Cat® Terrain v7 for Grading and Loading Caterpillar

Startup

The onboard software on the machine powers up when the ignition key switch of the machine is turned to the ON position.

The computer system completes the following prior to running the onboard application:

• BIOS Power On Self-Test (POST)

• Operating system startup

• Onboard software startup

Note: Once power has been applied to the onboard software, do not interrupt the power until the onboard software is running. While the system is starting up, cutting off the power may corrupt the software.

Modes of Operation

There are four modes of operation for the onboard software:

• Startup

• Normal operating

• Service

• Shutdown (new in v5.2)

Startup Mode

The onboard software enters startup mode when the ignition keyswitch is turned to the ON position. Each module in the system performs a POST. The results of the test are stored until the system enters Normal Operating mode.

Note: Improper startup can corrupt the onboard software.

Illustration 1	g03394918
G610 display module startup screen

G610 Display Module - A 30 second startup sequence begins. During the startup, the screen goes through several color transitions, then opens a screen with a Cat logo indicating that the onboard software is starting. The startup screen is shown in Illustration 1 .

For an Electric Rope Shovel (ERS) the startup may be longer than 30 seconds as the Terrain software and OPC Server software connect. After the Cat logo appears, the G610 display module appears mostly black for up to 1 minute. The onboard software then attempts to connect to the OPC server. If after 3.5 minutes the software does not connect to the OPC server, a warning message appears.

Touch the warning to close the message, if required. The onboard software continues to attempt to connect.

Normal Operating Mode

In normal operating mode, position data is continuously collected to perform the following operations:

• Calculate the productivity.

• Update the monitor display.

• Update the site information.

When using a GIS database, the startup may be longer than expected as the Terrain software and the GIS connect. Terrain stores the valid GIS data from within a 500 m radius of the machine on shutdown. This data is available to the operator while Terrain connects to the GIS.

Service Mode

In service mode, the monitor display is turned on, but the system is turned off. The operating system appears on the display. Use the service mode for managing files.

Menu - Opens the main menu

To use the display in service mode, complete these steps:

1. Start the display in Normal Operating Mode.

2. Open the main menu and select the optional menu item "System" > "Exit". Alternatively, select Alt + (Alt + F4) on a keyboard.

   The Terrain software shuts down, but the operating system and the FTP service continue to run. If the FTP service has stopped, open D:\CAES\ftp_server, and run the executable file "FTPserverApplet.exe".

3. If the "Exit" menu item is not available, allow this item in the master.config file.

Shutdown Mode (new in v5.2)

Use one of the following methods to shut down the onboard software:

• Turn off the ignition.

• Use the keyboard and select Alt + F4 (technician)

• Send a reboot or a shutdown command from the office software (office staff)

Illustration 2	g03746391
"System Shutdown"message

When the display shuts down using one of these methods, the message in Illustration 2 appears and 5 seconds later the display shuts down correctly.

Reference: For detailed information regarding the improper shutdown process, refer to Systems Operation, M0102735, "Cat^® Terrain v7 for Grading and Loading", "Shutdown Improper".

Satellite Receiver

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In order to prevent personal injury during installation and removal of the GPS receiver, use an approved access system in order to reach the mounting location of the GPS receiver on top of the cab.

Note: In the Warning above, the GPS receiver referenced is the MS952 GNSS receiver.

Illustration 3	g03409940
GNSS receivers mounted on machine

The two GNSS receivers and respective antennae for the receivers must be installed and connected for proper system operation. The blade control system will check for the GNSS receivers and other components during the power-up process.

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Once the system is placed in automatic mode, blade movement may occur. Ensure that all personnel are clear of the blade before you place the system in automatic mode. Personal injury or death from crushing could occur.

Error Messages

Table 1 lists error messages that may appear during system startup. If these messages appear, select "OK" , contact the site supervisor, and relay the message.

Startup Process

During Terrain software startup, the following occurs:

• The onboard system starts.

• The Electric Rope Shovel OPC Server software connects, if required.

• A radio link is established with the office.

• An accurate machine location is acquired.

• Your machine position is provided to other machines on the site.

• MineStar files are synchronized with the office.

• Delay states are synchronized with the office.

• Diagnostics files are sent to the office.

Messages are displayed indicating that starting work is unsafe until the startup process is complete and the messages clear.

The following actions can be performed during this process:

• Select "Alarm Off" to turn off the optional audible alarm, if equipped.

• Select "OK" to clear the warning messages temporarily.

Warnings

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The Terrain software must complete several processes before the machine is safe to move. Do not start work until all start-up messages have cleared. Starting work before all of the processes are complete may result in serious injury or death. If a warning message does not clear, contact the office.

Initial Warning

Illustration 4	g03377612
Machine initializing

If the message in Illustration 4 clears, start work. Otherwise, wait for a more detailed warning message.

The onboard software is checking the system that manages communication between the office and the machine. The white background indicates that the message will soon change.

No Position to Office

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Position data is not accurate enough for precise positioning. Errors in positioning will cause the indicated machine position on the display to be incorrect. The actual position of the machine may not appear on the display of nearby machines. Moving the machine may result in personal injury or death. Use extreme caution when working in this area. Contact the office if the condition persists.

Illustration 5	g03377614
Machine does not find valid position

Contact the office if the warning in Illustration 5 persists.

The onboard software has not sent the machine position of this machine to the office. The red background indicates that the problem is serious. Your machine will not appear on the display of nearby machines. A valid position is any position with position status higher than "Autonomous". "Autonomous" indicates the lowest type of precision available."

No All Machine Position Message from Office

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Position data is not accurate enough for precise positioning. Errors in positioning will cause the indicated machine position on the display to be incorrect. The actual position of the machine may not appear on the display of nearby machines. Moving the machine may result in personal injury or death. Use extreme caution when working in this area. Contact the office if the condition persists.

Illustration 6	g03377616
Waiting for AMP message from office

Contact the office if the warning in Illustration 6 persists.

Terrain uses an All Machine Position (AMP) system to send messages between the onboard software and the office software. The message in Illustration 6 occurs when the AMP message has not arrived due to any of the following circumstances:

• The IP address is incorrect in the office or on the machine.

• The mach_cfg.txt file is incorrect.

• There is loss of communication with the radio network.

The red background indicates that this problem is serious. Your machine will not appear on the display of nearby machines.

GNSS No Coordinate System on Machine

The error message "GNSS No Coordinate System" appears from "Terrain" v5.3 when there is no GNSS application file (appfile) on either the G610 display module or on the receivers. The user cannot close the message.

Altered Operator Message "Downgrade Firmware"

Illustration 7	g06087472

At each startup, the onboard software compares the latest firmware in the caes\temp folder to the firmware on the receiver. If the version number is a lower version than already installed on the receiver, the software checks before beginning to downgrade. The installer then presents the user with a dialog confirming whether to proceed.

Closing Error Messages

To clear error messages, complete these steps:

1. On the machine, select "OK".

2. Contact the office and do not move.

Force Activity and Auto Delay (New in v5.2)

A new force activity and auto delay feature has been added in v5.2. This feature provides the ability for an "Activity Select" dialog to open on startup after the operator logs on.

While the dialog opens, the activity is "unknown" and time is allocated to "unknown". If the dialog remains open, the "Delay" dialog may appear, if configured, and an auto delay may start with the delay code "unknown"

The auto delay feature captures and sends the reason for a machine delay to the office. The feature also sends the total time that the delay prevented the machine from working.

The onboard software continuously monitors the length of time the machine position is stationary. From v5.2 onwards, when the machine position is stationary for more than the Auto Delay time, the "Select Delay" dialog appears. The operator must enter a delay code for the screen to return to normal. The new delay takes effect from the time the machine position became stationary

Reference: For additional information, refer to Operation and Maintenance Manual, M0102733, "General Information (Operator Utilities)"Entering Delay Codes.

Turning on Blade Control

To turn on blade control, complete these steps:

1. Turn on the ignition switch.

   The G610 display module starts up, followed shortly after by the onboard software. The lower Status bar appears, and may show icons for alarms, blade control, and GNSS/GPS, radio, and network status.

2. After leaving time for the GNSS/GPS, radio and network status icons to clear, report any remaining icons or alarms. Refer to "Operator Display and Buttons and Icons" later in this section.

3. Check the brightness of the display.

4. Check for blade wear.

5. Select a design.

6. Select the blade control mode on the control keypad.

The blade control icon is only available on machines with the following:

• Correct firmware installed onto the ECM

• Correct Terrain for grading security options in the Terrain master.txt file

Illustration 8	g03476200
Status bar icons

Icons on the status bar provide the dozer operator with the status of the blade control.

Accuracy of Position

The satellite receiver supplies the position of the machine and the accuracy of the position to the onboard software.

Some things lessen the accuracy of the position, for example the presence of a high wall or the geometry of the current satellite constellation.

Illustration 9	g03426437
Digital window showing a green background color

Illustration 9 shows a Digital window with the background color set to display the "Current GPS Accuracy". In this case, the accuracy (A) corresponds to a green background color.

Illustration 10	g03426438
"GPS Diagnostics" window showing a green header color

The "GPS Diagnostics" window In Illustration 10 indicates a position accuracy (A) which corresponds to a green color in the header of the window.

To find the accuracy of your position, look for the color on the background of a Digital window designed to show "Current GPS Accuracy". Also look for the color of the header bar in the GPS Diagnostics window.

Green - High accuracy positioning indicating the work can be performed

Yellow - Moderate accuracy positioning

Magenta - Low accuracy positioning

Red - Lowest accuracy positioning: Successive outputs for position are highly variable.

If the color is yellow, purple, or red, then the functions of the onboard software that rely on accurate position stop working.

The following list describes functions that stop working when accuracy is not green:

• The software stops mapping.

• The gauge window does not show elevation.

• You cannot set spot locations (magenta/red) or mark a hazard (red).

If the accuracy is not green, decide whether to work based on the guidelines of your site.

Operator Display Buttons and Icons

Illustration 11	g03385242
Typical display

The following buttons and icons appear on the Status bars of the display:

• Operator and system information (upper bar)

• General status (lower bar, left)

• Radio, position, alarm, and warning (lower bar, right)

Note: There is no visual indication that distinguishes a button from an icon.

Operator and System Information

Illustration 12	g06087542
Upper Status bar with operator and system information (1) Upper Status bar (2) Operator button (3) Job Code button (4) Activity Code button (5) Information button (5a) Prime mode (prime) button (5b) Aux mode (auxiliary) button (5c) LHD mode (load, haul, dump) button (6) Machine Name (7) Date and Time (opens main menu)

Lower Status Bar

Illustration 13	g03385246
Lower Status bar displaying buttons and status of onboard software components

Left-hand Side of Lower Status bar

Illustration 14	g03385225
Buttons and KPI message on left-hand side of lower Status bar (8) Brightness button (9) Next Screen button (10) Key Performance Indicator message

Position, Network, and GIS Status

Illustration 15	g06088210
Position, network, and GIS status buttons / icon on right-hand side of lower Status bar (11) "No GPS" Position Status button (flashing) (12) "Low" Position Status button (13) MineStar Network button (G1) GIS Comms Old icon (G2) GIS Comms Bad icon

MineStar Network Button

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When operating a machine utilizing Terrain for grading and loading or using Detect, allow for proper start-up time. Before moving the machine within the area of autonomous operation, review the status bar and ensure that the on-board radio module and the satellite receiver are functioning and reliable. Moving the machine before the machine has established good radio communications, established an accurate position, and updated the mine model can cause the machine to not be seen by the autonomous mining truck and other equipment operating in the autonomous area which may result in serious injury or death.

Illustration 16	g06088211

Mute/Unmute Alarms Toggle Button

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Selecting the Mute Alarms button will mute all alarms now and in the future that the operator is allowed to mute. Using the Mute Alarms button is not recommended. When the on-board software initiates an event notification, no audible alarm will sound, and the event will only appear on the display. The operator may not see the event message on the display for the condition that caused the alarm. Use extra caution when operating with alarms muted. If the operator does not hear the alarm or see the event message, failure to take corrective action could result in serious injury or death.

Illustration 17	g03393374
Mute/ Unmute Alarms toggle button on right-hand side of lower Status bar (15) Mute Alarms button (16) Unmute Alarms button

Illustration 18	g03385250

When the Mute Alarms button (15) is pressed, the warning dialog in Illustration 18 asks the operator whether to continue and mute all allowable alarms.

Once "Yes" is selected, the alarm toggles to the Unmute Alarms button (16) with the slash. If this icon is selected again, all previously muted alarms are unmuted and the icon without the slash (15) is displayed again. This toggling sequence repeats each time the button is pressed.

Illustration 19	g03387064
Typical muted volume icons

The icon that is associated with the Unmute Alarms button (16) is similar to the muted volume icon that is displayed on similar devices.

For example, if you want to turn off the volume on your television, you press the mute button on your remote control. Your screen momentarily displays a volume or speaker symbol similar to those icons shown in Illustration 19 with a slash through the symbol. Selecting the mute button a second time displays the volume symbol and sound is restored.

Caution and Stop Alarm (Avoidance and Detect)

These alarms are used with both the Avoidance Strategy and the Detect Strategy.

Illustration 20	g03393375
Alarm buttons / icons on right-hand side of lower Status bar (17) Caution Alarm (18) Stop Alarm (19) Acknowledge Alarm button

The low-level Caution Alarm icon (17) warns that a machine is in an avoidance zone as follows:

Detect Strategy - The Caution (low level) alarm icon does not appear for the Detect strategy used with manned exclusion zones.

Avoidance Strategy - The buffers of the machine, but not the innermost buffer, crosses into a *.cat file Avoidance zone. The icon never flashes. The icon disappears from the Status bar when the machine buffers leave the Avoidance zone completely.

The high-level Stop Alarm icon (18) appears on the Status bar, along with an Acknowledge alarm button (19), based on the following:

Detect Strategy - The Body region around the machine crosses into a Detect-created Avoidance zone with the Manned Exclusion attribute. The icon flashes and an audible alarm sounds. The icon disappears from the Status bar when the Body region around the machine leaves the zone completely.

Avoidance Strategy - The innermost buffer of a machine crosses into a *.cat file Avoidance zone. The icon flashes and an audible alarm sounds. The icon replaces the preceding Caution alarm icon. The icon disappears from the Status bar when all buffers around the machine completely leave the zone.

Proximity Alarms

These alarms are Detect Strategy only.

Proximity alarms sound until the two machines are outside each others machine regions and the onboard software has successfully updated the office software.

Illustration 21	g03896105
Proximity alarms on right-hand side of lower Status bar (19) Acknowledge Alarm button (20) Caution Proximity Alarm icon (21) Critical Proximity Alarm icon (22) Stop Proximity Alarm icon (with Acknowledge Alarm button)

Informational Warning Icons and the PC Speaker Off Button

Illustration 22	g03385245
Informational warning icons on right-hand side of lower Status bar (23) Speed icon (24) Speaker button (25) Mine Model out of Date icon

(23) Speed Icon

The Speed icon appears or disappears based on the machine speed versus the speed established for a zone.

The Speed icon appears under the following conditions:

• The machine travels faster than the speed limit associated with the Class of the machine in Fleet office software.

• The machine travels faster than the speed limit associated with a zone.

Note: An autonomous exclusion zone is set up by the office software for use by autonomous trucks. Autonomous trucks entirely eliminate the need for human machine operators. The onboard software does not show autonomous exclusion zones on the display unless there is a speed limit attached to the zone.

Note: The speed-related icon also appears around the edge of the speed zone.

The speed-related icon disappears from the Status bar when the machine speed is reduced to below the limit, or the machine exits the speed zone.

(24) Speaker Button

Use the Speaker button with the mobile software and the onboard software.

On the G610 Display running Detect, the Speaker icon appears as follows:

• The G610 Display does not have a buzzer attached to the CAN bus, or the buzzer is not working.

• The G610 Display has a non-CAN buzzer attached.

Portable PCs, such as a laptop or a tablet, do not use the optional buzzer. Instead, portable PCs use an internal speaker controlled by the operating system of the portable PC. The internal speaker volume may be too low or may be muted independently of the mobile software.

Illustration 23	g03391537
"Volume Mixer" dialog

To ensure that the operator realizes that the speaker is too low or is muted, the mobile software checks the operating system regularly. If the speaker is too low or is muted, the Speaker button appears. Double-click the Speaker button to open a mixer dialog similar to Illustration 23.

• To unmute the speakers, click the red and blue speaker-mute icon and adjust the Device Speakers volume to at least 50%.

• To close the dialog with no change to the speaker volume, click the "Exit" button (top right-hand side).

If at any stage while the mobile software is running the operator mutes the speakers, the Speaker button appears.

(25) Mine Model out of Date icon

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When entering a dynamic lane in the autonomous zone, ensure that the Mine Model Out of Date icon is not present in the status bar. If this icon is present, the machine does not have the most recent Lanes files. Entering the autonomous zone when this icon is present may result in serious injury or death. Contact the office or the Command Center controller and request that the most recent Lanes files be sent to the machine.

The Mine Model out of Date icon is used with the Command with Detect Strategy only.

Dynamic lanes are used in load and dump areas. Dynamic lanes are created automatically by the office software when the loader operator sets spot locations. Unlike static lanes, dynamic lanes are created and deleted automatically by the office software as required.

Lanes can change regularly in load and dump areas and require extra caution when the machine enters these areas. When entering a dynamic area in the autonomous zone, ensure that the Mine Model out of Date icon is not present in the Status bar. If this icon is present, your machine does not have the most current Lanes file.

Reference: For additional information, refer to ""Operation and Maintenance Manual, M0102733, "Cat Command"Entering a Dynamic Area.

14 Day Trial License

From v5.2 onwards, a 14 Day Trial License may be used on your site for new installations and upgrades of the onboard software. The license allows users to operate the display without a valid Terrain v5.2 security key while counting down from 14 days to 0 (zero) days. At day 0, the software stops working.

From midnight of the day of installation, the site has 14 days to receive a valid security key from the dealer.

Illustration 24	g03725757
Security key icon has counted down to 0 days.

Illustration 25	g03725758
"Security Error" dialog

At day 0 the icon flashes continuously and the "Security Error" dialog in Illustration 25 appears:

The operator can clear the message by selecting the OK (2) button on the dialog, but cannot change the screen. In effect, the software cannot run.

Shutdown

The onboard software shuts down in the following situations:

Normal Shutdown - The onboard software shuts down in response to turning the ignition keyswitch to the OFF position. The application will require a few seconds to complete all pending actions. During this time, the system maintains power to the display. Once the application has shut down completely, the screen goes dark.

Forced Shutdown - The onboard software shuts down when an event is detected that may cause data loss or a complication in the running of the system. An example would be where the hard drive only has 2 MB of space available.

Illegal Shutdown - The onboard software shuts down when the operator display loses power and the backup battery has insufficient power to close the display properly.

Shutting Down Blade Control

The onboard software stops using the following blade control modes under specific conditions:

• Rough Grade Control

• Grade Control

• Grade Protection

Blade control is not used when the operator applies the parking brake, activates the implement shutoff switch, or lifts from the seat.