Installation Procedure for Mounting the Rear Radar On Certain Cat Products{7347, 7605} Caterpillar


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Installation Procedure for Mounting the Rear Radar On Certain Cat<SUP>&reg;</SUP> Products{7347, 7605} [REHS9751]
ELECTRICAL AND STARTING SYSTEM
ELECTRICAL GP
1.1. Introduction
2.1. Important Safety Information
3.1. Installation Procedure
Soil Compactor:
825K (S/N: SEE1-UP; 2331-UP)
Wheel Dozer:
824K (S/N: RWB1-UP; 2341-UP)

Introduction

This Special Instruction provides the installation procedure for mounting the rear radar on certain Cat® Products.

Important Safety Information

Do not perform any procedure in this Special Instruction until you have read this Special Instruction and you understand this information. Use only proper tools and observe all precautions that pertain to the use of those tools. Failure to follow these procedures can result in personal injury. The following procedures should also be observed.

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

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

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

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

Ensure that the product will not be damaged or the product will not be made unsafe by the operation, lubrication, maintenance, or repair procedures used.

------ WARNING! ------

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.

----------------------

------ WARNING! ------

Accidental engine starting can cause injury or death to personnel working on the equipment.

To avoid accidental engine starting, turn the battery disconnect switch to the OFF position. Remove the key for the battery disconnect switch. Use a secure padlock in order to lock the battery compartment access door.

Place a Do Not Operate tag at the Start/Stop switch location to inform personnel that the equipment is being worked on.

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------ WARNING! ------

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
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NOTICE

Before carrying out arc welding on the machine or on any equipment attached to the machine, disconnect all power and ground leads from the batteries in order to avoid possible damage to electronic components.


Installation Procedure

Table 1
462-5011 Sensor Wiring Gp    
Qty     Part Number     Description    
2     5P-1076     Hard Washer    
5     7K-1181     Cable Strap    
3     8T-4121     Hard Washer    
1     8T-4133     Nut    
2     8T-4136     Bolt    
2     8T-4139     Bolt    
4     8T-4971     Bolt    
1     8X-6102     Block    
4     9X-6165     Washer    
1     130-5300     Clip    
1     160-8708     Bracket As    
4     198-4775     Hard Washer    
1     204-2281     Cable Strap    
1     204-8000     Cable Tie Mounting    
1     311-8143     Bracket    
1     363-7101     Bracket    
1     374-3605     Object Detection Box Gp    
1     374-6425     Wiring Harness    



Illustration 1g03730638

Chassis Schematic for 824K/825K




Illustration 2g03726832

824K and 825K Rear View

(1) 428-6688 Plate

(2) 381-5530 Cooling Ar

(3) 397-1265 Guard As




Illustration 3g03726837

462-5011 Sensor Wiring Gp

(4) 130-5300 Clip

(5) 374-6425 Wiring Harness

(6) 7K-1181 Cable Strap

(7) 160-8708 Bracket As

(8) 204-8000 Cable Tie Mounting

(9) 8T-4136 Bolt

(10) 8T-4121 Hard Washer

(11) 311-8143 Bracket

(12) 8T-4133 Nut

(13) 374-3605 Object Detection Box Gp

(14) 8T-4139 Bolt

(15) 5P-1076 Hard Washer

(16) 363-7101 Bracket

(17) 8X-6102 Block




    Illustration 4g03727356

    (3) 397-1265 Guard As

    (18) 8T-4137 Bolt

    (19) 397-1297 Angle As

  1. Remove six 8T-4137 Bolts (18) securing 397-1265 Guard As (3) .

  1. Remove 397-1265 Guard As (3) .



    Illustration 5g03727357

    (3) 397-1265 Guard As

    (17) 8X-6102 Block

    (19) 397-1297 Angle As

    (20) 398-8634 Plate




    Illustration 6g03727384

    Location of the Welding Block

  1. Weld 8X-6102 Block (17) onto 398-8634 Plate (20) .



    Illustration 7g03738928

    (16) 363-7101 Bracket

    (21) 430-8391 Sensor and Mounting

    (22) 198-4775 Hard Washers

    (23) 9X-6165 Washers

    (24) 8T-4971 Bolts

  1. Attach the 430-8391 Sensor and Mounting (21) to the 363-7101 Bracket (16) with four 8T-4971 Bolts (24), four 9X-6165 Washers (23), and four 198-4775 Hard Washers (22). Place the four 198-4775 Hard Washers (22) between the 430-8391 Sensor and Mounting (21) and the 363-7101 Bracket (16). The four 9X-6165 Washers (23) will be placed between the 8T-4971 Bolts (24) and the 363-7101 Bracket (16). Refer to Illustration 7.

    Note: Snug the bolts but do not fully tighten. After the installation is completed, final adjustments will be necessary.

  1. Connect the 374-6425 Wiring Harness (5) to the 430-8391 Sensor and Mounting (21) .



    Illustration 8g03738930

    (6) 7K-1181 Cable Strap

    (16) 363-7101 Bracket

    (21) 430-8391 Sensor and Mounting

    (25) 7T-1099 Link

  1. Use one 7K-1181 Cable Strap (6) to secure the 374-6425 Wiring Harness (5) and 430-8391 Sensor and Mounting (21) pigtail to the 7T-1099 Link (25) on the bottom of the 430-8391 Sensor and Mounting (21). Refer to Illustration 8.



    Illustration 9g03738931

    (14) 8T-4139 Bolts

    (15) 5P-1076 Hard Washers

    (16) 363-7101 Bracket

    (17) 8X-6102 Block

  1. Attach the 363-7101 Bracket (16) to the 8X-6102 Block (17) located on the rear bumper. Use two 8T-4139 Bolts (14) and two 5P-1076 Hard Washers (15). Refer to Illustration 9.

    Note: Snug the bolts but do not fully tighten. After the installation is completed, final adjustments will be necessary.




    Illustration 10g03730019

    (26) 397-1273 Angle

  1. Drill 11 mm (0.43 inch) hole in 397-1273 Angle (26) in 397-1297 Angle As (19), part of the 397-1385 Radiator Guard Gp .



    Illustration 11g03730063

  1. Secure 311-8143 Bracket (11) to 397-1297 Angle As (19), with a 8T-4136 Bolt (9), two 8T-4121 Hard Washers (10), and 8T-4133 Nut (12). Secure 374-6425 Wiring Harness (5), with a 7K-1181 Cable Strap (6) .



    Illustration 12g03730108

  1. Illustration 12 shows mounting fit-up for 311-8143 Bracket (11) .



    Illustration 13g03730115

    (27) 397-1275 Bracket

    (28) 8T-4192 Bolt


  1. Secure 160-8708 Bracket As (7) to 397-1275 Bracket (27) with existing 8T-4192 Bolt (28) and 5P-1076 Hard Washer (15). Secure 204-8000 Cable Tie Mounting (8) to 160-8708 Bracket As (7) with 8T-4136 Bolt (9) and 8T-4121 Hard Washer (10). Secure 374-6425 Wiring Harness (5) with 7K-1181 Cable Strap (6) .



    Illustration 14g03730130

    (29) 384-3356 Rear Harness As

    (30) 397-1390 Baffle As

  1. Secure 374-6425 Wiring Harness (5) to 384-3356 Rear Harness As (29) with 7K-1181 Cable Strap (6). The 374-6425 Wiring Harness (5) to follow 384-3356 Rear Harness As (29) through 397-1390 Baffle As (30) .



    Illustration 15g03730138

    Harness runs behind 397-1379 Door As (33) and 397-1296 Radiator Guard As (32) .

    (31) 381-5535 Radiator Guard Gp

    (32) 397-1296 Radiator Guard As

    (33) 397-1379 Door As




    Illustration 16g03730610

  1. Route 374-6425 Wiring Harness (5) along 384-3356 Rear Harness As (29), securing with 7K-1181 Cable Strap (6) .



    Illustration 17g03730619

  1. Remove 428-6688 Plate (1) to access the harness connection.



    Illustration 18g03730612

    Harness connection located behind 428-6688 Plate (1)

    (34) 384-3343 Chassis Harness As

    (35) 155-2273 Connector Plug As (CH-C16)

    (36) 8T-4935 Weld Boss

    (37) 3E-3382 Connector Receptacle As (HC-C1)

  1. Secure 130-5300 Clip (4) using existing 8T-4136 Bolt (9) and 8T-4121 Hard Washer (10). Connect 3E-3382 Connector Receptacle As (HC-C1) (37) in 384-3356 Rear Harness As (29) to 155-2273 Connector Plug As (CH-C16) (35) in 384-3343 Chassis Harness As (34) .

After mounting and making harness connections, set the angle and azimuth as listed in Table 2.

Once the hardware installation is completed, software supporting camera and radars must be installed. Refer to SIS Web for the latest software. The latest software will be listed in the Object Detection software Service Magazine for the AVSpare Touch Screen Display. The Object Detection serial number prefixes are DTK and DTJ.

Table 2
Machine     Angle     Azimuth    
824K/825K     0     0    

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