Installation of Cat® Terrain for Landfill Compactors, Motor Graders, Wheel Dozers, and Wheel Loaders {7605} Caterpillar

Landfill Compactor

All

Machine Control and Guidance Products

TERRAIN GRADING (S/N: TFE1-UP)

TERRAIN LOADING (S/N: TFL1-UP)

TERRAIN OFFICE (S/N: TER1-UP)

Motor Grader

All

Wheel Dozer

All

Wheel Loader

All

Introduction

This Special Instruction provides information for installing the following Cat^®Terrain for grading and loading hardware components on the listed wheel loaders, wheel dozers, landfill compactors, and motor graders:

• 389-0318 Installation Gp

• 389-0344 Installation Gp

The installation requires 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:

• Satellite receiver, receiver harness, and chassis harness Installation

• Wireless machine radio installation

• Main rear harness assembly installation

• Monitor display installation

• Main front harness assembly installation

• Battery backup installation

• Power supply wiring and fuse installation

• Initial power checks

• Machine ID worksheet entries

• Dimension measurements and measure up

Operation and Maintenance Manual

The operation of Terrain for grading and loading on-board software is covered in the Operation and Maintenance Manual, SEBU8814, "Cat^® Terrain for Grading and Loading". Refer to this manual for more information.

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

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

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 implement to the ground. Permit only one operator on the machine. Keep all other personnel away from machine or in view of the operator. Engage the parking brake. Stop the engine. Move the hydraulic control levers to all positions to release the pressure in the hydraulic system.

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

Illustration 1	g00037860

Use steps and handholds whenever 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 implement to the ground. Permit only one operator on the machine. Keep all other personnel away from machine or in view of the operator. Engage the parking brake. Stop the engine. Move the hydraulic control levers to all positions to release the pressure in the hydraulic system.

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 required to install the Terrain 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.

Table 1

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

Parts Lists

The 389-0344 Terrain Electronics Ar contains the receiver, the display, and a USB memory module. The USB memory module contains files for the monitor operating software, system documentation, and a schematic diagram of the system.

Table 2

Contents of the 389-0344 Terrain Electronics Ar
Part Number	Part Name	Notes
353-2794	Satellite Receiver	MS992 receiver
392-9004	USB Memory Module	Contains operational files and documentation
389-8217	Monitor Display	G610 Display with loaded operating system

The 389-0318 Terrain Installation Ar contains the four kits that are listed in Table 3. The kits are broken down in Tables 4 through 7.

Table 3

Contents of 389-0318 Terrain Installation Arrangement
Part Number	Part Name	Description
167-8604	Monitor Mounting Group	Dash/ceiling mounting group for display
291-2176	Receiver Mounting Group
389-0332	Monitor Mounting Group	Display mounting group
389-0335	Machine Wiring Group	Terrain

Table 4

Contents of 167-8604 Monitor Mounting Gp
Qty	Part Number	Part Name	Notes
4	0S-0509	Bolt	3/8-16
4	5M-2894	Hard Washer
4	8X-7422	Boss	3/8-16
1	147-3417	Mount As

Table 5

Contents of 291-2176 Receiver Mounting Group
QTY	Part Number	Part Name	Description
1	0L-1169	Bolt	5/8-11
1	5K-5962	Boss	5/8-11
1	5P-4624	Bolt	5/8-11
4	8T-4121	Hard Washer
4	8T-4195	Bolt	M10
1	289-9633	Plate

Table 6

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

Table 7

Contents of 389-0335 Terrain Wiring Group
QTY	Part Number	Part Name	Description
4	2L-8067	Terminal
4	2L-8071	Terminal
4	2L-8079	Terminal
2	3S-8665	Clip	For harness
3	5P-6264	Grommet
15	8M-2773	Clip
4	8T-0325	Bolt	M5 For battery
4	8T-0328	Hard Washer	For battery
1	167-8703	Wire	Power supply
1	167-8984	Battery
1	265-8147	Harness	Fuse
1	278-7396	Wire
1	285-6651	Harness As	CAN terminator
1	285-6657	Harness As	Receiver jumper
1	290-2928	Harness As
2	292-1120	Mounting Block	For battery
1	383-3027	Harness As
1	383-3028	Harness As
1	389-0333	Cable As

Optional Items

The optional items in Table 8 may also be required during the installation. These parts are not provided in the 389-0318 Terrain Installation Ar.

Table 8

Optional Parts Needed for Terrain Installation (Not included in the 389-0318 Terrain Installation Ar)
Part Number	Part Name	Description
3E-5239	Relay	Used for optional Reverse Auto-Calibration option
4C-4200	Paint	CAT Yellow
7K-1181	Cable Strap	Straps for securing harness
7T-1099	Link	Weld links for harness routing
141-5830	Silicone Sealant	RTV for grommets

Cat^® Terrain Components

Illustration 2	g03015939
Representation of cables, harnesses, and main system components

Illustration 2 shows the connections between the cables, harnesses, and the Terrain components that are described within this instruction. Refer to the "Terrain System Diagram v10 05092012.pdf" in the following folder on the USB memory module for a complete wiring schematic of the Terrain system.

• 02 System Documentation\System Diagrams\v4.5

Note: If the machine is in the following list, then ensure that the machine does not have the Terrain ARO option from the factory. If the machine has the Terrain ARO option, then refer to Special Instruction, REHS7235, "Installation of Cat^® Terrain 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 Terrain ARO option from the factory. If the machine does have the Terrain ARO option, then refer to Special Instruction, REHS7236, "Installation of Cat^® Terrain 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

Illustration 3	g02972676
Terrain system components (1) 389-8217 Monitor Display (G610) (2) 393-2794 Satellite Receiver

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 a Caterpillar Technical Communicator for detailed instructions as to how to proceed with the installation.

Summary of Welding and Potential Welding by Sections

Table 9

Welding	Section
Yes	Receiver, receiver harness, and chassis harness
Possible	Machine radio installation
Possible	Mounting and connecting the radio harness
Possible	Main rear harness assembly installation
Possible	Monitor display installation
Possible	Main front harness assembly installation
Yes	Battery backup installation
No	Power supply wiring and fuse installation

Installing the Receiver, Receiver Harness, and Chassis Harness

Note: This installation procedure requires welding.

Note: The terms receiver, GPS or GNSS receiver, satellite receiver, and Positioning Module (PM) are synonymous. This manual uses the terms receiver and satellite receiver.

Illustration 4	g02980736
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 allows the 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 satellite receiver. This method eliminates the need for welding, drilling, or tapping the machine.

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Illustration 5	g02977748
(10 ) 353-2794 Satellite Receiver shown on 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 6	g01434535
   The 5K-5962 Boss is shown welded to the ROPS 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 7	g02972596
   The 353-2794 Satellite Receiver is shown mounted on the top side of the ROPS using 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: Mount the satellite receiver 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 Harness As (receiver) (13) to the connector on the satellite receiver. Route the harness across the roof to the ROPS post.
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   Illustration 8	g02977759
   The optional 7T-1099 Links are shown. These weld links are attached to the ROPS. The links are used for routing the receiver harness across the roof of the cab.

5. Secure the receiver 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 389-0335 Machine Wiring Group.

6. Connect the 12-pin connector of the receiver harness to the 12-pin connector of the 290-2928 Harness As (main rear).
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   Illustration 9	g01435010
   (12) 290-2928 Harness As (chassis) (13) 285-6657 Harness As (receiver) (14) 285-6651 Harness As (CAN terminator)

7. Connect the CAN terminator (14) to the 8-pin connector near the end of the chassis harness (12).
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   Illustration 10	g01470994
   The chassis harness is shown routed down the ROPS post.

8. Route the chassis harness (12) down the back of the left ROPS post to the mounting location of the 383-3028 Harness As (main rear). This location is beneath the floor plate of the cab. This is the recommended routing.

9. Secure the 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 389-0335 Machine Wiring Group.

Note: If available, use the ROPS harness guide bracket to protect the harness. Refer to Illustration 10.

Installing the Machine Radio

Illustration 11	g03005040
389-0333 Cable As (Radio) (1) P1 to main rear harness (2) P2 to Ethernet of customer supplied radio for power

A machine radio is not supplied with Terrain. The 389-0333 Cable As (Ethernet) connects to the rear main harness using a 12-pin (key D) connector (1). The opposite end of the radio harness employs a standard RJ-45 Ethernet connector (2) with power provided through the connector for a third-party radio.

Note: The 900x radio from previous CAES systems can be replaced by the Cyan radio. The radio, which is country-specific, is ordered separately.

The customer determines the location and mounting procedure for the radio. Suggested mounting procedures include:

• Utilizing existing light brackets (if equipped)

• Welding bosses to the machine and using a radio mounting bracket

• Mounting the radio inside the cab and mount an external antenna outside the cab

Ensure the following when choosing a mounting location:

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

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

Using Power Over Ethernet

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

If utilizing PoE technology, then move the following wires from the 2-pin DT connector to the 12-pin DT connector of the radio harness:

• Power: 1-BU(Blue)

• Ground: 2-BK(Black)

Installing the Main Rear Harness

Note: Welding may be required during this installation.

The 383-3028 Harness As (main rear) routes from the 383-3027 Harness As (main front) to either the 389-0333 Harness As (radio) or else to the 290-2928 Harness As (20-FT) (chassis).

1. Route the main rear harness.

2. Connect the 12-pin connectors of the main front harness to the main rear harness.

3. Route the main rear harness under the floor plate toward the main front harness that is located near the dash.

4. Secure the main 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 389-0335 Machine Wiring Gp.

Installing the Monitor Display

Note: If the machine is in the following list, then refer to Special Instruction, REHS7235, "Installation of Cat^® Terrain 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, REHS7236, "Installation of Cat^® Terrain 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 display within the cab of the machine. Consider the following requirements when choosing the location:

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

• Choose a location that does not block the visibility of the operator to risk areas around the machine.

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

Consider the following when choosing the location for the display:

• Ease of reference to work in progress

• Accessibility to the touch screen

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

• View of safety films within the cab

• Direct or mirrored views of the operator

• Ability of 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 12	g02980737
Typical display mounting location

There are two options for installing the 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 13	g02980738
The optional mounting location is shown on a compactor. The display is mounted in the 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 14	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 4.

   Note: If mounting the display to the ceiling, then score the padding, the lining, or the insulation material. Remove the scored material. Remove enough material 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 383-3032 Bracket to the bosses. Use the four bolts and four washers that were removed in Step 4.
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   Illustration 15	g01513986
   The exploded view of 150-1893 Vibration Isolator Mounting Group is shown. (1) 389-8217 Monitor Display Gp (34) 383-3032 Bracket (35) 8T-4205 Hard Washer (36) 8T-9364 Bolt (1/4-20) (39) 8C-5607 Isolation Mount (40) 8C-5608 Spacer (41) 9X-6165 Washer (42) 4M-5282 Bolt (1/4-20)

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   Illustration 16	g02980677
   389-3032 Bracket for mounting monitor display with isolation mounts installed

7. Assemble the eight 8C-5607 Isolation Mounts (39) and the four 8C-5608 Spacers (40) to the u-shaped 383-3032 Bracket. Use four 9X-6165 Washers (41) and four 4M-5282 Bolts (42). Refer to Illustration 15.

   Note: Tighten the bolts to Caterpillar standard torque specifications.

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   Illustration 17	g01513379
   Ceiling/dash adapter (43) 147-3417 Mount (44) 4M-5282 Bolts (1/4-20) (45) 9X-6165 Washers

8. Attach the 383-3032 Bracket to the 147-3417 Mount (43). Use four 4M-5282 Bolts (44) and four 9X-6165 Washers (45) from the 389-0322 Monitor Mounting Group. Refer to Illustration 17.

   Note: Tighten the bolts to Caterpillar standard torque specifications.

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   Illustration 18	g02980017
   Display tilted after installation of lower bolts to ease installation of cables

9. Attach the monitor display to the 389-3032 Bracket. Install the lower 8T-9364 Bolts and 8T-4205 Hard Washers first to allow the display to tilt and ease installation of the harnesses.

   Note: The remaining bolts and washers will be connected beginning in Step 12 after the harnesses are installed.

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

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

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    Illustration 19	g03005033
    G610 harness installation (1) Monitor display (2) P1 (70 pin) of main front harness (3) (not used) (4) P3 of main front harness to USB port (5) P2 of main front harness to power port

11. Install the main front harness connectors to the display.

    1. Connect the 70-pin connector to the display.

    2. Connect the black (key B) 12-pin connector to the USB port (bottom).

    3. Connect the gray (key A) 12-pin connector to the power port (middle).

       Note: The top 12-pin connector port is not used.

12. Install the third 8T-9364 Bolt (1/4-20) and 8T-4205 Hard Washer to the left-hand top of the display.
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    Illustration 20	g02980218
    Front harness installed on bracket (9) 383-3027 Harness As (34) 389-3032 Bracket (46) 130-5300 Clips (47) Receptacle

13. Attach the 130-5300 Clip (46) to the outside of the 389-3032 Bracket (34). Use the last 8T-9364 Bolt (1/4-20) and 8T-4205 Hard Washer. Refer to Illustration 20.

14. Install the 370-4060 Receptacle to the 237-0164 Plug of the main front harness.

15. Attach the 237-0164 Plug to the 130-5300 Clip. Refer to Illustration 20.

Installing the Main Front Harness

The 383-3027 Harness As (main front) routes between the 389-8217 Monitor Display (G610), the 167-8984 Battery, and the 383-3028 Harness As.

1. Route the main front harness. For ease of routing, start routing the harness at the display. Continue routing the harness to the 167-8984 Battery (backup) and to the connection of the 383-3028 Harness As (main rear). This method of routing ensures that there is no need to remove the 70-pin connector from the harness.

2. Route the main front harness from the display to the intended location of the connection for the main 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 12-pin connector of the main front harness to the 12-pin connector of the main rear harness.

4. Route the 3-pin power connection to the mounting location of the battery backup. This 3-pin connector breaks off from the main front harness.
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   Illustration 21	g01513994
   The main front harness is shown securely clamped. (9) main front harness (46) 8M-2773 Clip

5. As shown in Illustration 21, secure the main 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 389-0335 Machine Wiring Gp.

Battery Backup

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

The battery backup supplies the on-board software with temporary power. Power is supplied for a short time in the event of an abrupt, unplanned loss of power to the machine. The battery backup stores power for approximately 5 minutes. This delay provides enough time for the operator to shut down the on-board software safely.

The two connectors from the battery connect to mating connectors on the 167-8703 Wire (power supply) and the 383-3027 Harness As (front main). The 265-8147 Harness As (fuse) can be mounted on either side of the battery. The design of the connectors ensures a correct connection to the mating connector. Locate the battery backup to ensure that the power supply lead from the front main harness can reach the battery.

Note: There are several acceptable mounting locations for the battery backup on the machine. Observe the following criteria when choosing a location:

• The overall dimensions of two 292-1120 Mounting Blocks while attached to the battery backup

• Accommodation for the standard, unaltered length of the 383-3027 Harness As (main front)

• Adequate accessibility to the battery

• Normal, safe functioning of the machine

Fuse Harness

The 265-8147 Harness As (fuse) is a three wire inline connection. The fuse harness is used to protect the Terrain hardware components.

Illustration 23	g01455641

Install the harness in one of the following locations:

3A - Between the power supply wire (2) and the battery backup (3)

3B - Between the battery backup (3) and the main front harness (16)

Locate the harness in an area of the site that allows for ease of replacement of the fuses, if required.

Installing the Battery Backup

Note: This procedure may require welding.

Perform the following procedure to install the battery backup.

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Illustration 24	g01817855
Exploded view of mounting for battery backup (3) 167-8984 Battery Gp (backup) (3C) 8T-0325 Bolts (M5) (3D) 8T-0328 Hard Washers (3E) 292-1120 Mounting Blocks

1. Bolt the two 292-1120 Mounting Blocks (3E) to the battery backup (3). Use the 8T-0325 Bolts (3C) and the 8T-0328 Hard Washers (3D).

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

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

4. Remove the mounting blocks from the battery backup.

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

6. Verity that the flange holes of the battery line up with the tapped holes in the mounting blocks.

7. Permanently weld the mounting blocks.

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

9. Once the paint has dried, bolt the battery backup to the machine. Use the 8T-0325 Bolts and the 8T-0328 Hard Washers.

   Note: Tighten the bolts to Caterpillar standard torque specifications.

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

10. If using a TC900B radio, then locate a 205-4285 Power Converter (12V/24V Inverter) near the battery.

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

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

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

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

Note: Tighten the bolts to Caterpillar standard torque specifications.

Installing the Power Harness and Fuses

The 167-8703 Wire As (power supply) is provided with the 389-0335 Machine Wiring Gp. Use the power supply wire to connect the 167-8984 Battery Gp (backup) to the machine power supply. Connect the power and key switched power through a 10 amp fuse.

Illustration 25	g01268941
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 the following Steps, use a 2L-8067 Terminal, a 2L-8071 Terminal, or a 2L-8079 Terminal. These Terminals are included in the 389-0335 Machine Wiring Gp.

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

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

5. Connect the BK "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 Terrain 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 the key switch to the OFF position.

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

3. Check for 0 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 Gp.

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 (circle one of the following): Grade, Ore, OrePlus, Compaction

Grade Tolerance (provided by site)____________________

Setting the Language

The operator can use the user interface of the on-board software in either English, French, Spanish, Portuguese, or Swedish. The default is English. Enable one of the non-default languages using a line of code containing a language identifier from Table 10.

Note: The on-board software receives tasks from other applications such as Task List Manager. These tasks can be sent in any language that is supported by the keyboard and operating system being used. The on-board software receives these tasks in any language that the operating system supports.

Table 10

Language	Language Identifier
French	fra
Spanish	esp
Swedish	sve
Portuguese	prt

To set the language of the user interface, add the following line to the startcaes.cmd file before running the file:

• SET lang=<language identifier>

Illustration 26	g02340196

The line must be added before the c:\caes\exe line. For example, to set the language of the user interface to Spanish, add the following line as shown in Illustration 26:

• SET lang=esp

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 machine configuration file (mach_cfg.txt) file by hand.

Reference: For information on using the MCU, select Start > All Programs > Cat MineStar System and Tools > Machine Configuration Utility.

Reference: For information on adding the machine in Cat MineStar System, refer to Systems Operation, RENR9562, "Cat^® Terrain User Guide".

Performing the Dimension Measurements and Measure Up

1. Perform the calibration for the machine as listed in the specific section for your machine in "Performing the Calibrations".

2. Open the MCU.

3. Select the machine name.

4. Select Machine > Machine Dimensions. Enter the dimensions.

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

6. Ask the Terrain Site Champion to send out a site-specific application file for the receiver.

7. Restart the on-board system and verify the accuracy of the receiver as follows:

   1. Move the machine origin to a known point.

   2. Compare the Northing, Easting, and Elevation.

Performing the Calibrations

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

When a measurement refers to the phase center, the phase center is located 12.8 cm (5.0 inch) from the bottom of the receiver.

Illustration 27	g02980337
Measuring for the phase center (48) ( 10) 353-2794 Receiver (48) Phase center

Reference: Refer to "Machine Dimensions" in the MCU Help for the following steps:

Calibrating Wheel Loaders

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Illustration 28	g03099718
MCU screen shot of machine dimensions

1. Measure the machine GPS receiver offsets.

   Reference: Refer to the sample 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 front axle will be a positive number. The "Y" measurement that is taken behind the front axle will be a negative number.

   Show/hide table

   Illustration 29	g02980337
   Measuring for the phase center (48) ( 10) 353-2794 Receiver (48) Phase center

   1. GPS x: Measure the distance from the phase center (48) of the receiver (10) to the centerline of the machine.

      Note: The phase center is located 12.8 cm (5.0 inch) (double-sided arrow) from the bottom of the receiver.

   2. GPS y: Measure the distance from the phase center (48) of the receiver (10) to the center of the front axle of the machine.

   3. GPS z: Measure the distance from the phase center (48) of the 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.

Calibrating Wheel Dozers and Landfill Compactors

Illustration 30	g01513906
MCU screen shot of machine dimensions

1. Measure the machine GPS receiver offsets.

   Refer to the sample MCU screen shot, Illustration 30, 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 phase center (48) of the receiver (10) to the centerline of the machine.

   2. GPS y: Measure the distance from the phase center (48) of the receiver (10) to the center of the front axle of the machine.

   3. GPS z: Measure the distance from the phase center (48) of the receiver (10) to the bottom of the drums.

      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.

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

Calibrating Motor Graders

Illustration 31	g01513833
MCU screen shot of machine dimensions

1. Measure the machine GPS receiver offsets.

   Refer to the sample MCU screen shot, Illustration 31, 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 phase center (48) of the receiver (10) to the centerline of the machine.

   2. GPS y: Measure the distance from the phase center (48) of the receiver (10) to the center of the rear axle of the machine.

   3. GPS z: Measure the distance from the phase center (48) of the 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.