TFL REHS7238-03 v5 Measure Up

3/29/2019 Terrain Loading TFL00001-UP (MACHINE)(SEBP7000 - 08) - Documentation
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Welcome: t080srba
Product: TERRAIN LOADING
Model: - TERRAIN LOADING TFL
Configuration: Terrain Loading TFL00001-UP (MACHINE)
Special Instruction
Installation of Cat® Terrain for Excavators{7605}
Media Number -REHS7238-03 Publication Date -02/04/2015 Date Updated -02/04/2015
i05966791
Installation of Cat® Terrain for Excavators{7605}

SMCS - 7605
Excavator: All
Machine Control and Guidance Products:
TERRAIN GRADING (S/N: TFE1-UP)
TERRAIN LOADING (S/N: TFL1-UP)
TERRAIN OFFICE (S/N: TER1-UP)
Introduction
This Special Instruction provides information for installing the following Cat® Terrain for grading and
loading hardware components on the listed excavators.
389-0324 Terrain Installation Gp
389-0345 Electronics 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 is separated into the following procedures:
Receiver installation
Angle sensor installations
Pressure switch installation
Machine radio installation
Display module installation
Battery backup installation
Harness installations
Calibration and measure up procedures
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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.
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.
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
Machine swings. Stay back. Crushing hazard could cause serious injury
or death.
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.
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.
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 mounting the machine. Use steps and handholds whenever dismounting
the machine. Before mounting the machine, clean the step and the handholds. Inspect the step and handholds.
Make all necessary repairs.
Face the machine whenever mounting the machine and whenever dismounting the machine. Maintain a
three-point contact with the step and with handholds.
Note: Three-point contact can be both feet and one hand. Three-point contact can also be 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 carrying tools or supplies. Do not try to dismount the machine when carrying
tools or supplies. Use a hand line to pull equipment onto the platform. Do not use any controls as handholds
when entering the cab or when exiting the cab.
General Preparation
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 that is 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 keys for the machine.
Required Tools
The tools that are listed in Table 1 are required to install the Terrain components for excavators. The list
contains the recommended Caterpillar service tools. The list also contains tools for general use that do not
have a specified part number.
Table 1
Part Number Description
1U-7230 Hand Tool Group (Screwdrivers)

1U-9369 Measuring Tape
8T-9293 Torque Wrench (1/2 inch Drive)
9S-1748 Socket Wrench Set (1/2 Inch Drive)

9S-3263 Thread Lock Compound
194-3584 Socket Wrench Set (Torx screw)

199-6156 Socket Wrench Set (1/2 Inch Drive )
389-0331 Tool Group (Terrain Service Kit)

389-0330 Tool Group (Measure-up Kit)
Not specified Drill Bit Set
Not specified Hole Punch Set

Not specified Fish Tape
Not specified Cable Ties/Clips

Not specified Tap Set
Optional Items
The optional items in Table 2 may also be required during the installation. These parts are not provided in the
389-0324 Terrain Installation Ar .
Table 2
Optional Parts Needed for Terrain Installation
(Not included in the 389-0324 Terrain Installation Ar )
Part Number Part Name Notes

3E-5239 Relay Used for 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
167-8709 Alarm Annunciator
205-4285 Electrical Converter 24V/12V converter for use with TC900B radios
285-6653 Radio Harness Extension harness for radio or receiver
Parts Lists
The 389-0345 Electronics Gp contains two receivers, a display module, 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 3
Contents of the 389-0345 Electronics Gp
353-2794 Satellite Receiver MS992 receiver (2 each)
392-9004 USB Memory Module Contains operational files and documentation
389-8217 Display Module G610 monitor display with loaded operating system
The 389-0324 Terrain Installation Ar contains the items listed in Table 4 used during installation of the
Terrain hardware. Tables 5 through 10 describe the contents of the kits.
Table 4
Contents of 389-0324 Terrain Installation Ar
167-8604 Monitor Mounting Gp For G610 display module

291-5398 Receiver Mounting Gp For receiver (2 each)
292-0306 Sensor Wiring Gp Terrain
292-0308 Sensor Wiring Gp CAES

389-0332 Monitor Mounting Gp
389-0338 Machine Wiring Gp Machine
Table 5
Contents of 167-8604 Monitor Mounting Gp
QTY Part Number Part Name Notes
4 0S-0509 Bolt 3/8-16
1 147-3417 Mount Ceiling or dash mount

4 3Y-7829 Boss Weld, 3/8-16
4 5M-2894 Hard Washer
4 8X-7422 Boss Weld, 3/8-16
Table 6
Contents of 291-5398 Receiver Mounting Gp (two kits)
4 5D-0353 Locking Bolt
4 6V-8801 Nut
4 8M-2770 Clip
4 8T-4121 Hard Washer
4 8T-4195 Bolt

8 8T-5360 Washer
8 8T-9380 Bolt
1 147-3449 Plate Antenna

1 156-8045 Plate CAES
1 289-9630 Plate CAES
Table 7
Contents of 292-0308 Installation Gp

3 312-0754 Angle Sensor As AS450C
1 312-0755 Angle Sensor As Pitch/roll
4 322-0221 Housing Bracket

4 322-0222 Cover
Table 8
Contents of 292-0306 Sensor Wiring Gp
100 3S-2093 Cable Strap

12 4D-7794 Clip
10 4P-7581 Clip Ladder type
16 5C-7261 Nut Hex

16 5P-4115 Hard Washer
12 8M-2770 Clip Loop

16 8T-4136 Bolt Hex head
16 8T-4171 Bolt Hex head
3 8T-8737 Seal Plug

16 9R-2060 Boss
1 134-2540 Receptacle CAN terminator
4 243-4108 Harness As Sensor

1 243-4111 Harness As Switch
1 276-4084 Harness As Terminator adapter
2 311-8687 Harness As Sensor (16 m)
2 311-8688 Harness As Sensor (8 m)
Table 9
Contents of 389-0332 Monitor Mounting Gp
1/4-20
4 4M-5282 Bolt
Display module bracket to dash bracket
6 7K-1181 Cable Strap
8 8C-5607 Isolation Mount
4 8C-5608 Spacer
4 8T-9364 Bolt 1/4-20
4 9X-6165 Washer Display module bracket to dash bracket
2 130-5300 Clip
1 383-3032 Bracket
Table 10
Contents of 389-0338 Machine Wiring Gp (Terrain)

4 2L-8067 Terminal
4 2L-8071 Terminal
4 2L-8079 Terminal
2 3S-8665 Clip Harness

3 5P-6264 Grommet
30 8M-2773 Clip
M5
4 8T-0325 Bolt
For battery
4 8T-0328 Hard Washer For battery
1 167-8703 Wire As Power supply
1 167-8984 Battery
1 265-8147 Harness Fuse
1 278-7396 Wire As
1 285-6655 Harness As Chassis
1 285-6656 Wiring Harness Second receiver crossover

2 285-6657 Wiring Harness Receiver jumper
1 383-3027 Wiring Harness Main front
1 383-3028 Wiring Harness Main rear

2 292-1120 Mounting Block For Battery
1 311-8690 Harness As Receiver extension
System Overview
(5) Data radio (customer supplied)
(6) (7) receiver
(21) (22) Pressure sensors
(29) Machine body pitch and roll sensor
(30) Boom tilt sensor
(31) Stick tilt sensor
(32-A) Bucket tilt sensor
(32-B) Alternate location for bucket tilt sensor
Terrain for excavators includes two receivers, various sensors, and a display module. Illustration 2 shows the
location of these components.
Terrain Components
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Dual receiver Terrain hardware architecture
Illustration 3 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 Terrain.
02 System Documentation\System Diagrams\v4.5
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 before proceeding with the installation.
Primary Cat® Terrain components for dual receiver machines
(1) G610 display module
(6) Satellite receiver
(21) Pressure switch
(29) Pitch and roll angle sensor
(30) Boom angle sensor
(31) Stick angle sensor
(32) Bucket angle sensor
Note: Contact your Caterpillar Technical Communicator or Original Equipment Manufacturer (OEM) dealer
for proper pressure switches (not shown) for the pressure ranges of the hydraulic system.
Summary of Welding and Potential Welding by Sections

Table 11
Welding Section
Yes Receiver, receiver harness, and chassis harness

Possible Machine radio installation
Possible Main rear harness assembly installation
Possible Display module installation

Possible Main front harness assembly installation
Yes Battery backup installation
No Power supply wiring and fuse installation
Installing the Receivers
Note: This installation procedure requires welding.
Note: The terms Receiver, GPS or GNSS receiver, satellite receiver, and positioning module are
synonymous. This manual uses the terms receiver and satellite receiver.
Refer to Special Instruction, REHS1729, "Fabricating The CAES Antenna Masts (4 Foot Mast and 7 Foot
Mast)" for instructions that detail the construction of two 4 foot masts for the two receivers.
Table 12
Installation Parts List for 353-2794 Satellite Receiver
QTY Part #
Part Name Notes
2 The site must build suitable masts for the receivers.
8T- Hard Washer

8 M10 Washer for receiver
4121 (Receiver)
8T-
8 Bolt M10 Bolt for receiver
4195
8T-
16 Bolt 7/16-14 Bolts to attach masts to machine
9380
8T-
16 Hard Washer 7/16-14 Washers to attach masts to machine
5360
147-
2 Plate Utilized to build masts for the receivers
3449
156- On machine base plate that must be welded to machine and is used to
2 Plate
8045 attach receiver masts to machine
285- Wiring Harness
2 Receiver harness (jumper) (optional)
6657
353- Satellite
2 MS990 receiver
2794 Receiver
Use the following steps to attach the 156-8045 Plate to the counterbalance that is on the machine:
1. Park the machine on a level surface with the bucket on the ground. Check that the mounting plates are
level in the front, back, left, and right. These checks ensure that the masts will be mounted vertically.
156-8045 Plate mounted to machine with receiver mast mounted to plate
2. Position the plates as near to the sides of the counterbalance as possible.
3. Make sure that the receivers will not extend past the sides of the counterbalance. If the receivers
extend too far, the receivers may get damaged.
4. Position the plates so that the receivers will avoid possible overhead obstructions.
5. Position the plates so that the receivers are high enough to receive clear signals from the satellites. Do
not position the plates so the receivers are so high the machine cannot enter a height-restricted area
such as the shop.
Note: There is no requirement to attach the plates to the highest point of the counterbalance.
6. Weld the plates securely to the counterbalance to minimize movement and vibration.
7. Attach the receiver masts to the plates. Use the 8T-9380 Bolts (7/16-14) and the 8T-5360 Washers .
Receivers mounted to masts
8. Attach a receiver to each of the masts. Use four 8T-4195 Bolts and four 8T-4121 Hard Washers .
Note: Mount the receivers to allow the operator easy visibility of the LEDs when outside of the cab.
The location may be determined by site preference.
9. The 285-6657 Wiring Harness may be installed at this time. Refer to ""Installing the Harnesses" " for
detailed instructions.
Installing the Angle Sensors

Terrain uses an angle sensor to determine the pitch and the roll of the excavator. The system also uses three
angle sensors to determine the tilt positions of the boom, stick, and bucket relative to the machine centerline.
Table 13
Position and Angle Sensors Parts List
Optional
4C-4198 Paint
Caterpillar Medium Gloss Black: Used to paint welded areas
4C-4200 Optional
Paint
Caterpillar High Gloss Yellow: Used to paint welded areas
333-2850 Sensor Wiring Sensor installation group with mounting hardware
Previous to version 3.2, CAESultra for excavators used the following sensors:
AS7 Single Axis Sensor - Used to measure the tilt of the boom, stick, and bucket
AS7 Dual Axis Sensor - Used to measure the pitch of the machine body
Version 3.2 and later systems use the following sensors:
AS450C - Used to measure the tilt of the boom, stick, and bucket
AS460C - Used to measure the pitch of the machine body
Reference To configure a CAESultra v4.0 and later machine, refer to Special Instruction, REHS4456,
"Installation of the Pitch and Roll Angle Sensor for CAESultra".
ReferenceTo configure a Terrain v4.5 and later machine, refer to Special Instruction, REHS7229,
"Installation of the Pitch and Roll Angle Sensor for Cat® Terrain".
ReferenceFor instruction on programming the angle sensors, refer to Systems Operation, UENR2509, "Cat®
Terrain for Grading and Loading", "As-Built Surfaces".
The feedback from these four sensors provides an accurate representation on the display module of the
boom, stick, and bucket positions relative to the ground.
AS450 Angle Sensor
All of the sensors have the same physical appearance as the sensor that is shown in Illustration 7. The only
difference is that the 312-0755 Angle Sensor has a decal on the sensor that indicates the pitch and roll of the
sensor.
The bracket assemblies are mounted to the machine using weld bosses. The sensors are then installed on the
bracket assemblies. Illustration 8 shows a cutaway view of a typical sensor that is located inside the
mounting bracket. The cover is installed.
Note: While setting up the angle sensors for welding and installation, temporarily route the sensor harnesses.
Ensure that the harnesses can be connected using the proposed locations for the sensors. Refer to ""Installing
the Harnesses" " for additional information.
Note: The 322-0222 Covers are installed after the harness assemblies are installed and the sensors are
connected to the harness assemblies.
Cutaway view of a typical sensor
(46) 8T-4171 Bolt (M6), 5P-4115 Hard Washer
(47) 322-0222 Cover
(48) 322-0221 Bracket
(49) 312-0754 Angle Sensor (AS450C) or 312-0755 Angle Sensor (AS460C)
(50) 5C-7261 Nut (M8) and 8T-4224 Hard Washer
(51) 8T-4136 Bolt and 8T-4121 Hard Washer
(52) 9R-2060 Boss
Installing the Pitch and Roll Angle Sensor
Note: This procedure requires welding.
The 312-0755 Angle Sensor is used to measure the pitch and the roll of the machine. Check the label on the
sensor before installation.
When mounting the angle sensor, consider the following points:
Select a central, level mounting location that is square to the machine.
Select a location that protects the sensor from damage.
Orient the 322-0221 Bracket for the angle sensor so that the harness points towards the rear of the
machine.
Select a solid mounting location so that the only measurement is the machine body pitch and roll.
Select a mounting location that is clear of the boom movement.
Select a mounting location that the 311-8688 Sensor Harness can reach from the display module.
Use the following steps to install the Angle Sensor :
1. Bolt the 9R-2060 Bosses to the 322-0221 Bracket by using 8T-4136 Bolts (M10) and 8T-4121 Hard
Washers . Use the sensor bracket and bosses as a template to locate the welding points for the bosses.
2. Tack weld the bosses to the body.
3. Remove the 322-0221 Bracket and finish welding the bosses to the machine.
4. Once the welding has cooled, paint the bosses to prevent the bosses from rusting.
5. Once the paint has dried, bolt the 322-0221 Bracket to the machine. Use 8T-4136 Bolts (M10) and 8T-
4121 Hard Washers . Torque the bolts to 25 ± 6 N·m (18.4 ± 4.4 lb ft).
Installed 312-0755 Angle Sensor for pitch and roll
6. Bolt the 312-0755 Angle Sensor to the 322-0221 Bracket . Use the 5C-7261 Nuts (M8) and the 8T-
4224 Hard Washers . Torque the nuts to 25 ± 6 N·m (18.4 ± 4.4 lb ft).
Installing the Boom Angle Sensor

The 312-0754 Angle Sensor is used to measure the tilt of the boom. Check the label on the sensor before
installation.
Use the following steps to mount the angle sensor:
1. Place the machine on level ground.
2. Select a location on the boom for the 322-0221 Bracket . Consider the following before welding the
bracket:
Ensure that the mounting bracket is parallel to the centerline of the boom. The boom may
require a welded spacer so that the mounting bracket is parallel to the centerline of the boom.
Ensure that the face of the mounting bracket is vertical when the bracket is mounted.
Ensure that the mounting bracket is free from obstructions throughout the full boom movement.
Ensure that the cables can be attached to the angle sensor.
Ensure that the cables are protected from damage throughout the full boom movement.
3. Bolt the 9R-2060 Bosses to the 322-0221 Bracket . Use 8T-4136 Bolts (M10) and 8T-4121 Hard
Washers . Use the sensor bracket and bosses as a template to locate the welding points for the bosses.
4. Position the 322-0221 Bracket adhering to the notes above from Step 2. The orientation of the sensor
cable will be compensated for when the calibration procedure is performed.
5. Tack weld the bosses to the boom.
Note: Never weld across the boom or the stick of the machine. Always weld in a lengthwise direction.
Never weld within 75 mm (3 inch) of an existing weld.
6. Remove the 322-0221 Bracket and finish welding the bosses to the boom.
312-0754 Angle Sensor installed on the boom
9. Bolt the 312-0754 Angle Sensor to the 322-0221 Bracket . Use the 5C-7261 Nuts Nut (M8) and the
8T-4224 Hard Washers . Torque the nuts to 25 ± 6 N·m (18.4 ± 4.4 lb ft).
Installing the Stick Angle Sensor
The 312-0754 Angle Sensor is used to measure the tilt of the stick. Check the label on the sensor before
installation.
Use the following steps to mount the sensor:
1. Select a location on the stick for the 322-0221 Bracket . Consider the following before welding the
bracket:
Ensure that the mounting bracket is parallel to the centerline of the stick. The stick may require a
welded spacer so that the mounting bracket is parallel to the centerline of the stick.
Ensure that the mounting bracket is free from any obstruction throughout the full stick
movement.
Ensure that the cables can easily attach to the tilt sensor and that the cables are protected from
damage throughout the full stick movement.
Washers . Use the sensor bracket and bosses as a template to locate the boss welding points.
3. Position the 322-0221 Bracket adhering to the notes above from Step 1. The orientation of the sensor
cable will be compensated for when the calibration procedure is performed.
4. Tack weld the bosses to the stick.
Note: Never weld across the stick of the machine. Always weld in the lengthwise direction. Never
weld within 75 mm (3 inch) of an existing weld.
The 312-0754 Angle Sensor installed on the stick
8. Bolt the 312-0754 Angle Sensor to the 322-0221 Bracket . Use the 5C-7261 Nuts (M8) and the 8T-
4224 Hard Washers . Torque the nuts to 25 ± 6 N·m (18.4 ± 4.4 lb ft).
Installing the Bucket Angle Sensor

The 312-0754 Angle Sensor is used to measure the tilt of the bucket. Check the label on the sensor before
installation.
The sensor can be mounted on the bucket or else the sensor can be mounted on the bucket linkage. The
bucket linkage is the linkage that is at the end of the bucket ram and the stick.
Use the following steps to mount the sensor:
1. Select a location on either the bucket linkage or the bucket for the 322-0221 Bracket . Consider the
following before welding the bracket:
Ensure that the bucket linkage or the bucket can move throughout the full movement without
damage to the mounting bracket or the cables.
Find a protected location on the back side of the bucket if the sensor is mounted on the bucket.
Washers . Use the sensor bracket and bosses as a template to locate the boss welding points.
3. Position the 322-0221 Bracket adhering to the notes above from Step 1.
Note: The orientation of the sensor cable will be compensated for when the calibration procedure is
performed.
4. Tack weld the bosses to the bucket or to the bucket linkage.
The 312-0754 Angle Sensor installed on the bucket
8. Bolt the 312-0754 Angle Sensor to the 322-0221 Bracket . Use the 5C-7261 Nuts Nut (M8) and the
8T-4224 Hard Washers . Torque the nuts to 25 ± 6 N·m (18.4 ± 4.4 lb ft).
Note: Provide additional protection for the angle sensor. Ensure that the device movement does not inhibit
machine movement and that there is adequate movement for the cables around the linkages.
Installing the Pressure Switches

Terrain can use a set of pressure switches located on the hydraulic lines of the stick and bucket to determine
the bucket "load/dump" state.
Note: The customer must provide the pressure switches and the fittings with the appropriate pressure range
for the machine size. Proved a switch that only changes state at a pressure that is greater than 50% of system
pressure. Contact MineStar Solutions Sales and Product Support for assistance in selecting the switches.
(21) Pressure switch
(21A) "Quick connect" adapter for the pressure switch
Note: In most instances, install the pressure switches on the head end of the cylinder. A pressure switch
sensor quick connect adapter can be installed for easy fitting.
Pressure switch sensors (21) and (22) installed on the stick and on the bucket hydraulic lines.
Two pressure switches are used in the system. The first pressure switch is used for "stick in" and the second
switch is used for "bucket curl".
The pressure sensors alone cannot accurately determine the dig state. The pressure sensors can only indicate
an increase in pressure caused by resistance against the bucket. An increase in detected hydraulic pressure
can be achieved in different machine applications, for example:
Loading the bucket with material
Working on a high wall
For this reason, a combination of pressure switches and angle sensors must be used to determine the dig
state.
Load State - The angle of the bucket sensor is used in combination with the pressure switches to determine
whether the bucket is being loaded.
Dump State - The dump state is detected by observing the bucket angle.
The pressure switches change between on and off by detecting whether the pressure is above or below a
threshold. The threshold is set by the type of pressure sensor.
As the excavator digs and unloads, the change in pressure that is detected by the sensors is irregular. The
pressure crosses the threshold s detected by the switch numerous times as the pressure changes from high to
low and back again. For this reason a filter can be applied to switch inputs so that a smooth transition is
observed.
Note: For Terrain and CAESultra v4.0 and later systems, the machine configuration settings that are outlined
here and below are configured in the MCU in the "Features> Machine> Switches" section.
Debounce On - Specifies the minimum amount of time that must elapse (from the last switch transition)
before the "Switch On" state change is accepted by the on-board software
Debounce Off - Specifies the minimum amount of time that must elapse (from the last switch transition)
before the "Switch Off" state change is accepted by the on-board software
Illustration 15 shows the change in pressure and the method that the debounce settings use to detect a smooth
change in the pressure switch threshold.
The pressure switches may be either a normally open type switch or a normally closed type switch.
Normally open switches wired in series
If the switches are normally open, then the switches must be wired in series as shown in Illustration 16.
Normally closed switches wired in parallel
If the switches are normally closed, then the switches must be wired in parallel as shown in Illustration 17.
The "Switch Type State" setting must be used to define the type of pressure switch that is installed.
Switch State - Defines whether a switch type is normally closed or normally open.
Note: Although any input switch can be utilized for the pressure switch inputs, the Input Switch "5" is
customarily used. Input Switch 5 sets pin 37 to detect the "load/dump" function.
Configuring Sensors for Load Switches

Configure the items in Table 14 for the load switch to utilize the pressure switches for the loading
functionality.
Table 14
Parameter
Value Notes
Input Enabled
This switch corresponds to Pin 37 of the D3:C4 Nav 10.4.monitor display
Switch 5
Action Load This setting defines the action of the switch input.
Switch Normally This setting defines whether an input switch e is Normally Closed or Normally
State Open Open.
300 This setting specifies the minimum amount of time that must elapse (from the
Debounce
(default) last switch transition) before the "Switch On" state change is accepted by the on-
On
board software. This value may vary by switch specifications.
300 This parameter specifies the minimum amount of time that must elapse (from the
Debounce
(default) last switch transition) before the "Switch Off" state change is accepted by the on-
Off
board software. This time may vary by switch specifications.
Min 300 This setting specifies the minimum time (in milliseconds) that is allowed
Repeat (default) between two successive sets of changes to a switch. This time may vary by
Rate machine loading characteristics.
Point
0 This setting is not required for configuring the excavator load switch.
Switch
Type
Activity
Switch Up 0 This setting is not required for configuring the excavator load switch.
Installing the Machine Radio
389-0333 Cable As
(1) P1 to 383-3028 Wiring Harness (main rear)
(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 383-3028
Wiring Harness using a 12-pin (key D) connector. The opposite end of the radio harness employs a standard
RJ-45 Ethernet connector 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 2pin DT connector to the 12-pin DT
connector 389-0333 Cable As :
Power: 1-BU
Ground: 2-BK
Installing the Display Module

Position the display module within the cab of the machine. Consider the following requirements when
choosing the location:
Place the display module 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 module near the plane that the operator normally views during operations that
benefit most from the use of the on-board software. Ideally, locate the display module no more than 30
degrees from this viewing angle.
Consider the following when choosing the location for the display module:
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
(1A) 383-3032 Bracket
(1B) 147-3417 Mount
(1C) Site fabricated display module mount pedestal
Display module mounting group
(1) 389-8217 Display Module
(46) 383-3032 Bracket
(47) 8T-4205 Hard Washer
(48) 8T-9364 Bolt (1/4-20)
(49) 4M-5282 Bolt (1/4-20)
(50) 9X-6165 Washer
(51) 8C-5608 Spacer
(52) 8C-5607 Isolation Mount
Isolation mounts installed to 389-3032 Bracket
Refer to Illustration 20 for a detailed view of the shock mount detail when attaching the display module to
the 383-3032 Bracket . Refer to Illustration 22 if using the ceiling/dash adapter.
167-8604 Monitor Mounting Group
(A) 147-3417 Mount
(B) 0S-0509 Bolt (3/8-16)
(C) 5M-2894 Hard Washer
Depending on the machine and the location of the display module, the installation may require customization
by modifying the ceiling/dash adapter mount.
Note: The 150-1893 Vibration Isolator Mounting Group consists of the items in callouts (49) through (52).
This display module in Illustration 23 is mounted in front upper right corner of the cab using a site fabricated
ceiling bracket.
The display module is connected to the rest of the system using the 70-pin connector end of the main front
harness.
ReferenceRefer to ""Installing the Main Front and Main Rear Harness" " for the correct procedure in routing
the main front harness.
383-3027 Wiring Harness installed on bracket
(9) 383-3027 Wiring Harness (main front)
(34) 389-3032 Bracket

(46) 130-5300 Clips
(47) Receptacle
The 389-0322 Monitor Mounting Group also contains a 130-5300 Clip . Referring to Illustration 24, use this
clip to secure the service connection for the serial cable. Choose a location that is convenient to service
personnel but does not obstruct the view of the operator. Choose the location that is best for the site.
Battery Backup
Mounted 167-8984 Battery Gp (backup)
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 Wiring Harness (main front). 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 main front 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 Wiring Harness (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.
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.
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.
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.
14. Once the paint has dried, bolt the converter to the bosses
Note: Tighten the bolts to Caterpillar standard torque specifications.
Installing the Power Supply Wire and Fuses

The 167-8703 Wire As (power supply) is provided with the 389-0338 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.
Electrical schematic for power harness and fuse installation
Note: The two fuses that are shown in Illustration 28 can be supplied by utilizing the 265-8147 Harness As
Referring to the electrical schematic in Illustration 28, perform the following steps:
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 389-0338 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.
Installing the Terrain Harnesses

Note: Route and restrain harnesses 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,
contact your Caterpillar Technical Communicator for detailed instructions as to how to proceed with the
installation.
This section describes the installation of the harnesses listed in Table 15.
Table 15
Harnesses for Dual Receiver Installation
167-8703 Wire System power
243-4108 Sensor Harness 3 foot

311-8687 Sensor Harness
311-8688 Sensor Harness
243-4111 Switch Harness

278-7396 Wire Non-TC900B radio
285-6655 Chassis Harness System, 75 foot
285-6656 Wiring Harness HEX crossover harness for second receiver

285-6657 Wiring Harness For MS992 receiver, 2 each
311-8690 Harness As HEX extension harness
383-3027 Wiring Harness Main front

383-3028 Wiring Harness Main rear
ReferenceDuring the installations, refer to Illustration 3 in the "Terrain Components" section for a basic
overview of the components and harnesses that are to be installed.
Note: Do not cut off any part of any harness unless instructed to do so. Bundle, tie wrap, and store any extra
harness in a convenient place.
Note: The harnesses are marked with tape at the location of the last splice. If the harness is cut, do not cut
the harness shorter than the tape. If the harness is cut shorter than the tape, then the spliced wires could be
cut.
Installing the Main Front and Main Rear Harnesses

Table 16
167-8984 Battery Battery backup

285-6655 Harness As System chassis

Referring to Table 16, use the following instructions to install and connect the 383-3027 Wiring Harness
(main front) and the 383-3028 Wiring Harness (main rear).
1. The main front harness connects between the display module, power at the battery, and the main rear
harness.
2. From the monitor, route the main front harness to the location of the battery and connect the 3-pin
connector. The connectors on both the battery and the main front harness are matched.
3. Route the 12-pin connector on the main front harness to the location under the cab where the main rear
harness is to be installed.
4. Connect the 12-pin connector on the main front harness to the 12-pin connector on the main rear
harness.
5. The main rear harness connects between the main front harness, the radio harness, the battery (if
required), and the chassis harness.
6. Locate the 12-pin connector on the main rear harness in a location that provides easy connection to the
chassis harness. Choose a location that provides easy access for connecting the 285-6649 Harness As .
This harness is used for performing the Terrain sensor and receiver calibration.
Front harness securely clamped
7. Secure the main rear harness. Use 3S-8665 Clips , 8M-2773 Clips , or 7K-1181 Cable Straps .
Installing the Auxiliary Harness

Table 17
151-6320 Wire Removal Tool
155-2269 Connector Plug
243-4111 Switch Harness

285-6655 Chassis Harness Chassis

Table 18
Table for Wires for Auxiliary Harness

Wire Color Signal From P9 Pin To
BU SW +24 1 P3 pin 12
BU DIG 6 2 P1 pin 69
YL CAN2 HI 3 P3 pin 6
GN CAN 2 LO 4 P3 pin 5
PU DIG 5 5 P1 pin 67
BK - BAT 6 P3 pin 11
Use the auxiliary harness to connect the pressure switches and the various system sensors to the 383-3027
Wiring Harness (main front).
Detailed view of the auxiliary harness
(53) Bare wires connect into the mating connector of P9 of 383-3027 Wiring Harness (main front).
(54) Connection to 311-8688 Sensor Harness
(55) Connection to switch harness
(56) 155-2269 Connector Plug to connect to wire 105 (pin 58) from main front harness.
Referring to Table 17 and the wiring chart in Table 18, use the following steps to install the Auxiliary
Harness :
1. Terminate wires from the auxiliary harness using a green stripped Deuctsh pin and connector.
2. Plug the harness into P9 on the 383-3027 Wiring Harness and route harness.
3. Connect the auxiliary harness to the switch harness.
Note: Locate the 12-pin connector on the main rear harness in a location that provides ease of connection to
the chassis harness. The location must also provide ready access for connecting a service cable during the
sensor and the receiver calibration procedures.
Installing the Chassis Harness and the Receiver Harnesses
Table 19
285-6655 Chassis Harness System harness (75 foot)

285-6656 Wiring Harness HEX crossover harness (second receiver)
285-6657 Wiring Harness For MS992 receiver (2 each)

311-8690 Control Harness HEX extension harness
Table 20
353-2794 Receiver Harness Installation Parts List
8 5D-0353 Locking Bolt 3/18-16 Bolts for clips to secure harness

8 6V-8801 Nut 3/18-16 nuts for clips
8 8M-2770 Clip Used to clip harness down to mast
16 8T-4896 Hard Washer 3/18-16 washers for clips
Referring to Table 19, use the following instructions to install and connect the receiver chassis harness. The
harness is connected between the main rear harness and the rear of the machine where the receivers are
located. Additionally, use these instructions to connect the second receiver chassis harness and the two
receiver harnesses.
Permanently mount the receiver harnesses in a safe position that protects the harnesses from mechanical
damage. When installing the harnesses, consider the following points:
Route the harnesses and secure the harnesses so that no service panels are obstructed.
Protect the harnesses when passing over or through any sharp metal edges.
Avoid locations that are near a source of heat.
1. Connect one receiver harness to the left receiver. Fasten the harness near the connector to reduce strain
on the connector. Fasten the harness down the mast. Use the included clips, bolts, washers, and nuts.
Note: Fasten the 12-pin connector in an area that is secure, yet still accessible.
Note: Left and right are defined from behind the machine and looking forward toward the cab.
Receiver harness routing down the mast of the receiver
2. Connect the second receiver harness to the right receiver. Fasten the harness near the connector to
reduce the strain on the connector. Fasten the harness by routing the harness down the mast.
3. Connect the second receiver harness to the right receiver harness. Route this harness over to the left
receiver.
Note: On large machines, the 311-8690 Harness As (receiver extension) may be needed.
4. Connect the chassis harness to the 12-pin connector on the left receiver harness. Connect the 8-pin
connector to the second receiver harness or to the control harness, if required.
5. Route the chassis harness from the rear of the machine to the location in the cab of the main rear
harness. Any extra harness can be stored in the body of the machine near this harness.
6. Secure the harness with clips and cable ties.
7. Connect the chassis harness to the 12-pin connector of the main rear harness.
8. Create a coil for any excess harness. Use cable ties to secure the harness.
9. Check that all connectors are tight.
Installing the Sensor Harnesses
Table 21
4 102-8805 Receptacle Kit
1 134-2540 Receptacle CAN terminator

4 243-4108 Sensor Harness As
1 276-4084 Harness As
2 311-8687 Sensor Harness 16 M, one bare end

2 311-8688 Sensor Harness 8 M, one bare end
3 312-0754 Angle Sensor Boom, stick, bucket
1 312-0755 Angle Sensor Pitch and roll
Table 22
Wire Reference Wire Color
Pin Number Signal Name
311-8687 Harness 243-4108 Harness
1 (1) + Battery BR-105 RD
2 Spare BU-A741 BU
3 CAN HI GN-F711 GN
4 CAN LO GY-F712 WH
5 Spare PU-A742 BR
6 (1) Ground BK-229 BK

(1) Use larger green-striped socket
Note: If a 389-0331 Tool Group (service kit) is available, utilize the 291-1502 Harness As with the 291-1386
Harness As (Hex Sensor) to program the 312-0754 Angle Sensor as boom, stick, and bucket sensors before
mounting on the machine. If not done, then once the sensors are installed, each of the sensors will need to be
disconnected and programmed one sensor at a time.
ReferenceFor information on programming the locations of the arms, refer to the section entitled "Arm
Sensor Connections".
ReferenceFor information on the 389-0331 Tool Group (service kit), refer to Special Instruction,
REHS7225, "Cat® Terrain Tool Group".
Use the following steps to connect the angle sensors from the main harness. Refer to Table 21, Table 22, and
Illustration 32.
Angle sensor wiring diagram
(A) Harnesses with bare ends
(B) Body pitch and roll sensor and harnesses located on body
(C) Boom sensor and harnesses located on the boom
(D) Stick sensor and harnesses located on the stick
(E) Bucket sensor, harness, and CAN terminator located on the bucket or nearby on the stick
(23) 276-4084 Wiring Harness (system harness adapter)
(24) 311-8688 Sensor Harness (HEX) (8 m) (one bare end)
(26) 311-8687 Sensor Harness (HEX) (16 m) (one bare end
(28) 243-4108 Sensor Harness (short)
(29) 312-0755 Angle Sensor (AS460C pitch and roll)
(30) 312-0754 Angle Sensor (AS450 boom)
(31) 312-0754 Angle Sensor (AS450C stick)
(32) 312-0754 Angle Sensor (AS450C bucket)
(33) 134-2540 Receptacle
Consider the following points when routing the harnesses to the sensors:
Utilize the routing of the hydraulic lines to route the harnesses correctly. This action will ensure that
enough harness is available throughout all machine movements.
Make sure that the harness is protected from mechanical damage.
Route the harness so that the harness does not prevent access to any service panels.
If the harness passes over or through any sharp metal edges, protect harness at those locations.
Secure the harness. Use cable ties.
Secure the harness near each connector to reduce strain on the connector.
Due to the location of the Y splits on the angle sensor harnesses and the need to shorten and install ends on
the harnesses, use the following sequence to install the harnesses:
Bucket sensor to the stick sensor
Stick sensor to the boom sensor
Boom sensor to the body pitch and roll sensor
Body pitch and roll sensor back to the Main harness
Note: This sequence may be altered as required by the site or the specific installation.
1. Connect the short sensor harness to the bucket sensor.
2. Route the short sensor harness to an 8 m sensor harness. This harness will route toward the stick
sensor. Use care to route the harness away from any potential pinch points. Secure the harness to the
machine. Use tie straps.
Note: The connection between the 8 m harness and the short harness may be either on the bucket or on
the stick, as required.
3. Install the adapter harness and the CAN terminator on the other Y-end of the 8 m harness. Secure the
harness to the machine.
4. Route and attach the 8 m harness over the machine linkage. The harness will route from the bucket
sensor location back to the stick sensor. Follow the hose routing. Use as much of the machine as
possible to protect the harness. Use the clips and the tie straps to secure the harness.
5. Connect another short sensor harness to the stick sensor and route the harness. Ensure that the 8 m
harness from the bucket sensor and a 16 m harness that will route to the boom sensor can be
connected.
6. Ensure that the 16 m harness can connect to the short harness to the stick sensor and the 8 m harness to
the bucket sensor.
7. Cut the 8 m harness for the bucket sensor to an appropriate length at the bare end. Use a receptacle kit
to attach a connector to the bare end of the harness.
8. Install a piece of 125-7876 Heat Shrink Tube over the end of the cut braiding. This action ensures that
the braiding does not fray.
9. Attach the wires to the connector pins as specified in Table 22.
Note: In the receptacle kit, the pins with a green stripe are to be used for the red and black wires. The
remaining pins are to be used for the remaining wires.
10. Connect the 8 m and 16 m harnesses together. Ensure that the short harness to the stick sensor is
connected.
11. Route the 16 m sensor harness. Attach the harness over the machine linkage. Route the harness from
the stick sensor location back to the boom sensor. Follow the hose routing and use as much of the
machine as possible to protect the harness. Use the clips and the plastic straps to secure the harness.
12. Connect another short harness to the boom sensor. Route the harness to ensure that the 16 m harness
from the stick sensor and a new 16 m harness that will route toward the body sensor can be connected.
13. Ensure that the 16 m harness that leads to the body can connect with both the short harness to the
boom sensor and the 16 m harness that goes to the stick sensor and the bucket sensor.
14. Cut the 16 m harness for the stick sensor and the bucket sensor to an appropriate length at the bare end.
Use a receptacle kit to attach a connector to the bare end of the harness.
15. Install a piece of 125-7876 Heat Shrink Tube over the end of the cut braiding to prevent the braiding
from fraying.
16. Attach the wires to the connector pins as specified in Table 22.
17. Connect the two 16 m harnesses together. Ensure that the short harness to the boom sensor is
connected.
18. Attach the 16 m sensor harness. Route the harness over the machine linkage from the boom sensor
location to the body pitch and roll sensor. Follow the hose routing and use as much of the machine as
possible to protect the harness. Use the clips and the plastic straps to secure the harness.
19. Connect another short harness to the body pitch and roll sensor. Ensure that the location of the harness
allows the 16 m harness from the boom sensor and an 8 m harness that will route toward the system
wiring harness can be connected.
20. Ensure that the 8 m harness that leads to the system wiring harness can connect with both the short
harness to the body sensor and the 16 m harness that goes to the boom, stick, and bucket sensors.
21. Cut the 16 m harness for the boom, stick, and bucket sensors to an appropriate length at the bare end.
Use a receptacle kit to attach a connector to the bare end of the harness.
from fraying.
23. Attach the wires to the connector pins. Refer to Table 22.
24. Connect the 8 m harness and the 16 m harnesses together. Ensure that the short harness to the body
sensor is connected.
25. Attach the 8 m sensor harness. Route the harness over the machine from the body sensor location back
to the system wiring harness. Follow the hose routing and use as much of the machine as possible to
protect the harness. Use the clips and the plastic straps to secure the harness.
26. At the system wiring harness, ensure that the 8 m harness that leads to the angle sensors is in a location
that the 8 m harness can be cut to length and can be connected to the system wiring harness.
27. Cut the 8 m harness for the angle sensors to an appropriate length at the bare end. Use a receptacle kit
to attach a connector to the bare end of the harness.
from fraying.
29. Attach the wires to the connector pins. Refer to Table 22.
30. Connect the system wiring harness and the 8 m harnesses together.
31. Verify that all of the connectors are tight and that all of the harnesses are secured.
Installing the Pressure Switch Harness

A 243-4111 Switch Harness is provided with the installation kit.
Consider the following points when routing the pressure sensor switch harness:
Ensure that the cable is protected from mechanical damage.
Route the cable so that the cable does not prevent access to any service panels.
Protect the cable where the cable passes over or through any sharp metal edges.

Performing the Initial Power Checks

Before applying power to the on-board software 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 .
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 23.
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 23
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>
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 33:
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.
ReferenceFor more information about using the MCU, select Start > All Programs > Cat MineStar System
and Tools > Machine Configuration Utility.
ReferenceFor 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
NOTICE
Enter correct details. Any errors transfer directly into the finished as-
built surface file.
The system components must be calibrated after installation and before operation. The calibration
information is used for various purposes including the following:
Bucket positioning
Current elevation
Coverage
Material identification
Machine graphics
Note: The calibrations that are in this section assume that all system hardware components have been
installed.
The completed calibration process provides the following information:
Relative position of the slave receiver to the master receiver
Relative position of the master receiver to the center of the boom pivot
Relative position of the slave receiver to the center of the boom pivot
Alignment of the machine relative to the two receivers
Machine body pitch sensor offset angle
Boom, stick, and bucket tilt sensor offset angles
Boom, stick, and bucket dimensions
Machine body dimensions
Boom pivot height above the ground
Enter the following sets of machine dimensions during the installation process:
Dimensions used for showing the position of other machines, entered in the MCU
Dimensions used for the calibration process
To set up the machine in the office, use 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.
5. Ask the Terrain Site Champion to send out a site-specific application file for the receiver.
ReferenceFor Step 5 through Step 6, refer to Systems Operation, UENR2509, "Cat® Terrain for
Grading and Loading".
6. Restart the on-board software and verify the accuracy of the receiver as follows:
a. Move the machine origin to a known point.
b. Compare the Northing, Easting, and Elevation.
Other Machines
In the MCU, enter the machine width and machine length used to show the position of other machines on the
display module.
To enter the machine dimension values, do one of the following:
While at the machine, enter the values into the MCU on a laptop.
Write down the values and take the values or radio the values to the office. In the office, enter the
values in the MCU.
Preparing for the Calibration

Required Equipment
Excavator calibration kit
The 389-0330 Tool Group (Excavation Calibration Kit), shown in Illustration 34 and consisting of the items
listed in Table 24, is required for calibration of a machine with MS990 receivers.
Table 24
Callout Part Number Part Description
43169-10
57 Range pole and bipod
(Trimble PN)
58 285-6649 Receiver cable
59 254-7377 3- jaw chuck
60 See Note Water level tube
61 6V-9449 Carrying case
62 289-9631 Plate
63 Tape measure, not included in the supplied kit
Water level tube
Note: The water level tube (60) that is shown in Illustration 35 is a simple device. Use this device to measure
the vertical offset between linkage points. When the tube is not being used, the tube is filled with water. Caps
are placed on the tube ends to stop the water from escaping.
Machine Requirements
The following measures must be observed during the calibration procedures:
Park the machine on flat ground.
The machine must be able to rotate through 180 degrees without the tracks moving.
The boom, the stick, and the bucket must be able to extend in at least one direction fully.
Continue to run the machine engine throughout the calibration procedure.
Programming and Calibrating Sensors on Dual Antenna Machines

For information about programming and calibrating sensors on a single antenna machine, refer to Special
Instruction, REHS7229, "Installation of the Pitch and Roll Angle Sensor for Cat® Terrain", "Programming
Angle Sensors".
When installers attach sensors to a dual antenna machine, there are four stages of work:
Installation
Configuration
Programming
Calibration
The order in which these stages occur depends on the preferred workflow of the installer and the type of
machine. For example, since sensors must be programmed with no other sensors attached to the harness,
installers working on a very large machine might program all sensors before attaching the sensors to the arm.
Sensors can be placed in various locations on the machine or programmed as replacements for other sensors.
The two possible programming options are:
Programming a new AS4xx sensor
Programming an AS4xx sensor to replace an AS7 sensor
This section covers the instructions for both options.
Replacing a Sensor
NOTICE
Ensure that only one sensor is connected to the harness during the
configuration. Failure to connect only one sensor at a time could
render the sensors unusable.
Before the arm sensors can be used, specify the segment of the arm to which each sensor is mounted. Only
one arm sensor at a time can be connected to the system harness during the configuration procedure.
Once all of the arm sensors have been configured, each 243-4108 Sensor Harness As can be reconnected for
the boom, the stick, and the bucket. The 322-0222 Covers can then be installed on the sensors by using 8T-
4171 Bolts (M6) and 5P-4115 Hard Washers.
Replacing AS4xx Sensors
If the 312-0754 Angle Sensors (AS450) have not yet been programmed as boom, stick and bucket, follow the
directions in Special Instruction, REHS7232, "Replacement of the Position and Inclination Sensors for Cat®
Terrain". If the sensors have been configured, then continue to ""Calibration Overview" ".
Note: If the arm sensor is removed, remount the sensor on the arm segment for which the sensor was
configured or reprogram the sensor.
Replacing an AS7 Sensor with an AS4xx Sensor
If replacing an AS7 sensor with an AS4xx sensor, Refer to Special Instruction, REHS7232, "Replacement of
the Position and Inclination Sensors for Cat® Terrain".
Modifying the Machine Configuration File
Before selecting the location of the sensor, enter the type of sensors expected by the machine configuration
file as follows:
1. Open the MCU.
2. Highlight the machine name in the left-hand pane.
3. Select Communications > Comms Port Settings > CAN Sensor Port.
D3:C4 Nav 10.4 Display - Select CAN Sensor Port =1.
G610 Display - The port number is hardcoded. The user does not need to do anything for this setting
4. Select Machine > Sensors.
The relevant "Use <sensor name> Sensor" settings appear in the right-hand pane.
5. In "Calibration File Name", enter the correct name for the calibration file. The default name is
"calibration.txt".
To use an AS450 sensor to measure inclination on a boom, stick or bucket, refer to ""Enabling the
Calibration Menu" ".
To use an AS460 sensor on the body of the machine to measure pitch and roll:
1. Select the "Use Roll Sensor" checkbox to enable this function.
2. Select "AS460" from the "Type" drop-down box.
3. Select the "Use Pitch Sensor" checkbox to enable this function.
4. Select "AS460" from the "Type" drop-down box.
5. Select "Pitch Sensor Offset" to enable this function.
Note: Leave the "Offset" value set to zero at this stage.
For a dual antenna machine, the "Use AS7 Sensor" setting appears. This setting lets the system instruct
a programmable sensor to behave as either an AS7 sensor or an AS4xx sensor.
6. Perform one of the following tasks for the selected sensor:
AS4xx sensor - Disable the "Use AS7 Sensor" setting
AS7 sensor - Enable the "Use AS7 Sensor" setting.
7. Select "File".
8. Select "Send to MineStar".
9. Restart the on-board software.
Enabling the Calibration Menu

Before selecting the location of the sensor:
1. Open the master configuration file master.txt in the on-board software on the display module.
2. Configure the following:
$ Calibration Menu =1
3. Save the master.txt file.
4. Restart the on-board software.
The "Calibration" menu can now be opened from the main menu.
Note: If a calibration file cannot be found, then the system automatically enables the "Calibration"
menu. If this setting is not set in the master.txt file, then the "Calibration" menu is disabled after a
calibration file has been written.
Selecting the Location of the Sensor

To finish programming the sensor, select the location of the sensor.
Note: Ensure that only one sensor is connected to the harness during this procedure. Failure to connect only
one sensor at a time could render the sensors unusable.
1. Within the on-board software, open the main menu.
2. Select "Calibration".
3. Select "Sensors". The "Change Sensor Type" dialog appears.
Note: The "Current Sensor" field shows the current configuration of the sensor.
To use an AS450 sensor to measure the inclination on a boom, stick or bucket:
1. Touch the appropriate radio button in the "New type" box.
2. When the correct selection is shown, touch the "Change" button.
The "Inform" dialog appears indicating whether the change was successful.
3. Touch "OK".
The "Inform" dialog closes and the "Change Sensor Type" dialog appears again.
4. Confirm that the "Current Sensor" field shows the new sensor location correctly and that the "Raw"
value updates in the adjacent field.
5. Touch "Done".
The "Change Sensor Type" dialog closes.
To use an AS460 sensor to measure pitch and roll on the body of a machine:
1. Open Diagnostics > Sensors.
Note: Do not open the Calibration > Set Sensor Ids window because the machine configuration file
settings will overwrite the "Set Sensor Ids" settings.
2. Verify that both pitch and roll appear and that raw data is coming in.
Calibration Overview
"Linkage Calibration Wizard" flowchart
Use the Linkage Calibration Wizard to calibrate the machine. There are two calibrations (Linkage and GPS)
that must be completed. Both of these calibrations consist of individual calibrations and are required
measurements that appear on successive pages as the wizard progresses.
The on-board software provides both graphical elements and step by step written instructions on each page
of the wizard. The instructions are designed to ensure that calibration information can be entered correctly.
As each step of the process is completed, the wizard opens up the next page. The calibration process can be
canceled at any time.
The graphical elements found in the wizard include red and blue arrows. Red arrows indicate calibration
information that is used in calculations that require accurate measurements. Blue arrows indicate calibration
information that is used for graphics only.
Each arrow is associated with an entry button. The buttons are labeled with a value. The value of the label
indicates the current calibration value. This value is edited by selecting the associated button.
After the calibrations are completed, a calibration summary provides an overview of the results of the
calibration. The calibration summary allows access to any stage of the calibration procedure.
The calibration results are stored onboard in the display module in the calibration text ("Calibration.txt") file.
This text file is not written until after completion of the calibration wizard.
The calibration values can be modified at any time after the initial calibration is completed. When any value
is modified, a new text file is written and the existing file is archived.
Illustration 38 provides a basic overview of the calibration process. Titles in bold print correspond to later
subsections that provide a detailed explanation of each step of the calibration process. The flow is slightly
different depending on whether the bucket sensor is mounted on the linkage or is mounted on the bucket.
Calibrating the Linkage

Note: This calibration section assumes that all system hardware components have been installed.
Start the linkage calibration as follows:
1. Start the on-board software and open the main menu.
2. Select "Calibration". The "Calibration" submenu appears.
Linkage Calibration wizard > Machine Calibrations - Dimensions
3. Select "Linkage Calibration Wizard" from the Calibration menu. The first page of the Linkage
calibration, entitled "Machine Calibration - Dimensions", appears.
Specifying the Machine Body Dimensions

Specify the machine body dimensions using the first page of the linkage calibration wizard entitled "Machine
Calibration - Dimensions". These dimensions include the width of the machine body, the height of the
machine body, and the height of the boom pin.
Exploded view of "Machine Calibration - Dimensions" page
1. Select the leftmost calibration button (67) on the "Machine Calibration - Dimensions" page. Using the
pop-up keypad, enter the body width of the machine. The on-board software uses the body width to
display machine icons to the correct scale.
2. Select the rightmost calibration button (68). Using the popup keypad, enter the body length of the
machine. The body length is also used for displaying correctly scaled machine icons.
3. Select the lower calibration button (69). Enter the boom pin height above the ground. The boom pin
height is the vertical distance from the track of the machine on the ground to the center of the boom
pivot.
Note: Boom pin height is used for current elevation updates and must be measured accurately.
4. After the three machine body dimensions have been entered, select the "Next" button. The "Pitch
Angle Calibration" page appears. Alternatively, select the "Reset" button to reset all machine body
dimensions to the original values.
Calibrating the Pitch Angle Sensor
The pitch sensor, which is mounted on the body of the machine, provides the on-board software with the
pitch of the body. The body pitch is used in determining the machine pitch and the boom pivot position. The
boom pivot position is used in determining the bucket position.
"Pitch Angle Calibration" page
Use the "Pitch Angle Calibration" to determine the pitch angle offset. The pitch angle offset adjusts the raw
pitch sensor value to the actual machine body pitch value. This page appears after the machine calibration
dimensions have been entered and the "Next" button is selected.
Reference""Specifying the Machine Body Dimensions" "
Perform the pitch angle calibration as follows:
1. Park the machine on a flat area of ground. Locate the machine such that the body can be rotated
through 180 degrees without moving the tracks. Data from a GPS reference station is not required.
The information window after sampling is complete
Note: The on-board software requires 50 pitch sensor samples. Do not move the machine while
sampling is in progress.
2. Select the "Start" button. The information window in the "Pitch Angle Calibration" page turns red.
This color indicates that the on-board software is sampling the pitch sensor values. The information
window turns yellow when sampling is complete.
3. Follow the instructions in the information window and, without moving the tracks, rotate the machine
through 180 degrees until the angle is 0 (zero). When the machine has rotated within +/- 2 degrees of
the full 180 degrees, the information window turns green and the "End" button activates.
4. Select the "End" button. The information window turns red as the on-board software samples the pitch
sensor values. When sampling is complete, the information window turns green. The "Last Sample"
field shows the offset angle that has been determined from the first set of samples.
5. Select the "Add" button. The offset angle from the "Last Sample" field appears in the "Avg Offset
Angle" field. The "Samples" field increments to "1".
The "Last Sample" field displays the results for the current calibration. The "Avg Offset Angle" field
displays the average of all the added offset angles.
6. To ensure accuracy, perform multiple pitch offset angle calibrations by selecting the "Start" button and
repeating steps 3 through 5.
Each time another offset angle calibration is performed, the "Samples" field increments by one count.
7. When a satisfactory "Avg Offset Angle" is displayed, select the "Next" button. The "Boom Calibration
- Dimensions" page appears.
If a satisfactory "Avg Offset Angle" is not displayed, then select "Reset" to start the pitch angle
calibration again. At that time, both the "Avg Offset Angle" field and the "Samples" field are reset to 0
(zero).
Specifying the Boom Dimensions

Use the "Boom Calibration - Dimensions" page to specify the width, height, and length dimensions of the
boom of the machine.
Note: Before measuring any dimensions, ensure that the bucket is placed on the ground so that any leakage
from the cylinders does not affect the dimension that is being measured.
This page appears after the pitch offset angle dimensions have been entered and the "Next" button is
selected.
Reference""Calibrating the Pitch Angle Sensor" "
Perform the boom dimensions calibration as follows:
Boom Calibration - Dimensions page
1. Select the leftmost calibration button (70) on the "Boom Calibration - Dimensions" page. Enter the
boom width of the machine. The on-board software uses the boom width to display machine icons to
the correct scale.
2. Select the rightmost calibration button (71). Enter the boom height of the machine. Measure the boom
height when the boom is roughly level. The boom height is the vertical distance from the uppermost
point of the boom to the line joining the two ends of the boom. The boom height is also used for
displaying correctly scaled machine icons.
Measuring the boom length
3. Select the lower calibration button (72). Enter the boom length. The boom length (73) is the distance
from the center of the boom pivot to the center of the stick pivot.
Note: Boom length is used to determine bucket position and must be measured accurately.
4. After the three boom dimensions have been entered, select the "Next" button. The "Boom Calibration -
Angles" page appears. Alternatively, select the "Reset" button to reset all boom calibration values to
the original values.
Calibrating the Boom Angle Sensor

The boom tilt sensor that is mounted on the side of the boom measures the angle of the boom. The boom
angle is used in determining the bucket position of the machine.
Use the "Boom Calibration - Angles" page to establish the boom offset angle. This page appears after the
boom calibration dimensions have been entered and the "Next" button is selected.
Reference""Specifying the Boom Dimensions" "
The boom offset angle adjusts the raw tilt sensor value to the correct boom angle value.
The boom offset angle is determined using the water level tube to measure the difference in height between
the center of the boom pivot and the center of the stick pivot. The height difference is then compared with
the raw sensor data to determine the boom offset angle.
Note: A survey or other device can also be utilized to measure the height difference of these pivots.
ReferenceFor instructions on measuring the height difference, refer to the section entitled ""Measuring the
Height Difference Using the Water Level Tube " ".
Boom Calibration - Angles page
Perform the Boom Angle calibration as follows:
1. Use the toggle button that is located just above the "Add" button to specify on which side of the boom
the tilt sensor is mounted.
Toggle the button to "Left" if the tilt sensor is mounted on the left side of the boom as seen from the
cab toward the bucket. Toggle the button to "Right" if the tilt sensor is mounted on the right side of the
boom.
2. Lower the boom until the boom pivot and the stick pivot are roughly level with each other.
3. Place the bucket on the ground so that any leakage from the cylinders does not affect the angle that is
being measured.
4. Using the water level tube, measure the difference in height between the center of the boom pivot and
the center of the stick pivot.
5. Select the "Height Difference" button. Enter the height difference as measured using the water level
tube.
If the center of the stick pivot is higher than the center of the boom pivot, then enter the height
difference as a positive value. If the center of the stick pivot is lower than the center of the boom pivot,
then enter the height difference as a negative value.
After this measurement has been entered, the system calculates the offset angle and displays the
calculated value in the "Last Sample" field.
6. Select the "Add" button. The offset angle from the "Last Sample" field appears in the "Average Offset"
field. The "Samples" field increments to "1".
7. To ensure greater accuracy, perform multiple samples. Take at least four samples. Additional samples
are performed by moving the boom up or down and repeating steps 4 through 6. When the "Add"
button is selected, the "Average Offset" field updates with an average of all offset angle samples that
have been performed. Each time a new average is calculated, the "Samples" field increases by one
count.
8. When a satisfactory average angle offset is displayed, select the "Next" button. The "Stick Calibration
- Dimensions" page appears. Alternatively, select the "Reset" button to reset the average offset angle to
the previous value and reset the "Samples" field to 0 (zero).
Specifying the Stick Dimensions

Use the "Stick Calibration - Dimensions" page to specify the height, width, and length dimensions of the
stick.
from the cylinders does not affect the dimension that is being measured.
This page appears after the boom offset angle has been established and the "Next" button is selected.
Reference""Calibrating the Boom Angle Sensor" "
Stick Calibration - Dimensions page
Perform the stick dimensions calibration as follows:
1. Select the leftmost calibration button (74) on the "Stick Calibration - Dimensions" page. Enter the stick
width of the machine. The on-board software uses the stick width to display machine icons to the
correct scale.
2. Select the rightmost calibration button (75). Enter the stick height of the machine. The stick height is
the thickest part of the stick. The stick height is also used for displaying correctly scaled machine
icons.
Measuring the stick length
3. Select the lower calibration button (76). Enter the stick length of the machine. The stick length (77) is
the distance from the center of the stick pivot to the center of the bucket pivot.
Note: The stick length is used to determine bucket position and must be measured accurately.
4. After the stick dimensions have been entered, select the "Next" button. The "Stick Calibration -
Angles" page appears. Alternatively, select the "Reset" button to return all stick calibration values to
Calibrating the Stick Angle Sensor

The stick tilt sensor, which is mounted on the side of the stick, measures the angle of the stick. The stick
angle is used in determining the bucket position.
The "Stick Calibration - Angles" page is used to establish the stick offset angle. The stick offset angle adjusts
the raw tilt sensor value to the correct stick angle value. This page appears after the machine stick
Reference""Specifying the Stick Dimensions" "
The stick offset angle is determined by using the water level tube to measure the height difference between
the center of the stick pivot and the center of the bucket pivot. The height difference is then compared with
the raw sensor data to determine the stick offset angle.
Height Difference Using the Water Level Tube " ".
Stick Calibration - Angles page
Note: To access the pivots and measure the height difference, position the stick over high ground or use a
ladder, if needed.
Perform the stick angle calibration as follows:
1. Use the toggle button that is located just above the "Add" button to specify on which side of the stick
Toggle the button to "Left" if the tilt sensor is mounted on the left side of the stick as viewed from the
cab toward the bucket. Toggle the button to "Right" if the tilt sensor is mounted on the right side of the
stick.
2. Move the stick until the stick pivot and the bucket pivot are roughly level with each other.
Note: Place the bucket on the ground so that any leakage from the cylinders does not affect the angle
that is being measured.
3. Using the water level tube, measure the difference in height between the center of the stick pivot and
the center of the bucket pivot.
tube. If the center of the bucket pivot is higher than the center of the stick pivot, then enter the height
difference as a positive value. If the center of the bucket pivot is lower than the center of the stick
pivot, then enter the height difference as a negative value. After this measurement has been entered,
the system calculates the offset angle and displays the calculated value in the "Last Sample" field (81) .
5. Select the "Add" button. The offset angle from the "Last Sample" field appears in the "Average Offset"
field. The "Sample Count" field increments to "1".
6. To ensure greater accuracy, perform multiple sample measurements. Take at least four samples.
Additional samples are performed by moving the stick up or down and repeating steps 3 through 5.
When the "Add" button is selected, the "Average Offset" field updates with an average of all offset
angle samples that have been performed. Each time a new average is calculated, the "Sample Count"
field increases by one count.
7. When a satisfactory offset angle for the stick tilt sensor is displayed, select the "Next" button. The
"Bucket Sensor Mount" dialog page appears. Alternatively, select the "Reset" button to reset the
Average Offset to the previous value and reset the Sample Count to 0 (zero).
Selecting the Mounting Location for the Bucket Sensor
"Bucket Sensor Mount" dialog page
Use the "Bucket Sensor Mount" dialog to select the mounting location for the bucket sensor. This dialog
appears after the stick offset angle has been established and the "Next" button is selected.
Reference""Calibrating the Stick Angle Sensor" "
Mount the bucket sensor on either the bucket or else on the bucket linkage. The calibration sequence and the
corresponding page that is displayed is based on the location selected in this dialog.
If the sensor is mounted on the bucket linkage, select "Yes" in the dialog and then proceed to the section
entitled ""Specifying the Link Dimensions" "
If the sensor is mounted on the bucket, select "No" in the dialog and continue with the next section" Bucket
Calibration - Dimensions for Sensor On Bucket".
Specifying the Bucket Dimensions

Use the "Bucket Calibration - Dimensions" page to specify the width, height, and length dimensions of the
machine bucket. This page appears when "No" is selected on the "Bucket Sensor Mount" dialog page.
Reference""Mounting the Bucket Sensor" "
Bucket Calibration - Dimensions page
Perform the calibration for a bucket-mounted bucket sensor as follows:
Measuring the width of the cutting edge of the bucket
1. Select the leftmost calibration button (78) on the "Bucket Calibration - Dimensions" page. Enter the
width (81) of the bucket cutting edge.
Note: The bucket cutting edge width is used for coverage and must be measured accurately.
2. Select the rightmost calibration button (79). Enter the bucket height. The bucket height, which is also
known as the "struck capacity", is the bucket volume below the strike off plane. The on-board software
uses the bucket height to display machine icons to the correct scale.
Measuring the bucket length
3. Select the lower calibration button (80). Enter the bucket length. The bucket length (82) is the distance
from the center of the bucket pivot to the center of the bucket cutting edge.
Note: Bucket length is used to determine bucket tip position and must be measured accurately.
4. When all bucket dimensions have been entered, select the "Next" button. The "Bucket Calibration -
Angles" page appears. Alternatively, select the "Reset" button to reset all bucket calibration values to
Calibrating the Bucket Angle Sensor
The Bucket tilt sensor, which is mounted on the side of the bucket, measures the angle of the bucket. The
bucket angle is used in determining the bucket tip position
Use the "Bucket Calibration - Angles " page to establish the bucket offset angle. The bucket offset angle
adjusts the raw tilt sensor value to the correct bucket angle value. This page appears after all bucket
Reference""Specifying the Bucket Dimensions" "
The bucket offset angle is determined by using the water level tube to measure the height difference between
the center of the bucket pivot and the center of the bucket tip. The height difference is then compared with
the raw sensor data to determine the bucket offset angle.
from the cylinders does not affect the angles that are being measured.
Height Difference Using the Water Level Tube" ".
Bucket Calibration - Angles page
The "Bucket Calibration - Angles " calibration is completed as follows:
1. Use the toggle button that is located just above the "Add" button to specify to which side of the bucket
Toggle the button to "Left" if the tilt sensor is mounted on the left side of the Bucket as viewed from
the cab toward the bucket. Toggle the button to "Right" if the tilt sensor is mounted on the right side of
the Bucket.
2. When calibrating a tilt sensor that is mounted on an excavator bucket, curl the bucket in (as if loaded)
until the center of the bucket pivot is roughly level with the bucket cutting edge.
3. Using the water level tube, measure the difference in height between the center of the bucket pivot and
the bucket cutting edge.
tube. If the bucket cutting edge is higher than the center of the bucket pivot, then enter the height
difference as a positive value. If the cutting edge is below the center of the bucket pivot, then enter the
height difference as a negative value. After this measurement has been entered, the system calculates
the offset angle and displays the calculated value in the "Last Sample" field.
5. Select the "Add" button. The offset angle from the "Last Sample" field appears in the "Average Offset
Angle" field. The "Samples" field increments to "1".
are performed by curling the bucket either in or out and repeating steps 3 to 5.
Note: Do not take measurements when the angle between the stick end and the bucket tip are within
45 degrees of vertical. If measurements are taken under these conditions, errors can be introduced to
the calibration process.
When the"Add" button is selected, the "Average Offset Angle" field updates with an average of all
offset angle calibrations that have been performed. Each time the systems calculates a new average,
the "Samples" field increases by one count.
7. When a satisfactory average offset angle is displayed, select the"Next" button. The "GPS Calibration"
page appears. Alternatively, select the "Reset" button to reset the "Average Offset Angle" to the
previous value and reset the "Samples" field to 0 (zero).
After the bucket calibration for the bucket mounted tilt sensor is completed, proceed to the section entitled
""GPS Calibration" "
Specifying the Link Dimensions

Use the "Link Calibration - Dimensions" page to determine the relationships between the tilt sensor angle
and the bucket angle. This page appears when "Yes" is selected on the "Bucket Sensor Mount" dialog page.
Reference""Mounting the Bucket Sensor" "
The calibration for a tilt sensor that is mounted on the bucket linkage determines the relationship between the
tilt sensor angle and the bucket angle. To establish the relationship between the tilt sensor angle and the
bucket angle, a series of four linkage measurements are required.
from the cylinders does not affect the angles that are being measured.
Position the stick and the bucket so the angle between (83) and (84) is as close to 90 degrees as is possible. If
the machine has a tilt bucket, then ensure that the bucket is level.
Perform the measurement relationships for a linkage-mounted bucket sensor as follows:
1. Select the top left button (86) on the page. Enter the "Stick Link to Bucket Length" dimension (83) .
2. Select the top right button (85) on the page. Enter the "Stick to Cylinder Link" dimension (84) .
3. Select the bottom left button (89) on the page. Enter the "Bucket Pins Length" (87) dimension.
4. Select the bottom right button (90) on the page. Enter the "Cylinder to Bucket Link" (88) dimension.
5. After all four relationships have been entered, select the"Next" button. The "Bucket Calibrations:
Dimensions" page opens. Alternatively, select the "Reset" button to reset all link calibration values to
Specifying the Bucket Dimensions for a Linkage-mounted Bucket Sensor

Use the "Bucket Calibration - Dimensions" page to specify the width, height, and length dimensions of the
bucket. This page appears after the four relationships on the "Link Calibration - Dimensions" page have been
established.
Reference""Specifying the Link Dimensions" "
Bucket Calibration - Dimensions page
To specify the bucket dimensions for a linkage-mounted bucket sensor, perform the following on the "Bucket
Calibration - Dimensions" page:
Measuring the bucket width
1. Select the leftmost calibration button (91) on the "Bucket Calibration - Dimensions" page. Measure the
width (94) of the bucket cutting edge and enter this measurement.
Note: The bucket cutting edge width is used for coverage and must be measured accurately.
2. Select the rightmost calibration button (92). Enter the bucket height. The bucket height, which is also
known as the "struck capacity", is the bucket volume below the strike-off plane. The on-board software
uses the bucket height to display machine icons to the correct scale.
Measuring the bucket length
3. Select the lower calibration button (93). Enter the bucket length. The bucket length (95) is the distance
from the center of the bucket pivot to the center of the bucket cutting edge.
Note: The bucket length is used to determine bucket tip position and must be measured accurately.
4. After the three bucket dimensions have been entered, select the "Next" button. The "Bucket
Calibration - Linkage Angles" page appears. Alternatively, select the "Reset" button to return all
bucket dimensions to the original values.
Specifying the Bucket Linkage Offset Angle

The bucket tilt sensor is used to measure the angle of the bucket. The "Bucket Calibration - Linkage Angles"
calibration determines the offset angle that is required to adjust the tilt sensor readings to true angles.
The bucket offset angle is determined by using the water level tube. This tube is used to measure the height
difference between the center of the pivot at the cylinder end of the link and the center of the pivot at the
stick end of the link.
Height Difference Using the Water Level Tube" ".
Bucket Calibration - Linkage Angles page
Perform the"Bucket calibration: Linkage Angles" calibration as follows:
1. Use the toggle button that is located just above the "Add" button to specify on which side of the bucket
linkage the tilt sensor is mounted.
Toggle the button to "Left" if the tilt sensor is mounted on the left side of the bucket linkage as viewed
from the cab towards the bucket. Toggle the button to "Right" if the tilt sensor is mounted on the right
side of the bucket linkage.
2. When calibrating a tilt sensor that is mounted on the bucket linkage, place the "Stick to Cylinder Link"
approximately level.
3. Using the water level tube, measure the difference in height between the pivots of the "Stick to
Cylinder Link".
4. Select the "Height Difference" button. Enter the height difference, as measured using the water level
tube. If the center point of the pivot at the cylinder end of the link is lower than the center of the pivot
at the stick end of the link, then enter the height difference as a positive value. If the center of the pivot
at the cylinder end of the link is higher than the center of the pivot at the stick end of the link, then
enter the height difference as a negative value. After the value has been entered, the system calculates
the offset angle and displays the calculated value in the "Last Sample" field.
5. Select the "Add" button. The offset angle from the "Last Sample" field appears in the "Average Offset
Angle" field. The "Samples" field increments by one count.
are performed by moving the "Stick to Cylinder Link" up or down and repeating steps 3 to 5.
7. When the displayed average offset angle is satisfactory, select the "Next" button. The "Stick pin to
Bucket to Link Angle" page appears. Alternatively, select the "Reset" button to reset the "Average
Offset Angle" field to the previous value and reset the "Samples" field to 0 (zero).
Specifying the Stick Pin to Bucket to Link Angle

Use the "Stick Pin to Bucket to Link Angle" calibration to determine the angle from the center of the pivots
from the stick, the bucket, and the bucket link. This angle is a fixed angle and helps to orientate the bucket
linkage with respect to the boom pivot.
The "Stick Pin to Bucket to Link Angle" page
Perform the "Stick Pin to Bucket to Link Angle" calibration as follows:
1. To measure the distance from the stick pivot to the bucket tip, position the bucket and the stick in a
similar position as shown.
Measuring the Stick pivot to the bucket tip
2. Accurately measure the distance (97) from the center of the stick pivot to the bucket tip.
3. Select the upper button (98) on the "Stick Pin to Bucket to Link Angle" page. Enter the distance from
the center of the stick pivot to the bucket tip.
Measuring the bucket tip to the bucket link
4. Accurately measure the distance (99) from the bucket tip to the center of the pivot for the bucket link.
5. Select the lower button (96) in the "Stick Pin to Bucket to Link Angle" page. Enter the distance from
the tip of the bucket to the center of the bucket link pivot.
The system calculates the angle from the center of the pivots from stick, the bucket, and the bucket
link. The calculated value is displayed in the "Stick Pin to Bucket to Link Angle" field.
6. Select "Next". The "Bucket Calibration - Fixed Angle" page appears. Alternatively, select the "Reset"
button to reset the "Stick Pin to Bucket to Link Angle" field to the original value.
Specifying the Fixed Angle for the Bucket

Use the "Bucket Calibration - Fixed Angle" calibration to determine the angle between a line that passes
through the bucket pins and a line that passes through the bucket pivot and the bucket tip. The angle of the
two bucket pins is defined by the position of the linkage. This angle is then applied to calculate the position
of the bucket tip.
The Bucket Calibration - Fixed Angle page
Perform the "Bucket Calibration - Fixed Angle" calibration as follows:
Measuring the pivot at the cylinder link to the bucket pivot
1. Accurately measure the length (103) from the center of the pivot at the cylinder link to the center of
the bucket pivot.
2. Select the rightmost button (100) on the "Bucket Calibration - Fixed Angle" page. Enter the length
from the center of the pivot at the cylinder link to the center of the bucket pivot.
Measuring the bucket tip to the bucket link
3. Accurately measure the length (102) from the bucket tip to the center of the bucket linkage pivot on
the stick.
4. Select the leftmost button (101). Enter the length from the bucket tip to the center of the bucket linkage
pivot on the stick.
5. The angle from the bucket tip to the center of the bucket pivot to the center of the linkage pivot on the
bucket is calculated and displayed in the "Angle" field. Select the "Add" button. The angle is included
in the "Average Angle" field. The "Samples" field increases by one count.
6. To improve the accuracy of the fixed angle for the bucket, perform multiple sets of measurements by
moving the bucket and then repeating steps 1 through 5.
7. When a satisfactory fixed bucket angle is displayed, select the "Next" button. The "GPS Calibration"
page appears. Alternatively, select the "Reset" button to reset the "Average Angle" to the original
value.
GPS Calibration
Note: This calibration section assumes that all system hardware components have been installed.
The "GPS Calibration" determines the following relationships:
Relative position of the slave receiver to the master receiver
Relative position of the receivers to the center of the boom pivot
Machine alignment relative to the two receivers
Communicating with the Receiver

On the G610 display module, day to day communication with the satellite receiver occurs automatically over
a CAN bus. However, for calibration the current harness limits the installer to calibrating a receiver using a
serial port.
To enable the display module to use a serial port for calibrating the receiver:
1. Open the master.txt file.
2. Add "$ GPS Over CAN =0" to the master.txt file to disable the on-board software from using the CAN
bus for calibrating the receiver.
3. Save the master.txt file and reboot the display module.
4. Calibrate the machine. The calibration process is described in the following sections:
""Specifying the Parameters" "
""Calibrating the Receiver" "
""Completing the Calibration" "
5. Once the system is calibrated, open the master.txt file and edit "$ GPS Over CAN =1" to enable the
on-board software to use the CAN bus for day to day receiver communications.
6. Save the master.txt file and reboot the on-board software.
Specifying the Parameters
Use the "GPS Calibration" setup to specify the following calibration parameters:
Minimum accuracy for position samples used in the calibration
Number of samples that must be taken during the calibration
Height of the receiver above the center of the boom pivot when the receiver is located over the boom
pivot
Initial "GPS Calibration" page
Use the following steps to prepare for the calibration:
1. Select the "Advanced" button on the "GPS Calibration" page. The "GPS Calibration Setup" dialog
appears.
The "GPS Calibration Setup" dialog.
Note: Position error is an estimate of the position accuracy. Later versions of receiver firmware
provide position error with each position update. The calibration is suspended when the accuracy is not
acceptable.
Note: If the position error is unavailable, then the calibration requires a "fixed real time kinematic"
(RTK) position mode.
2. If the maximum acceptable position error used in the calibration needs to be modified, then select the
"GPS Accuracy" button.
3. If the number of positions that must be observed during calibration is to be modified, then select the
"GPS Samples" button.
4. Measure the distance (A) from the base of the range pole to the top of the lower housing on the
receiver. Enter the measurement into the "Boom Pin Pole Height" field.
5. Select "OK" to save the calibration setup and return to the "GPS Calibration" wizard. Alternatively,
select "Cancel" to exit without saving any changes.
Calibrating the Receiver

Use the following steps to perform the "GPS Calibration":
1. Position the machine with the bucket tip on the ground. Ensure that there is sufficient room to extend
the boom, stick, and bucket fully.
"GPS Calibration" dialog after "Pin Pole Height" has been entered
2. With the two receivers in the normal working positions, select the "Start" button. The information
window turns red indicating that the on-board software is taking position samples and machine body
pitch samples.
The progress bar graphically indicates the sampling progress. The value next to the bar indicates how
many position samples are still to be taken.
The following fields can be observed below the progress bar:
East - Displays the current averaged difference between master receiver easting and the slave receiver
easting
North - Displays the current averaged difference between master receiver northing and slave receiver
northing
Elevation - Displays the current averaged difference between master receiver elevation and the slave
receiver elevation
Distance - Displays the current averaged slope distance between the master receiver and the slave
receiver
3. Once the initial set of position measurements are taken, instructions prompt the user to move the slave
antenna to the boom pin.
ReferenceFor instructions on locating the slave receiver at the boom pin, refer to the section entitled
""Locating the Slave Receiver at the Boom Pivot" ".
Note: During this process, both receivers have been powered down and lost communications with the
radio and the display module. The receivers have also lost positioning signals. Ensure that the system
has had enough time to reacquire communications before continuing.
"GPS Calibration" dialog after sampling is complete
4. Disconnect the 12-pin connector of the 383-3027 Harness As (main rear) from the 285-6655 Harness
As (chassis). Connect the 285-6649 Harness As (HEX calibration) between the main rear harness and
the chassis harness.
5. Locate the range pole and receiver at the boom pin using the 3-jaw chuck and the range pole target.
The range pole must be set up to the right of the center of the boom pin center.
Slave receiver mounted on the right side of the boom pivot
6. Once the slave receiver is in position, select the "Start" button on the "GPS Calibration" page. The on-
board software begins sampling again.
When the system has finished sampling positions, the "GPS Calibration Boom Width" page appears.
"GPS Calibration Boom Width" page
7. Select the "Width" button on the "GPS Calibration Boom Width" page. Enter the distance from the
centerline of the boom to the center of the range pole.
ReferenceFor detailed instructions for measuring the boom width, see the section entitled ""Measuring
the Distance from Boom Pivot Center to the Range Pole" ".
"GPS Calibration" page after boom width has been entered
8. Select "OK" on the "GPS Calibration Boom Width" page. The width is saved and the "GPS Calibration
Boom Width" page is closed. The information window in the "GPS Calibration" page turns green and
contains instructions to position the receiver at the bucket tip.
Note: Ensure that the range pole is positioned in line with the boom center and bucket center. The
range pole does not have to be exactly on the edge of the bucket tip. The purpose of this set of
observations is to determine the longitudinal axis of the machine.
9. Confirm that the boom, stick, and bucket are extended. Confirm that the bucket tip is on the ground.
Use the bipod to position the range pole at the center point of the bucket tip.
Range pole set up at the center of the bucket tip
10. Select the "Start" button on the "GPS Calibration" page. The information window turns red while the
on-board software samples receiver data. When the sampling is complete, the information window in
the "GPS Calibration" dialog turns green. The window contains instructions to return the slave receiver
to the original (normal) position on the machine.
The "GPS Calibration" dialog after sampling is complete
11. Install the slave receiver to the machine in the normal operating position. Use the four 8T-4195 Bolts .
12. Reconnect the receiver. Use the installed receiver cable.
13. Remove the 12-pin connectors of the 285-6649 Harness As .
14. Reconnect the connectors of the main rear harness to the chassis harness.
Note: During this process, both receivers have been powered down and lost communications with the
radio and the display module. The receivers have also lost positioning signals. Ensure that the system
has had enough time to reacquire communications before you continue.
The "GPS Calibration" page indicating to rotate the machine
15. Select the "Start" button in the "GPS Calibration" page. The information window turns yellow. The
instructions in the information window require the machine to be rotated 180 degrees to the angle of 0
(zero).
Rotate the machine 180 degrees. Monitor the Progress bar and the value next to the progress bar while
rotating the machine the full 180 degrees.
16. Select the "Start" button. The information window turns red while the on-board software samples
positioning data. When sampling is complete, the information window turns green.
"GPS Calibration" dialog after completing the receiver calibration
17. The "GPS Calibration" dialog indicates that the "Next" button is to be selected. Select the "Next"
button. The "Calibration Summary" page appears.
Completing the GPS Calibration

The calibration summary provides a complete summary of all calibration values from both the linkage
calibration and the receiver calibration. No calibration information has been written to the calibration file at
this stage.
The "Calibration Summary" page
The following information is displayed in the "Calibration Summary" page.
Pitch/Machine group box - Reports the machine dimensions and the result of the machine pitch calibration
Boom, Stick, and Bucket group boxes - Report the results and entries for both dimension calibrations and
for angle calibrations
Antenna Positions - Displays the results of the receiver calibration
Ant 1 - Shows the offset of the master antenna in the X, Y, and Z planes, from the center of the boom pivot
Ant 2 - Shows the offset of the slave antenna, in the X, Y, and Z planes, from the center of the boom pivot
Reference frame for machine offsets
(104) Master antenna
(105) Horizontal distance from master antenna in Y direction
(106) Slave antenna
(107) Horizontal distance from master antenna in X position
(108) Vertical distance (elevation) from master antenna in Z direction
The machine reference frame is centered on the boom pivot center point. The Y axis is the longitudinal axis
of the machine. The X axis is from the left side of the machine to the right side of the machine. The Z axis is
the vertical axis of the machine.
Calibration Settings
Calibration values are written as settings in the calibration file. The calibration file is edited using the
calibration wizard. The keys cannot be entered manually.
The following settings are written to the calibration file:
AntX 0 - Specifies the horizontal distance in the X axis from the master antenna to the center of the boom
pivot
AntY 0 - Specifies the horizontal distance in the Y axis from the master antenna to the center of the boom
pivot
AntZ 0 - Specifies the horizontal distance in the Y axis from the master antenna to the center of the boom
pivot
AntX 1 - Specifies the horizontal distance in the X axis from the slave antenna to the center of the boom
pivot
AntY 1 - Specifies the horizontal distance in the Y axis from the slave antenna to the center of the boom
pivot
AntZ 1 - Specifies the vertical distance from the slave antenna to the center of the boom pivot
Boom Sensor Left - Specifies of the boom to which the boom tilt sensor is mounted
Boom Sensor Offset - Specifies the offset angle that is applied to the raw boom angle
Bucket Sensor Left - Specifies side of the bucket to which the bucket tilt sensor is mounted
Bucket Sensor Offset - Specifies the offset angle that is applied to the raw bucket angle
Excavator Boom Height - Specifies the boom height of the machine
Excavator Boom Length - Specifies the boom length of the machine
Excavator Boom Width - Specifies the boom width of the machine
Excavator Boom Pin Height - Specifies the height of the center of the boom pin above the machine track on
the ground
Excavator Bucket Height - Specifies the bucket height of the machine
Excavator Bucket Length - Specifies the bucket length of the machine
Excavator Bucket Pins Length - Specifies the distance between the pins of the bucket.
Excavator Bucket Pins To Tip Angle - Specifies the angle formed between the bucket tip and the pins of
the bucket.
Excavator Bucket Width - Specifies the bucket width of the machine
Excavator Bucket Sensor On Link - Specifies that the tilt sensor for the bucket is installed on the bucket
link
Excavator Cylinder To Bucket Length - Specifies the length of the cylinder to bucket link
Excavator Machine Length - Specifies the length of the body of the machine
Excavator Machine Width - Specifies the width of the body of the machine
Excavator Stick Height - Specifies the stick height of the machine
Excavator Stick Length - Specifies the stick length of the machine
Excavator Stick Link To Bucket Length - Specifies the distance from the center of the bucket link pivot on
the stick to center of the bucket pivot
Excavator Stick To Cylinder Link Length - Specifies the distance from the center of the bucket link pivot
on the stick to the center of the cylinder link
Excavator Stick To Link Angle - Specifies the angle from the center of the pivots from the stick, bucket,
and bucket link on the stick
Excavator Stick Width - Specifies the stick width of the machine
Pitch Sensor Offset - Specifies the offset angle that is applied to the raw machine pitch angle
Roll Sensor Offset - Specifies the offset angle that is applied to the raw roll angle
Stick Sensor Left - Specifies side of the stick to which the stick tilt sensor is mounted
Stick Sensor Offset - Specifies the offset angle that is applied to the raw stick angle
Modifying the Calibration Values

If the calibration menu is enabled, then any part of the machine calibration can be edited or changed at any
time. When any part of the calibration is modified, then a new calibration file is written and the existing
calibration file is archived.
Use the "Calibration Summary" page to review all calibration results. Use the "Modify" button in the
associated group box in the calibration summary to perform the following tasks
Edit dimensions for a specific calibration
Reset and repeat a specific calibration
Add additional calibration sets to a specific calibration
Open the "Calibration Summary" using the following steps.
1. Select "Calibration" from the main menu in the on-board software. The "Calibration" submenu
appears.
2. Select "Calibration Summary" from the calibration submenu. The "Calibration Summary" page
appears.
Modifying the Machine Body Dimensions and the Pitch Angle Offset
Modify the machine body dimension and/or pitch angle offset using the following steps:
1. Select the "Modify" button in the "Pitch/Machine" group box. The "Machine Calibration -
Dimensions" page appears.
2. Follow the steps detailed in the sections entitled ""Specifying the Machine Body Dimensions" " and
""Calibrating the Pitch Angle Sensor" "
3. If the modifications are complete, follow the steps detailed in the section entitled ""Completing the
Positioning Calibration" ". Alternatively, select the "Cancel" button to escape from the procedure
without writing to the calibration file.
Reference""Terminating the Positioning Calibration" "
Modifying the Boom Calibration
Modify the machine boom dimension and/or the boom angle offset using the following steps:
1. Select the "Modify" button in the "Boom" group box. The "Boom Calibration - Dimensions" page
appears.
2. Select the calibration that is to be changed, and then enter the new calibration value.
ReferenceFor detailed instructions, refer to the steps in the sections entitled ""Specifying the Boom
Dimensions" " and ""Calibrating the Boom Angle Sensor" "
3. Continue this same process with each value that is to be changed. When all modifications are
complete, follow the steps detailed in the section entitled ""Completing the Positioning Calibration" ".
Alternatively, select the "Cancel" button to escape from the procedure without writing changes to the
calibration file.
Modifying the Stick Calibration
Modify the machine stick dimension and/or stick angle offset using the following steps:
1. Select the "Modify" button in the "Stick" group box. The "Stick Calibration - Dimensions" page
appears.
2. Select the calibration that is to be changed, and then enter the new calibration value. For detailed
instruction, refer to the steps in the section entitled""Specifying the Stick Dimensions" " and the
section entitled ""Calibrating the Stick Angle Sensor" "
calibration file.
Modifying the Bucket Calibration
Modify the machine bucket dimension and/or bucket angle offset using the following steps:
1. Select the "Modify" button in the "Bucket" group box. The "Bucket Sensor Mount" dialog page
appears.
instruction, refer to the steps in the section entitled ""Mounting the Bucket Sensor" "
calibration file.
Modifying the GPS Calibration
Modify the machine positioning calibration using the following steps:
1. Enable the G610 display module to use a serial port for calibrating the receiver:
a. Open the "master.txt "file.
b. Add "$ GPS Over CAN =0" to the master.txt file to disable the on-board software from using the
CAN bus for calibrating the receiver.
c. Save the master.txt file and reboot the display module.
2. Select the "Modify" button in the "Antenna Positions" group box. The "GPS Calibration" page
appears.
instructions, refer to the steps in the section entitled ""GPS Calibration Process" ".
calibration file.
5. Once the system is calibrated, open the master.txt file and edit "$ GPS Over CAN =1" to enable the
on-board software to use the CAN bus for day to day receiver communications
6. Save the master.txt file and reboot the on-board software.
Terminating the GPS Calibration

Select the "Cancel" button at any stage to exit the calibration. The "Confirm Calibration Cancel " dialog
appears.
Confirm cancellation of the calibration
Confirm the cancellation by selecting the "Yes" button in the "Confirm Calibration Cancel" dialog. The
calibration procedure ends, the calibration dialogs close, and the "Calibration Summary" page appears.
Alternatively, select the "No" button to return to the calibration procedure.
Measuring the Height Difference Using the Water Level Tube

Note: The water level tube is a rudimentary way to measure the height difference between two objects.
Other, more accurate methods, such as a laser level or an optical survey device can be used to measure the
vertical offset if these devices are available on the site.
The water level tube measurements require two people. Use the following steps to measure the height
differences:
1. Remove the caps from both ends of the water level tube.
Water level at each end of the water tube is the same
2. Hold the two ends of the tube together. The water levels (109) must be identical at both ends of the
tube. If the levels are not identical, check that there are no air bubbles in the tube and no kinks
restricting the water flow.
The water level in the water tube is held level with the center of the boom pivot
3. Hold one end of the water level tube so that the water level in the tube is level with the center of the
first pivot (110) point.
Measuring the vertical distance from the water level to the center of the stick pivot. The measured height difference (112) is
95 cm.
4. While maintaining the water level at the center of the first pivot (110) point, hold the second end of the
water level tube next to the center of the second pivot (111) point.
5. When the water level is steady, measure the vertical distance (112) from the center of second pivot
point to the water level (113) in the water level tube. This measurement is the height difference that is
required for the calibration.
Measuring the Distance from the Boom Pivot Center to the Range
Pole
This measurement is crucial to machine bucket position and must be measured accurately
Using the following steps, measure the distance from the range pole target to the boom centerline:
Mark in line with the center of the bucket
1. Mark the center line (114) of the boom between the boom pivots (115) .
Slave receiver mounted to the right of center of the boom
2. Screw the boom pin center finder into the boom pivot.
Ensure that the boom pivot center finder is located at either the center of the boom pivot or, as shown
in Illustration 85, to the right of the center of the boom pivot.
3. Insert the range pole target into the boom pin center finder.
4. Set up the range pole on the range pole target. Ensure that the range pole is vertical.
Measuring the horizontal distance (117) from the center of the boom pivot to the center of the range pole
5. Measure the distance (117) from the marked centerline (116) of the boom to the center (118) of the
range pole.
Locating the Slave Receiver at the Boom Pivot

The following steps provide instructions for locating the slave receiver over the boom pivot for the
positioning calibration:
1. Disconnect the installed 285-6657 Wiring Harness from the slave (right) receiver.
2. Disconnect the 12-pin connector of the 290-1918 Harness As from the 285-6655 Chassis Harness .
3. Connect the 285-6649 HEX Calibration Harness between the 290-1918 Harness As and the 285-6655
Chassis Harness .
4. Remove the slave receiver from the machine mast.
5. Use four 8T-4195 Bolts (119) from the receiver Mast Mount to mount the receiver to the 289-9631
Plate (121) .
Bottom of the receiver with the Calibration Plate attached
(119) 8T-4195 Bolts
(120) Threaded hole for range pole.
(121) 289-9631 Plate
(122) Receiver
6. Screw the range pole into the threaded hole (120) of the calibration plate (121) that is attached to the
bottom of the receiver.
Sl i t d th l
Slave receiver mounted on the range pole
(121) 289-9631 Plate
(122) receiver
(123) Range pole
(124) Range pole bipod
7. Connect the slave receiver to the main harness in the cab, using the calibration harness that is in the
calibration kit.
8. The calibration kit contains a device that is used for locating the center of the boom pin during the
calibration process.
Use the following steps to locate the 3-jaw chuck and the range pole target into the bolt hole in the
center of the boom pivot of the machine:
Parts for the 3-jaw chuck
(125) 3-jaw chuck
(126) Range pole target
(127) Allen wrench
(128) Chuck key
a. Insert the center tool pins into the bore of the boom pin on the left side of the machine.
b. Using the chuck key, increase the diameter until the locating pins are snug against the inner bore
of the pin.
Note: Do not over-torque the chuck as this action will bend the locating pins.
c. Install the range pole target into the end of the chuck.
d. Measure the distance from the center of the boom pin to the target. Record this value for later
use in the calibration.
The 3-jaw chuck.
(128) Chuck key
(129) Chuck jaw identity number
(130) Inner threaded holes for the chuck jaws
(131) Chuck jaw
e. The 3-jaw chuck can be used for pin bores of up to 3 inches (75mm). The jaws of the chuck are
numbered and the corresponding location (129) for each jaw is also marked on the chuck near
where the jaw is installed.
For machines with larger pins, the chuck jaws (131) may be removed and, as shown in
Illustration 90, inserted in the outer threaded holes. Use the Allen wrench in the kit to remove
the pins and reinstall the pins in the outer set of holes.
Note: After relocating the jaws, ensure that the jaws move in and move out at equal distances
from the center.
Range pole that is located at boom pivot
9. Place the bottom point (132) of the range pole into the range pole target (126). Level and secure the
range pole using the bipod.
For added stability, perform the following actions:
Locate the area where the bipod joins the pole as high a possible up the pole.
Secure the pole using ropes, tie downs, or bungy cords.
Entering the Calibration Dimensions

Ensure that the dimensions that are coded red in the calibration wizard are measured accurately.
The form below in Illustrations 92 and 93 includes all of the dimensions that must be measured for the
machine calibration when the tilt sensor is mounted on the bucket linkage. Complete all of the calibration
dimension measurements and enter the dimensions into the spaces provided on the form. Enter the values
from the form into the calibration pages as the calibration wizard is stepped through.
Note: There are some measurements on the form that are not required when the bucket tilt sensor is mounted
on the bucket.
Note: Use a photocopy of the form to avoid climbing in and out of the cab during the calibration.
Copyright 1993 - 2019 Caterpillar Inc. Fri Mar 29 2019 07:04:50 GMT+0800 (Australian Western Standard Time)
All Rights Reserved.
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3/29/2019 Terrain Loading TFL00001-UP (MACHINE)(SEBP7000 - 08) - Documentation

Installation of Cat® Terrain for Excavators{7605}

389-0324 Terrain Installation Gp

The installation is separated into the following procedures:

Angle sensor installations

Pressure switch installation

Machine radio installation

Display module installation

Battery backup installation

Calibration and measure up procedures

Operation and Maintenance Manual

Important Safety Information

Electrocution Hazard! Keep the machine and attachments a safe distance

Accidental engine starting can cause injury or death to personnel

To avoid accidental engine starting, disconnect the battery cable from

Place a Do Not Operate tag at the Start/Stop switch location to inform

Personal injury or death can result from sudden machine movement.

Sudden movement of the machine can cause injury to persons on or

Prevent possible injury by performing the procedure that follows before

Move the machine to a smooth horizontal location. Move away from

Engage the parking brake. Stop the engine.

Read and understand the manufacturer's instructions and your

See "American National Standard Z49.1, Safety in Welding and

American Welding Society

See "OSHA Safety and Health Standards, 29 CFR 1910", available

U.S. Department of Labor

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 keys for the machine.

1U-7230 Hand Tool Group (Screwdrivers)

8T-9293 Torque Wrench (1/2 inch Drive)

9S-1748 Socket Wrench Set (1/2 Inch Drive)

194-3584 Socket Wrench Set (Torx screw)

389-0331 Tool Group (Terrain Service Kit)

Not specified Drill Bit Set

Not specified Hole Punch Set

Not specified Cable Ties/Clips

Part Number Part Name Notes

3E-5239 Relay Used for Reverse Auto-Calibration option

4C-4200 Paint CAT Yellow

7T-1099 Link Weld links for harness routing

167-8709 Alarm Annunciator

285-6653 Radio Harness Extension harness for radio or receiver

167-8604 Monitor Mounting Gp For G610 display module

292-0308 Sensor Wiring Gp CAES

QTY Part Number Part Name Notes

4 0S-0509 Bolt 3/8-16

1 147-3417 Mount Ceiling or dash mount

8 8T-4896 Hard Washer

1 147-3449 Plate Antenna

QTY Part Number Part Name Notes

4 322-0221 Housing Bracket

100 3S-2093 Cable Strap

16 5C-7261 Nut Hex

16 8T-4121 Hard Washer

3 8T-8737 Seal Plug

4 243-4108 Harness As Sensor

2 311-8688 Harness As Sensor (8 m)

QTY Part Number Part Name Notes

2 3S-8665 Clip Harness

1 285-6656 Wiring Harness Second receiver crossover

1 383-3028 Wiring Harness Main rear