Topcon 3D-MC MAX User manual

3D-MCMAX
MC-X3
Caterpillar D5/D6 Dozer
Installation Manual

3D-MCMAX
MC-X3
Caterpillar D5/D6 Dozer
Installation Manual
©Copyright June, 2021
All contents in this manual are copyrighted by Topcon. All rights reserved.
The information contained herein may not be used, accessed, copied, stored, displayed, sold, modified,
published, distributed, or otherwise reproduced without express written consent from Topcon.
Part Number 1049060-01
Revision A

P/N: 1049060-01 ii
Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv
Terms and Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv
Manual Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vi
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Product Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Preparing for Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Required Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Required Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Required Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Bench Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Machine Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Component Installation Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
General Guidance on Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
TS-i4 IMU Sensor Orientation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Installing TS-i4 Blade Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Installing TS-i4 C-Frame Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
TS-i4 IMU Sensor Cable Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Installing TS-i4 Body Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Installing Cable Access Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Installing MC-X3 Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Installing GNSS Receivers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Install Main GNSS Receiver. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Install Auxiliary GNSS Receiver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Installing Diversity Antenna . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
Installing Radio Antenna . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
Cable Routing From GNSS Receivers and Antennas to MC-X3 . . . . . . . . . . . . . . . . . . . 2-16
Installing GX-55 Touchscreen Display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
Completing MC-X3 Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
Measurement, Configuration, and Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
Completing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
Regulatory Information and Safety Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
General Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
RF Radiation Hazard Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Regulatory Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Table of Contents

Table of Contents
iii P/N: 1049060-01
FCC Statements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
IC Statements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Déclaration de conformité IC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
EU Product Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
EU Declaration of Conformity (Radio Equipment Directive 2014/53/EU) . . . . . . . . . . . . 3-4
Open Source Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

P/N: 1049060-01 iv
Preface
Thank you for purchasing this Topcon product. The materials available in this Manual (the “Manual”)
have been prepared by Topcon Positioning Systems, Inc. (“TPS”) for owners of the covered Topcon
product (the “Product”), and are designed to assist owners with the Product. Use of the Product is
subject to these terms and conditions (the “Terms and Conditions”).
Terms and Conditions
Use
This Product is designed to be used by a professional. The user should have a good knowledge of the
safe use of the Product and implement the types of safety procedures recommended by the local
government protection agency for both private use and commercial job sites.
Copyrights
All information contained in this Manual is the intellectual property of, and copyrighted material of TPS.
All rights are reserved. Do not use, access, copy, store, display, create derivative works of, sell, modify,
publish, distribute, or allow any third party access to, any graphics, content, information or data in this
Manual without TPS’s express written consent and may only use such information for the care and
operation of the Product. The information and data in this Manual are a valuable asset of TPS and are
developed by the expenditure of considerable work, time and money, and are the result of original
selection, coordination and arrangement by TPS.
Trademarks
(List the appropriate product(s) here, including all trademarks), Topcon® and Topcon Positioning
Systems™ are trademarks or registered trademarks of TPS. Windows® is a registered trademark of
Microsoft Corporation. The Bluetooth® word mark and logos are owned by Bluetooth SIG, Inc. and any
use of such marks by Topcon Positioning Systems, Inc. is used under license. Other product and
company names mentioned herein may be trademarks of their respective owners.
Disclaimer of Warranty
EXCEPT FOR ANY WARRANTIES IN AN APPENDIX OR A WARRANTY CARD ACCOMPANYING THE
PRODUCT, THIS MANUAL AND THE PRODUCT ARE PROVIDED “AS-IS.” THERE ARE NO OTHER
WARRANTIES. TPS DISCLAIMS ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS
FOR ANY PARTICULAR USE OR PURPOSE.
Limitation of Liability
TPS AND ITS DISTRIBUTORS SHALL NOT BE LIABLE FOR TECHNICAL OR EDITORIAL ERRORS OR
OMISSIONS CONTAINED HEREIN; NOR FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES
RESULTING FROM THE FURNISHING, PERFORMANCE OR USE OF THIS MATERIAL OR THE
PRODUCT. SUCH DISCLAIMED INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDE BUT ARE
NOT LIMITED TO LOSS OF TIME, LOSS OR DESTRUCTION OF DATA, DAMAGE TO OR LOSS OF
LIVESTOCK AND/OR CROPS, LOSS OF PROFIT, SAVINGS OR REVENUE, OR LOSS USE OF THE
PRODUCT.
Please read the terms and conditions carefully.

Preface
vP/N: 1049060-01
IN ADDITION, TPS IS NOT RESPONSIBLE OR LIABLE FOR DAMAGES OR COSTS INCURRED IN
CONNECTION WITH OBTAINING SUBSTITUTE PRODUCTS OR SOFTWARE, CLAIMS BY OTHERS,
INCONVENIENCE, OR ANY OTHER COSTS. IN ALL CASES, TPS SHALL HAVE NO LIABILITY FOR
DAMAGES OR OTHERWISE TO YOU OR ANY OTHER PERSON OR ENTITY IN EXCESS OF THE
PURCHASE PRICE PAID FOR THE PRODUCT.
License Agreement
Use of any computer programs or software supplied by TPS or downloaded from a TPS website (the
“Software”) in connection with the receiver constitutes acceptance of these Terms and Conditions in
this Manual and an agreement to abide by these Terms and Conditions. The user is granted a
personal, non-exclusive, non-transferable license to use such Software under the terms stated herein
and in any case only with a single receiver or single computer. You may not assign or transfer the
Software or this license without the express written consent of TPS. This license is effective until
terminated. You may terminate the license at any time by destroying the Software and Manual. TPS
may terminate the license if you fail to comply with any of the Terms or Conditions. You agree to
destroy the Software and manual upon termination of the use of the receiver. All ownership, copyright
and other intellectual property rights in and to the Software belong to TPS. If these license terms are
not acceptable, return any unused software and manual.
Website; Other Statements
No statement contained at the TPS website (or any other website) or in any other advertisements or
TPS literature or made by an employee or independent contractor of TPS modifies these Terms and
Conditions (including the Software license, warranty and limitation of liability).
Technical Documentation and Utility Software
On the Topcon Support website (www.topconpositioning.com/support), or the Topcon Support app
(myTopcon NOW!) you can download manuals, technical documentation, training material, and
various utility software to help you set up and use your Topcon product. The website and app also
offer registration resources, training, and technical assistance.
Register for a free account at https://www.topconpositioning.com/accounts/profile/create today to
download this material.
Safety
Improper use of the Product can lead to injury to persons or property and/or malfunction of the
Product. The Product should only be repaired by authorized TPS warranty service centers.
Miscellaneous
The above Terms and Conditions may be amended, modified, superseded, or canceled, at any time
by TPS. The above Terms and Conditions will be governed by, and construed in accordance with,
the laws of the State of California, without reference to conflict of laws.

Preface
vi
P/N: 1049060-01
Manual Conventions
This manual uses the following conventions:
Convention Description Example
Bold Menu, or drop-down menu selection File > Exit (Click the File menu and click
Exit)
Name of a dialog box or screen From the Connection screen...
Button or key commands Click Finish.
Mono User supplied text or variable Type guest , and click Enter.
Italic Reference to another manual or help document Refer to the Topcon Reference Manual .
Notification that one or more steps may be taken to reduce effort, time,
and/or expense.
Further information to note about system configuration, maintenance, or
setup.
Supplementary information that if disregarded can have an adverse effect
on system operation, system performance, data integrity, or measurements.
Notification that an action has the potential to result in minor personal
injury, system damage, loss of data, or loss of warranty.
Notification that an action has the potential to result in personal injury or
property damage.
Notification that an action has the potential to result in severe personal
injury or death.

Product Description P/N: 1049060-01 1-1
Introduction
Product Description
3D-MCMAX integrated 3D machine control system together with the MC-X3 controller combines TS-i4
IMU sensors, GNSS receivers, and a GX-55 touchscreen display for the Topcon dozer grade control
system. This manual covers the installation procedure for the 3D-MCMAX integrated 3D machine control
system with MC-X3 control for the Caterpillar D5 and D6 dozers (Figure 1-1).
Preparing for Installation
Following the processes and recommendations in this section will help ensure that your installation
goes smoothly and minimizes the amount of time a machine is away from the work site.
Required Hardware
Open the hardware boxes and use the packing lists to confirm that all system items are present and
undamaged.
Figure 1-1: Major Hardware Parts—Dozer
HW KIT, DZR CR D5/D6 MAX X3 i3, P/N 1041569-01, is required for this
installation.
GR-i3/GR-i3F
Receivers (2 PLCS) GX-55 Touchscreen
Display
TS-i4 IMU Sensors
(3 PLCS - Body, C-Frame, Blade)
MC-X3 Controller
HW KIT, DZR CR D5/D6 MAX X3 i3, P/N 1041569-01, also includes hydraulic hose
and weld-on hose clamps. These should be cut to fit and used as needed to
protect cables, particularly for the blade, C-Frame, and body TS-i4 sensors.

Introduction
Preparing for Installation 1-2
P/N: 1049060-01
Figure 1-2: Caterpillar 3D-MCMAX D5/D6 Dozer System Diagram
TS-i4
BLADE
4060-0586 TERMINATOR
TS-i4
C-FRAME
TS-i4
BODY
4060-0586 TERMINATOR
3020-0526 TEE
3020-0623 TEE
MACHINE INTERFACE CONNECTOR (’3rd PARTY ARO’)
3-PIN
DEUTSCH
6-PIN
DEUTSCH UNSWITCHED
VOLTAGE SUPPLY (’3rd PARTY ARO’)
4060-0586 TERMINATOR
3020-0623
TEE
SPLICE
QTY 2
1040764-01
1033631-02
1041039-01 1041037-01
AUX GR-i3/GR-i3F MAIN GR-i3/GR-i3F
1040763-01
GX-55
MC-X3
SERIAL EXTERNAL RADIO
POPULATE GX-55
PINS AFTER
ROUTING CABLE

Introduction
Bench Test
1-3 P/N: 1049060-01
Required Tools
•MC Systems Calibration Kit, P/N 1031278-01
•Metric wrench set
•English wrench set
•Allen wrench set (English and metric)
•Drill
•Hole saw
•Grinder
•Sharp utility knife
•Wire cutters
•Standard screwdriver
•Tape measure
•Permanent marker or another marking pen
•Smart Level
•Spray paint (if needed, color to match machine paint)
Required Personnel
A qualified welder is required to install brackets for mounting system components and hose clamps
for system cables. Be sure to arrange for a qualified welder to be on site for the planned installation.
Bench Test
A Bench Test procedure should be performed in advance of the actual machine installation.
Machine Inspection
Perform a machine inspection to confirm that the dozer is in an acceptable condition for machine
control applications.
●Look for any damage that would prevent the installation and operation of the components.
●Ask the operator to perform machine movements to confirm that the hydraulic system operates
within normal parameters.
Component Installation Locations
●Identify all sensors and bracket installation locations.
For complete information about performing a Bench Test, refer to the Bench Test
procedure described in the MC-X Dozer Systems Reference Installation and
Calibration Manual (P/N 1044736-01).
It is important to consider freedom of movement for various machine parts
when routing cables, as well as the potential for debris striking installed
components.

Introduction
Component Installation Locations 1-4
P/N: 1049060-01
●Map out cable routing and hose clamp weld locations before welding.
●Be strategic when selecting locations and use a permanent marker to identify and outline
locations and orientations for the welder so that there are no problems.
●All inside machine measurements are taken in relation to the right blade tip (from the perspective
of the operator in the cab).
○Taking measurements may be easier if all sensor and cable routings are installed on the
right side of the machine.
General Guidance on Installation
The heat of welding can release toxic smoke from the area of the weld.
Follow established welding practices and use appropriate personal
protective equipment.
Welds at or near the top edge of platform brackets could prevent the
TS-i4 Sensor Guard Covers from seating properly.
Mounting brackets for TS-i4 IMU sensors used on the Blade, C-Frame, and
Body are shipped unpainted. Topcon strongly recommends painting these
brackets, after welding, to prevent rust and corrosion. Ensure threaded
holes remain free of paint.
Ensure that the mounting area is free of debris/dirt and that any existing
weld spatter/beads, burrs, etc., have been ground down so that the mount
will not be skewed when mounted.
Do not install the TS-i4 Sensor Guard Covers (P/N 1032188-01 or
P/N 1034177-01) on the standoffs until after the system has been fully
measured up and calibrated.
Magnetic mounts are not an approved permanent mounting method for the
TS-i4 IMU sensors or the GR-i3/GR-i3F receivers. Images including
magnetic mounts for TS-i4 IMU sensors or GR-i3/GR-i3F receivers or parts
of different machines are presented solely for general guidance.

TS-i4 IMU Sensor Orientation P/N: 1049060-01 2-1
Installation
TS-i4 IMU Sensor Orientation
The TS-i4 IMU sensor orientation is described using the X, Y, and Z axes where Z runs up and down,
X runs lengthwise across the sensor and through the connectors, and Y runs across the width or the
edge with no connectors (Figure 2-1).
Figure 2-1: TS-i4 IMU Sensor Orientation
Follow the specific installation instructions for each TS-i4 IMU sensor installation location.
Installing TS-i4 Blade Sensor
The TS-i4 Blade sensor is installed on the back of the dozer blade using the TS-i4 Blade Mounting
Bracket Kit (P/N 1040650-01).
Orientations:
•Parallel to the blade’s cutting edge bolts with connectors (X-axis) facing left and right (Figure 2-1).
•Label Up or Label Down (Z-axis vertical, refer to Figure 2-1).
•Installed on the left or right side on the back of the dozer blade (Figure 2-2 on page 2-2).
1. Map out the cable routing, clearance for protective cable cover, and hose clamp locations to
identify a suitable location for the weld plate.
2. Consider the range of movement for the blade, supporting structure, hydraulic cylinders, and
hydraulic hoses when routing cables.
Use the TS-i4 IMU sensor with the lowest serial number for the Blade and the TS-i4
IMU sensor with the highest serial number for the Body.

Installation
Installing TS-i4 Blade Sensor 2-2
P/N: 1049060-01
3. Provide adequate clearance for connection to protected M12 cable, strain relief plates, and
cover.
4. Minimize the potential for debris striking the TS-i4 IMU sensor.
5. Prepare the back of the blade by removing any debris in the area where the TS-i4 IMU sensor
will be installed (Figure 2-2).
Figure 2-2: TS-i4 Blade Sensor Installation Location
6. Position the 4 Hole Weld-on plate (P/N 9625-1009), provided in TS-i4 Dozer Base Platform
bracket, P/N 1040755-01 (Figure 2-3), on the back of the blade.
7. Use a smart level to ensure the plate is level and parallel to the cutting edge bolts.
8. Use a permanent marker to outline the 4 Hole Weld-on plate location on the blade for welding.
Figure 2-3: TS-i4 Dozer Blade Base Platform Bracket, P/N 1040755-01
TS-i4 IMU sensor can be mounted on either the
left or right side on the back of the blade.
TS-i4 SENSOR
HOSE STRAIN
RELIEF PLATE
M16 x 18 HH
8 PLCS
WASHER,
.31 X .75 X .06
4 PLCS
COVER
STANDOFF, M-F
M6 x 30MM
4 PLCS
TS-i4 IMU SENSOR
4 HOLE WELD-ON PLATE
TS-i4 DOZER BASE
PLATFORM
WASHER, .42X.81X.12
4 PLCS
M10-1.5 X 25 HH
4 PLCS
TERMINATOR
WASHER, FLAT
M6 - THICK STEEL
2 PLCS

Installation
Installing TS-i4 Blade Sensor
2-3 P/N: 1049060-01
9. Prepare the welding area (Figure 2-4). Grind off the paint on the blade where welds will be
applied. To allow a proper weld, grind off the paint on the blade where welds will be applied. It is
typically sufficient to weld along the two short sides of the weld plate. However, depending on
the design of the blade, it may be necessary to weld along one or both of the long sides of the
weld plate to ensure rigid attachment to the blade.
Figure 2-4: Mark Weld Plate Location and Grind Weld Area
10. Orient and level the weld plate (Figure 2-4).
11. Clamp the weld plate to the blade using magnets or another suitable method. The weld plate
should be positioned within 2 degrees of the plane of the cutting edge bolts (Figure 2-5).
Figure 2-5: Position and Weld the Weld Plate
Welding preparation is not machine-specific. Figure 2-4 and Figure 2-5 are
intended to illustrate the preparation process and may include different
machine makes and/or models.
The heat of welding can release toxic smoke. Follow established practices
for removing paint in weld area. Wear an appropriate respirator or mask.

Installation
Installing TS-i4 Blade Sensor 2-4
P/N: 1049060-01
12. Weld the 4 Hole Weld-on plate (Figure 2-3 on page 2-2) to the back of the dozer blade, using a
suitable welding method (Wire Welding or Stick Welding), weld the 4 Hole Weld-on plate to the
back of the dozer blade. The weld leg size should be 6 mm (1/4 inch), and weld lengths should
be at least 50 mm (2 inches).
13. Remove any weld slag using a slag hammer or other suitable tool. Clean off the weld by
scrubbing with a wire brush to prepare it for painting.
14. Paint the plate and welds with a rust-preventive paint in a color matching the machine to
prevent rust and corrosion.
15. Secure the TS-i4 Dozer Base Platform bracket to the weld-on plate using the supplied M10
bolts and washers.
16. Mount the TS-i4 IMU sensor to the TS-i4 Dozer Base Platform bracket, using two inside pairs
of drilled holes (A) and the supplied hex screws (Figure 2-6).
Figure 2-6: Drilled Holes in TS-i4 Dozer Base Platform Bracket
17. Use two of the standoffs to secure one strain relief plate to the TS-i4 Dozer Base Platform
bracket using drilled holes (B) as shown in Figure 2-6. The strain relief plate should face
towards the center of the blade.
18. Use one flat M6 washer as spacer under each standoff on the side with the terminator. Screw
the standoffs into the TS-i4 Dozer Base Platform bracket (Figure 2-3 on page 2-2).
19. Attach the terminator to the outside connector of the TS-i4 IMU sensor (Figure 2-3 on
page 2-2).
20. Ask the operator to move the blade through the entire range of blade positions. Determine the
length of protective hydraulic hose needed to protect the M12 cable from the TS-i4 Blade
sensor to the planned location of the TS-i4 C-Frame sensor.
21. Cut the protective hydraulic hose to the required length.
22. Determine where to position the provided weld-on hose clamps to secure the protected M12
cable from the TS-i4 Blade sensor.
23. Weld the weld-on hose clamps.
24. Thread the M12 cable for the TS-i4 Blade sensor through the protective hydraulic hose.
A
B
B

Installation
Installing TS-i4 C-Frame Sensor
2-5 P/N: 1049060-01
Figure 2-7: Secure and Protect the TS-i4 Blade Sensor
25. Connect the M12 cable to the inside connector of the TS-i4 Blade sensor (Figure 2-7).
26. Use two hose clamps to secure the protected M12 cable in position on strain relief plate
(Figure 2-7).
27. Secure the protected M12 cable in the weld-on hose clamps.
Installing TS-i4 C-Frame Sensor
The TS-i4 C-Frame sensor is mounted on the frame between the TS-i4 Blade sensor and the dozer’s
front grill using the 3rd TS-i4 Add-On Kit (P/N 1043613-01).
Orientations:
•Label Up or with Label Down (Z-axis vertical refer to Figure 2-1 on page 2-1).
•Mounted with connectors (X-axis) either parallel to the dozer blade or parallel to the centerline of
the body (refer to Figure 2-1 on page 2-1).
1. Map out the cable routing, clearance for protective cable cover, and hose clamp locations to
identify a suitable location for the weld plate.
2. Consider the range of movement for the blade, supporting structure, hydraulic cylinders, and
hydraulic hoses when routing cables.
3. Provide adequate clearance for connection to protected M12 cable, strain relief plates, and
cover.
4. Remove any debris in the area where the TS-i4 IMU sensor will be installed.
Standoff
(4 PLCS)
M6 Washer as
Spacer (2 PLCS)
Strain Relief
Plate
M12 Cable Protected
with Hydraulic Hose
Hose Clamps
(2 PLCS)
Terminator

Installation
Installing TS-i4 C-Frame Sensor 2-6
P/N: 1049060-01
Figure 2-8: TS-i4 Sensor Secured to C-Frame
5. Position the Excavator TS-i4 Guard Weld-On Base plate (P/N 1032189-01) from the 3rd TS-i4
Add On Kit (P/N 1043613-01) either parallel to the dozer blade or parallel to the centerline of the
body (Figure 2-8).
6. Use a permanent marker to outline the weld-on plate location on the C-frame for welding.
7. Prepare the welding area by grinding off the paint around the area where the weld-on plate will
be installed.
8. Position the weld-on plate using clamps or magnets.
9. Weld the weld-on plate to the dozer C-Frame, using a suitable welding method (Wire Welding or
Stick Welding). The weld leg size should be 6 mm (1/4 inch), and weld lengths should be at least
50 mm (2 inches).
10. Remove any weld slag using a slag hammer or other suitable tool. Scrub off the weld with a wire
brush to prepare it for painting.
11. Paint the weld-on plate and welds with rust-preventive paint, in a color that matches the
machine. Keep threaded holes clear of paint.
12. Mount the TS-i4 IMU sensor to the weld-on plate.
13. Use four standoffs to secure two strain relief plates to the weld-on plate (Figure 2-8).
14. Connect the protected M12 cable from the TS-i4 Blade sensor to the TS-i4 C-Frame sensor.
15. Secure the protected M12 cable from TS-i4 Blade sensor to the TS-i4 C-Frame sensor strain
relief plate using two hose clamps (Figure 2-8).
Strain Relief
Plate (2 PLCS)
Standoff
(4 PLCS)
Protected
M12 Cable
Hose Clamp
(4 PLCS)

Installation
TS-i4 IMU Sensor Cable Routing
2-7 P/N: 1049060-01
TS-i4 IMU Sensor Cable Routing
Figure 2-9: M12 Cable Route from TS-i4 Blade Sensor to Body Sensor and Machine Entrance
1. Determine the amount of protective hydraulic hose that will be required to protect the M12
cable from the TS-i4 C-Frame sensor to the machine entrance point (under cab floor),
following the existing cables and cable troughs (Figure 2-9).
2. Cut the hydraulic hose to the required length. Using a grinder or file, clean off any sharp burrs.
3. Determine where to position the provided weld-on hose clamps for welding to the machine.
4. Weld the weld-on hose clamps that will be used to secure the protected M12 cable from the
TS-i4 C-Frame sensor.
5. Feed the M12 cable through the protective hydraulic hose.
6. Route the protected M12 cable from the TS-i4 C-Frame sensor to the area where the TS-i4
Body sensor will be installed following existing hydraulic lines (Figure 2-9)
7. Connect the protected M12 cable to the TS-i4 C-Frame sensor.
8. Secure the protected M12 cable to the weld-on hose clamps.
9. Secure the protected M12 cable to the TS-i4 C-Frame sensor on the strain relief plate using
two hose clamps (Figure 2-8 on page 2-6).
M12 Cable from TS-i4
Blade sensor to TS-i4
C-Frame sensor
TS-i4
Blade
sensor
TS-i4
C-Frame
sensor
TS-i4
Body
sensor
M12
Cable
Route
Machine
entrance
point to
MC-X3

Installation
Installing TS-i4 Body Sensor 2-8
P/N: 1049060-01
Installing TS-i4 Body Sensor
The TS-i4 Body sensor can be located under the tracks of the machine (Figure 2-10). It is mounted
to the outside of the dozer body using: TS-i4 Body Mounting Kit (P/N 1040867-01) and 4 Hole Weld-
on plate from the Blade/Body IMU Weld Plate & Hardware Kit (P/N 1047707-01) as shown in
Figure 2-10.
Figure 2-10: TS-i4 Body Sensor Installation Locations for D5 & D6
Orientations:
•Installed with Label Up or Label Down (Z-axis vertical Figure 2-1 on page 2-1).
•Installed with connectors (X-axis) facing towards the rear and front of the machine (Figure 2-1 on
page 2-1).
•Position the weld-on plate so that it is:
○Flat against the sidewall surface.
○Parallel with bottom of tracks.
○On the tractor frame and not on the isolated cab mounted above the tractor frame.
Welding should be done on the thick sidewall and not on access panels.
○Protected from mechanical wear and physical damage.
1. Position the weld-on plate from the Blade/Body IMU Weld Plate & Hardware Kit
(P/N 1047707-01) so that it is parallel to the centerline of the dozer body.
2. Use a permanent marker to outline the weld-on plate location for welding.
3. Position the weld-on hose clamps on the body side wall. Do not position them onto any access
panels.
4. Use a permanent marker to outline the weld-on hose clamp locations on the body for welding.
TS-i4 IMU sensor can be located on
either the left or the right side of machine
Ensure that the mounting location does not inhibit future machine servicing needs.

Installation
Installing TS-i4 Body Sensor
2-9 P/N: 1049060-01
5. Prepare the welding areas by grinding off the paint around the area where the weld-on plate will
be installed.
6. Position the weld-on plate using clamps or magnets so that it is within two degrees of the plane
of the grouser pads.
Figure 2-11: TS-i4 Dozer Base Platform (P/N 1040755-01) for TS-i4 Body Sensor Installation
7. Weld the weld-on plate to the dozer body using a suitable welding method (Wire Welding or
Stick Welding). The weld leg size should be 6 mm (1/4 inch), and weld lengths should be at least
50 mm (2 inches).
8. Position the weld-on hose clamps.
9. Weld the weld-on hose clamps to the dozer body using a suitable welding method.
10. Remove any weld slag using a slag hammer or other suitable tool. Scrub off the welds with a
wire brush to prepare them for painting.
11. Paint the weld bracket, weld-on hose clamps, and welds using rust-preventive paint, in a color
that matches the machine.
12. Secure the TS-i4 Dozer Base Platform bracket (P/N 1040755-01) to the weld-on plate
(Figure 2-11) using the supplied M10 bolts and washers.
13. Mount the TS-i4 IMU sensor to the TS-i4 Dozer Base Platform bracket using the two inside
pairs of drilled holes (A) and the supplied hex screws (Figure 2-6 on page 2-4).
14. Use two standoffs to secure each of the strain relief plates to the TS-i4 Dozer Base Platform
bracket using drilled holes (B) as shown in Figure 2-6 on page 2-4.