Bar fits through the slot (176) in the Housing.

6. Replace the bolts in the instrument cluster housing that were removed in Step 2.

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Illustration 169	g01383807

7. Attach the Light Bar to the top of the Instrument Cluster housing.

Mounting The Display In The Motor Grader

The Display is mounted below the Instrument Cluster.

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Illustration 170	g01383844

1. Attach the 4 Bolts (165) and 2 Clips (166) in order to secure the Display Brackets in the cab of the Motor Grader.

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Illustration 171	g01383903

2. Attach the Light Bar Connectors (167) to the Clips (166) that were installed in Step 1.

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Illustration 172	g01400083

3. Route the harness through the u-shaped cutout (A) .

4. Attach the Harness Connectors to the Light Bar Connectors (167) .

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Illustration 173	g01383910

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Illustration 174	g01384049

5. Mount the Display to the Display Brackets.

   The top of the Bracket that is attached to the Display will fit into a slot (169) in the Display Bracket that is mounted in the cab of the Motor Grader. Refer to Illustration 173.

   The bottom of the Bracket that is attached to the Display has a slot that will slip around 273-5924 Control Knob (170) and 117-8929 Washer (171). Refer to Illustration 174.

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Illustration 175	g01400088

6. Run the harness through the u-shaped cutout (B) .

7. Attach the Harness (172) to the Display.

Display Operation

Illustration 176	g01287477
(80) LCD (81) Soft Keys Labels (82) Hard Keys (83) Escape Key (84) Next Key (85) Power Key (86) "+" Key (87) Arrow Keys (88) "-" Key (89) "OK" Key (90) Menu Key (91) Data Card Slot

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

The Display (1) is used in order to operate the AccuGrade System. The Display (1) has a LCD screen in order to show information and a keypad for entering information.

Power Key

The Power Key (85) turns the Display (1) on and off:

In order to turn on the Display (1), ensure that the ignition switch is in the ON position. Then, press the Power Key (85) .

In order to turn off the Display (1), press and hold the Power Key (85) for several seconds, until the Display (1) shuts down. This delay reduces the risk of inadvertently shutting off the power. You can turn off the AccuGrade System from any screen or from any dialog.

Soft Keys

The Soft Keys (81) are "graphical keys" that appear at the side of the screen. In order to activate the displayed function, press the Hard Key that is located to the right of the Soft Key (81) .

For example, to select the Menu Screen, press the Hard Key that is located adjacent to the "Menu" Soft Key.

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

If a Hard Key has no function in a screen or the Hard Key has no function in a dialog, the Soft Key (81) is blank.

The text on a Soft Key (81) can show one of the following details:

• A description of the Soft Key function. (For example, "Vertical Offset" allows the entry of an offset from the reference elevation.)

• The file or the setting that has been selected

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

Some Soft Keys (81) will appear in more than one dialog. The function of the Soft Key is the same function.

Note: For simplification purposes, for the remainder of this manual, the Hard Keys (82) will be referred to by the Soft Key that is adjacent to the Hard Key.

Hard Keys

The Hard Keys (82) are the six physical keys that are located immediately to the right of the LCD screen. Hard Keys (82) are used in order to operate the function that is shown on the Soft Key (81) that is located to the right of the soft key.

Note: For simplification purposes, for the remainder of this manual, the Hard Keys (82) will be referred to by the Soft Key that is adjacent to the Hard Key.

Arrow Keys

Use the Arrow Keys (87) in order to perform the following actions:

• move within menus and lists.

• enter text or numbers into fields for entering data in the dialogs.

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

Navigating within menus and lists

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

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

2. Press the "OK" key.

Entering data

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

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

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

Display Brightness

The brightness of the Display can be adjusted.

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

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

Working with Dialogs

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

Press the Arrow Keys (87) on the Display (1) in order to enter data:

The up arrow steps through the upper case letters, the numbers "0" to "9", the decimal point, the negative sign, the positive sign and a space.

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

The down arrow steps through a space, the positive sign, the negative sign, the decimal point, the numbers "0"to "9" and the upper case letters.

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

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

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

Dialogs may contain any of the following items:

Text fields - Use the text fields in order to enter your own information. For example, when you set up the name of your level surface design or sloping surface design, use the Arrow Keys (87) in order to enter this data.

Number fields - Use the number fields in order to enter required values. For example, when you set up the vertical and horizontal offset, use the Arrow Keys (87) in order to enter values into these fields.

List boxes - List options or possible selections. Use the Arrow Keys (87) in order to select the listed item.

Warnings

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

The "No GPS Receiver Data" warning appears when a machine is not receiving GPS data.

Language Configuration

The firmware for the CD700 display will be translated into the list of languages below.

• Czech (CZE)

• Danish (DAN)

• Dutch (NLD)

• US English (USA)

• UK English (GBR)

• Finnish (FIN)

• French (FRA)

• German (DEU)

• Icelandic (ICE)

• Italian (ITA)

• Norwegian (NOR)

• Polish (POL)

• Portuguese (PRT)

• Romanian (RUM)

• Spanish (ESP)

• Swedish (SWE)

The system is shipped with the factory installed US English firmware.

Changing Languages

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Illustration 177	g01287477
(80) LCD (81) Soft Keys Labels (82) Hard Keys (83) Escape Key (84) Next Key (85) Power Key (86) "+" Key (87) Arrow Keys (88) "-" Key (89) "OK" Key (90) Menu Key (91) Data Card Slot

1. Power system up in Service Mode by turning machine key to "ON" position.

2. Press and hold the "OK" Key (89) while pressing the Power Key (85) .

3. Press the Menu Key (90) .

4. Press the "Installation" hard key.

5. Use the Arrow Keys (87) in order to scroll to "Select Language".

6. Press the "OK" Key (89) .

7. Select the language.

8. Press the "OK" Key (89) .

Working With The Setup Menus

Use the "Setup Menu" dialogs in order to access the AccuGrade System setup items. The "Setup Menu" dialogs are available in Normal, Service, and Training mode. However, different dialogs and items become available for the mode you select. Service Mode provides access to all of the Configuration and Installation options. In Normal Mode, the dialogs and options are predefined and may only be changed by reverting to Service Mode. In Training Mode, menus and options relating to control devices are not displayed. Refer to Table 37 for more details.

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

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

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

1. Press the "MENU" key.

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

Setup Menu - Configuration

Items in the "Setup Menu - Configuration" dialog include troubleshooting items as well as system variables and settings. By default, some of these items are visible in Service Mode only, while others are visible in all modes. The options are as shown in Table 37.

Table 37

Setup Menu - Configuration Item	Mode	Information Reference: Systems Operation, Troubleshooting, Testing and Adjusting, KENR6319, "AccuGrade® - CD700 Grade Control System (GPS/ATS/Laser/Sonic/Cross Slope)"
Select Design	Normal Mode Service Mode	Systems Operation, "Select Design"
GPS Accuracy	Normal Mode Service Mode	Systems Operation, "GPS Accuracy"
Blade Wear	All Modes	Systems Operation, "Blade Wear"
Vertical Setup	Normal Mode Service Mode	Systems Operation, "Vertical Setup"
Increment Adjustment Switch	Service Mode	Systems Operation, "Vertical Offset Increment"
Lightbar Scales	All Modes	Systems Operation, "Light Bar Scales"
Display and Lightbar Brightness Setting	All Modes	Systems Operation, "Display and Light Bar Brightness (Display and Lightbar)"
Calibrate Sensors	Normal Mode Service Mode	Testing and Adjusting, "Angle Sensor - Calibrate"
Map Recording	Service Mode	Systems Operation, "Map Recording"
Valve Speed	Normal Mode Service Mode	Testing and Adjusting, "Blade Reaction Time - Adjust"
Adjust Bolt Hole	Service Mode	Systems Operation, "Adjust Bolt Hole"
Avoidance Zone	Service Mode	Systems Operation, "Avoidance Zone"
Text Items	Service Mode	Systems Operation, "Text Items"
Plan View	Service Mode	Systems Operation, "Plan View"
Beeper	Service Mode	Systems Operation, "Beeper"
Save Settings	Service Mode	Systems Operation, "Display Settings"
Restore Settings	All Modes	Systems Operation, "Display Settings"
GPS Receiver Configuration	Service Mode	Systems Operation, "Receiver Configuration"
Diagnostics	Normal Mode Service Mode	Troubleshooting, " Diagnostic Capabilities"

"Setup Menu - Installation"

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

Depending on the current machine configuration, different options are available from the "Setup Menu - Installation" dialog. The options are shown in table 38.

Table 38

Setup Menu - Configuration Item	Mode	Information Reference: Systems Operation, Troubleshooting, Testing and Adjusting, KENR6319, "AccuGrade® - CD700 Grade Control System (GPS/ATS/Laser/Sonic/Cross Slope)"
Machine Settings	Service Mode	Testing and Adjusting, "Machine Type"
Units	Service Mode	Systems Operation, "Display Units"
Machine Dimensions	Service Mode	Testing and Adjusting, "Machine Dimensions - Set"
GPS Option Keys	Service Mode	Testing and Adjusting, "GPS Option Keys"
Machine Radio Configuration	Service Mode	Systems Operation, "Radio Utility"
Lightbar Connections	Service Mode	Testing and Adjusting, "Light Bar - Set"
Valve Calibration	Service Mode	Testing and Adjusting, "Bank Valve (Grade Control) - Calibrate"
Wireless Communications Support	Service Mode	Systems Operation, "Wireless Communications"
Production Reporting	Service Mode	Systems Operation, "Production Reporting"
Upgrade Firmware	Service Mode	Systems Operation, "Receiver Firmware Upgrade, Display Firmware Upgrade, Angle Sensor Firmware Upgrade"
Software Support Option	Service Mode	Systems Operation, "Software Support Option"
Select Language	Service Mode	Systems Operation, "Select Language"
Guidance Hours	Service Mode
Operator Configuration	Service Mode	Systems Operation, "Operator Access"

Display Registration and Activation

The AccuGrade display must be registered and activated by the dealer before it can be used. When you register the display, you will receive a unique Registration Key to be used to activate the display. This registration process will allow for display to be upgraded as software upgrades are released.

Obtaining A Registration Key

Refer to the following steps in order to obtain the Registration Key for the Display.

1. Obtain and record the serial number from identification plate on display.

2. Go to the following website: "www.techproductregistration.com"

3. Complete registration form on website.

   Refer to Special Instruction, REHS3666, "Software Activation for the AccuGrade^® Display".

   Note: If access to website is not available, call 888-223-7539 for manual registration.

4. When data fields are complete, select "Submit" on web form.

   You will be asked to review the data again and confirm your input.

   1. Review the information.

   2. Select Confirm.

      Within 30 minutes, an e-mail will be sent to the dealer's e-mail address that was submitted on the web form. This e-mail will have the Registration Key number in order to activate the display.

   3. Provide the Registration Key number to the appropriate person in order to enter into the display.

      Save this registration information for future reference.

Entering A Registration Key Into The Display

Refer to the following steps in order to enter a Registration Key into the Display.

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Illustration 178	g01314647

1. Power system up by turning machine key to "ON" position and pressing the Power Key (85) .

   The Display will power up. A screen similar to Illustration 178 will appear.

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Illustration 179	g01314650

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Illustration 180	g01314651

2. Perform one of the two options below:
   • Copy the Registration Key file obtained above to the root folder of the Data Card. Press "OK".

   • Enter the 24 character option key obtained above. To do this, use the arrow keys on the keypad of the display. Press "OK" key.

   If successful, the Option Keys File Loaded dialog appears. Refer to Illustration 180. This indicates that one option key has been loaded successfully.

3. Press the "OK" key.

   The Plan View appears.

   Note: If the key does not activate, verify that key was entered correctly. Verify that the serial number on identification plate is the same as electronic serial number.

Configuring the Grade/Slope ECM for H Series Motor Graders

The Implement/Valve Control ECM is shipped from the factory with the status of the AccuGrade System in the "Not Installed" state. Configure the Implement/Valve Control ECM to the "Installed" state before using the system. Use the following procedure in order to configure the Implement/Valve Control ECM.

Procedure

1. Connect the 196-0055 Data Link Cable Assembly between the 171-4401 Communication Adapter Assembly and the Electronic Technician.

2. Connect the 207-6845 Adapter Cable Assembly between the 171-4401 Communication Adapter Assembly and the diagnostic connector of the machine.

3. Turn the Key Start switch to the "ON" position.

4. Open up the Electronic Technician software and select the Grade/Slope Control.

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Illustration 181	g01181296

5. Select the "Configuration" option in the "Service Menu".

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Illustration 182	g01181331

6. Double click on the "AccuGrade System Installation Status" parameter.

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Illustration 183	g01181333

7. Change the new value to "Installed" and click the "OK" button.

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Illustration 184	g01181336

8. Click on the "Yes" button.

9. Verify that the correct sales model is selected. If the selected sales model is incorrect, repeat this procedure for the "Product Sales Model" parameter.

Software Enable Attachment Procedure For M Series Motor Graders

1. Obtain a factory password at "http://fps.cat.com". Refer to Special Instruction, REHS1238, "Obtaining Factory Passwords and Software Enabled Attachments"

2. Connect to ET.

3. Click on "Service/Configuration".

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Illustration 185	g01314485

4. Double Click "AccuGrade System Installation Status" in the following directory:
   • "Implement xxM/Implement Parameters"

   Note: This directory will be changed to "Implement xxM/AccuGrade" in the future

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Illustration 186	g01314487

5. Select "Installed" from drop down list and then click "OK".

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Illustration 187	g01314488

6. Click "OK" again.

7. Enter Factory Passwords, then click "OK".

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Illustration 188	g01314489

8. AccuGrade is installed

Note: If you are going to enable AccuGrade, ignore this Step 9 and continue to Step 10.

9. A key cycle is needed for other ECMs to recognize AccuGrade.

10. After AccuGrade is installed, the user can enable it.

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Illustration 189	g01314490

11. Double click "AccuGrade Enable Status".

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Illustration 190	g01314491

12. Select "Enabled" and then click "OK".

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Illustration 191	g01314492

13. Click on "Yes".

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Illustration 192	g01314493

14. "AccuGrade Enable Status" is enabled.

15. Cycle the key for the machine start switch.

Software Enable Attachment (Temporary Installation) Procedure For M Series Motor Graders

1. Connect to ET.

2. Click on "Service/Configuration".

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Illustration 193	g01460739

3. Double click "Accugrade Temporary Installation Status". Select "Installed".

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Illustration 194	g01460750

4. The "AccuGrade Temporary Installation Status" is now installed.

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Illustration 195	g01460751

Note: The "AccuGrade Temporary Installation Status" will remain installed for 50 hours. After the 50 hour time period expires the system will revert back to a uninstalled state.

5. Cycle the key for the machine start switch.

Enabling E/H Access

In order for the AccuGrade system to Operate in Automatic Mode the E/H system may need to be set as installed by a Software Enabled Attachment (SEA). Refer to the Machine Price List for verification if an SEA is required. If an SEA is required, Refer to Special Instruction, REHS1238, "Obtaining Factory Password and Software Enabled Attachments" for more information.

Illustration 196 is an example of where the AccuGrade E/H SEA is located. Most AccuGrade E/H SEAs are located under the Implement ECM.

Illustration 196	g01313134

Wireless Communication Option

AccuGrade Wireless Communication is an available option for the AccuGrade V10 CD700 Display. This option provides the site manager the ability to transmit updated design information to the machines on site, perform basic remote diagnostics and send simple text messages to the machines. This option can be purchased and installed on each CD700 Display.

Option Key Purchase Procedure

1. Refer to the appropriate AccuGrade price list to order the AccuGrade CD700 Wireless Communication Option Key.

2. Order the key per the instructions on the price list.

3. Record the following information: wireless key reference number, order dealer code and order reference number.

4. Obtain and record the serial number from identification plate on display to have wireless communications option activated.

5. Go to the website: "www.techproductregistration.com".

6. Complete option key activation form on website.

   Refer to Special Instruction, REHS3666, "Software Activation for the AccuGrade^® Display".

   Note: If access to the website is not available, call 888-223-7539 for key administration.

7. When the data fields are complete, select "Submit" on web form.

   You will be asked to review the data again and confirm your input. Review information and select "Confirm" or select "Back" and edit the information.

   Within 30 minutes an e-mail will be sent to the dealer e-mail address submitted on the web form. This e-mail will have the option key number to activate the option on the requested display. A phone call will be made to phone number submitted on web form to confirm e-mail with option key number was received. Provide this key to the appropriate person to have installed on display. Save this option key information for future reference. An invoice will be sent from Antares for the purchase of the option key.

Procedure For Entering The Registration Key Into The Display

1. Power the system up in Service Mode by turning machine key to "ON" position.

2. Press and hold the "OK" Key (89) while pressing the Power Key "12".

3. Press the Menu Key (90) .

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Illustration 197	g01451159

4. Press the "Installation" Hard Key.

5. Use the Arrow Keys (87) in order to select "Software Support Option".

6. Press the "OK" key (89) .

7. Perform one of the two options below:
   • Copy the Wireless Option key file to the root folder of a data card. Insert the Data Card. The Display will read the key.

   • Enter the 24 character option key that was obtained above. To do this, use the Arrow Keys (87) on the Display. Press the "OK" Key (89) .

   If the procedure is successful, the Option Keys File Loaded dialog appears. This indicates that one option key has been loaded successfully.

8. Press the "OK" Key (89) .

   The Plan View appears.

   Note: If key does not activate, verify that key was entered correctly. Verify that the serial number on identification plate is the same as electronic serial number

Machine Settings

Use Service mode in order to change the settings that affect the operation of the AccuGrade System.

Note: If you lack experience with the AccuGrade System, use extreme care when you are in Service mode so that you do not accidentally change the AccuGrade System settings.

In order to turn on Service mode, press and hold down the "OK" key as you press the Power key. Make sure that you hold down the "OK" key until the Display (1) shows the opening screen.

In order to turn off Service mode, turn off the Display (1). In order to do this press and hold the Power key.

You can perform the following functions in Service Mode:

• Set the machine settings

• Set units

• Set machine dimensions

• Set the light bar connections

• Set plan view options

• Set machine radio configuration

• Calibrate the valves

• Update the firmware of components

• Customize the operator configuration

• Set the production recording options

• Set the warning distance for avoidance zone detection

• Select the text items to be shown

• Configure the beeper

• Save display or machine settings

• Update the GPS receiver configuration

• Adjust increment switches

• Configure wireless communication

• Select language

• Enter GPS option keys

You can perform the following functions in Normal Mode:

• Set blade wear

• Adjust vertical setup

• Adjust valve speed

• Adjust light bar scales

• View guidance hours

• Calibrate sensors

• Set software support options

• Edit the GPS accuracy mode

• Set the display and light bar brightness

• Restore display or machine settings

• Perform GPS receiver tests and log GPS data

• Perform advanced diagnostics

For more information, refer to the Systems Operation, "Machine Type (Machine Settings)" in order to access the "Machine Settings" dialog.

Configure The Machine Type

You can configure a new machine with the "Machine Settings" dialog.

1. Start the Display (1) in Service mode.

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

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Illustration 198	g01450890

3. Use the down Arrow Key or the up Arrow Key until "Machine Settings" is highlighted. Press the "OK" key. A dialog that is similar to Illustration 198 appears.

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Illustration 199	g01378900

4. Press the "Edit Machine" Hard Key and use the down Arrow Key or the up Arrow Key until "Grader" is highlighted. Press the "OK" key. A dialog that is similar to Illustration 199 appears.

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Illustration 200	g01378903

5. Use the down Arrow Key or the up Arrow Key until the desired "System Type" is highlighted. Press the "OK" key. A dialog similar to Illustration 201 appears.

   Note: The Sonic Sensor is not listed in the System Type dialog because it is a plug and play device. The Sonic Sensor must be set up in the "Vertical Setup" menu.

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Illustration 201	g01379123

6. Select the mast position for single GPS and ATS systems, if applicable.

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Illustration 202	g01315141

7. Select/deselect the fixed sensors that are mounted on the machine by pressing the upper right soft key.

8. Press the "OK" key.

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Illustration 203	g01310328

9. For GPS and ATS systems, use the down Arrow Key or the up Arrow Key until the desired "Radio Type" is highlighted. Press the "OK" key.

   Select "TCXXXC/CRXXXC". Caterpillar systems normally use the TC900C/CR900 Data Radio (6) or the TC450C radio.

   If a 3rd party radio is selected, the data is passed over RS232. Refer to Customer Supplied Radio within this document.

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Illustration 204	g01310339

10. Use the down Arrow Key or the up Arrow Key until the desired "Lightbar" option is highlighted.

11. Press the "OK" key.

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Illustration 205	g01310346

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

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

Configure The Units

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

Note: Caterpillar recommends setting the distance Units as Meters (m) in order to perform the machine measure up.

Perform the following steps in order to set the units.

1. Start the Display (1) in Service mode.

2. Press the Menu button.

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

4. Use down Arrow Key or the up Arrow Key until "Units" is highlighted.

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Illustration 206	g01310351

5. Press the "OK" key. By default, the "Distance Units" dialog is selected. The dialog in Illustration 206 appears.

6. Do the following as necessary from any of the "Units" dialogs.
   • Press the "Distance" Hard Key in order to select the distance units.

   • Press the "Speed" Hard Key in order to select the speed units.

   • Press the "Grade" Hard Key in order to select the grade units.

   • Press the "Cross Slope" Hard Key in order to select the cross slope units.

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

   Distance - Distance values appear on the screen in the following formats.

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

   • International feet - as "ft"

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

   Speed - Speed can be shown in the following formats.

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

   • Miles per hour - "mph"

   Grade - Grade values can be shown in the following formats:

   • Percentage - as "%"

   • Ratio - as "rise : run" (default)

   Cross Slope - Cross slope values can be shown in the following formats:

   • Percentage - as "%" (default)

   • Ratio - as "rise : run"

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

   • 1000 (default)

   • 1+000.00

   • 10+00.00

   • 1/000.00

7. When any or all of the units have been set, press the "OK" key in order to save the settings and return to the "Setup Menu - Installation".

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

Setting the Light Bars

The AccuGrade System has three light bars:

• Two vertical light bars for cut/fill mode

• One horizontal left/right light bar

Each light bar can be used in any position, but the light bar must be individually set for that position. You set only one light bar at a time. In order to set the connections for the light bar, perform the following procedure:

Note: The horizontal light bar is only used for ATS and GPS.

1. Press and hold the "OK" key while powering up the display in order to access the Service mode.

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

3. Press the up Arrow Key or the down Arrow Key until "Lightbar Connections" is highlighted.

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Illustration 207	g01310390

4. Press "OK".

   The "Lightbar Connections" dialog will be shown on the Display (1) .

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

6. Press "SET" for the connected light bar. A pattern of Light Emitting Diodes (LEDs) is illuminated on the connected light bar. This should match the pattern that is shown in Illustration 207. If the light bar LEDs are illuminated at the wrong end, press "INVERT".

7. Disconnect the light bar.

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

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

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

    All changes take effect immediately.

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

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

"Machine Radio Configuration"

The "Machine Radio Configuration" utility allows you to change the network number or the frequency channel on Data Radios. The "Machine Radio Configuration" utility runs on the Display.

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

1. In Service mode, select the "Installation" Hard Key from the "Setup" menu.

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Illustration 208	g01451159

2. Press the up arrow or the down arrow until "Machine Radio Configuration" is highlighted.

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

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Illustration 209	g01301489

4. Use the Arrow Keys (87) in order to select the same network as the base station for TC900C Radios. Use the Arrow Keys (87) to select the same frequency as the base station for TC450C Radios.

"Display's Radio Port"

When a third party radio is used, the Display for the AccuGrade System allows the user to adjust the following communication parameters:

• Baud Rate

• Parity

The "Display's Radio Port" settings sets the speed at which the Display communicates with the radio. These settings do not affect the speed of data transfer though the air between radios. Refer to the following Steps in order to adjust the "Display's Radio Port" settings.

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Illustration 210	g01287477
(80) LCD Screen (81) Soft Keys (82) Hard Keys (83) Escape Key (84) Next Key (85) Power Key (86) "+" Key (87) Arrow Keys (88) "-" Key (89) "OK" Key (90) Menu Key (91) Data Card Slot

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

   Note: Hold the "OK" Key (89) while pressing the Power Key (85) in order to start the AccuGrade System in "Service" mode.

2. Press the Menu Key (90) .

3. Select the Hard Key that is located beside the "Installation" Hard Key from the "Setup Menu".

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Illustration 211	g01451159

4. Press the up arrow or the down arrow until "Display's Radio Port" is highlighted.

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Illustration 212	g01288144

5. Press the "OK" key (89) .

   A screen that is similar to Illustration 212 will appear.

6. Press the up arrow or the down arrow in order to adjust the "Baud Rate". Press the Next Key (84) in order to toggle between the Display Radio Port fields

7. Press the up arrow or the down arrow in order to adjust the "Parity".

8. Press the "OK" key (89) .

Configuring The GPS Receiver

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

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

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

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

2. Hold the "OK" key (89) while pressing the Power Key (85) in order to start the AccuGrade System in Service mode.

3. Press the Menu key in order to access the "Setup Menu".

4. From the "Setup Menu - Configuration" dialog, press the down Arrow Key or the up Arrow Key until "GPS Receiver Configuration" is highlighted.

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Illustration 213	g01310396

5. Press the "OK" key. The "GPS Receiver Configuration" dialog appears. This is shown in illustration 213.

   All GPS receiver configuration files in the root folder of the data card are listed on the Display (1) .

6. Press the down Arrow Key or the up Arrow Key in order to select the correct .cfg file.

7. Press the "OK" key. The AccuGrade System sends the .cfg file to the system and also provides status information. The following text will be shown on the Display:
   • "Loading. Please wait ..."

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

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

   Make sure that you check the GPS configuration file was properly sent. In order to do this, position the left blade tip on a known point and compare the coordinates that appear on the Display (1) with the known coordinates of the point.

Measurement Procedure for Motor Graders

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If the system is in Automatic Mode, blade movement may occur. Ensure that the system is in Manual Mode. Personal injury or death from crushing could occur if the system is not in Manual Mode.

Note: Refer to the ""Machine Measurements" " Section of this publication in order to record the measurements that are taken during this procedure.

The system requires machine dimensions to calculate the cross slope from the cross slope sensors. This section describes the procedure for measuring the dimensions.

Note: For dual GPS systems that do not use the cross-slope sensors, continue to ""Measuring The Position Of The Mast" ".

Center the Blade

Make sure that the blade is perpendicular to the main frame.

1. Park the machine on level ground.

2. Put the frame in the straight position.

3. Make sure that the front wheels of the grader are vertical.

4. Make sure that the link bar is centered with the locking pin in the middle hole.

5. Level the blade with a level.

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Illustration 214	g01079442

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Illustration 215	g01101537

6. Measure the distance from each side of the moldboard for the blade to the corresponding blade beam.

7. Shift the blade to the side until the measurements are equal.

   The distances that are measured should be within 12.7 mm (0.5 inch) of each other.

Rotation of the Blade

Note: Make sure that the blade is level.

Note: Make sure that the machine is on a level surface.

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Illustration 216	g01079446

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Illustration 217	g01108390

1. Locate a point at the front of the frame that is also centered on the frame.

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Illustration 218	g01108395

2. Measure from the point that is shown in Illustration 217 to the edge of the moldboard that is located on each end of the blade

3. Rotate the blade until the measurements are equal.

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Illustration 219	g01389826
Zero Alignment Gauge (M Series)

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Illustration 220	g01389831
Zero Alignment Gauge (H Series)

4. Loosen the bolt(s) in order to adjust the Bracket (82) of the zero alignment gauge.

5. Line up the pointers.

6. Tighten the bolts.

   Note: Do not move the machine. The machine is ready for machine measure up and the system calibrations.

Measuring The Position Of The Mast

Note: For AccuGrade systems that are setup for SLOPE only, continue on to Calibrations.

The angle bracket of the mast has 7 bolt holes:

• Bolt hole 1 is nearest to the front of the grader.

• Bolt hole 7 is nearest to the cab of the grader.

You must position the blade and the machine correctly in order to record the following measurements for each antenna:

• Height above the cutting edge bolts

• Distance from the cutting edge bolts

• Distance from the blade tip to the antenna

Illustration 221 shows the angle bracket in bolt hole 5.

Illustration 221	g01189157
Angle bracket in bolt hole 5

Alignment of the Machine and the Blade

Complete the following steps in order to position the machine and make measurements :

Note: A measure up will need to be performed on each bolt hole that the operator plans on using. Bolt holes 3-5 are the most common bolt holes used.

1. Select a bolt hole according to the measurement of the position of the blade and the antenna.

2. Rest the blade on the ground and make sure that the cutting edge bolts are level.

3. Pitch the moldboard forward until the left mast is vertical in the forward or backward direction.

Carry out these steps and consider the following points:

• When the machine is straight the blade is horizontal and touching the ground. Use a spirit level to position the machine. Refer to Illustration 222.

Illustration 222	g01189161
Balancing the cutting edge

• Make sure that both sides of the blade are level.

• Use the spirit level in order to ensure that the left mast is vertical in the forward or backward direction. You may need to make minor adjustments by pitching the moldboard. If you move the moldboard you must check the blade level by following the procedure above.

• Measure both masts in this position. Even if the right mast is not absolutely vertical do not move the blade before completing all of the measurements.

The machine is now ready to perform all measurements.

Note: The machine and the blade must be in the same position for each bolt hole during the operation of the AccuGrade System.

Note: If the machine is on uneven ground place a board under each blade tip. The boards must be horizontal and held at the same height. The boards must be large so that the plumb bob can touch the boards from any part of the ground plane of the GPS antenna.

Using The Measurement Tool

The 266-2916 GPS Measuring Assembly for the Receiver allows you to measure the height of the Receiver above the blade and the horizontal offsets of the Receiver from the blade.

The 266-2916 GPS Measuring Assembly consists of the following components:

• A length of alloy that is angled with slots and mounting holes on both sides

• Mounting bracket of a Receiver

Note: See Illustration 223.

Illustration 223	g01189264
Measurement tool and mounting bracket

Before you start the measurement you need to mount the angled alloy on the mounting bracket. The measurement tool must be mounted on the correct side so that the units are marked on the horizontal surface. Mount the measurement tool on top of the mast of the GPS receiver during the process of measurement.

Note: Caterpillar recommends using the Metric slots for more precise measurements.

Measuring the Receiver Offsets

Note: First measure the offsets of the Receiver on the left side. Then measure the offsets of the Receiver on the right side. For Single mast GPS systems and ATS systems, only measure the side that the mast is mounted.

To make these measurements, you need the following equipment:

• 266-2916 GPS Measuring Assembly

• Steel tape or ruler

• Spirit level or straight edge

• Plumb bob

• String line

• Steel framing square

• Ladder

Note: Use the 266-2916 GPS Measuring Assembly instead of measuring directly to the Receiver (20). If you do not have a measurement tool for the Receiver, the measurement of height should be made to the top of the lower housing on the Receiver (20) .

Complete the following steps for the measurement of the offset of the Receiver (20) from the mounting bolts of the cutting edge :

1. Remove the Receiver from the mast.

2. Slide the mounting bracket onto the top of the mast.

3. Rotate the measurement tool to a perpendicular position. The measurement tool must point forward. See Illustration 224.

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Illustration 224	g01189282
Measurement tool in a parallel position with the center line of the grader

4. Secure the plumb bob line on one of the notches in the measurement tool so that the plumb bob line hangs in front of the mounting bolts of the cutting edge.

   Note: For ATS systems, be sure that the electric mast is retracted all the way.

5. Measure the distance from the plumb bob line to the center of the mounting bolts of the cutting edge. Use the steel framing square in order to perform the measurement. See Illustration 225.

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Illustration 225	g01189285
Measuring from the plumb bob line to the center of the mounting bolts of the cutting edge

6. Subtract the value from Step 5 from the distance on the notch of the measurement tool for the distance backward from the mounting bolts of the cutting to the antenna.

   Note: If the center of the GPS antenna is in front of the center of the mounting bolts of the cutting edge the difference is a negative value.

7. Record the difference into the "Back from cutting edge bolts" field in the "Mast Positions" dialog.

   Record the difference on the Grader Record Sheet found in this manual.

Complete the following steps for measuring the height of the Receiver (20) above the mounting bolts of the cutting edge:

1. Leave the measurement tool in the position for the measurement of the distance backward from the bolts of the cutting edge.

2. Make sure that the spirit level or the straight edge is level before taking the measurement.

3. Anchor the measuring tape onto the measurement tool and measure the vertical distance to the middle of the mounting bolts of the cutting edge. See Illustrations 226 and 227.

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Illustration 226	g01189296
Measuring from the measurement tool

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Illustration 227	g01189298
Measuring to the center of the mounting bolts of the cutting edge

4. Record this value on the "Grader Record Sheet" found in this manual.

Complete the following steps for the measurement of the offsets from the Receiver (20) to the outside of the blade tip :

1. Rotate the measurement tool so that the tool is parallel to the cutting edge of the blade and the tool extends beyond the edge of the blade. See Illustration 228.

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Illustration 228	g01189307
Aligning the measurement tool

2. Secure the plumb bob line from a notch in the measurement tool. The plumb bob line must hang past the edge of the blade.

   Note: Remember the notch that secures the plumb bob line.

3. Measure the distance from the tip of the blade to the intersection of the square and the plumb bob line. See Illustration 229.

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Illustration 229	g01189314
Measuring from the blade tip to the plumb bob

4. Subtract the value from the measurement in Step 3 from the distance on the notch of the measurement tool for the Antenna in from the blade tip distance.

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

5. Record this value on the "Grader Record Sheet".

6. Perform the Mast measurements for the other mast and the other bolt holes that will be used.

Blade Dimension Measurements

This section outlines the measurements required for the blade, cutting edge and rippers.

Measuring the Blade Height

To measure the blade height, complete the following steps:

1. Measure the distance from the center of the cutting edge mounting bolts to the top of the blade. See Illustration 230.

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Illustration 230	g01189319
Measuring the blade height

2. Record the value into the on the "Grader Record Sheet".

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

Measuring the Blade Width Between Tips

To measure the blade width, complete the following steps:

1. Measure the distance that is shown in Illustration 231.

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Illustration 231	g01189324
Measuring the blade width between tips

2. Record the value on the "Grader Record Sheet".

   The AccuGrade System uses the Blade width between tips measurement along with the Antenna in from blade tip measurement for system verification during start-up.

Measuring the Distance between the Lift Rams

To measure the distance between the lift rams, complete the following steps:

1. Measure the distance shown in Illustration 232.

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Illustration 232	g01189404
Distance between the lift ram balls

2. Record this value on the "Grader Record Sheet".

Measuring the Cutting Edge

To measure the cutting edge at any bolt hole position use the spirit level and the steel tape.

Measurement bolt hole

Record the number of the bolt hole that is in use for this measurement on the Grader Record Sheet.

Note: Bolt hole 1 is nearest to the front of the grader and bolt hole 7 is nearest to the operator's cab.

Measuring the horizontal distance

To measure the horizontal distance from the center of the cutting edge bolts to the cutting edge complete the following steps:

1. Stand the spirit level against the front of the cutting edge.

2. Make sure the spirit level is vertical.

3. Measure the horizontal distance from the center of the cutting edge mounting bolts to the spirit level. See Illustration 233.

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Illustration 233	g01189413
Measuring the horizontal distance

4. Record this value on the "Grader Record Sheet".

Measuring the vertical distance

To measure the vertical distance from the center of the cutting edge bolts to the cutting edge, complete the following steps:

1. Rest the spirit level on the center of the cutting edge mounting bolts.

2. Make sure the spirit level is horizontal.

3. Measure the vertical distance from the bottom edge of the spirit level to the tip of the cutting edge. See Illustration 234.

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Illustration 234	g01189451
Measuring the vertical distance

4. Record this value on the Grader Record Sheet.

Measuring the RIpper Distance

To measure the ripper distance back from cutting edge bolts, complete the following steps:

1. Lower the rippers to the ground.

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

3. Record this value on the "Grader Record Sheet".

Note: When measuring up a machine, always enter a distance in the Ripper Distance field. If the machine does not have rippers, enter the distance to the back of the machine. This distance is used in order to calculate the back of the machine for Avoidance Zone warnings.

Measuring the Machine Body

To measure the distance back from the cutting edge to be used for avoidance zone calculations, complete the following steps:

1. Measure the distance from the front of the machine to the cutting edge.

2. Record this value on the "Grader Record Sheet".

3. Measure the distance from the back of the machine to the cutting edge.

4. Record this value on the "Grader Record Sheet".

Enter the Machine Dimensions

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

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Illustration 235	g01287477
(80) LCD (81) Soft Keys Labels (82) Hard Keys (83) Escape Key (84) Next Key (85) Power Key (86) "+" Key (87) Arrow Keys (88) "-" Key (89) "OK" Key (90) Menu Key (91) Data Card Slot

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

   Note: Hold the "OK" Key (89) and Power on the Display (1) in order to start the AccuGrade System in "Service" mode.

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

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

2. Press the Menu key.

   This will display the "Setup Menu".

   Refer to Illustration 236.

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Illustration 236	g01451159

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

   Use the Arrow Keys (87) to select the "Machine Dimensions" option.

4. Press the "OK" Key (89) .

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Illustration 237	g01310398

5. Select the "Mast Dimension" option with the up arrow or down Arrow Keys (87) .

6. Press the "OK" Key (89) .
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   Illustration 238	g01310400

   1. Use the arrow soft key in order to navigate through the menus screens and enter the data with the Arrow Keys (87) .
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   Illustration 239	g01310533

   2. Use the Bolt Holes menu to indicate which bolt holes will be used.

   3. Use the Arrow keys to select the bolt hole.

   4. When you have selected the bolt hole, click on the upper right soft key.
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   Illustration 240	g01310563

   5. Press the Arrow Keys in order to select where the measurements were taken from. Choose from one of the following options in the "Measure height to" option:
      • "Measure-up tool"

      • "Top of lower housing"

      • "Top of mast"

   6. Use the Mast Measurements option to enter the dimension that were recorded for the masts.

      The following measurements need to be recorded for the Left Mast:

      • Back from cutting edge bolts

      • Above cutting edge bolts

      • In from blade tip

      The following measurements need to be recorded for the Right Mast:

      • Back from cutting edge bolts

      • Above cutting edge bolts

      • In from blade tip

7. Press the "OK" Key (89) in order to move to the next page.

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Illustration 241	g01310576

8. Press the "Finish" Hard Key to return to the "Machine Dimensions" menu.

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Illustration 242	g01310586

9. Use the Arrow Keys (87) to select the "Machine Dimensions" option and press the "OK" Key (89) .

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Illustration 243	g01310594

10. Use the Arrow Keys (87) to enter the blade dimensions. Use the Next Key (84) in order to navigate between options.

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Illustration 244	g01310636

11. When all the information has been entered, press the "Cutting Edge" Hard Key.

    Use the Arrow Keys (87) to enter the bolt hole that is used for the measure up procedure.

    Use the Arrow Keys (87) to enter the cutting edge dimensions. Use the Next Key (84) to navigate between options.

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Illustration 245	g01310661

12. When all the information has been entered, press the "Ripper" Hard Key.

    Use the Arrow Keys (87) to enter the ripper distance back from cutting edge. If the machine is not equipped with a ripper, use 0.00.

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Illustration 246	g01310664

13. When all the information has been entered, press the "Machine Body" Hard Key.

    Use the Arrow Keys (87) to enter the "Machine Dimensions" menu. Use the Next Key (84) to navigate between options.

14. When all the information has been entered, press the "OK" Key (89) to save the data and exit.

Machine Settings

Table 39

Configuration Menu	Softkey	Field	Setting/value
Vertical Guidance Point		Vertical Guidance Point
Vertical Offset Switch Increment		Switch Increment
Lightbar Scales	"Vertical"	Vertical Tolerance
Lightbar Scales	"Horizontal"	Horizontal Tolerance
Valve Speed	"Lift"	Lift
Valve Speed	"Sideshift"	Sideshift
Adjust Bolt Hole		Bolt Hole
Avoidance Zone		Warning distance
Machine Settings		Machine type	Grader
Machine Settings		Number of GPS antennas
Machine Settings		Lift valve type
Machine Settings		Radio type
Machine Settings		Laser receiver
Machine Settings		Laser mast side

Display Settings

Table 40

Configuration Menu	Softkey	Field	Setting/value
Vertical Offset Switch Increment		Switch increment
Lightbar Scales	"Vertical"	Vertical Tolerance
Lightbar Scales	"Horizontal"	Horizontal Tolerance
Text Items	"Plan View"	Line 1
Text Items	"Plan View"	Line 2
Text Items	"Plan View"	Line 3
Text Items	"Plan View"	Line 4
Text Items	"Plan View"	Line 5
Text Items	"Cross-section"	Line 1
Text Items	"Cross-section"	Line 2
Text Items	"Cross-section"	Line 3
Text Items	"Cross-section"	Line 4
Text Items	"Cross-section"	Line 5
Text Items	"Text View 1"	Line 1
Text Items	"Text View 1"	Line 2
Text Items	"Text View 1"	Line 3
Text Items	"Text View 1"	Line 4
Text Items	"Text View 1"	Line 5
Text Items	"Text View 2"	Line 1
Text Items	"Text View 2"	Line 2
Text Items	"Text View 2"	Line 3
Text Items	"Text View 2"	Line 4
Text Items	"Text View 2"	Line 5
Text Items	"Profile View"	Line 1
Text Items	"Profile View"	Line 2
Text Items	"Profile View"	Line 3
Text Items	"Profile View"	Line 4
Text Items	"Profile View"	Line 5
Map Recording		Map Recording

Table 41

Installation Menu	Softkey	Field	Setting/value
Machine Settings		Machine type	Grader
Machine Settings		Number of GPS antennas
Machine Settings		Grade control
Machine Settings		Lift valve type
Machine Settings		Sideshift valve type
Machine Settings		Laser receiver
Machine Settings		Laser mast side
Units	"Distance"	Distance Units
Units	"Speed"	Distance Units
Units	"Grade"	Grade Units
Units	"Cross Slope"	Cross Slope Units
Units	"Station Format"	Station Format
Wireless Communications Support		FTP Support

Machine Measurements

Use the Tables below in order to record the measurements of the machine.

Table 42

Units
Machine
Date

Mast Measurments

Illustration 247	g01456866
Fixed Mast

Illustration 248	g01457037
Electric Mast

Use Table 44 and 45 in order to enter the bolt hole measurements. Record the measurements for up to three of the seven bolt holes that are available on each side.

Table 43

Measure Height to:
Measure-Up Tool
Top of lower housing
Top of mast

Table 44

Left Mast	Bolt hole:	Bolt hole:	Bolt hole:
A. Back from cutting edge bolts (- = fwd)
B. Above cutting edge bolts
C. In from blade tip (- = out)
Electric Mast
D. Mast lean in from blade tip in degrees (- = out)
E. Mast lean back in degrees (- = forward)

Table 45

Right Mast	Bolt hole:	Bolt hole:	Bolt hole:
A. Back from cutting edge bolts (- = fwd)
B. Above cutting edge bolts
C. In from blade tip (- = out)
Electric Mast
D. Mast lean in from blade tip in degrees (- = out)
E. Mast lean back in degrees (- = forward)

Blade Measurements

Illustration 249	g01457040
Blade Measurements

Table 46

Measurment	Value
F. Blade Height
G. Blade width between tips
H. Distance between lift rams

Cutting Edge Measurements

Illustration 250	g01457043
Cutting Edge Measurements

Table 47

Measurement	Value
Edge measurement (Edge: H. / V. or Edge: Angle
Measurement bolt hole
I = Cutting edge horizontal distance / J = Cutting edge height
K = Cutting edge vertical distance / L = Cutting edge angle

Ripper and Machine Body Measurements

Illustration 251	g01457046
Ripper Measurements

Table 48

Measurement	Value
M. Ripper back from cutting edge
N. Distance from the front of the machine to the cutting edge
O. Distance from the back of the machine to the cutting edge

Calibrations

Note: Do not perform calibrations of the Valve Control ECM that are available in the Caterpillar Electronic Technician. The Calibrations Procedures will degrade the system performance of the Valve Control ECM on H series motor graders. However, they must be performed on M Series motor graders before the AccuGrade calibrations are performed.

Two calibrations are required to be performed prior to operating the system by the AccuGrade System. These calibrations are listed here:

• Sensor Calibration

• Valve Calibration

The Sensor calibration must be performed prior to the Valve Calibrations in order to allow the system to determine the position of the blade.

Note: For dual GPS systems that do not use the cross-slope, only a valve calibration will need to be performed.

Calibration of the Cross Slope Sensors

The Full Sensor calibration guides you through the calibration of the three sensors that make up the cross slope sensors (the Rotation Sensor, the Mainfall Sensor, and the blade slope sensor). Before carrying out a full sensor calibration, check the following items:

Setup (Machine)

• Make sure you have a suitable location in order to perform the calibrations. The location must be a hard, flat surface and there must be enough room in order to turn the motor grader around.

• Make sure the center shift link bar on the motor grader is in the center hole.

• Remove all articulation, wheel-lean, and circle center shift from the motor grader.

• Check the tire pressure of all tires on the motor grader.

• Rotate the blade so that the blade is perpendicular to the main frame.

Note: Use the zero pointer.

• Center the moldboard using the side shift.

To calibrate the cross-slope sensors, complete the following steps:

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Illustration 252	g01450850

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Illustration 253	g01455855

1. Use the Arrow Keys (87) in order to scroll to "Calibrate Sensors" on the "Setup Menu - Configuration" menu.

   Refer to Illustration 253.

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Illustration 254	g01301241

2. Use the Arrow Keys (87) in order to scroll to "Mainfall, blade slope, and rotation Sensors" on the "Calibrate Sensors" window.

   Refer to Illustration 254.

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Illustration 255	g01301242

3. Press the "OK" Key (89) .

   A window that is similar to Illustration 255 appears.

   Follow the instructions in the window.

   1. Park on a smooth hard surface.

   2. Remove the wheel lean and articulation.

   3. Center the A-Frame and the blade

   4. Rotate the circle in order to square the blade.

   5. Position the blade on the ground.

   6. Mark the blade and the tire positions as shown in Illustration 255.

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Illustration 256	g01301268

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Illustration 257	g01301291

4. Press the "OK" Key (89) .

   The AccuGrade System will begin to calculate the measurements.

   Refer to Illustration 256.

   When the AccuGrade System has completed calculations, the window that is shown in Illustration 257 will appear.

   Refer to Step 4.a through Step 4.c in order to align the blade.

   1. Turn the machine around.

   2. Set the blade on the marks that were made in Step 3.f.

   3. Set the blade on the ground.

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Illustration 258	g01301301

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Illustration 259	g01301303

5. Press the "OK" Key (89) .

   The AccuGrade System will begin to calculate the measurements.

   Refer to Illustration 258.

   When the AccuGrade System has completed calculations, the window that is shown in Illustration 259 will appear.

   Refer to Step 5.a through Step 5.b in order to align the blade.

   1. Move the machine in order to align the front and the rear tire marks.

   2. Set the blade on the ground.

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Illustration 260	g01301310

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Illustration 261	g01300628

6. Press the "OK" Key (89) .

   The AccuGrade System will begin to calculate the measurements.

   Refer to Illustration 260.

   When the AccuGrade System has completed calculations, the window that is shown in Illustration 261 will appear.

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Illustration 262	g01301341

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Illustration 263	g01301241

7. Press the "Finish" Hard Key.

   The AccuGrade System will update the information. Refer to Illustration 262.

   You will be returned to the "Calibrate Sensors" window. Refer to Illustration 263.

8. End of Procedure

Valve Calibration

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Do not operate this system unless you are fully trained on this equipment. To avoid injury, the machines park brake must be engaged prior to starting the calibration. Maintain adequate clearance from people and objects as the blade may move abruptly during automatic hydraulic valve calibration.

A valve calibration must be completed because most Pulse Width Modulated valves have loose manufacturing tolerances. Each valve will respond differently to a given command. A valve calibration determines the way that the valve responds to a given command. A valve calibration will determine the velocity of the blade when a command is given in order to drive the valves at a specific percent. Additionally, a valve calibration will create a curve (valve) for use in automatic tuning of the valve drives.

Note: Be sure all machine calibrations have been performed before performing AccuGrade valve calibrations.

Note: To ensure the best performance (grading), the valve calibration should be performed with the hydraulic system at the operating temperature.

Note: Before you begin to grade, make sure that the machine reaches the temperature that was used during the calibration of the valves. This will ensure the proper performance of the system. Perform the following steps in order to make sure that the hydraulic system is at the operating temperature before performing any calibrations.

Note: For dual GPS systems that do not use the cross-slope sensors, a 292-0300 Calibration Kit is needed in order to complete a valve calibration. Mount the 276-6146 Position Sensor Assembly onto the location for the blade slope sensor. Connect the sensor using a 254-9951 Coil Cable or the 236-2356 Blade Slope harness. Once the valve calibration is complete, Caterpillar recommends using the 276-6146 Position Sensor Assembly as the Mainfall Sensor. Complete a Sensor calibration if a Mainfall Sensor is installed.

1. Start the engine.

   Allow the engine temperature to rise to the operating temperature.

2. Cycle implements.

3. Begin warming the implement hydraulic system.

   1. After implements have been cycled, elevate engine speed and cycle the circle drive.

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   NOTICE
   It is important to not stall a very cold hydraulic system for an extended period of time in order to avoid thermally shocking a valve, which could damage the hydraulic system.

   2. Intermittently stall the wheel lean while you continue to cycle the circle drive.

      Note: Do not stall the wheel lean for any more than 60 seconds at a time.

      Note: When you are calibrating the valves, the warm up procedure may need to be repeated after calibrating a valve on one side of the machine and before calibrating the valve on the other side.

      Note: The machine may need to be warmed up several times during the day if the machine idles and the machine cools for extended periods of time. The following types of sensors are required for valve calibration:

      • Blade Slope Sensor

      Note: Disconnect the Sonic Sensors (if equipped) when you are performing a valve calibration.

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Illustration 264	g01102552

Note: The rotation of the blade needs to be perpendicular within ± 5 degrees. Ensure that the alignment arrows on the circle are aligned.

4. Start the Display (1) in "Service" mode. Press and hold down the "OK" Key (89) as you press the Power key. Make sure that you hold down the "OK" Key (89) until the display shows the opening screen.

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Illustration 265	g01310691

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

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Illustration 266	g01389197

6. Select "Lift Valves".

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Illustration 267	g01310696

7. Press the up Arrow or down Arrows on the display until the "Valve Calibrate" option is highlighted. Press "OK".

   The screen in Illustration 267 appears.

8. Press the up Arrow or down Arrows on the display in order to choose the valve to calibrate.

   Refer to Illustration 267.

9. Press "OK".

   The screen in Illustration 268 appears.

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Illustration 268	g01310708

10. Complete the following actions:

    1. Park the machine on a level surface.

    2. Center the blade and make sure the blade is square to the machine.

    3. Check that the "Current blade slope:" value shown in the dialog decreases as the blade is raised up to the left.

11. Press "OK".

    The screen in Illustration 269 appears.

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Illustration 269	g01310714

12. Using both lift rams, raise the left blade tip up as far as possible and put the right blade tip on the ground.

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Illustration 270	g01310737

13. Press "OK".

    A dialog similar to Illustration 270 appears.

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Illustration 271	g01310747

14. Using the left ram only, move the left blade tip down until it is just above the ground. The Current blade slope reading increases.

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Illustration 272	g01310750

15. Press "OK".

    The system uses this information in order to calculate the angle the blade has moved through its range of tilt.

    A message appears warning that proceeding with the valve calibration will cause the blade to start moving.

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The valve calibration procedure causes the blade to move automatically. Ensure that all personnel are clear of the blade before you begin the valve calibration procedure. Personal injury or death from crushing could occur.

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Illustration 273	g01310752

16. Press "OK" in order to continue.

    The screen in Illustration 273 appears.

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Illustration 274	g01310757

17. Press the left Auto/Manual button to place the left valve in Automatic.

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Illustration 275	g01310758

18. Press "OK". The left valve calibration starts.

    The screen in Illustration 275 appears.

    A progress bar showing the progress of the calibration appears. The messages Initializing, Opening, Testing valve and Tuning appear on the dialog during the calibration. The blade automatically moves up and down during this process. The left valve calibration takes ten to fifteen minutes to complete.

    When complete, a dialog appears in order to inform you that the lift calibration was successful.

    Repeat the Valve Calibration for the Right Valve after the Left Valve has been successfully calibrated.

    Refer to ""Sideshift Calibration" " for information about calibrating the sideshift valve.

19. Press the "OK" button in order to enter the Calibration Mode.

Sideshift Calibration

Note: Sideshift calibration is used for GPS and ATS only.

Refer to the following procedure in order to calibrate the sideshift valve.

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Illustration 276	g01310691

1. From the "Setup Menu - Installation " menu, select "Valve Calibration". Press the "OK" key.

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Illustration 277	g01389277

2. From the "Valve Calibration - Select Type" menu, select "Sideshift Valve". Press the "OK" key.

   A "Safety Warning" screen will appear. Refer to Illustration 273.

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The valve calibration procedure causes the blade to move automatically. Ensure that all personnel are clear of the blade before you begin the valve calibration procedure. Personal injury or death from crushing could occur.

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Illustration 278	g01310752

3. Press "OK" in order to continue with the procedure.

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Illustration 279	g01389693

4. Adjust the slider until the blade moves approximately 2.50 cm (1.00 inch) per second.

5. Check the blade speed by pressing the "Test" button.

Linked EM400 Calibration

To carry out a linked lift mast calibration complete the following steps:

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Illustration 280	g01429362

1. Select the "Linked EM Calibration" calibration method.

   The "Linked EM400 Calibration" dialog appears. Refer to Illustration 280.

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Illustration 281	g01429370
Laser strike indication in the "Laser" dialog for Electric Masts

Note: Prior to measuring the elevation offset, the electric masts must be lowered in order to determine their retracted positions.

2. Press the arrow soft key.

   The masts are driven to the bottom of their travel range.

   Once calibration has finished, the "Linked EM400 Calibration" dialog appears. Refer to Illustration 281.

3. Press the arrow soft key.

   The mast offset is measured.

   Once calibration has finished, the "EM400 Calibration" dialog appears.

4. Press "Finish" in order to return to the "Calibrate Sensors" menu.

   If the calibration fails, refer to ""Adjusting Electric Masts To Get Laser Strike" ".

Adjusting Electric Masts To Get Laser Strike

Illustration 282	g01287477
(80) LCD (81) Soft Keys Labels (82) Hard Keys (83) Escape Key (84) Next Key (85) Power Key (86) "+" Key (87) Arrow Keys (88) "-" Key (89) "OK" Key (90) Menu Key (91) Data Card Slot

To adjust the elevation of a single or dual laser system using electric masts, complete the following steps:

1. Manually adjust the cross slope of the blade so that the cutting edge is parallel to the laser plane.

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Illustration 283	g01429426

2. From any guidance screen, press "Laser".

   The "Laser" dialog for electric masts appears.

3. Laser strike indication in the "Laser" dialog for electric masts.

Note: Illustration 283 shows the "Laser" dialog for a dual laser receiver system.

4. Use one of the following tools in order to adjust the height of the mast so that the laser strike indicator is approximately centered on the laser receiver graphic.
   • To raise the mast, press "Raise Mast(s)". Move the strike point downward.

   • To lower the mast, press "Lower Mast(s)". Move the strike point upward.

   • To stop the mast movement press the Escape key.

5. To return to the guidance screen. press the "OK" key (89) or the Escape Key (83) .

   If you move the masts through their full range of movement and are unable to register a laser strike, ask your site manager to reposition the laser transmitter.

Pre-Delivery Checklist

Machine Dimension Checkout

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

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

2. Hold the "OK" Key (89) while pressing the Power Key (85) in order to start the AccuGrade System in Service mode.

3. Press the Next Key (84) until the second text window appears that shows Northing, Easting and Elevation.

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

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

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

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

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

Function Checkout

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

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

2. Press the "OK" Key (89) .

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

3. Verify that all components are found and configured:
   • MS990 left

   • MS990 right

   • AS400

   • A4M1

   • CD700

4. Create a level plan or select a design from the sites card.

   Refer to the Operation and Maintenance Manual, SEBU8283.

5. Place the system in Auto.

6. Increment and Decrement the blade using joystick.

   Verify that the blade moves up when you increment the blade. Verify that the blade lowers when decremented.

7. Turn Park Brake On.

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

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

Save Machine Settings

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

1. Hold the "OK" Key (89) while pressing the Power Key (85) to start the AccuGrade System in Service mode.

2. Press the "Setup Menu" key in order to enter "Setup Menu - Configuration".

3. Select "Save Settings".

4. Press "OK".

5. Use the Arrow Keys (87) in order to select "Machine Settings".

6. Press the "OK" Key (89) .

7. Use the Arrow Keys (87) in order to name the file.

   Note: The serial number of the machine can be used for a file name.

8. Press the "OK" Key (89) .

9. Press and hold the Power Key (85) in order to power down the Display.

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

Machine Dimension Troubleshooting

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

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

3. Configure the text screen to show the following information:
   • "Northing"

   • "Easting"

   • "Elevation"

   • "Heading"

   • "V GPS Error"

4. Identify which measurement is off:

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

Customer Supplied Radio

The AccuGrade System for GPS must use a radio that is compatible with the local GPS base station radio. Caterpillar currently offers the TC900C, CR900 and TC450C for the AccuGrade System. These radios require Trimble infrastructure radios for compatibility. For sites that are using non-Trimble infrastructure, Customer Supplied Radios may be connected to the AccuGrade System. However, the Customer Supplied Radio will need to be configured for use with the AccuGrade System. This document outlines the wiring issues that must be addressed in order to provide communication with the AccuGrade System. Caterpillar makes no claim to compatibility with all radios. Additionally, Caterpillar assumes no responsibility for the performance of the system integrating Customer Supplied Radios.

The following recommendations must be considered when installing a customer supplied radio:

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

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

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

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

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

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

   1. Verify that 24 VDC nominal power is acceptable.

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

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

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

      • + BAT

      • GRND

      • TX

      • RX

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

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

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

      Note the pin number for the following connections:

      • + PWR

      • GRND

      • COM 2 TX

      • COM 2 RX

3. Wire the new cable.

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

Illustration 284	g01259989

Customer Supplied Radio Example

Field Conditions

• Existing AccuGrade compatible GPS base station

• Customer Supplied Radio at the GPS base station

Required

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

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

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

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

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

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

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

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

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

   • Ground

   • TXD

   • RXD

   • DTR

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

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

   • Ground

   • COM2 TXD

   • COM2 RXD

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

   ReferenceReference Systems Operation, RENR8083, "Radio Utility"

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

      Default Settings For The Display

      Baud rate ... 38400

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

      Parity ... None

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

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

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

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

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

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

Troubleshooting

No Power To Radio

• Verify connections to power and ground pins

• Verify input power required for radio

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

No Communication Through Radio

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

• If the radio is a Data Communications Equipment (DCE) device, modify the TX and the RX connections as shown in Illustration 285.

Illustration 285	g01260134

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

Radio Pin-Out Tables and Schematics

H Series and M Series

Illustration 286	g01260677

Note: Refer to the machine schematic for most recent version.

Table 49

8-PIN Connector			12-PIN Deutsch Connector
Pin	Description	Wire Number	Pin
A	+ Battery	L872	1
B	Ground	T744	2
C	COM 2 TXD	N961	10
D	COM 2 RXD	N958	11

Diagrams

247-6438 Sensor Wiring Group (120H through 163H)

Illustration 287	g01400092
(4) 244-1714 Position Sensor Group (BLADE ROTATION) (31) 8T-4191 Bolt (51) 7Y-0589 Bolt (53) 4K-8302 Clip (54) 8T-4244 Nut (56) 8T-4223 Hard Washer (57) 9X-2537 Bolt (81) Connector of the 243-3250 Sensor Harness Assembly (82) 251-2383 Bracket (32) 8T-4121 Hard Washer (85) 186-0359 Clip (89) Blade Slope Sensor Connector of the 236-2356 Sensor Harness Assembly

Illustration 288	g01213251
(3) 276-6146 Position Sensor Assembly (4) 244-1714 Position Sensor Group (BLADE ROTATION) (31) 8T-4191 Bolt (51) 7Y-0589 Bolt (53) 4K-8302 Clip (54) 8T-4244 Nut (56) 8T-4223 Hard Washer (57) 9X-2537 Bolt (78) 4-pin connector of the 243-3250 Sensor Harness Assembly (79) 243-3250 Sensor Harness Assembly (80) 236-2356 Sensor Harness Assembly (81) Connector of the 243-3250 Sensor Harness Assembly (82) 251-2383 Bracket (32) 8T-4121 Hard Washer (85) 186-0359 Clip (88) 4-pin connector of the 236-2356 Sensor Harness Assembly (89) Blade Slope Sensor Connector of the 236-2356 Sensor Harness Assembly

Illustration 289	g01206178
(3) 276-6146 Position Sensor Assembly (4) 244-1714 Position Sensor Group (BLADE ROTATION) (51) 7Y-0589 Bolt (57) 9X-2537 Bolt (78) 4-pin connector of the 243-3250 Sensor Harness Assembly (79) 243-3250 Sensor Harness Assembly (80) 236-2356 Sensor Harness Assembly (81) Connector of the 243-3250 Sensor Harness Assembly (85) 186-0359 Clip (88) 4-pin connector of the 236-2356 Sensor Harness Assembly (89) Blade Slope Sensor Connector of the 236-2356 Sensor Harness Assembly

Illustration 290	g01213256
(4) 244-1714 Position Sensor Group (BLADE ROTATION) (31) 8T-4191 Bolt (32) 8T-4121 Hard Washer (51) 7Y-0589 Bolt (53) 4K-8302 Clip (54) 8T-4244 Nut (56) 8T-4223 Hard Washer (57) 9X-2537 Bolt (64) 061-6665 Bolts (81) Connector of the 243-3250 Sensor Harness Assembly (82) 251-2383 Bracket (85) 186-0359 Clip (89) Blade Slope Sensor Connector of the 236-2356 Sensor Harness Assembly