Release Notes and Installation Procedure for Driver Safety System (DSS) Onboard Software {1926, 7000, 7348, 7606, 7960} Caterpillar

Machine Control and Guidance Products

CATSAFETY (S/N: SSX1-UP)

Introduction

This Special Instruction contains release notes and installation procedure for Driver Safety System (DSS) onboard software.

Do not perform any procedure in this Special Instruction until you have read the information and you understand the information.

Important Safety Information

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

A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools 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.

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.

Ground the equipment. Improper grounding will result in electrical current paths that are uncontrolled and unreliable. Uncontrolled electrical circuit paths can result in damage to the equipment. Uncontrolled electrical circuit paths can also cause electrical activity that may degrade the electronics and communications. Ensure that all grounds are secure and free of corrosion.

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Do not operate or work on this product unless you have read and understood the instruction and warnings in the relevant Operation and Maintenance Manuals and relevant service literature. Failure to follow the instructions or heed the warnings could result in injury or death. Proper care is your responsibility.

Note: Materials related to this product family can be found in the Caterpillar Service Information System by searching for media related to serial number (S/N: SSX).

Note: The software upgrade for the Cat Driver Safety System (DSS) will be available starting March 2018, version 4.4 will provide a host of usability, feature, and performance enhancements.

Note: The improved DSS software release is available to all customers using the Mining 3.1 and 4.0 hardware versions and DSS-H hardware. It is upgradable from previous software versions.

Terms for Reference

• The Electronic Control Module will be described as "Module" or "ECM".

• The on-board hardware or In Vehicle System will be referenced as "IVS".

• The off-board applications will be referred as "DSSi".

• Hardware Version 3.1 refers to 485-7946 Electronic Control Gp (ECMs) that are blue in color.

• Hardware Version 4.0 refers to 500-8876 Control (ECMs) that are black in color.

• "DSS-H" refers to the Highway Product which is green in color.

• Mining features are reference to software installed on the 3.1 and 4.0 hardware.

• "DSS-H" features are reference to software installed on the Highway hardware.

Hardware Compatibility

Improved DSS software files are available for both the version 3.1 and version 4.0 hardware series.

Required Parts

The new software part numbers and associated hardware are listed in Table .

DSSi Compatibility

Software version 4.4 should be used with DSSi version 2.12 and later. The web application can be accessed at the below address:

https://catdssi.com

Features and Improvements

The improved DSS software version v4.4 has various features and improvements that are listed below:

• Ability to update software releases over the air.

- Ability to update software releases over the air saves 1-2 hours of time per machine for software updates, by eliminating the need to physical connection to the unit for software upload and reconfiguration of the In-Vehicle System (IVS). Allows customer to adopt future software enhancements in a timely manner as opposed to scheduling and downing a machine.

• Ability to configure a fixed radius and suppress selected events in that radius.

- Allows customer to select areas and enables the system to suppress events such as off-road attention events at intersections, mine switch backs, and fixed infrastructure. Sample study shows 15% of distraction events can be reduced during typical safe driving behaviors at intersections.

• Updated patches to firmware vulnerability to the boot loader with a software lock and fixes existing units with corrupted carrier boards.

• All user level passwords have been changed.

• Enhancements to glance down logic to reduce glance down software classification as fatigue events.

• More detailed diagnostics sent to DSSi when VIMS ECM (A5N2) base machine data kit is installed.

• Built-in software tool to provide high-resolution event data to enable development of future algorithm enhancements and software improvements.

Changes from version 4.3

The improved software version 4.4 has the following changes from the previous version 4.3:

Use MSATA for non-OS Data (Mining 4.0)

During the image and install process, there is logic that determines if the device is 4.0 Mining Hardware and if it is, the MSATA drive is mounted as a filesystem (configured to be used) and all the DSS logging will then be logged to "/mnt/loggingpartition" using the same path names. Example: (/mnt/loggingpartition/home/dss/…)

When using MSATA anything that is not OS-related (all data pertaining to DSS and DSS logging) will be saved to a different physical memory which translates to different logging locations.

Note: With 4.0 Hardware log files will be located in the (/mnt/loggingpartition/home/dss/..).

Note: With 3.1 Hardware log file will be located in the /home/dss/logfiles and /logdisk directory).

Runlog names have been updated

Updated the logging mechanism for all logs.

All log files are now named in accordance with their top-level directories. Nothing is named only runlog as of this release.

Ability to Sanitize Global Positioning System (GPS) Locations from all Transmitted Files

While the system continues to use Global Positioning System (GPS) location data to make speed and location determination, this data (specific Latitude and Longitude values) are not logged in any way to the EODs that are sent up. There is a new configuration setting (Log Vehicle Location) that, if disabled, suppresses all GPS location information from being logged to all transmitted files. Latitue/Longitude values must be populated for DSSi. So they will come through as 200,200 and DSS will supply a flag indicating that we are suppressing vehicle location.

The system can now be configured to do not log GPS location info to all Event EODs (Fatigue, Distraction, Heartbeats, etc.,) while not losing any event detection functionality.

Note: Enabling this feature must be requested through CAT Zendesk support.

High-Quality Fatigue Events

New configuration settings have been added that allows a site to control if a High Quality Fatigue Events (HQFE) can be created, how often, how many per period, and how long videos should be that record a special research type event alongside a normal fatigue event. This does not impact normal fatigue capture with the normally defined Fatigue event being generated and uploaded in parallel with the new HQFE.

HQFEs are Fatigue events that are recorded and uploaded to the relay server and then sent back to Caterpillar. The files for these events are larger, uncompressed fatigue EODs that are generated for the sole purpose of being used for Research Data and Algorithm training to enable future product improvements.

Note: Enabling this feature must be requested through CAT Zendesk support.

Enable Location Based Services and Event Suppression (Mining 3.1/4.0)

A file will be built by the CAT support team with input from the dealer or customer.

When Location Based Services are configured to be used, the system will look for a file on the relay server at startup. The file will be downloaded and applied during the application launch.

When the file is applied and configured to do so, event behavior can be modified. Fatigues, Distractions, FOVs, Overspeed alerts and reporting can be suppressed and overspeed limits can be modified.

Location Based Services (LBS) provides the ability for the system to ingest Geo-Fence files, that provide circular areas defined by Latitude and Longitude points and a radius.

While the vehicle location is determined to be in a “Geo-Fence” this system can modify specific event rules for alerting and reporting purposes.

Note: Enablement of this feature must be requested through CAT Zendesk support by providing the following information:

• Suppression circle name.

• Center of suppression circle in decimal format Latitude and Longitude.

• Radius of suppression circle in meters.

• Special overspeed limit or no overspeed limit change.

• Events to be suppressed.

Enables Over the Air (OTA) Update of Future Software Releases (Mining 3.1/4.0)

• After successfully updating to v4.4 the OTA process can be used to update future onboard software releases without physical contact of the IVS.

• By creating different partitions on the IVS, an OTA package can be applied to the back office and downloaded. Once the package is downloaded the system will reimage and update at the next power cycle.

Note: Enablement of this feature must be requested through CAT Zendesk support and will be done in the future to update from 4.4 to 4.5 release packages.

Note: During the OTA process, there are instances where failure can occur and logic has been added to catch these failures with better resolution and logging such that better support can be applied.

Note: The OTA process will also record “OTA Failure EODs” where failure reason is sent up to DSSi with logic to ensure the old OS is loaded such that driver coverage is not lost.

Configuration File Merger Run during OTA Process

• During the OTA updating process, the older configuration file is merged into the new configuration file scheme automatically with the old settings, where applicable, are moved to the new configuration and any new settings are populated with default configurations.

• No need to load a new configuration during an OTA update.

• As the OTA represents newer software, the configuration merger will be run to ensure that the older configuration and its values are ported to the potentially different, new, configuration file without regression or loss of previous settings where applicable.

Implement 3G Recovery Logic (Mining 4.0 using Internal GSM Communication)

When configured to use a 3G connection and files fail to be uploaded to the configured server from the DSS box, logic kicks in that determines the state of the 3G modem. If the modem is determined to be disconnected from network for some configurable period, then the system will attempt to reset the modem. This process continues until either a network can be reached or the modem is reset for three times and the system rebooted.

New logic is in place that can better determine if a 3G connection has been lost during a trip that then triggers processes that attempt to recover the 3G connection in a timely manner.

Send Shutdown Reasons to DSSi

• New shutdown categories have been created that classify each type of shutdown into five subtypes ("Abnormal", "No End Type", "Normal", "Known System Failure"and "System Shutdown") and ten reasons ("Unknown", "No End Reason", "Ignition Off", "App Restart Limit", "Modem Lockout", "GPS Error", "High Temp Error", "Camera Error", "Carrier Board Failure", "3G Correction"). When either of these shutdown types is detected by the system, the Trip End EOD is updated with the appropriate flags notifying the "Shutdown Type" and "Shutdown Reason". Abnormal shutdown caused due to power cuts are reported in the Trip Start EOD of the next trip. These EODs are uploaded normally with DSSi parsing and displaying the information for Support and Monitoring team.

• The system now reports why a shutdown occurred and what kind of shutdown it was (normal or abnormal) via EODs that are sent to DSSi. This gives more insight into the Trip Cycle for each device, enables consumers to identify trends and speed up troubleshooting.

Updated Carrier Board Bootloader

• The new Carrier Board Bootloader now prevents lockout or corruption during startup and improved versioning information.

• New Carrier Board Bootloader included with version 4.4 has enhanced functionality that better handles the need to enter the bootloader mode to not expose firmware to possible corruption. A "handshake" element was added and ensures that the carrier board is ready to enter programming mode and that no other resources are being used.

Updated Carrier Board Firmware Update Process

• A new bootloader has been added to the CB during the imaging process that provides better control and information over the unit.

• The bootloader provides consistent version information across platforms.

• New bootloader uses a complicated handshake to prevent accidental corruption of the CB Bootloader

Carrier Board (CB) Recovery Logic

• On each boot, the Carrier Board update logic is run to determine if the firmware is up to date as well as checking for corruption. This is checked on every boot and has increased the boot time for a system that has corrupted FW to allow for recovery.

• On every boot, the Carrier Board update logic is run that queries the registers for current version information as well checking the integrity. If there is an update in the update directory for the CB firmware, the update process will be run. If the integrity of the Carrier Board firmware is found to be broken, the system will reload the "last good" firmware from a saved location in the memory.

• During this process, other logic will maintain firmware integrity while the system is checking update status and health.

Loading Page Displayed During Boot

• A "Loading Page" is displayed if a user tries to engage the web application while the Carrier Board update process is being run to prevent firmware corruption or anytime the application is not fully ready to launch.

• During the startup process, the carrier board is engaged with checks to state of the carrier board firmware and if it needs to be updated.

• If the "loading" page is seen, the web application will need to be refreshed before using the web application.

Default Configuration File Updated

• The new default configurations have been reviewed and agreed upon such that on any fresh image, the system can work with minimal interaction from the "Install Wizard".

• Default configuration has been baked into each image with agreed upon parameters that provide a “default” level of service right after install. With these, there should only need to be the minimal amount of post install configuration needed. Modifications are specific to platform.

Note: Default changes are listed below:

• Disable when speed not available is now unchecked by default for fatigue events.

• Distraction speed default is set to 15 KPH.

• Distraction time default is set to five seconds.

• Distraction angles are set to below values:

- Left and Right 35°

- Up and Down 30°

• When merging existing parameters ensure that these new defaults are the recommended settings, but can be over written.

Passwords for IVS Webpage and Root Folder Have Changed (Mining 3.1/4.0)

• All passwords used to access the system either from a maintenance terminal or web app have been changed to allow for dealers and customers to better restrict access to systems.

• The method to login to the device has not changed, only the passwords were changed.

• The passwords for "Technician" and "Admin" can be requested through CAT Zendesk Support.

Implemented a "Timeout Window" for System Restart on App Restart

• During runtime, if an app is restarted three times within this configured window, then the whole system will be started. If however, the app comes back up within the timeout window and stays up longer, then the counter is reset to zero. This ensures that the system stays active if possible.

• A configuration setting can now be set to allow the entire system restarts whenever an app reboots three times, and any value in between will be the number of minutes, default is 10 minutes. An app will have to restart three times in before a full system reboot occurs.

Bootstrap Logging Updated

• Bootstrap log will contain information logged to it on each run to capture messaging from other improved systems.

• Logic has been added to the Bootstrap logger that now captures all log messages that were originally only printed to the screen. These are now written to the bootstrap text file that is uploaded to DSSi.

Web App Improvements

Several improvements have been made to web app that are listed below:

• Never Use Default Route for Ethernet on Mining 4.0 is set to "DISABLED" on install.

- This setting should be checked only when the internal Wi-Fi or internal GSM modem is used on the Mining 4.0 systems.

- This setting should never be used on Mining 3.1 systems.

• Location Based Services (LBS) configuration enablement added to technician access.

• "Restart on GPS Error" configuration option has been removed from technician access.

• Removed ability to type in IP address for Wi-Fi IP in install wizard. Static internal wireless addressing is not currently supported in the software.

• Configuration settings added for Vehicle Data input from VIMS (A5N2) equipped machines.

• Fields for software update account name and password added.

Changes for Customers Using Manual Downloads

• Security changes have restricted the process for manually downloading EOD files.

• Manually downloading files using programs such as "WinSCP" will be limited.

Note: Contact support if your organization uses this process for updated process flow.

Driver Tracker Improvements

Head tracker

• Logic improvements to head pose calculations.

• All changes for better tracking when eyewear is worn included in v4.2 and v4.3 are carried forward.

Eye Lid Tracker

• All updated algorithms applied in 4.3 are carried forward.

Technician Notes

Refer the following changes, lessons learned, and common support inquiries given below:

• Mining 4.0 Hardware will not report an accurate CMOS battery value.

- To prevent the "drain" on the CMOS battery the circuit was modified and an accurate value will not be read through the software or displayed on the dashboard. The battery will now provide the expected 10-year life span. If issues with the real-time clock occur, contact CAT Zendesk support.

• Self-Test features using the 4.0 Camera are carried forward from the 4.3 branch of software.

• For machines that will be underground for their entire life cycle, verify that the relay server allows for connection to an NTP server for time. If the server does not, the systems must be bench configured and connected to GPS, so that time will synchronize the system clock.

• If the IVS LEDs illuminate solid red during the initial system flash, verify that the correct iso image has been applied to the software dongle. If an image for 3.1 hardware is applied to Mining 4.0 hardware the LEDs will illuminate solid red and the image will not mount. Remove the dongle and cycle power. The system will reboot to the previous state. The same applies for a 4.0 image on a 3.1 hardware set.

• The update on units with carrier board corruptions may not be successful. If a failure occurs contact CAT Zendesk support prior to any power cycles or re attempts at software installation.

Software Installation

USB Dongle Creation

Note: Contact CAT Zendesk support for issues and questions related to software image creation.

1. Download the appropriate iso image from the release section of "dealer.cat.com" and the v2.1.4 dongle creator.

2. The iso image should be placed on the desktop of the PC that will be used to build the USB dongle update drive.

3. Run the Dongle creator as an "Administrator" to successfully build the flash image.

IVS Software 4.4 update Process (Version 4.4.0.371118)

Read and Heed Warning

Note: The flash update process has changed. Read and Heed all instructions prior to installing software and review all notes for special attention.

Note: The process for units with stable carrier boards and carrier boards with issues are unique. Stable carrier boards will have functioning LED peripheral indicators and the reported CPU temperature will be a non-zero value.

Note: This update applies to units with 4.2 A and B and 4.3 A and B, any previous versions should be updated to one of the previously mentioned builds prior to updating to 4.4.

Note: This release requires the minimum DSSi version 2.12 unless special provisions are made for legacy self-hosted customers.

Unit Update with Stable Carrier Board (Mining 3.1/4.0)

Note: The preferred method to perform this recovery is with the system installed on a bench with a known good camera connected to port #2.

Note: Use a timer after step 7 to determine next step actions.

Note: If this process is not followed more corruption can occur that may not be field repairable.

Note: If a unit does not recover using this process, contact CAT Zendesk support before removing power.

Note: Disconnect the Ethernet cable during the update process except when required for the IVS wizard.

Note: Do not interrupt power during this process.

1. Create a software update dongle (USB drive) using a minimum 4GB device and IVS Recovery Dongle Creator V2.1.4 or greater.

2. Power OFF the system.

3. Remove the Ethernet connection to the network port.

4. Insert 4.4 software USB into USB port 1 of the IVS.

5. Power ON the unit.

6. The flash image will download and then the reimaging process will begin, this will take at least 20 seconds for the download, and can take up to 90 seconds.
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   Illustration 1	g06297024
   LEDs color change from Green to Orange

7. All LEDs will blink from Green to Orange as the update occurs, this will take up to 5 minutes (Refer to Illustration 1.
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   Illustration 2	g06297025
   LEDs illuminate in solid Red color

8. The Orange LED flashing will stop, now remove the USB, and wait for 60 seconds. (Refer to Illustration 2.)

9. All LEDs will illuminate with solid red.

10. The solid red LEDs will remain illuminated for at least 2 minutes and 30 seconds. Do not connect to the Ethernet port and do not remove power during this update. Doing either of these can lock the software loader and make the update unsuccessful.

11. The red LEDs will turn off and only the Green PSU light will remain illuminated followed by all lights flashing once. Then the PSU green LED only will illuminate for 15 seconds.

12. All LEDs will then flash Green to Red for 30 seconds.

13. Then all LEDs will turn off and only the Green PSU light will remain illuminated for 20 seconds.

14. All LEDs will blink red to green once indicating the completion of the installation and system reboot.

15. Only the PSU light will remain illuminated green until the system is configured and initialized.

16. Connect to the system using an Ethernet cable and use the default address 192.168.1.1 to access the DSS Install Wizard.

17. Complete the IVS Install Wizard and required configuration.

18. After completing the installation wizard, enter the Machine ID followed by the manufacture and machine model. Examples:

    1. HT1001 CAT 789D

    2. DT1002 Hitachi EH5000AC-3

    3. 1003 Komatsu 980E-4
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    Illustration 3	g06297026
    Dashboard view

19. Validate that the software version and the firmware version have updated by viewing the IVS dashboard (refer to Illustration 3. The software version will begin with 4.4.0 and the carrier board firmware version will be 1.3.0.

20. The technician password is changed as given below:

    1. User Name: dss

    2. Password: catdss01

Note: The preferred method to perform this recovery is with the system installed on a bench with a known good camera connected to port #2.

Note: Use a timer after step 7to determine next step actions.

Note: If this process is not followed more corruption can occur that may not be field repairable.

Note: If a unit does not recover using this process, contact CAT Zendesk support before removing power.

Note: Disconnect the Ethernet cable during the update process except when required for the IVS wizard.

Note: Do not interrupt power during this process.

1. Create a software update dongle (USB drive) using a minimum 4GB device and IVS Recovery Dongle Creator V2.1.4 or greater.

2. Power OFF the system.

3. Remove the Ethernet connection to the network port.

4. Insert 4.4 software USB into USB port 1 of the IVS.

5. Power ON the unit.

6. The flash image will download and then the reimaging process will begin.

7. Start a timer when the PSU light illuminates solid green. The lights for the peripheral will not illuminate until the software for the carrier board has been rewritten.

8. Remove the USB once the timer reaches five minutes.

9. The system will now check the carrier board firmware health and reboot three times over a period of eight minutes while the carrier board firmware is updated.

10. After the timer reaches 13 minutes, stop the timer and connect an Ethernet cable to begin the IVS installation wizard.

11. Connect to the system using an Ethernet cable and use the default address 192.168.1.1 to access the DSS Install Wizard.

12. Complete the IVS Install Wizard and required configuration.

13. After completing the installation wizard, enter the Machine ID followed by the manufacture and machine model. Examples:

    1. HT1001 CAT 789D

    2. DT1002 Hitachi EH5000AC-3

    3. 1003 Komatsu 980E-4

14. After the installation wizard has been completed, click through the pop up to allow the system to reboot.

15. Remove the Ethernet cable connection.

16. Reset the timer to zero and restart.

17. The boot loader will check the boot loader health and begin to update. This can take up to 6 minutes.

18. All LEDs will illuminate with solid red while the boot loader extracts.

19. After the LEDs have illuminated to solid red, wait up to an additional three minutes for the boot loader to apply.

20. The red LEDs will turn off and only the green PSU light will remain illuminated followed by all lights flashing once. Then the PSU green LED only will illuminate for 15 seconds.

21. All LEDs will then flash green to red for 30 seconds.

22. Then all LEDs will turn off and only the green PSU light will remain illuminated for 20 seconds.

23. All LEDs will blink from red to green once indicating the completion of the installation and system reboot.

24. The system will now boot to normal operational mode.

25. The timer can be stopped and reset.

26. Validate that the software version and the firmware version have updated by viewing the IVS dashboard. The software version will begin with 4.4.0 and the carrier board firmware version will be 1.3.0.

27. The technician password is changed as given below:

    1. User Name: dss

    2. Password: catdss01