Installation of the G610 Hardware for Cat® Terrain Attachment Ready Option for Large Wheel Loaders and Large Wheel Dozers {7605} Caterpillar

Machine Control and Guidance Products

TERRAIN GRADING (S/N: TFE1-UP)

TERRAIN LOADING (S/N: TFL1-UP)

TERRAIN OFFICE (S/N: TER1-UP)

Wheel Dozer

854K (S/N: KK31-UP; RM31-UP; KK61-UP; RM61-UP; H9K1-510; H8M1-511)

Wheel Loader

992K (S/N: 8801-616; KK21-UP; RM21-UP; KK41-UP; RM51-UP; ZMX1-649)

993K (S/N: Z4D1-502; Z4Z1-509)

994H (S/N: DWC1-523)

994K (S/N: MM91-UP; MRK1-UP; SMX1-UP)

Introduction

This Special Instruction provides information for installing the Cat ^®Terrain for grading and loading hardware components on the listed large wheel loaders and large wheel dozers equipped with the Cat^® Terrain Attachment Ready Option (ARO).

Note: Within this document, all references to Terrain refer to the onboard system for Terrain for grading and loading.

The installation includes the following procedures:

• Optional alarm installation

• Display module installation

• Machine radio installation

• Satellite receiver installation

• Setting the language of the software

• Machine dimensions and measure-up

Operation and Maintenance Manual

The operation of Terrain onboard software is covered in the Operation and Maintenance Manual, M0078762, "Cat^® Terrain v6 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. Also, ensure that the product will not be damaged or made unsafe by the operation, lubrication, maintenance, or repair procedures that are used.

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

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

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

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

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

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

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

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

2. Move away from other working machines and personnel.

3. Lower the work tools 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 that are listed below are required to install Terrain for large wheel loaders and large wheel dozers.

• #30 Torx driver with 1/4" ratchet wrench and extension

• 10mm 1/4" drive socket

• 4mm Allen wrench

Control Harness Serial Number Breaks

Use Table 1 to determine the control harness that must be ordered for Terrain v6 and later or for the harness that is in use "X" for your specific machine.

Parts Lists

The 389-0323 Terrain Installation Gp contains the satellite receiver, the display module, required hardware, and a USB memory module. The USB memory module contains files for the onboard operating software, system documentation, and a schematic diagram of the system.

The following groups are used:

New - 419-6931 Terrain Installation Gp

Upgrade - 419-6928 Terrain Installation Gp

The "Upgrade" group reuses the existing satellite receiver. The "New" group includes a new satellite receiver. The installation procedure is identical for both groups except for steps involving the satellite receiver.

The parts are listed in Table 2.

The following extra required parts are not included in the Installation Groups and are either provided with a new ARO or else retained from an uninstall of an existing D3:C4 Nav 10.4 Display:

• Four 8T-4136 Bolts

• Four 8T-4121 Hard Washers

Optional Items

The only optional item available with this kit is the audible alarm. The display must have an audible alarm installed when a site uses Proximity Awareness (Detect). The alarm is optional for other sites.

Table 3 lists the parts contained in the alarm installation kit.

Installing the Optional Alarm

Menu - Opens the main menu

To install the optional alarm, complete these steps:

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Illustration 2	g03789844
Alarm components (50) 383-3027 Harness As (main front) connector "P11" (51) 411-8287 Harness As connector "S1" (52) CAN connector with terminating resistor (53) 444-5691 Alarm (54) 411-8287 Harness As (alarm) connector "P2" (55) Magnetic mounts (1 on all four corners)

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

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

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

3. Attach the alarm to the clean surface.

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

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

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

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

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

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

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

   Notify the office if either of the following conditions exist:

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

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

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

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

System Overview

The primary Terrain components include a receiver, various inclination sensors, pressure switches, and a display module.

Illustration 3	g03384880
Terrain system components (1) 450-6213 Satellite Receiver (2) 559-5631 Display Module (G610 display with OS license)

Illustration 3 shows the primary Terrain components.

Illustration 4	g06383484
Representation of cables, harnesses, and main system components

Illustration 4 shows the general position of the cables, harnesses, and Terrain components that are described within this Special Instruction.

Refer to the Terrain G610 System Diagram in the following folder on the USB memory module for a complete wiring schematic of the Terrain system:

• 02 System Documentation\System Diagrams\v5.x

Terrain Components

See "Parts Lists", Table2and "Optional Items", Table 3.

Installing the Display Module

To install the display module, complete these steps:

1. If installed, uninstall the D3:C4 Nav 10.4 monitor display from the 249-0872 Bracket.

   1. Remove the four bolts and washers from the sides of the bracket.

      Retain the bolts and washers for installation of the G610 display module. The shock mounts may be discarded.

   2. Disconnect the 70-pin plug and (if installed) the M12 Ethernet connector on the end of the blue cable from the D3:C4 Nav 10.4 Display.

      Note: If the blue Ethernet cable is to be reused, the M12 connector must be replaced with an RJ45 plug. Otherwise an appropriate Ethernet patch cable may be used to connect to the broadband radio.

2. Remove the existing hardware.

   1. Remove the 249-0872 Bracket from the D3:C4 Nav 10.4 Display that is on the "A" post. Remove the bracket by removing the five button-head machine screws and the hex head bolt.

      If the bracket is not installed, remove the fasteners from the "A" post and retain all fasteners for use in future steps.

   2. Remove the existing annunciator from the 249-0872 Bracket and disconnect the two wires from the annunciator.

      The wires will not be connected in the new harness and may either be taped back or left bare. The annunciator will not be used with the new display module and may be discarded.

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   Illustration 5	g03227396

3. Take note of the positioning of the bracket parts:

   • The 392-3608 Bracket and the 420-5739 Bracket mount to the right of the G610 display module.

   • The 392-3609 Bracket and the 420-5739 Bracket mount to the left of the G610 display module.
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   Illustration 6	g03227398

4. Using the retained fasteners, mount the two brackets to the "A" post, as shown in Illustration 6.

   Note the position of the spacer, receptacle clips, and hex head bolt on the bottom-most fastener.

5. Connect either the 12-pin connector of the 490-6390 Control Harness (see Note) or both the 12-pin and the 8-pin connectors for the 519-2909 Control Harness As.

   Note: Refer to Table 2 for the control harness for your machine for this step and the remaining steps in this procedure.

   Use the 4mm Allen to tighten the receptacle.

6. Connect the 70-pin plug of the control harness to the G610 display module.

   Use the 4mm Allen to tighten the receptacle.

7. Connect the two 12-pin plugs that are closest to the 70-pin plug of the harness to the USB and CAN receptacles on the G610 display module.

   Note: The 12-pin plugs are keyed and only connect to the correct receptacles.

8. Using one of the retained 12-pin receptacles from the bracket clip, fasten the other 12-pin plug marked "Service" into the clip receptacle. Secure the receptacle by sliding the beveled slot onto the beveled flange of the clip.

9. Mount the G610 display module into the bracket assembly. Ensure that the wider border of the face of the display is at the top.

   1. Route the control harness behind the display and the top of the dash panel.

   2. Using the four bolts and washers that were removed in Step 1a, fasten the G610 display module to the bracket.

   3. Tighten the bolts to standard Caterpillar torque specifications.
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   Illustration 7	g03227397

10. Connect the RJ45 plug of the broadband radio. Connect the plug from either the modified blue Ethernet cable or the new Ethernet patch cable into the RJ45 receptacle on the 383-0333 Cable.

11. If this Installation is a new ARO Installation and not an upgrade, install the 450-6213 Satellite Receiver on the 350-2748 Plate.

    This plate is mounted on the rear of the cab roof. Use the four 8T-4136 Bolts and 8T-4121 Hard Washers.

    1. To mount the bolts for the satellite receiver from the bottom of the 350-2748 Plate, first remove the plate from the roof of the cab.

    2. Ensure that the position of the connector of the satellite receiver allows the operator to see the LED indicators from within cab.

    3. Tighten the 8T-4136 Bolts to Caterpillar standard torque specifications.

    4. Reinstall the 350-2748 Plate in the original location.

    5. Connect the 3-pin plug of the 167-8984 Battery GP (battery backup) to the 3-pin receptacle of the 337-5202 Control Harness.

    6. Connect the 3-pin receptacle of the battery backup to the 3-pin plug of the Roll Over Protective Structure (ROPS) harness.

    7. Connect the round connector of the ROPS harness to the satellite receiver.
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    Illustration 8	g03463518

12. Turn the key start switch to ON to apply power to the display module. The display boots up and a "CAT" logo appears on the screen.

13. Complete the installation of the application software.

    Reference: Refer to Special Instruction, REHS2992, "Installation and Configuration of the Cat^® Terrain v5.0 Onboard Software".

Installing the Machine Radio

Note: Welding may be required during this installation.

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

To install a machine radio, complete these steps:

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

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

2. Determine the mounting procedure for the radio.

   Suggested mounting procedures include:

   • Utilize the existing light brackets (if equipped).

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

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

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

   Consider the following requirements when choosing the location:

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

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

4. Install the machine radio in the desired location.
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   Illustration 9	g03474679
   389-0333 Cable As (Radio) (A) "P2" to Ethernet of customer supplied radio for power (B) "P1" to main rear harness

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

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

Using Power Over Ethernet

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

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 Satellite Receiver

To install the 450-6213 Satellite Receiver, complete these steps:.

Illustration 10	g03232837
(3) 253-2587 Plate (4) 8T-4137 Bolts (5) 8T-4121 Hard Washers

1. Locate the 253-2587 Plate (3) for the satellite receiver on top of the ROPS.

   The plate is already mounted on the top of the ROPS.

2. Ensure that the satellite receiver has an unobstructed view of the sky.

3. Remove the four 8T-4137 Bolts (5) and four 8T-4121 Hard Washers (6) to remove the plate from the top-rear of the ROPS. Save these parts. Refer to Illustration 10.
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   Illustration 11	g03232937
   (8) 450-6213 Satellite Receiver (3) 253-2587 Plate (6) 8T-4136 Bolts (4) (7) 8T-4121 Hard Washers

4. Mount the satellite receiver (8) onto the plate (3) using four bolts (6) and four hard washers (7).
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   Illustration 12	g03232957
   (8) 450-6213 Satellite Receiver (3) 253-2587 Plate (4) 8T-4137 Bolts (4) (5) 8T-4121 Hard Washers

5. Use the four bolts (4) and four hard washers (5) that were removed in Step 3 to mount the plate (3) on the top-rear of the ROPS. Refer to Illustration 12.

6. Tighten the bolts to Caterpillar standard torque specifications
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   Illustration 13	g03232959
   The configuration that is shown applies to 994K, 992K, and 854K machines. (8) 450-6213 Satellite Receiver (3) 253-2587 Plate (9) 263-7745 Control Harness

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   Illustration 14	g03232960
   The configuration that is shown applies to 993K machines. The control harness (11) is used on these machines. (3) 253-2587 Plate (10) Location of satellite receiver (11) 310-3449 Control Harness

7. Connect the control harness (11) to the satellite receiver (8).

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 or Ore) ____________________

Grade Tolerance (provided by site)____________________

Using a Serial Harness

On the G610 display module, GPS communication occurs automatically over a CAN bus. If using a non-ARO machine type with MS Series receiver, use CAN GNSS communications. If using an ARO machine type with MS Series receiver, use serial GNSS communications.

To enable the G610 display module to use CAN GPS communications, add the following line of code to the master.txt file:

$ GPS Over CAN =1

This line of code disables the onboard software from using the CAN bus for GNSS communications.

Reference: To set up a G610 display module for and MS990 receiver, refer to Special Instruction, REHS2992, "Installation and Configuration of the Cat^® Terrain v5.0 Onboard Software", "Setting up an MS990 Receiver".

Setting the Language

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

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

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

Note: The onboard 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 in the office. The onboard software receives these tasks in any language that the operating system supports.

Menu - Opens the main menu

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

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Illustration 15	g03747546
"Select Language File" dialog

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

   The "Select Language File" dialog appears.

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

   • English (default)

   • French

   • Spanish

   • Swedish

   • Portuguese

   • Russian

   • Mongolian

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

   For example, to use the Spanishlanguage, select "5.0 Spanish".

3. Select "OK".

   Note: When the operator shuts down the onboard software, the selected language file is saved.

Reference: For information on advanced tasks such as editing the "Set Language File" dialog, installing a new language in the MCU, and using resource files and language identifiers, refer to Systems Operation, KEN8277, "Language Support".

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, "Terrain User Guide".

Performing the Dimension Measurements and Measure-up

To set up the machine in the office, complete these steps:

1. On the machine, measure the machine GPS receiver offsets and the machine dimensions.

   Reference: Refer to "Performing the Calibrations" in this document for your specific machine and "Machine Dimensions" in the MCU Help file for additional information.

2. In the MCU, complete the following steps:

   1. Open the MCU.

   2. Select the machine name.

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

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

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

4. Restart the onboard system and verify the accuracy of the satellite receiver as follows:

   1. Move the machine origin to a known point.

   2. Compare the Northing, Easting, and Elevation.

Performing the Calibrations

Phase Center

When a measurement refers to the phase center, the phase center is located 12.38 cm (4.87 inch) from the bottom of the receiver.

Illustration 16	g03790021
Measuring for the phase center (48) ( 8) 450-6213 Receiver (12) Phase center

X and Y Measurements

• The "X" measurement that is taken to the right of the centerline of the machine is a positive number.

• The "X" measurement that is taken to the left of the centerline of the machine is a negative number.

• 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 is a negative number.

Calibrating Wheel Loaders

Illustration 17	g03473780

Illustration 18	g03473781

To calibrate a wheel loader, complete these steps:

1. On the machine, measure the machine GPS receiver offsets.

   Reference: Refer to the side view in Illustration 17 and the sample MCU screen shot Illustration 18 as a reference guide and template to record the machine dimensions.

   1. GPS x - Measure the distance from the phase center (12) of the receiver (8) to the centerline of the machine.

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

   2. GPS y - Measure the distance from the phase center (12) of the receiver (8) to the center of the front axle of the machine.

   3. GPS z - Measure the distance from the phase center (12) of the receiver (8) to the bottom of the wheels.

2. On the machine, measure the following machine dimensions:

   1. Loader Bucket Width - Measure the distance between the outer edges of the bucket, measured across the cutting edge of the bucket.

   2. Loader Wheel Base - Measure the distance between the center line of the rear wheel axle and the center line of the front wheel axle measured parallel to the center line of the machine.

   3. Loader Maximum Reach - Measure the distance between the center line of the front axle and the maximum reach of the machine measured parallel to the machine center line.

   4. Loader Wheel Radius - Measure the distance between the center line of an axle and the outer edge of a tire measured perpendicular to the axle center line.

Calibrating Wheel Dozers

Illustration 19	g03473596
Machine Dimensions - Side View

Illustration 20	g03473597
Sample MCU screen shot

To calibrate a wheel dozer, complete these steps:

1. Measure the machine GPS receiver offsets.

   Reference: Refer to the side view in Illustration 19 and the sample MCU screen shot Illustration 20 as a reference guide and template to record the machine dimensions.

   1. GPS x - Measure the distance from the phase center (12) of the receiver (8) to the centerline of the machine.

   2. GPS y - Measure the distance from the phase center (12) of the receiver (8) to the center of the front axle of the machine.

   3. GPS z - Measure the distance from the phase center of the receiver to the bottom of the wheels.

2. On the machine, measure the following machine dimensions:

   1. Dozer Blade Position - Measure the distance between the center line of the rear idler axle and the front outside edge of the cutting edge of the blade measured parallel to the center line of the machine.

   2. Dozer Blade Width - Measure the distance between the outside edges of the cutting edge of the blade measured parallel to the blade cutting edge.