Procedure for Installing Retrofit Radar Holder for Cat® Object Detection Systems {7347, 7605} Caterpillar

Machine Control and Guidance Products

CAT DETECT (S/N: DTK1-UP)

Off-Highway Truck/Tractor

777F (S/N: JRP2576-UP)

777G (S/N: T5A1-UP; TNM104-UP; RDR106-UP; T4Y1-UP)

785D (S/N: DMC131-UP; MSY255-UP)

789C (S/N: 2BW1853-UP)

789D (S/N: SPD167-UP; SHH1-UP)

793F (S/N: SND1-UP; SSP205-UP)

793F AC (S/N: EMD76-UP)

795F AC (S/N: ERM168-UP)

797F (S/N: LAJ231-UP; WSP1-UP)

Wheel Dozer

854K (S/N: KK61-UP; RM61-UP; H9K180-UP; H8M191-UP)

Wheel Loader

988K (S/N: LWX1-UP; TWX1-UP)

992K (S/N: 880182-UP; KK41-UP; RM51-UP; ZMX240-UP)

993K (S/N: Z4D1-UP; Z8D1-UP; Z4Z1-UP; Z8Z1-UP)

994H (S/N: DWC297-UP)

Introduction

This Special Instruction outlines the procedure for Installing the Retrofit Radar Holder for Cat^® Object Detection Systems.

This Special Instruction covers the installation of an improved medium range radar holder. The improved holder addresses issues where the radar could generate false detections when no object was present in the field of view with the radar adjusted properly. A false detection can be either constant or intermittent and will usually go away with the removal of the enclosure cover for trouble shooting purposes.

Illustration 1	g03739846
Radar enclosures (1) Large factory short range enclosure (no retrofit holder needed) (2) Large retrofit short range enclosure (no retrofit holder needed) (3) Large retrofit and factory medium range enclosure (large retrofit holder needed) ( 461-6602 Service Kit) (4) Small retrofit and factory medium range enclosure (small retrofit holder needed) ( 461-6603 Service Kit)

There are two enclosure sizes for the Medium Range Radars. Large and Small. Refer to Illustration 1. The improved holder is not required for the short range sensors.

Anytime that the Object Detection system is evaluated, the latest software should be installed and azimuth and angles settings on the enclosures should be inspected to ensure that they are +/- 5 degrees from the recommended settings and that they provide appropriate coverage. Refer to Object Detection System Operations or Testing and Adjusting manual for the Object Detection System (serial prefix DTK) for settings and additional information. Refer to SIS Web Object Detection System Service Magazines for software information.

Important Safety Information

Work safely. Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs.

A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools in order to perform these functions properly.

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

Therefore, the warnings in this publication and the warnings that are on the product are not all inclusive. Ensure that any tool, procedure, work method, or operating technique you use that is not recommended by Caterpillar is safe.

Ensure that the product will not be damaged or the product will not be made unsafe by the operation, lubrication, maintenance, or repair procedures 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 Manual. Failure to follow the instructions or heed the warnings could result in injury or death. Contact your Caterpillar dealer for replacement manuals. Proper care is your responsibility.

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

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Sudden movement or accidental starting of the machine can cause personal injury or death to persons on or near the machine. To prevent personal injury or death, perform the following: Park the machine on a smooth level surface. Lower the blade and or attachments to the ground. Stop the engine and engage the parking brake. Block the wheels and install the steering frame lock. Turn the battery disconnect switch to the OFF position and remove the key. Place a Special Instruction, SEHS7332, "Do Not Operate" tag at the battery disconnect switch location to inform personnel that the machine is being worked on.

Installation Procedure for Large Retrofit Radar Holder

Perform the following procedure for Installing the Large Retrofit Radar Holder on Large Off-Highway Trucks with Factory 8 and 12 Radar Systems:

Required Parts

The required parts are listed in Table 1.

Procedure for Installing Large Retrofit Radar Holder on Large Off-Highway Trucks

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Illustration 2	g03732039
(5) Socket cap screws

1. Remove and discard the six socket cap screws (5) (not be reused for the new mounting) to open the radar box and set the cover aside.
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   Illustration 3	g03732040
   (6) Bolts

2. Remove and discard the four bolts (6) holding the plate inside the box.

3. Remove and discard the plate from the box.

4. Remove and discard the washers, rubber ISO mounts, and spacers.
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   Illustration 4	g03732041
   (7) Securing tabs

5. Remove and discard the two securing tabs (7) by taking out the corresponding bolts.
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   Illustration 5	g03732042
   (8) Phillips-head bolts

6. Remove the radar from the plate by taking out the two small Phillips-head bolts (8).
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   Illustration 6	g03732043

7. Slide the radar off the plate in the direction shown in Illustration 6.
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   Illustration 7	g03732044
   (9) 454-9634 Holder

8. Slide the radar into the new 454-9634 Holder (9).
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   Illustration 8	g03732045
   (10) 461-3288 Rivet

9. Secure the radar to the 454-9634 Holder (9) using two 461-3288 Rivets (10).
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   Illustration 9	g03732046
   (11) 3S-2093 Cable Strap

10. Route the pig tail of radar under the 454-9634 Holder (9) and secure the pig tail using 3S-2093 Cable Strap (11).
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    Illustration 10	g03732047
    Assembling the 454-9634 Holder

11. Prepare the 454-9634 Holder (9) for assembly by adding new six 8T-9655 Isolation Mounts and new three 459-4760 Spacers.
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    Illustration 11	g03732048
    (12) 1P-6522 Grommet

12. Route the harness of the radar out the hole in the bottom and add the new 1P-6522 Grommet (12).
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    Illustration 12	g03732049
    (13) 9N-0869 Hard Washers (14) 7X-2534 Bolts

13. Place the 454-9634 Holder (9) into the box and add new three 9N-0869 Hard Washers (13) and new three 7X-2534 Bolts (14).
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    Illustration 13	g03732050

14. Tighten the three 7X-2534 Bolts (14) and secure the new 454-9634 Holder (9) in the box.

15. Torque the 7X-2534 Bolts (14) to 12 N·m (106.2 lb in).

    Note: Do not overtighten the cover. Also, an appropriate thread lubricant may be applied at this time on the 7X-2534 Bolts (14) to ease assembly.

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    Illustration 14	g03732051
    (15) 260-6723 Bolts

16. Put the original cover back on the box using the new 6 260-6723 Bolts (15).
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    Illustration 15	g03732052

17. Torque the screws to 4 N·m (35.4 lb in) and then 8 N·m (70.8 lb in) using a "star" pattern. Refer to Illustration 15

Note: After installing the retrofit holder, the angle and azimuth should be checked and adjusted as needed. The latest version of Object Detection software should also be installed at this time, and the system calibration should be checked as outlined in the system operations manual. Refer to Systems Operation, UENR2507, "Cat^® Detect Object Detection System " for additional details.

Installation Procedure for Small Retrofit Radar Holder

Perform the following procedure for installing the small retrofit radar holder on Large Off-Highway with Retrofit 12 Radar Systems, Small Off-Highways Trucks, Large Wheel Loaders, and Motor Graders:

Required Parts

The required parts are listed in Table 2.

Procedure for Installing Small Retrofit Radar Holder on Large Off-Highway Trucks

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Illustration 16	g03738259
(16) Phillips-head screws

1. Remove and discard the eight Phillips-head screws (16) (not be reused for the new mounting) to open the radar box and set the cover aside.
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   Illustration 17	g03738260
   (17) Bolts

2. Remove and discard the four bolts (17) holding the plate inside the box.

3. Remove and discard the plate from the box.

4. Remove and discard the washers.
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   Illustration 18	g03738261
   (18) Securing tab

5. Remove and discard the securing tab (18) by taking out the bolt.
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   Illustration 19	g03738264
   (19) Phillips-head bolts

6. Remove the radar from the plate by taking out the two small Phillips-head bolts (19).
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   Illustration 20	g03738268

7. Slide the radar off the plate in the direction shown in Illustration 20.
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   Illustration 21	g03738266
   (20) 454-9636 Holder

8. Slide the radar into the 454-9636 Holder (20).
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   Illustration 22	g03738269
   (21) 461-3288 Rivet

9. Secure the radar to the 454-9636 Holder (20) using two 461-3288 Rivet (21).
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   Illustration 23	g03738271
   Assembling 454-9636 Holder

10. Prepare the 454-9636 Holder (20) for assembly by adding new six 8T-9655 Isolation Mounts and new three 438-4773 Spacer.
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    Illustration 24	g03738272
    (22) 1P-6522 Grommet

11. Route the harness of the radar out the hole in the bottom and add the new 1P-6522 Grommet (22).
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    Illustration 25	g03738273
    (23) 9N-0869 Hard Washers (24) 6V-8653 Bolts

12. Place the 454-9636 Holder (20) into the box and add new three 9N-0869 Hard Washers (23) and new three 6V-8653 Bolts (24).
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    Illustration 26	g03738274

13. Tighten the three 6V-8653 Bolts (24) and secure the new 454-9636 Holder (20) in the box.

14. Torque the 6V-8653 Bolts (24) to 12 N·m (106.2 lb in).
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    Illustration 27	g03738275
    (25) 095-0756 Screws

15. Put the original cover back on the box using the new eight 095-0756 Screws (25).

    Note: Do not overtighten the cover. Also, an appropriate thread lubricant may be applied at this time on the 095-0756 Screws (25) to ease assembly.

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    Illustration 28	g03738284

16. Torque the screws to 4 N·m (35.4 lb in) using a "star" pattern. Refer to Illustration 20.

Note: After installing the retrofit holder, the angle and azimuth should be checked and adjusted as needed. The latest version of Object Detection software should also be installed at this time, and the system calibration should be checked as outlined in the system operations manual. Refer to Systems Operation, UENR2507, "Cat^® Detect Object Detection System " for additional details.