Installation of CAESultra for Landfill Compactors, Motor Graders, Wheel Dozers, and Wheel Loaders{1408, 7009, 7010, 7338, 733T, 7490, 7604} Caterpillar

Machine Control & Guidance Products:

CAES ULTRA (S/N: 2TZ1-UP)

Landfill Compactor: All

Motor Grader: All

Wheel Dozer: All

Wheel Loader: All

Introduction

This Special Instruction provides information for the installation of the 285-6661 CAESultra Electronic Kit and the Radio Kit.

The procedures describe the installation process for the Computer Aided Earthmoving System on Wheel Loaders, Wheel Dozers, Landfill Compactors, and Motor Graders. The installation will require welding, cutting holes, using electrical tools, and using mechanical tools. After a technician has completed the first installation process, future installations should require 6 to 8 hours for completion.

The installation process can be separated into the following procedures:

• GPS Receiver, GPS Receiver Harness, and Chassis Harness Installation

• Machine Radio Installation

• Rear Harness Assembly Installation

• Operator Display Installation

• Front Harness Assembly Installation

• Battery Backup Installation

• Power Harness and Fuse Installation

• Initial Power Checks

• Machine ID Worksheet Entries

• Dimension Measurements and Measure Up

Operation and Maintenance Manual

Locate the Operation and Maintenance Manual, SMBU8513, "Muti-lanuage CD". Print the Operation and Maintenance Manual of the desired language and secure the manual in the cab of the machine.

The operation of CAESultra is covered in the Operation and Maintenance Manual, SEBU8513, "CAESultra". Refer to this manual for more information.

Important Safety Information

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

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

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

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

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

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

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

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

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

Illustration 1	g00037860

Use steps and handholds whenever you mount the machine. Use steps and handholds whenever you dismount the machine. Before you mount the machine, clean the step and the handholds. Inspect the step and handholds. Make all necessary repairs.

Face the machine whenever you mount the machine and whenever you dismount the machine. Maintain a three-point contact with the step and with handholds.

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

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

General Preparation

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

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

1. Move the machine to a suitable location. The location should be smooth, level, and out of direct sunlight.

2. Move away from other working machines and personnel.

3. Lower the bucket to the ground.

4. Stop the engine.

5. Engage the machine brake.

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

Required Tools

The tools in Table 1 are recommended by Caterpillar to install the CAESultra system on Wheel Loaders, Wheel Dozers, Landfill Compactors, and Motor Graders. The list contains the recommended Caterpillar service tools, as well as general-purpose tools with no specified part number.

Optional Items

The optional items in Table 2 may also be required during the installation. These parts are not provided in the 285-6661 CAES Installation Arrangement .

Parts Lists

The CAES Electronics Ar contains the receiver, the display, and a software CD.

The 285-6661 CAES Installation Arrangement contains the four kits that are listed in Table 4. These kits are used during the installation of the CAESultra system. The kits are broken down in Tables 5 through 8.

Using the Machine Configuration Utility

The Machine Configuration Utility (MCU) is a tool that configures advanced machine settings. The software replaces the previous method of editing the mach_cfg.txt file by hand.

ReferenceFor more information about using the MCU, refer to the "MCU Getting Started Guide" or the MCU Help file. Both resources are available through the Menu bar in the MCU. Alternatively, select Start > All Programs > Cat MineStar System and Tools > Machine Configuration Utility.

Note: To use the MCU, the machine must be added in Cat® MineStar^TM System.

ReferenceFor information on adding the machine in Cat MineStar System, refer to the "Cat MineStar System User Manual".

Language Support on the Display

CEASultra now supports French, Spanish, Portuguese, and Swedish on the user display. To enable one of these languages, a line of code containing a language identifier from Table 9 is used.

Note: Tasks can be sent in any language that is supported by the keyboard and operating system being used. CAESultra receives these tasks in any language that the CAESultra operating system supports.

Add the following line before the c:\caes\exe line to the CAES startcaes.cmd file before running the file:

• SET lang=<language identifier>

Illustration 2	g02340196

For example, to set the language of the user interface to Spanish, add the following line as shown in Illustration 2:

• SET lang=esp

CAESultra Components

Illustration 3	g01477954
Representation of cables, harnesses, and main CAESultra components. This diagram is not drawn to scale. (1) 291-2199 Monitor Display Group (D3:C4 Nav 10.4) (2) 167-8703 Wire (3) 265-8147 Fuse Harness (4) 167-8984 Battery (RECHARGEABLE, 24-VOLT) (5) TC900B or TC900C Radio (6) 205-4285 Power Converter (24-VOLT TO 12-VOLT) or 278-7396 Wire (TC900C) (7) 290-1918 Rear Harness (8) 285-6654 Radio Harness (9) 290-1917 Front Harness (10) 353-2794 Satellite Receiver (GNSS, MS990) (11) Service Connection for the keyboard (12) 290-2928 Chassis Harness (20-FT) (13) 285-6657 Wiring Harness (RECEIVER) (14) 285-6651 Wiring Harness (TERMINATION) (15) Service Connection: Serial Cable

Illustration 3 shows the connections between the cables, harnesses, and the CAESultra components that are described within this instruction.

Note: This illustration is only a representation. The illustration does not accurately reflect the relative dimensions or sizes of any of the cables, harnesses, or components.

Note: If the machine is in the following list, then ensure that the machine does not have the CAES ARO option from the factory. If the machine has this option, then refer to Special Instruction, REHS4850, "Installation of CAESultra Attachment Ready Option for Landfill Compactors and Wheel Dozers" for installation instructions.

• 824H Wheel Dozer

• 834H Wheel Dozer

• 826H Landfill Compactor

• 836H Landfill Compactor

Note: If the machine is in the following list, then ensure that the machine does not have the CAES ARO option from the factory. If the machine does have this option, then refer to Special Instruction, REHS4851, "Installation of CAESultra Attachment Ready Option for Large Wheel Loaders" for installation instructions.

• 854K Wheel Dozer

• 992K Large Wheel Loader

• 993K Large Wheel Loader

• 994F Large Wheel Loader

For a complete wiring schematic of the CAESutra v4.0 system, refer to 288-5836 CAES Diagram in the 285-6661 CAES Installation Arrangement .

Illustration 4	g01514048
CAESultra System Components (1) 291-2199 Monitor Display Group (5) TC900B or TC900C Radio (10) 353-2794 Satellite Receiver (GNSS, MS990)

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

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

Summary of Welding and Potential Welding by Sections

Installation of the GPS Receiver, GPS Receiver Harness, and Chassis Harness

Note: This installation procedure requires welding.

Note: The terms "GPS Receiver", Satellite Receiver, and "Positioning Module" are synonymous. This manual uses the terms GPS Receiver and Satellite Receiver.

Illustration 5	g01434501
The 353-2794 Satellite Receiver is shown mounted on the top side of the ROPS.

The 353-2794 Satellite Receiver must be mounted on top of the ROPS as close to the centerline of the machine as practical. This location will allow this GNSS Receiver to have an unobstructed view of the sky.

Note: On a 992G Wheel Loader, Caterpillar recommends using the existing threaded hole of the front lifting eye for mounting the GNSS receiver. This method eliminates the need for welding, drilling, or tapping the machine.

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Illustration 6	g01434517
(10 ) The 353-2794 Satellite Receiver is shown mounted on the centerline of the machine.

1. Weld the 5k-5962 Boss (5/8-11) as close as possible to the centerline of the machine on top of the ROPS.

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Illustration 7	g01434535
The 5K-5962 Boss is shown welded to the roof of the machine.

2. Position the 289-9633 Plate over the Boss and fasten with the 5P-4624 Bolt .

   Note: Apply anti-seize compound to the bolt thread.

   Note: Tighten the bolt to Caterpillar standard torque specifications.

   Note: If required, the tube on the 289-9633 Plate can be shortened to 100 mm Follow the correct cutting procedures. If the tube is cut, then the 0L-1169 Bolt (5/8-11) should be used.

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Illustration 8	g01263696
The 353-2794 Satellite Receiver is shown mounted to the shortened 289-9633 Plate .

3. Attach the 353-2794 Satellite Receiver to the 289-9633 Plate . Use four 8T-4195 Bolts (M10) and four 8T-4121 Hard Washers . These parts are included in the 291-2176 Receiver Mounting Group .

   Note: The 353-2794 Satellite Receiver should be mounted to allow the operator easy visibility of the LEDs when outside of the cab. This location may be determined by site preference.

4. Attach the 285-6657 Wiring Harness (13) to the connector on the 353-2794 Satellite Receiver . Route the harness across the roof to the ROPS post.

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Illustration 9	g01434593
The Optional 7T-1099 Links are shown. These weld links are attached to the ROPS. The links are used for routing the 285-6657 GPS Receiver Harness across the roof of the cab.

5. Secure the 285-6657 Wiring Harness for the GPS Receiver. Use 3S-8665 Clips , 8M-2773 Clips , or 7K-1181 Cable Straps . If the harness passes through any holes in the machine, protect the harness. Use a protective wrap or use a 5P-6264 Grommet . These parts are included in the 291-2177 Machine Wiring Group .

6. Connect the 12-pin connector of the 285-6657 Wiring Harness to the 12-pin connector of the 290-2928 Chassis Harness .

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Illustration 10	g01435010
(12) 290-2928 Chassis Harness (13) 285-6657 Wiring Harness for the GPS Receiver (14) 285-6651 Wiring Harness

7. Connect the 285-6651 Wiring Harness (14) to the 8-pin connector near the end of the 290-2928 Chassis Harness (12) .

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Illustration 11	g01470994
The 290-2928 Chassis Harness (12) is shown routed down the ROPS post.

8. Route the 290-2928 Chassis Harness (12) down the back of the left ROPS post to the mounting location of the 290-1918 Rear Harness . This location is beneath the floor plate of the cab. This routing recommended.

9. Secure the 290-2928 Chassis Harness. Use 3S-8665 Clips , 8M-2773 Clips , or 7K-1181 Cable Straps . If the harness passes through any holes in the machine, protect the harness. Use a protective wrap or use a 5P-6264 Grommet . These parts are included in the 291-2177 Machine Wiring Group .

Note: If available, use the ROPS harness guide bracket to protect the harness. Refer to Illustration 11.

Machine Radio Installation

The 322-7178 Radio Mounting Group or the 167-8602 Radio Mounting Group are not required for third-party radios. These groups are only used for TCxxx radios or CRxxx radios.

Note: If using a Third Party Radio solution, the ""Machine Radio Installation" " section can be skipped.

Note: Welding may be required during this installation.

There are two options for installing the machine radio.

• The radio can be mounted by utilizing the lighting mounts.

• The radio can be mounted by utilizing the 9R-2160 Bosses .

1. Determine the option that will be used for the installation.
   • If the bracket will be mounted to the existing lighting mounts of the machine, then proceed to Step 2.

   • If the bracket will be mounted to the bosses, then proceed to Step 5

2. Remove the bolts from the light brackets that are on either side of the machine.

   Note: On Wheel Loaders, Caterpillar recommends using the existing threaded holes of the backup light brackets.

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Illustration 12	g01513323
The radio is shown mounted to the 149-8196 Plate (37) via the lighting mounts.

3. Install the 149-8196 Plate (37). Use the bolts that were removed in Step 2.

   Note: Tighten the bolts to Caterpillar standard torque specifications.

4. Proceed to Step 10.

   Note: Ensure that the radio is mounted at least 3 feet from the GPS receiver or any other transmitting radio or antenna on the machine. This location maximizes reception of the radio. Also, ensure that the radio antenna has 360 degrees of visibility.

5. Attach the four 9R-2160 Bosses to the 149-8196 Plate . Use four 8T-7547 Bolts (1/4 - 20) and 4 8T-4224 Hard Washers .

6. Mark the location of the bosses. Use the plate as a template.

7. Remove the bosses from the plate.

8. Weld the bosses to the locations that you marked.

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Illustration 13	g01434661
The radio is shown mounted using the 9R-2160 Bosses and the 149-8196 Plate .

9. Mount the plate to the bosses. Use four 8T-7547 Bolts (1/4 - 20) and 4 8T-4224 Hard Washers .

   Note: Tighten the bolts to Caterpillar standard torque specifications.

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Illustration 14	g01471352
Radio and mounting bracket (5) Radio (37) 149-8196 Plate (38) 167-8610 Bracket (39) 8C-5607 Isolation Mount (40) 8C-5608 Spacer (41) 9X-6165 Washer (42) 4M-5282 Bolt

10. Attach the radio to the 167-8610 Bracket . Use four 167-8999 Bolts . The bolts are included with the radio.

    Note: Ensure that the radio has been properly configured and that the correct firmware has been installed before mounting the radio. Refer to Special Instruction, REHS2585, "MCG Flash User Guide".

11. Attach the 140-7480 Mounting Bracket to the bottom of the radio. Use the remaining two 167-8999 Bolts . The bolts are included with the radio.

12. Attach the 140-7480 Mounting Bracket to the 167-8610 Bracket . Use two 5S-7349 Bolts (1/4-20) and two 8T-4205 Hard Washers .

    Note: If the 211-0100 Antenna has been removed from the radio, install the antenna on the radio. Use a 38 mm (1.5 inch) wrench. Torque the antenna to 8 N·m (6 lb ft).

13. Assemble the six 8C-5607 Isolation Mounts and the three 8C-5608 Spacers to the 167-8610 Bracket . Refer to Illustration 14.

14. Mount the 167-8610 Bracket to the 149-8196 Plate . Use three 4M-5282 Bolts (1/4-20) and three 9X-6165 Washers .

Routing and Connecting the Radio Harness

Perform the following procedure after the radio has been mounted.

1. Connect the 285-6654 Radio Harness to the radio.

2. Route the 285-6654 Radio Harness down the ROPS post to the 290-1918 Rear Harness . This assembly is near the base of the ROPS support.

   Note: A 9V-2818 Grommet should be used to protect the harness if the harness is being routed through any drilled holes. These grommets are included in the 167-8602 Radio Mounting Group .

   Note: If additional length is needed for routing, then install the optional 285-6653 Radio Harness .

Installing the Rear Harness

The 290-1918 Rear Harness routes from the 290-1917 Front Harness to either the 285-6654 Radio Harness or else to the optional 285-6653 Radio Harness and the 290-1918 Rear Harness .

1. Route the 290-1918 Rear Harness .

2. Connect the 8-pin and the 12-pin connectors of the 290-1918 Rear Harness (6) to the 8-pin connector of the 285-6654 Radio Harness (8) and to the 12-pin connector of the 290-2928 Chassis Harness (12) .

3. Route the 290-1918 Rear Harness under the floor plate towards the 290-1917 Front Harness .

Note: Route the harness in a location for ease of connection to the optional 205-4285 Power Converter if needed for a TC900B radio.

4. Secure the 290-1918 Rear Harness . Use 3S-8665 Clips , 8M-2773 Clips , or 7K-1181 Cable Straps . If the harness passes through any holes in the machine, protect the harness. Use a protective wrap or use a 5P-6264 Grommet . These parts are included in the 291-2177 Machine Wiring Group .

   Use one of the following methods to connect the 6-pin connector of the 290-1918 Rear Harness .

   • If a TC900C or newer radio is being used on the machine, then proceed to Step 5.

   • If a TC900B radio or older is being used on the machine, then a 205-4285 Power Converter is needed. Proceed to Step 7.

5. Connect the 6-pin connector of the 290-1918 Rear Harness to the 6-pin connector of the 278-7396 Wire .

6. The installation of the 290-1918 Rear Harness is complete. Proceed to the ""Installing the Operator Display" " section.

7. Mount the 205-4285 Power Converter on the machine. There are several acceptable mounting locations for the Converter. The following criteria must be considered when the location is selected.
   • The location should support the overall dimensions of the Converter. The dimensions are 115 mm (4.5 inch) by 77 mm (3.0).

   • The location should accommodate both the standard length and the unaltered length of the 290-1918 Rear Harness .

   • The location should have adequate accessibility.

   • The location should not interfere with normal, safe functioning of the machine.

   Note: The recommended mounting location of the Converter is inside the cab below the floor plate.

   1. Attach the flanges of the Converter to the two 5 mm bosses. Use two 5 mm Bolts and two washers.

   2. Position the Converter in the desired location.

   3. Mark the location of the bosses. Use the Converter as a template.

   4. Remove the Converter from the bosses.

   5. Weld the bosses to the marked locations.

   6. Fasten the Converter to the machine. Use two 5 mm bolts and two washers.

      Note: Tighten the bolts to Caterpillar standard torque specifications.

Installing the Operator Display

Note: If the machine is in the following list, then refer to Special Instruction, REHS4850, "Installation of CAESultra Attachment Ready Option for Landfill Compactors and Wheel Dozers" for alternative display mounting options.

• 824H Wheel Dozer

• 834H Wheel Dozer

• 826H Landfill Compactor

• 836H Landfill Compactor

Note: If the machine is in the following list, then refer to Special Instruction, REHS4851, "Installation of CAESultra Attachment Ready Option for Large Wheel Loaders and Large Wheel Dozers" for alternative display mounting options

• 854K Wheel Dozer

• 992K Large Wheel Loader

• 993K Large Wheel Loader

• 994F Large Wheel Loader

Position the 291-2199 Monitor Display Group within the cab of the machine. The following requirements should be considered when choosing the location:

• The Display should be placed within 1.2 m (4 ft) of the eye of the operator.

• The Display should be in a location that does not block the visibility of the operator to risk areas around the machine.

• The Display should be located near the plane that the operator normally views during operations that benefit most from the use of CAES. Ideally, the Display should be located no more than 30 degrees from this viewing angle.

Additionally, consider the following when choosing the location:

• Ease of reference to work in progress

• Accessibility to the touch screen

• Operator comfort (resting position of the arm and leg)

• View of safety films within the cab by the operator

• Direct or mirrored views of the operator

• Ability of the operator to enter or exit the cab

• Exposure of the screen to excessive glare from the sun

• Use of operator controls

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

Illustration 15	g01514052
Typical display mounting location

There are two options for installing the D3:C4 Nav 10.4 Display.

• The Display can be mounted to the top side of the dash panel.

• The Display can be mounted to the bottom side of the roof.

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Illustration 16	g01514067
The optional mounting location is shown on a compactor. The display is mounted in front upper right corner of the cab using a site fabricated ceiling bracket.

1. Determine the option that will be used for the installation.

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Illustration 17	g01516333
Contents of 167-8604 Monitor Mounting Group (26) 8X-7422 Boss (27) 147-3417 Mount (28) 3Y-7829 Boss (29) 5M-2894 Hard Washer (30) 0S-0509 Bolt

2. Attach the 8X-7422 Bosses (26) to the 147-3417 Mount (27). Use the mounting hardware in Table 14.
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   Table 14

   Contents of 167-8604 Monitor Mounting Group
   QTY	Part Number	Part Name	Description
   4	0S-0509	Bolt	3/8-16
   4	3Y-7829	Boss	3/8-16
   4	5M-2894	Hard Washer
   4	8X-7422	Boss	3/8-16
   1	147-3417	Mount

   Note: If mounting the display to the ceiling, then score the padding, the lining, or the insulation. Remove the scored material. Remove enough insulation to allow sufficient space for welding the bosses.

   Note: Use the optional 3Y-7829 Bosses (28) with the 8X-7422 Bosses (26) if additional length is needed to mount the 147-3417 Mount (27) .

3. Mark the location of the bosses. Use the 147-3417 Mount as a template.

4. Remove the bolts, washers, and bosses from the 147-3417 Mount .

5. Weld the bosses to the marked locations.

6. Mount the 221-3453 Bracket to the bosses. Use the four bolts and four washers that were removed in Step 4.

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Illustration 18	g01513986
The exploded view of 150-1893 Vibration Isolator Mounting Group is shown. (1) 291-2199 Monitor Display Group (34) 221-3453 Bracket (35) 8T-4205 Hard Washer (36) 8T-9364 Bolt (1/4-20) (39) 8C-5607 Isolation Mount (40) 8C-5608 Spacer (41) 9X-6165 Washer (42) 4M-5282 Bolt (1/4-20)

7. Assemble the eight 8C-5607 Isolation Mounts (39) and the four 8C-5608 Spacers (40) to the u-shaped 221-3453 Bracket . Use four 9X-6165 Washers (41) and four 4M-5282 Bolts (42). Refer to Illustration 18.

   Note: Tighten the bolts to Caterpillar standard torque specifications.

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Illustration 19	g01513379
Ceiling/Dash adapter (43) 147-3417 Mount (44) 4M-5282 Bolts (1/4-20) (45) 9X-6165 Washers

8. Attach the 221-3453 Bracket to the 147-3417 Mount (43). Use four 4M-5282 Bolts (44) and four 9X-6165 Washers (45) from the 225-5362 Monitor Mounting Group . Refer to Illustration 19.

   Note: Tighten the bolts to Caterpillar standard torque specifications.

9. Remove the 126-1774 Connector Cover from the 70-pin connector of the 290-1917 Front Harness .

   Note: The 126-1774 Connector Cover is removed because this cover limits the ability to adjust the angle of the display.

10. Connect the 70-pin connector of the 290-1917 Front Harness to the 291-2199 Monitor Display Group .

11. Attach the 291-2199 Monitor Display Group to the 221-3453 Bracket . Use three of the four 8T-9364 Bolts and 8T-4205 Hard Washers .

    Note: The fourth bolt and washer will be connected in Step 12.

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Illustration 20	g01513992
(9) 290-1917 Front Harness (34) 221-3453 Bracket (46) 130-5300 Clips (47) Dust covers

12. Attach the two 130-5300 Clips (46) to the outside of the 221-3453 Bracket (34). Use the last 8T-9364 Bolt (1/4-20) and 8T-4205 Hard Washer . Refer to Illustration 20.

13. Attach the 4-pin and the 6-pin service connector dust covers (47) that are located on the 290-1917 Front Harness (9) to the 130-5300 Clips (46). Refer to Illustration 20.

14. Secure the two ring terminal wires that are on the 290-1917 Front Harness near the 70-pin connector. Alternatively, install the optional 167-8709 Alarm .

Installing the Front Harness

The 290-1917 Front Harness routes between the 291-2199 Monitor Display Group , 167-8984 Battery , power, and the 290-1918 Rear Harness .

1. Route the 290-1917 Front Harness . For ease of routing, start routing the harness at the Display. Continue routing the harness to the 167-8984 Battery and to the connection of the 290-1918 Rear Harness . This method of routing ensures that there is no need to remove to the 70-pin connector.

2. Route the 290-1917 Front Harness from the Display to the intended location of the connection for the 290-1918 Rear Harness . The harness can be routed behind the dash and through the floor plate. The harness can also be routed through the headliner and then down a support post to the floor plate.

3. Connect the 8-pin connector of the 290-1917 Front Harness to the 8-pin connector of the 290-1918 Rear Harness .

4. Route the 3-pin power connection to the mounting location of the 167-8984 Battery . This 3-pin connector breaks off from the 290-1917 Front Harness .

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Illustration 21	g01513994
The 290-1917 Front Main Harness is shown securely clamped. (9) 290-1917 Front Harness (46) 8M-2773 Clip

5. As shown in Illustration 21, secure the 290-1917 Front Harness (9). Use 3S-8665 Clips , 8M-2773 Clips (46), or 7K-1181 Cable Straps . If the harness passes through any holes in the machine, protect the harness. Use a protective wrap or use a 5P-6264 Grommet . These parts are included in the 291-2177 Machine Wiring Group .

Battery Backup

Illustration 22	g01434701
The installed 167-8984 Battery (Battery Backup) is shown.

The 167-8984 Battery (Battery Backup) supplies the CAESultra with temporary power. Power is supplied for a short time in the event of an abrupt, unplanned loss of power to the machine. The battery stores power for approximately 5 minutes. This delay provides enough time for the operator to shut down the CAESultra system safely

There are several acceptable mounting locations for the 167-8984 Battery on the machine. The location that is chosen should consider the following criteria:

• The overall battery dimensions of 215 mm (8.5 inch) by 215 mm (8.5 inch)

• Adequate accommodations for both the standard length and the unaltered length of the 290-1917 Front Harness

• Adequate accessibility to the battery

• Normal, safe functioning of the machine

Installing the Battery Backup

This installation may require welding on the machine.

Perform the following steps to install the 167-8984 Battery (Battery Backup).

1. Attach the two 292-1120 Mounting Block to the 167-8984 Battery . Use four 8T-0325 Bolts (M5) and four 8T-0328 Hard Washers .

2. Position the 167-8984 Battery in the desired location and mark the location of the bosses. Use the 167-8984 Battery as a template.

   Note: If required, score and remove padding, lining, or insulation. Remove enough insulation to allow room to weld the bosses.

3. Remove the 167-8984 Battery from the bosses.

4. Weld the bosses to the marked locations.

5. Mount the 167-8984 Battery to the 292-1120 Mounting Blocks . Use four 8T-0325 Bolts (M5) and four 8T-0328 Hard Washers .

   Note: Tighten the bolts to Caterpillar standard torque specifications.

6. Connect the 3-pin connector of the 290-1917 Front Harness to the 3-pin connector of the 167-8984 Battery .

   Note: The 167-8984 Battery must be located so that the leads of the 167-8703 Wire can reach the battery.

7. Connect the 265-8147 Wiring Harness to the 3-pin connector of the 167-8984 Battery

   Note: Connect the power and check voltage before connecting the 3-pin connector of the 167-8703 Wire from the opposite side of the 265-8147 Fuse Harness .

Installing the Power Harness and the Fuses

The 167-8703 Wire (Power Harness) is provided with the 291-2177 CAES Wiring Group . Use the 167-8703 Wire to connect the 167-8984 Battery to the power supply of the machine.

Illustration 23	g01479356
Electrical schematic for Power Harness and installation of the fuses

1. Turn the disconnect switch to the OFF position.

2. Route the 167-8703 Wire from the 167-8984 Battery to the "Run" relay.

   Note: For Steps Use a 2L-8067 Terminal , a 2L-8071 Terminal or a 2L-8079 Terminal . These Terminals are included in the 291-2177 Machine Wiring Group .

3. Connect the RED "+24 volt" wire to the supply side of the "Run" relay.

4. Connect the PINK "Switched +24 volt" wire to the switched side of the "Run" relay.

5. Connect the BLACK "Ground" wire to a ground lug.

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

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

Performing the Initial Power Checks

Before applying power to the CAESultra System for the first time, verify the voltage at the following power connections.

Pin A - Positive

Pin B - Negative

Pin C - Switched positive

1. Turn off the Key switch.

2. Check for 24 V between Pin A and Pin B.

3. Check for zero V between Pin B and Pin C.

4. Turn the key switch to the ON position

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

5. Check for 24 V between Pin B and Pin C.

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

Machine ID Worksheet Entries

Enter the following information for future reference:

Machine ID Number____________________

Machine Name____________________

Display Serial Number____________________

Machine Dimensions____________________

Radio Serial Number____________________

Application (Grade, Ore, OrePlus, Compaction)____________________

Grade Tolerance (provided by Mine)____________________

Machine Dimensions and Measure Up

Beginning with v4.0, machine dimensions can be entered either onboard straight into CAESultra, or into the MCU.

Entering Machine Dimensions using the MCU.

To enter dimensions using the MCU, perform the following:

1. Open the MCU.

2. Select the machine name.

3. Select Machine > Machine Dimensions. Enter the dimensions. Follow the procedures in the ""Performing the Calibrations" " section.

4. In the Menu Bar, select File > Send to Cat MineStar System.

5. Restart CAESultra.

Entering Machine Dimensions Using CAESultra

To enter the dimensions using CAESultra, perform the following:

1. Open the CAESultra main menu.

2. Select Machine > Machine Dimensions. Enter the dimensions for the machine.

   Note: The "X" measurement (positive or negative) must not exceed half the blade width of the machine.

3. Press "OK". The values are automatically sent to the office.

4. Open the MCU and select the machine name.

5. In the Menu Bar, select File > Send to Cat MineStar System.

6. Restart CAESultra.

   Note: Until the new configuration file is received and CAESultra is restarted, CAESultra will continue to use the old machine dimensions for positioning and guidance purposes. If an installer returns to the machine dimensions dialog, the dialog will display the old dimensions.

Performing the Calibrations

Calibrating Wheel Loaders

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Illustration 24	g01513997
CAESultra or MCU screen shot of machine dimensions Enter correct details. Any errors transfer directly into the finished surface.

1. Measure the machine GPS Receiver offsets.

   ReferenceRefer to the sample CAESultra or MCU screen shot, Illustration 24, as a reference guide and template to record the machine dimensions.

   Note: The "X" measurement that is taken to the right of the centerline of the machine will be a positive number. The "X" measurement that is taken to the left of the centerline of the machine will be a negative number.

   Note: The "Y" measurement that is taken in front of the front axle will be a positive number. The "Y" measurement that is taken behind the front axle will be a negative number.

   1. GPS x: Measure the distance from the center of the GPS Receiver (10) to the centerline of the machine.

   2. GPS y: Measure the distance from the center of the GPS Receiver (10) to the center of the front axle of the machine.
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   Illustration 25	g01514069
   (10) 353-2794 GPS Receiver (48) Phase Center

   Note: The Phase Center is located 12.8 cm (5.0 inch) from the bottom of the receiver.

   3. GPS z: Measure the distance from the Phase Center housing (48) of the GPS Receiver (10) to the bottom of the wheels.

   4. Bucket Width: Measure the width of the machine from the outside edges of the bucket.

   5. Wheel Base: Measure the distance from the center of the front axle to the center of the rear axle.

   6. Maximum Reach: Measure the distance from the center of the front axle to the front edge of the bucket.

   7. Wheel Radius: Measure the distance from the center of one of the wheels to the outside edge the same wheel.

   8. Bench Height: Use the site-specific bench height.

2. Move the machine origin to a known point.

3. Compare the Northing, Easting, and Elevation.

Calibrating Wheel Dozers and Landfill Compactors

Illustration 26	g01513906
CAESultra and MCU screen shot of machine dimensions

Enter correct details. Any errors transfer directly into the finished surface.

1. Measure the machine GPS Receiver offsets.

   Refer to the sample CAESultra and MCU screen shot, Illustration 26, as a reference guide and template to record the machine dimensions.

   Note: The "X" measurement that is taken to the right of the center line of the machine will be a positive number. The "X" measurement that is taken to the left of the center line of the machine will be a negative number.

   Note: The "Y" measurement that is taken in front of the front axle will be a positive number. The "Y" measurement that is taken behind the front axle will be a negative number.

   1. GPS x: Measure the distance from the center of the GPS Receiver (10) to the centerline of the machine.

   2. GPS y: Measure the distance from the center of the GPS Receiver (10) to the center of the front axle of the machine.
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   Illustration 27	g01514069
   (10) 353-2794 GPS Receiver (48) Phase Center

   Note: The Phase Center is located 12.8 cm (5.0 inch) from the bottom of the receiver.

   3. GPS z: Measure the distance from the Phase Center housing (48) of the GPS Receiver (10) to the bottom of the drums.

      Note: When the machine will be used on soft terrain, measure to the bottom of the drum. When the machine will be used on hard terrain, measure to the bottom of the tamper feet.

   4. Width over drums: Measure the width of the machine from the outside edges of the drums.

   5. Drum width: Measure the outside width of one drum.

   6. Wheel Base: Measure the distance between the center of the front axle to the center of the rear axle.

      Note: To ensure accurate results, measure both sides of the machine and then average the number.

      ReferenceRefer to Systems Operation, KENR8275, " CAESultral" for the remaining Steps.

2. Move the machine origin to a known point.

3. Compare the Northing, Easting, and Elevation.

Calibrating Motor Graders

Illustration 28	g01513833
CAESultra and MCU screen shot of machine dimensions

Enter correct details. Any errors transfer directly into the finished surface.

1. Measure the machine GPS Receiver offsets.

   Refer to the sample CAESultra or MCU screen shot, Illustration 28, as a reference guide and template to record the machine dimensions.

   Note: The "X" measurement that is taken to the right of the centerline of the machine will be a positive number. The "X" measurement that is taken to the left of the centerline of the machine will be a negative number.

   Note: The "Y" measurement that is taken in front of the rear axle will be a positive number. The "Y" measurement that is taken behind the rear axle will be a negative number.

   1. GPS x: Measure the distance from the center of the GPS Receiver (10) to the centerline of the machine.

   2. GPS y: Measure the distance from the center of the GPS Receiver (10) to the center of the rear axle of the machine.
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   Illustration 29	g01514069
   (10) 353-2794 GPS Receiver (48) Phase Center

   Note: The Phase Center is located 12.8 cm (5.0 inch) from the bottom of the receiver.

   3. GPS z: Measure the distance from the Phase Center housing (48) of the GPS Receiver (10) to the bottom of the wheels.

   4. Blade position: Measure the distance between the center of the blade to the center of the rear axle.

   5. Machine width: Measure the distance from the outside edge of one wheel to the outside edge of the opposite wheel.

   6. Wheel Base: Measure the distance between the center of the front axle to the center of the rear axle.

   7. Blade Length: Measure the outside width of the blade.

      Note: To ensure accurate results, measure both sides of the machine and then average the number.

2. Move the machine origin to a known point.

3. Compare the Northing, Easting, and Elevation.