Installation and Configuration of Cat® Terrain v5.0 On-board Software{7605} Caterpillar

Machine Control and Guidance Products:

TERRAIN GRADING (S/N: TFE1-UP)

TERRAIN LOADING (S/N: TFL1-UP)

TERRAIN OFFICE (S/N: TER1-UP)

Introduction

Terrain is a capability set of Cat MineStar System that is designed specifically for use in mining. Coupling the appropriate on-board system and office software gives mines the ability to manage grading and loading from a single integrated application suite.

On loaders and shovels, Terrain provides the operator with the exact boundaries of material blocks without the need for survey stakes. The progress of work is clearly displayed via a high-resolution color screen.

Avoidance or "Do Not Enter" work areas can be defined to generate visual and audible alarms upon transgression.

The on-board system uses Real Time Kinematic (RTK), and On-The-Fly (OTF) GNSS technology. This technology provides high accuracy in both horizontal and vertical planes when augmented by an on-site GNSS reference station.

High-speed infrastructure radios provide the link between office and mobile machines for GNSS corrections and two-way data transmission. Work progress information is automatically transmitted to the site office for display and update of engineering design files.

Note: Within this document, the designations "x" or "xx" are placeholders specifying all versions of a given prefix. For instance when referring to versions of software v4.x represents all v4 versions to date, including v4.0, v4.0.5, and v4.1, v4.2 and v4.5.

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:

1. Always set the parking brake of the machine before any work is performed on the machine.

2. Always shut the engine off before loading the on-board software on the machine.

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. Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.

Therefore, the warnings in this publication and the warnings that are on the product are not all inclusive. If a tool, a procedure, a work method, or operating technique that is not specifically recommended by Caterpillar is used, ensure that it is safe for you and for other people to use.

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

Release Notes

For detailed information about the new features in Terrain for grading and loading, refer to Special Instruction, REHS4695, "Release Notes for Cat^® Terrain v5.0 On-board Software".

For detailed information about new features and how to install Terrain mobile software, refer to Special Instruction, REHS7424, "Installation of Cat^® Terrain Mobile v5.0 Software on a Supervisor Truck".

Cat^® Terrain v5.0 System Architecture

Illustration 1	g03382225

Parts List

The Terrain v5.0 software is available as a new installation or as an upgrade.

Machine Install Kits

The electronics kits listed in Table 1 are used for installing a new v5.0 439-4341 Display Module (G610).

Table 1

Cat® Terrain v5.0 Installation Kits
Part Number	Description
389-0344	Terrain Electronics Ar (Single antenna)
389-0345	Terrain Electronics Ar (Dual antenna)
389-0346	Terrain Electronics Ar (ARO equipped)

The kits contain a G610 display module. The display module has an integrated touchscreen and is preloaded with the v5.0 software.

The v5.0 software is available by downloading or from a 392-9004 Module (memory, USB) .

Audible Alarm (Annunciator)

The display must have an audible alarm installed when a site uses Proximity Awareness (Detect). The alarm is optional for other sites.

Table 2 lists the parts contained in the alarm installation kit.

Table 2

435-4719 Alarm Gp Basic (Terrain)
Part Number	Part Name	Notes
441-8287	Harness As	Connects to audible alarm and 383-3027 Wiring Harness (Main Front)
444-5691	Alarm As	Audible CAN alarm

Service Tools

ReferenceRefer to Special Instruction, REHS7225, "Cat^® Terrain Tool Group" for detailed information.

Required Tools

The tools in Table 3 are required to service Terrain v.5.0.

Table 3

Part Number	Description	Purpose
324-3358	Keyboard	Configures system using the Windows operating system
383-3031	Cable As	Service harness

Optional Tools

The optional tools in Table 4 are used for the specific purpose listed.

Table 4

Part Number	Description	Purpose
291-1502	Wiring Harness (PC serial port to display harness)	Required when using HyperTerminal to transfer files
167-8964	Power Supply Adapter (Keyboard to display AC to DC converter)	Required if the 167-8955 Battery Cable is not used for supplying power

Install and Upgrade Requirements for the Site

Pre-requisites

The install and upgrade instructions contained in this document assume that the following pre-requisites have been fulfilled:

• The security keys have been obtained.

• The option keys have been obtained.

• The office software has been verified.

• The USB memory module is for the correct version.

Note: Contact your Cat dealer for additional information.

Security Keys

The user must obtain new security keys when moving from Terrain v4.x to Terrain v5.0.

Option Key

If using a third-party satellite receiver (one not supplied in the install kit), the following option key to support the receiver is still available in v5.0:

314-7600 Option Key - CAESultra with OEM (single antenna)

This key is not listed on the price sheet. Contact your Cat dealer for additional information.

Cat MineStar System

Existing - Machine currently using CAESultra or Terrain in Cat MineStar System

New - Newly commissioned machine or one that has been working already, that is being added to Terrain for grading and loading software for the first time

An existing machine must be set up in Cat MineStar System to move to Terrain v5.0. If the existing machine is not set up in Cat MineStar System, one of the following may be a better choice:

• Treat the machine as a new machine and redo all machine files.

• Keep all existing machine files and upgrade the D3:C4 Nav 10.4 monitor display to v4.0 first.

Receivers for Site Awareness

Site Awareness includes:

• Detect

• Command for Hauling

• PositionReport2 (PR2) messages

All existing MS8xx and MS9xx receivers can be used with Site Awareness.

Office Software

Check the following:

• For an existing machine, ensure that the machine is in radio contact with the office.

• Ensure that the required information such as surface snippets, productivity files, and other information has been downloaded from the machine.

• Ensure that the installation of Cat MineStar System is complete and Cat MineStar System communicates with MCUserver and MCUclient. Refer to Special Instruction, REHS7327, "Installation and Administration of Cat^® Terrain".

USB Memory Module and Executable Files

Verify that the USB memory module is for the correct version. The on-board software, receiver firmware, other utilities, and documentation are supplied on a single USB memory module. There are no CDs.

The USB memory module contains the following executable files:

• TerrainMobile.5.0.500.exe

• TerrainUpgrade.5.0.xxx.exe

• TerrainDemo.5.0.500

Installing Terrain v5.0

This section provides instruction for installing the on-board software on a display module.

These instructions apply to:

• New installs

• Swapping the display module

• Upgrading

Icons are used throughout the text to help the installer decide whether a particular section applies to the required installation.

Look for the following icons to determine which sections apply to your machine:

Illustration 2	g03384227

New Install - This display has never been used before, or has been wiped of all Terrain files.

Swap Display - As for a New Install, but the machine exists in the office software, and there may be machine-specific files that must be copied to the new display.

Upgrade - This is a G610 display currently using Terrain software on the site

The Terrain Upgrade executable creates the following folder:

• C:\TerrainUpgrade\Version 5.0.xxx.xxxxx

The contents of this folder allow the site to upgrade existing displays remotely, or to use a USB memory module to place the software on a display that is not in communication with the office.

Unpacking the Executable

New Install - Read this section if you are commissioning a new machine.

Swap Display - Read this section if you are swapping any existing display for a new G610 display module.

Upgrade - Read this section if you are upgrading an existing G610 display module.

To download and run the Terrain executable file, complete these steps:

1. Plug the USB memory module into the office computer.

   The "Autoplay" dialog opens.

2. Select "Open folder to view files in Windows Explorer".

   A new Windows Explorer window opens showing the contents of the USB memory module.

3. Select "Start" > "(My) Computer" to open a second copy of Windows Explorer on the office computer.

   Note: Windows Explorer will be accessed either from "Computer" or "My Computer" depending on your current Windows operating system.

4. Copy the following file from the USB memory module to a storage folder on the office PC:

   TerrainUpgrade.5.0.xxx.exe

   Loading this file onto the office PC allows the user to accept licensing agreements, send out to the machine, and restart the on-board software, all from the office.

5. Double-click "TerrainUpgrade.5.0.xxx.exe".

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Illustration 3	g03382228

6. From the drop-down menu, select the language the Setup wizard will use during the installation.

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7. When the Welcome screen appears, click "Next".

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8. Read the license agreement. To continue, select "I accept the agreement" and then click "Next".

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9. Click "Next" to extract the installer executable to the default folder on the office PC, or browse for another folder.

10. Click "Next".

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Illustration 7	g03384232

11. Check the summary page, and click "Install".

    The bar in the "Extracting files..." pane tracks the install process. The "Completing the Terrain Setup Wizard" window appears.

12. Select "Finish".

13. Open the folder used in Step 9 to store the executable file. The default file is C:\TerrainUpgrade\Version 5.0.xxx.exe.

14. Copy "TerrainInstaller.5.0.xxx.exe" onto the USB memory module.

15. Eject the USB memory module from the office computer.

Running the Display Module in the Office

New Install - Read this section if you are commissioning a new machine.

Swap Display - Read this section if you are swapping any existing display for a new G610 display module.

Many sites find it easier to set up and run a new display in an office environment before installing the display on the machine.

To run the display in the office, complete these steps:

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Illustration 8	g03382226
(1) 12-pin Deutch connector (2) 383-3031 Harness As

1. Connect the brown 12-pin Deutch connector (1) on the main harness to the 383-3031 Harness As (machine service port) (2). The 12-pin Deutsch connector has a groove that limits the type of service harness that may be attached.

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Illustration 9	g03382528
Service harness (3) Ethernet port (4) USB port (5) USB port

2. Connect the keyboard to either of the USB ports (4) (5) on the service harness.

   If desired, the USB memory module can be connected to the second USB port on the service harness.

3. Connect the display module to power.

   The display module starts up and the keyboard functions.

4. Wait for the display module to fully boot before proceeding.

5. Select "Start" > "(My) Computer" to open Windows Explorer on the display module.

6. Select the "D" drive.

   The D drive opens with no files listed.

Using Keyboard Shortcuts

Many tasks can be completed more efficiently by using a combination of keys on the keyboard or the touchscreen to complete the task.

The following keyboard shortcuts are used to complete the listed tasks:

Start/window icon + E - Open an Explorer window.

Alt + tab - Cycle through open windows or applications.

Alt + (Alt + F4) - Shut the window or application. Select Alt, then select Alt and F4 together to use this shortcut.

Alt + F - Open a menu on Notepad or Explorer.

Ctrl + F - Open the "Find" dialog.

Menu key - Open a menu in the on-board software when the on-board software is the main screen.

Ctrl C - Copy the highlighted file or folder.

Ctrl Z - Undo a copy.

Ctrl X - Cut the highlighted file or folder.

Ctrl V - Paste a copied file or folder.

The following touchscreen shortcuts are used to complete the listed tasks:

"Start" > "(My) Computer" - Open the Explorer window.

"Edit" > "Copy" - Copy the highlighted file or folder.

"Edit" > "Undo Copy" - Undo a copy.

"Edit" > "Cut" - Cut the highlighted file or folder.

"Edit" > "Paste" - Paste a copied file or folder.

Copying the Files from the Office

Swap Display - Read this section if you are swapping any existing display for a new G610 display module.

An existing machine already has a set of files that will be used on the new display module.

To copy files from the machine folder in the office software onto the USB memory module, complete these steps:

1. Plug the USB memory module into the office computer. The "Autoplay" dialog opens.

2. Select "Open folder to view files in Windows Explorer".

   A new Windows Explorer window opens showing the contents of the USB memory module.

3. Select "Start" > "(My) Computer" to open a second copy of Windows Explorer on the office computer.

4. Copy the following files onto the USB memory module from the listed folders:

   appfile.cfg - caes/temp

   *.mwf files - caes/minester

   wincfg.txt - caes/config

   file_cfg.txt - caes/config

   master.txt - caes/config

   Loading these files onto the display module allows the user to check the display module after installing the software, but before going out into the field.

5. Eject the USB memory module from the office computer.

Pasting Files onto the Display Module

New Install - Read this section if you are commissioning a new machine.

Swap Display - Read this section if you are swapping any existing display for a new G610 display module.

An existing machine already has a set of files that will be used on the new display module.

To paste the on-board software installer, "TerrainInstaller.5.0.xxx.exe", and other files onto the display module, complete these steps:

1. Check that the display module is running.

2. Plug the USB memory module into the USB port on the service harness or the USB hub.

3. Select "Start" > "(My) Computer" on the display module.

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Illustration 10	g03382227

4. In the list of "Devices with removable storage", select the USB memory module.

   The USB memory module opens showing a list of files similar to the files in Illustration 10.

5. Open "Caterpillar\01 System Software\Terrain Software".

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Illustration 11	g03382224

6. Highlight the on-board software installer, "TerrainInstaller.5.0.xxx.exe".

7. Copy "TerrainInstaller.5.0.xxx.exe" from the USB memory module to the D drive of the display module.

   The D drive will now have one file visible, "TerrainInstaller.5.0.xxx.exe".

   Note: Users who do not have a USB hub attached will not have a keyboard. To copy the executable file using the touchscreen, highlight the file and touch Edit > Copy. Select the D drive, and touch Edit > Paste.

8. If required, copy other files from the USB memory module to the D drive of the display module.

   Copy into the following folders:

   appfile.cfg - caes/temp

   *.mwf files - caes/minestar

   wincfg.txt - caes/config

   file_cfg.tx - caes/config

   master.txt - caes/config

9. Wait for a few seconds to allow the file to download, then remove the USB memory module from the USB port.

   Note: There is no "Eject" option on the display module.

Running the Installer Executable File

New Install - Read this section if you are commissioning a new machine.

Swap Display - Read this section if you are swapping any existing display for a new G610 display module.

Upgrade - Read this section if you are upgrading an existing G610 display module.

This is the main part of the installation and may happen either in the office or on-board the machine.

To run the installer executable file, complete these steps:

1. Plug in the keyboard and ensure that the following are available:
   • Security keys

   • Site requirements for TightVNC, if installing

   • Machine ID

   • Machine name

   Additionally, the following from Cat MineStar System are required:

   • Office TMAC IP address

   • Office TMAC Port

   • Default MineStar IP Address

   • Default MineStar Port

2. If this is an upgrade sent from the office, complete these steps:

   1. Send the "TerrainInstaller.5.0.xxx.exe" from "C:\TerrainUpgrade\Version 5.0.xxx.exe" to the machine.

   2. Close the current on-board software.

   3. Complete the installation remotely using FTP or another remote connection.

3. If upgrading or installing on the display module, double-click "TerrainInstaller.5.0.xxx.exe".

   The Setup wizard appears.

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Illustration 12	g03382228

4. From the drop-down menu, select the language the Setup wizard will use during the installation.

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5. When the Welcome screen appears, click "Next".

   A license agreement appears.

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6. To continue, read the license agreement, select "I accept the agreement", and click "Next".

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Illustration 15	g03382231

7. Select the type of installation.

   "New Installation" - New installs or swapping up from a D3:C4 Nav 10.4 monitor display

   "Upgrade Installation" - Upgrading an existing machine currently using a G610 display module

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Illustration 16	g03382232
Summary page

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Install progress bar

8. Check the summary page, and click "Install".

   The bar in the "Extracting files..." pane tracks the install process.

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Illustration 18	g03412321

9. The G610 display communicates with the receiver using a Controller Area Network (CAN) port. Select "Serial" if this machine is an Attachment Ready Option (ARO) machine or if, for any other reason, the receiver and display communicate using a serial-only harness.

10. Click "Next" to continue.

11. If this is a new display, continue with Step 12.

    If upgrading an existing machine currently using a G610 display module, this is the final step. The "Completing the Terrain Setup Wizard"window appears. Select "Finish".

    The upgrade installation overwrites the minimum number of files needed to upgrade an existing machine currently using a G610 display module.

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Illustration 19	g03382234

12. Select one of the following TightVNC installation options:

    Yes - The Terrain on-board software install process pauses and the TightVNC installer opens. For a description of the TightVNC install process, refer to "Installing TightVNC". Once you finish the TightVNC install process, the Terrain install process continues as below.

    No - The Terrain on-board software install process continues as below.

    Note: The easiest time to install TightVNC is at this prompt.

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Illustration 20	g03382235

13. Enter the two new security keys for this display.

    Entering the information now allows the installer to check the network information before moving to the field.

    Select "Cancel" to skip this step and enter into the MCU later.

    Note: The "Serial Number" field is disabled for input.

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Illustration 21	g03382236

14. Enter the "Machine ID" and the "Machine Name" as defined in Cat MineStar System.

15. Enter the following information as defined in Cat MineStar System.
    • Office TMAC IP address

    • Office TMAC Port

    • Default MineStar IP Address

    • Default MineStar Port

    To enter these four values at a later time, open the mach_cfg.txt file and enter the values by hand. It is then essential to send a new mch_cfg.txt file created by the MCU to clear error messages that appear in the office software.

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Illustration 22	g03382237

16. Click "Finish".

    The new installation sets up a Terrain folder structure and files similar to those shown in Illustration 22.

17. Open the USB memory module.

18. Transfer the files that were copied from the office computer into the corresponding folders on the D drive of the display module.

19. Remove the USB memory module and store the module in a safe location.

Installing TightVNC

This section contains detailed information for installing TightVNC.

TightVNC is free software which enables the office to view the display module remotely on a specified machine. Load TightVNC software onto each display module that you want to view from the office.

The easiest time to install TightVNC is at the prompt during the software install process.

Reference""Running the Installer Executable File" ".

Users can also install TightVNC at another time, directly from the USB memory module.

If TightVNC has been installed, continue to""Restarting and Checking the On-board Software" ".

New Install - Read this section if you are commissioning a new machine.

Swap Display - Read this section if you are swapping any existing display for a new G610 display module.

Upgrade - Read this section if you are upgrading an existing G610 display module.

If installing TightVNC from the USB memory module, first complete the following:

1. Open the USB memory module.

2. Navigate to "Caterpillar" > "04 Utilities" > "TightVNC" > "Set Up TightVNC".

3. Run the "tightvnc-2.0.4-setup.exe" installer and accept the default location for the program.

If installing TightVNC during the software install process, continue with Step 2 below.

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Illustration 23	g03382238

1. Run the TightVNC installer. The "TightVNC x.x.x Setup Wizard" opens.

2. Click "Next". The license agreement appears.

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Illustration 24	g03382239

3. Click "I Agree" to accept the license agreement.

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Illustration 25	g03382240

4. In the "Custom" drop-down list, check "TightVNC Server" and uncheck "TightVNC Viewer" to install TightVNC onto the display module.

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Illustration 26	g03382241

5. Accept the default location for TightVNC and click "Next".

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Illustration 27	g03384241

6. Select the Start Menu folder in which you would like to create the shortcuts for the program and click "Next".

   Note: You can also enter a name to create a new folder.

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7. Accept the default location for the program shortcuts and click "Next".

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8. Check or uncheck any additional tasks, or leave as default settings and click "Next".

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9. Secure the TigthtVNC Server.

   1. Enter a password if passwords are used on the site. Remember or record the password because the password may be needed at a later date.

   2. Ensure that "Protect control interface with an administrative password " is unchecked and click "Install".

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Illustration 31	g03382244

10. Click "Next" to accept the install.

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11. Click "Finish" to complete the install.

Configuring TightVNC

TightVNC - Enables the TightVNC "Service Configuration" dialog

Illustration 33	g03382247

To configure TightVNC, complete these steps:

1. Open "Start" > "All Programs" > "TightVNC" and start the TightVNC service on the display module.

   The first time TightVNC starts, the "TightVNC Service Configuration" dialog appears.

2. Complete the following changes and click "OK".

   1. Change "Screen polling cycle:" to 200ms.

   2. Keep the default values in the remaining fields.

   3. Keep "Show icon in the notification area" checked to determine if TightVNC is running.

3. Restart the display module and check the following:
   • TightVNC is loaded on startup each time. Look for the TightVNC icon at the bottom, right-hand side of the screen.

   • The screen polling is set to 200ms. Select the "TightVNC Service Configuration" dialog, "Server" tab.

   • The password is set (if needed). Double-click to show the "TightVNC Service Configuration" dialog, "Administration" tab to check whether a password is needed.

   • The office can view the display module.

4. If installing TightVNC during software installation, the installation of TightVNC is complete.

   If installing TightVNC at a later date outside the TerrainInstaller 5.0.xxx.exe, continue below.

5. Open D:\caes\exe.

6. Highlight the "writechangestodisk.cmd" file and press "Enter".

   A window flashes briefly on the screen. The installation of TightVNC is complete.

Restarting and Checking the On-board Software

New Install - Read this section if you are commissioning a new machine.

Swap Display - Read this section if you are swapping any existing display for a new G610 display module.

Check the network settings before moving the display module out to the machine.

Menu - Opens the main menu

Information Button - Opens the "About Terrain" dialog

To restart and check the on-board software, complete these steps:

1. In the main menu, select "Start" > "Shut Down".

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Illustration 34	g03382586
Typical screen after restart

2. Select "Restart" from the drop-down menu.

   The display module goes black, and then restarts. After a few seconds the on-board software starts, showing the default screen overlaid with avoidance zone and warnings.

   The machine appears as an arrow because the office has not assigned the machine type to the display module.

   Note: While the harness remains connected to the power supply, this method is a safe way to restart the operating system and the on-board software while in the office.

3. Select or touch the Information button to open the "About Terrain " dialog.

4. Check that the machine name and machine ID are correct.

5. In the main menu, select "Diagnostics" > "Network Information" to open the "Network Information" screen.

6. Check that the following are correct:
   • Office TMAC IP address

   • Office TMAC Port

   • Default MineStar IP Address

   • Default MineStar Port

7. Close the on-board software by selecting the keyboard shortcut Alt + F4.

8. Disconnect the display module from the harness.

Correcting Basic Errors

If the "Basic Diagnostics" screen appears during the check, read the description of the error and correct the errors.

To correct security, IP address, or port errors, complete these steps:

1. On the keyboard, select Alt, then Alt + F4.

   Note: Select Alt, then select Alt and F4 together to use this shortcut.

2. Copy "TerrainInstaller.5.0.xxx.exe" from the USB memory module to the display module.

3. Double click "TerrainInstaller.5.0.xxx.exe" and run the Setup wizard.

4. Enter the correct values.

5. Click "Finish".

6. In the main menu, select "Start" > "Shut Down".

7. Select "Restart" from the drop-down menu to restart the display module.

8. Check the "Terrain About" and "Network Information" screens again.

Using NetConfig XP to Configure the Ethernet Port

This section contains installation instructions for a site using a mesh radio network.

New Install - Read this section if you are commissioning a new machine.

Terrain v4.5 and later versions include a network configuration tool called NetConfig XP in the "D:\NetConfigXP" folder. This tool is used to configure the display module for use in a mesh radio network.

Menu - Opens the main menu

If this installation is for a site using a mesh radio network, complete these steps:

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Illustration 35	g03382588

1. Open Explorer, navigate to the "D:\NetConfigXP" folder, and then launch the "NetConfigXPE.exe" file.

   The "Net Config XP" window appears.

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Illustration 36	g03382591

2. Configure the display module settings in the "Net Config XP" window.

   1. Enter the computer name. The "Computer Name" field shows a unique name for the display module.

      Alternatively, enter a unique network name for this display module as provided by the site network administrator.

   2. Select "Inter(R) 82579LM Gigabit Network Connection #2" from the "Network Interface" drop-down menu.

   3. Select the following options:

      Use the following IP address: - Use of fixed IP addresses is recommended because these addresses are more reliable than depending on a server to supply IP addresses dynamically

      Use the following DNS server addresses: - The Terrain Site Champion will determine if this option is required for the site.

   4. Enter the appropriate information in the remaining fields.

      Note: The IP address information and DNS server addresses are provided by the site network administrator.

3. Touch the "OK" button.

   The "System Restart" screen appears.

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Illustration 37	g03382594

4. Select "Yes" to restart the system.

   A "System Shutdown" dialog appears, the display module shuts down, and then restarts.

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Illustration 38	g03382602
Sample "Network Information" diagnostic screen

5. When the display module restarts, open the main menu and select "Diagnostics" > "Network Info" to open the "Network Information" diagnostic screen to check the settings.

Illustration 38 shows a sample "Network Information" diagnostic screen.

The display module is now ready to take out to the machine or can be used to replace the D3:C4 Nav 10.4 monitor display on an existing machine.

Configuring the Machine Settings

New Install - Read this section if you are commissioning a new machine.

Swap Display - Read this section if you are swapping any existing display for a new G610 display module.

Upgrade - Read this section if you are upgrading an existing G610 display module.

The Machine Configuration Utility (MCU) is an office tool that is used to configure settings in the mach_cfg.txt file.

Reference For information about the MCU, refer to the "MCU Getting Started Guide". The guide is located in "Start" > "All Programs" > "Caterpillar" > "Machine Configuration Utility" > "Getting Started Guide".

To configure machine settings, complete these steps:

1. Open the MCU on an office computer.

2. Highlight the machine name.

3. Select "Machine" > "Security".

4. If commissioning a new machine, enter the Serial Number for a new display module, or verify that the existing Serial Number is correct.

5. Enter the new Serial Number Key and CAES Key.

6. Select "Machine" > "Machine Dimensions".

7. Enter the machine dimensions or check that the machine dimensions are correct.

8. Clear any validation errors in the message window at the bottom of the MCU dialog.

9. Enter any site or machine data relevant to this machine.

10. After entering all data, select any other feature or field in the MCU. This action saves all entered data.

ReferenceFor a description of MCU features and validation errors, refer to the MCU Help file, "Machine Configuration Utility Navigation".

While in the MCU, access the MCU Help file by either of the following:

• Press F1 while on a highlighted feature.

• Select "Help" from the "Help" menu.

Setting up an MS990 Receiver

New Install - Read this section if you are commissioning a new machine.

Swap Display - Read this section if you are swapping any existing display for a new G610 display module.

Upgrade - Read this section if you are upgrading an existing G610 display module.

• Use the instructions in this section for machines using an MS990 receiver with a G610 display module.

• Skip this section if using the G610 display module with an MS980 or an MS992 receiver.

Note: The recommended firmware for the MS990 receiver is v4.49/3.21 for single and dual antenna operations. If an MS990 receiver has any other firmware, reflash the receiver with v4.49/3.21 software and change the configuration to CAN corrections.

To set up a G610 display module for an MS990 receiver, complete these steps:

1. Once connected to the MS990 receiver, open WinFlash.

2. From the "Device Configuration" menu, select "MS9xx Receiver" and the appropriate PC serial port, then click "Next".

3. From the "Operations" menu, select "Load GPS software", then click Next.

   The "Select Firmware" dialog appears.

4. Select "MS990 FW v3.21", then click "Next".

5. On the "Current Settings" screen, review the information, then click "Finish".

   A progress bar appears.

   Note: If the current firmware is later than v3.21, a message states that a downgrade of firmware will be completed.

6. Once the upgrade of the new firmware is complete, click "Menu" to return to the "Operations" menu.

7. Exit WinFlash.

8. Open the master.txt file in the "CAES\config" folder on-board and ensure that the following key, which allows communication to occur over the serial port, is included:
   • "$ GPS Over CAN =0"

   If this key is not included, enter the key, save the master.txt file, and reboot the display module.

Sending the Machine Configuration File to the Machine

New Install - Read this section if you are commissioning a new machine.

Swap Display - Read this section if you are swapping any existing display for a new G610 display module.

Upgrade - Read this section if you are upgrading an existing G610 display module.

Once the configuration of the machine is complete, send the new machine configuration file (mach_cfg.txt) to the machine.

Note: The mach_cfg.txt file can only be sent after all of the validation errors in the MCU have been cleared for the selected machine. The presence of errors is noted by a red or yellow symbol next to the name of the machine.

Menu - Opens the main menu

To send the machine configuration file to the machine, complete these steps:

1. Verify that Cat FTP Server is running on the machine.

   1. Start the on-board software.

   2. In the main menu, open "Diagnostics" > "File transfers".

   3. Verify that the "FTP Status" is "Up".

2. In the MCU machine selection pane, highlight the machine from which the mach_cfg.txt file should be sent.

3. In the MCU menu, select "File" > "Send to Cat MineStar System".

   The yellow dot to the left of the machine name will turn green indicating that the file has been sent. Cat MineStar System automatically sends the file to the on-board software. The file is not used by the machine until after the machine is rebooted.

Rebooting the On-board Software

Reboot the on-board software after sending the machine configuration file to the machine.

New Install - Read this section if you are commissioning a new machine.

Swap Display - Read this section if you are swapping any existing display for a new G610 display module.

to reboot the on-board software, complete these steps:

Upgrade - Read this section if you are upgrading an existing G610 display module.

1. Ensure that the most recent design and as-built surface files have been sent to the machine.

2. Open the office software.

3. Select the name of the machine to be rebooted.

4. Right-click on the machine and select "Reboot".

   ReferenceRefer to Systems Operation, RENR9562, "Cat^® Terrain Office Software".

   You have now successfully installed or upgraded Terrain for grading and loading on-board software onto a G610 display module.

Checking the Alarm

New Install - Read this section if you are commissioning a new machine.

Swap Display - Read this section if you are swapping any existing display for a new G610 display module.

Upgrade - Read this section if you are upgrading an existing G610 display module.

The alarm, or annunciator, is normally an optional piece of hardware, but is mandatory when using the following modules:

• Command for hauling

• Detect

Menu - Opens the main menu

Use one of the following methods to verify the operation of the annunciator:

Startup - Start the on-board software and listen for short audible sound.

Buzzer Test - Open the main menu and select "Diagnostics" > "Buzzer Test" and listen for a short audible sound.

Notify the office if:

• The annunciator is connected, but no audible sound is heard.

• The annunciator volume is either too loud or too quiet.

Upgrading Existing CAESultra Machines to v5.0

This section provides additional instruction for replacing a D3:C4 Nav 10.4 monitor display with a G610 display module at a site running Cat MineStar System.

These instructions assume that the site meets the pre-requisites for installing the on-board software as listed in ""Install and Upgrade Requirements for the Site" ".

Table 5 provides a comparison between installing a G610 display module onto a machine for the first time, and changing an existing machine to use the G610 display module.

Table 5

Step	New Installation	Replacement
1. In office	Install the on-board software directly onto the display module.
2. Add machine to Cat MineStar System.	Create the machine.	Currently in Cat MineStar System
3. On display module	Run "TerrainInstaller.5.0.xxx.exe". Enter security information. Install TightVNC if required.
	N/A	Copy files from the office.
4. Check the display module	Restart and check the display module while still in the office. Reference ""Restarting and Checking the On-board Software" ".
5. On the machine	Install the hardware.	Check MS990 receiver firmware.
6. Ethernet port	Use NetConfig XP to configure the ethernet port.
7. In MCU, for all machines:	Configure MCU settings. Note: The minimum requirement is to re-enter the new v5.0 security keys.
8. Enter machine dimensions.	Enter the dimensions of the machine in the MCU in this step, or in the MCU after Step 7. Reference: ""Entering Machine Dimensions" ".
9. In MCU, send configuration.	Initiate sending the machine configuration file to Cat MineStar System and to the machine. Go to File > Send to Cat MineStar System.
10.Reboot the on-board software.	Reboot the on-board software from Cat MineStar System. The reboot will install the new version of the software with the new configuration file. Note: This step may take an extended time depending on the number of files to be deleted.

For instruction on installing Terrain v5.0 on-board software, refer to ""Installing Terrain v5.0" ".

Table 6 summarizes the documents required when upgrading between various versions of the on-board software.

Table 6

Upgrading From	Reference
Pre v3.2 to v3.2	Contact a Cat Dealer
v3.2 to v5.0	REHS2992 (this document)
No on-board software to new v5.0 installation
v4.xx on-board software to new v5.0 installation

Table 7 provides additional keys used for upgrading from a version prior to v4.0 that used METSmanager for the office software. A Cat Dealer can provide information for using these keys.

Table 7

Keys	v3.2.2	v4.x
$ Machine ID =	METS machine ID	Cat MineStar System machine ID
$ Office Ftp Address =	METS PC IP Address	Cat MineStar System server IP Address
$ Office TMAC Address =
$ Office TMAC Port =	12345	16020
$ Default Minestar Address =	MineStar Gateway PC IP Address	Cat MineStar System server IP Address
$ Default Minestar Port =	16020	16020
$ Position Time Interval =	N/A	300
$ Position Distance Interval =	N/A	1000

900 MHz Radio Partial Compatibility

In general, the existing features supported by the former CAES and AQUILA applications on a 900 MHz radio network are also supported within Terrain on a 900 MHz radio network.

However, Terrain is specifically designed to allow a large amount of information to flow throughout the mining process. As such, a robust high speed wireless network linking the machines to the mine office is required to take full advantage of all the product features.

The following features are not supported on a 900 MHz radio network:

• Automatic terrain sharing (machine restart, change of primary design file): Manual updates initiated from the office or from the on-board system can be performed, but should be used carefully and limited to very few machines concurrently as radio network performance can be negatively impacted.

• Drill-to-drill hole status sharing

• Task assignment

• Positional awareness: Includes real-time information on radio communication status (will be delayed) and GNSS status (will be unavailable) for Detect, Command, and Site Awareness.

• Existing 900 MHz radio networks will need to utilize FTP file transfers as opposed to the UDP / TMAC protocol.

Upgrading From a TC900 Radio Network to an IP Network

This section provides instruction for using a D3:C4 Nav 10.4 monitor display to change an existing machine from using a TC900 radio network to using an IP network (Ethernet).

Do not complete the steps within this section if continuing to use a TC900 radio network.

Note: To function with Cat MineStar System, the CAESultra radio network must support FTP.

Illustration 39	g03382605
Converting from a TC900 radio network to an IP network

Illustration 39 outlines the procedures to follow when CAESultra is upgraded to v5.0 with a G610 display module. The process flow depends on the current and the intended radio protocol that is to be used at the site.

Note: There is no TC900 support for v5.0. TC900s are supported in v3.5.

The following steps apply only if a TC900 is being used with CAESultra v3.1, v3.2, or v3.2.2 installed on the monitor display. If an older version of CAESultra is installed on the monitor display, then install the v3.2 software first.

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NOTICE
All steps below must be completed in the sequence that is provided to prevent the corruption of the D3:C4 Nav 10.4 monitor display.

To upgrade from using a TC900 radio network to using an IP network, complete these steps in the order listed:

1. Verify that the CAESultra software is installed.

   If CAESultra software is not installed, then go to Step 3.

2. Rename the "D:\startcaes.cmd" file.

   1. Using a service keyboard, open Windows Explorer.

   2. Rename the "D:\startcaes.cmd" file to "D:\startcaes.txt".

   3. If the following statement appears, select "YES".

      "Are you sure that you want to change the extension"

3. Reboot the monitor display.

   1. Using the Down Arrow key, select the following option:

      "NTe w/o Write Filter"

   2. Press the "Enter" key.

      The monitor display begins to start again.

   3. Before continuing, wait until the monitor display starts completely.

4. Using the keyboard, close any programs that are running.

5. Using Windows Explorer, launch the "NetConfigNT.exe" file.

   This file is in the "D:\NetConfgNT" folder. A warning appears.

   If the following message is received, then the monitor display was not in the correct mode when the power was applied to the monitor display:

   "NetConfig requires write enabled mode. Netconfig will now exit"

   If this message is received, go back to Step 3 and reboot the monitor display.

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Illustration 40	g03382628

6. Select "OK".

   The "NETconfigNT 1.0.1" screen appears.

7. Select the "Enable Network Interface" radio button.

8. Select the "Use the following IP address": radio button.

   1. The "IP address" should be the address of the machine.

      Note: Obtain a list of approved IP addresses from the Terrain Site Champion.

   2. On the Cat MineStar System computer, type "ipconfig" (without the quotation marks) at a Command prompt to see the subnet mask and IP address.

      "Subnet mask" - Should match the subnet mask of the Cat MineStar System computer

      "Default gateway" - Should be the IP address of the Cat MineStar System computer

9. Select the "Use the following DNS server addresses:" radio button.

10. Set the "Preferred DNS server" to match the "Default gateway" address from Step 8.b.

11. Select the "Enable Network Interface:" radio button.

12. Select "Apply". A confirmation screen appears.

13. Shut down all programs that are currently running, including any Windows Explorer that is running in the background.

14. Select "Yes".

    The monitor display starts again.

15. Rename the "D:\startcaes.txt" file.

    1. Using a service keyboard, open Windows Explorer.

    2. Rename the "D:\startcaes.txt" file to "D:\startcaes.cmd".

    3. If the following statement appears, select "YES".

       "Are you sure that you want to change the extension"

16. Start the monitor display again.

17. Send a file from Cat MineStar System to check communication with the monitor display.

General Procedures

The following general procedures are described in the sections below:

• Installing the hardware

• Obtaining security keys

• Verifying that Cat FTP Server is running

• Backing up the on-board files

• Editing the mach_cfg.txt file

• Sending files from a computer to the display module

• Using the "upgrades" folder

• Inputting dimensions

• Using Screen Configuration Utility

• Configuring the receiver

• Upgrading MCG Flash

• Using MS Controller

• Checking Measure-up and Calibration

Installing the Hardware

Existing Machine

The monitor display is mounted on a u-shaped mounting bracket. To swap a D3:C4 Nav 10.4 monitor display with a G610 display module in a non-ARO machine, change the mounting bracket as follows:

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Illustration 41	g03382641
(6) Mounting bracket (7) Bolt (8) Lower bracket (9) D3:C4 Nav 10.4 monitor display

1. Remove the D3:C4 Nav 10.4 monitor display (9) from the mounting bracket (6) by undoing the four bolts (7) and the isolation mounts.

2. Undo the harness connectors.

3. Remove the existing mounting bracket (6) from the existing lower bracket (8) by removing the four bolts and the isolation mounts.

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Illustration 42	g03382643
383-3032 Bracket with isolation mounts in place

4. Attach the 383-3032 Bracket to the current lower bracket (7). Use four 4M-5282 Bolts (1/4-20) and four 9X-6165 Washers from the 389-0332 Monitor Mounting Gp .

5. Tighten the bolts to Caterpillar standard torque specifications.

6. Attach the 439-4341 Display Module to the 383-3032 Bracket .

   Install the lower 8T-9364 Bolts and 8T-4205 Hard Washers first to allow the display module to tilt and ease installation of the harnesses.

7. Continue attaching the harnesses.

   ReferenceUse the Special Instruction that applies to the current machine type. Refer to the Special Instruction below for the listed ARO machines.

   REHS7230 - 994F Wheel Loader

   REHS7236 - 854K Wheel Dozer and 992K, 993K, and 994F Wheel Loader

New Machine

Using the Special Instruction that applies to the current machine type, install the hardware.

The installation requires welding, cutting holes, using electrical tools, and using mechanical tools. After a technician has completed the first installation process, future installations should require 6 to 8 hours to complete.

The installation process can be separated into the following procedures:

• Receiver, receiver harness, and chassis harness installation

• Wireless machine radio installation

• Rear harness installation

• Monitor display installation

• Front harness installation

• Battery backup installation

• Power harness and fuse Installation

• Dimension measurements and measure up

The dimensions measurement and measure up leads onto the final configuration steps for the on-board software.

When the installation process is finished, complete the following sections:

• ""Using NetConfig XP to Configure the Ethernet Port" "

• ""Configuring the Machine Settings" "

• ""Sending the Machine Configuration File to the Machine" "

• ""Rebooting the On-board Software" "

Obtaining Security Keys

This section describes the general procedure for obtaining Terrain security keys.

Capturing Serial Numbers for Existing Installations of METS

The following instructions describe using METSmanager to capture the serial numbers for existing installations of CAESultra prior to v4.0.

Note: If documentation exists for the "Machine ID" numbers and the "Display Serial Numbers", then these steps are not required.

To capture the serial numbers, complete these steps:

1. Open Windows Explorer on the METSmanager computer.

2. Select "METSmanagerData".

3. Select "metsdata".

4. Select "<machine id>".

5. Select "diags".

6. Select "2013" or the latest year.

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Illustration 43	g03382651
Sample diagnostic file (10) Machine ID (11) Display Serial Number

7. Use Microsoft Notepad to open the latest "diagnostic.dia" file. Refer to Illustration 43.

8. In a spreadsheet or other record keeping tool, record the following information:
   • Machine ID (10)

   • Display Serial Number (11)

   • Whether the machine is "Single Antenna", "Dual Antenna", or "Single Antenna with 3rd Party GPS"

   ReferenceRefer to ""Options for Security Keys " " for these options.

9. Repeat Steps 1 through 1 for every machine in METSmanager.

Capturing Serial Numbers for New Installations

For new installations of the on-board software, the serial number of the display module can be found on a label. Looking at the display module, the label is attached to the right side of the display module.

Enter the "Machine ID" numbers and the "Display Serial Numbers" from the documentation into a spreadsheet or other record keeping tool.

Capturing Serial Numbers for Existing Installations of Terrain

The following instructions describe using the office software to capture the serial numbers for existing installations after v4.0.

Note: If documentation exists for the "Machine ID" numbers and the "Display Serial Numbers", then these steps are not required.

To capture the serial numbers, complete these steps:

1. Open the MCU.

2. Select the machine name in the left-hand pane.

3. Select "Machine" > "Security" and record the security information.

Note: Repeat these steps for every machine where the information is needed.

Considerations of Machine Type, Configuration, and Product Family

Determine to which of the following machine types each machine belongs:

• Single Antenna

• Dual Antenna with Sensors

• Single Antenna 3rd Party GPS

Note: There is no option for "3rd Party GPS with Dual Antenna Systems".

Determine for which of the following uses the machine will be configured:

• Enable avoidance information output (Remote Control)

• Detect (Enabled by default for all machines)

• Command for hauling

Determine to which of the following product families each machine belongs:

• CAESultra

• CAES Screen Configuration Utility

• Terrain

• Terrain Screen Configuration Utility

Ordering the Security Keys

Security keys and security codes are changed for all major releases of the on-board software. The v5.0 software has new Serial Number Keys and CAES Keys.

Read ""Running the Installer Executable File" " to find out if security keys are required for the on-board software.

To order security keys, complete these steps:

1. Order the software activation key using one of the following methods:
   • Corporate Machine Orders Processing System (CMOPS)

   • Antares

   Note: Caterpillar will invoice the dealer for each software activation key that is ordered.

2. Retain the Machine Sales Order/Parts Sales Order (MSO/PSO) number after the order has been placed. This number is required to obtain the security keys for Terrain on-board software.

3. Record the "Dealer Code" and the "Part Number" that was ordered.

   Note: The dealer will receive the rights to one software activation key for each order.

Obtaining the Security Keys

When the invoice has been completed, submit a request for the security keys.

Note: Single receiver security keys will not work on a machine with dual receivers and sensors.

Security keys are accessed from the following web site:

www.techproductregistration.com

Illustration 44	g03382945

A "Customer Services - Key Order Completion" form will be displayed. All required information is marked with a red asterisk.

Illustration 45	g03382956

If more than one key is required, use the "Terrain Multiple Key Request Form" link at the bottom of the page.

Email the spreadsheet to:

registration@catsupport.com

Table 8 lists contact information for acquiring Software Keys or obtaining order support.

Table 8

Caterpillar Support (Software Key Distribution)
Phone	(888) 223-7539 (888-CAESKEY) (309) 266-2776 (1)
Fax	(309) 263-0127
E-mail	caeskey@catsupport.com

( 1 )

For use only if unable to use the 888 toll free number

To obtain security keys, complete these steps:

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Illustration 46	g03382946

1. Fill in the required information in the form. The form updates when a selection is made in one of the drop-down menus. Additional options appear with each update.

   1. Select "TERRAIN" or "TERRAIN SCREEN CONFIGURATION UTILTY" from the "Product Family:" field.

   2. Select the appropriate software from the "Activity:" field.
      • For a new installation, select "NEW INSTALL".

      • For an upgrade to an existing installation, select "UPGRADE".

      • For Screen Configuration Utility select "NEW INSTALL". There is no charge for this product.

   3. Select the current version number from the "Version:" field of the "Product Registration" section. The screen updates with the additional fields that are required.

   4. Complete the information in the following fields in the "Product Registration" section.

      "Display/PC Serial No:" - This value is the serial number of the computer.

      "Machine Type:" - Select the antenna configuration of your machine.

      "Order No:" - This value is the MSO/PSO number.

      "Part Number Ordered:" - Select the appropriate part number for your application.

      Note: The "Order No:" and "Part Number Ordered:" fields only apply to New Installs.

   5. Complete the following fields in the "Order By Information" section:
      • "Dealer Code:"

      • "Contact Name:"

      • "Phone No:"

      • "Email:"

   6. Select the correct "Application Usage:" from the drop-down menu in the "Customer Information" section.

   7. Complete the remainder of the form.

2. Select the "Submit" button at the bottom of the form.

   Within 30 minutes of completing the form, the dealer receives an e-mail containing the software activation key information and a follow-up phone call to confirm that the e-mail was received.

3. Save the software activation key information for future reference.

Verifying that Cat FTP Server is Running

Menu - Opens the main menu

To verify that Cat FTP Server is running on the display, complete these steps:

1. Start the on-board software.

2. In the main menu, open "Diagnostics" > "File transfers".

3. Verity that the "FTP Status" is "Up".

Backing Up CAESultra On-board

This section describes the general procedure for backing up CAESultra files.

If the site is upgrading from an older version, then back up the following files into the "D:\Save" folder:

• D:\CAES\config\mach_cfg.txt

• D:\CAES\config

• D:\CAES\data (whole folder)

• D:\CAES\temp\appfile.cfg

• D:\CAES\minestar\Default Operator.mwf

• D:\ NetConfigNT\cse.ini

Delete everything on the D: drive, except the "Save" directory.

Changing the Communication from METSmanager

This section describes the general procedure for changing CAESultra from communicating with METSmanager to communicating with Cat MineStar System. METSmanager and Cat MineStar System communicate using different values for various keys.

Note: The following instructions apply only to sites running METSmanager or CAESoffice Suite.

To change the values, complete these steps:

1. Edit keys in the mach_cfg.txt file. Table 9 describes the changes to make in the file.
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   Table 9

   Key	v3.2.2	v4.x
   $ Machine ID =	Machine ID in METS>	Machine ID in Cat MineStar System>
   $ Office Ftp Address =	METS PC IP Address>	Cat MineStar System server IP Address>
   $ Office TMAC Address =	METS PC IP Address>	Cat MineStar System server IP Address>
   $ Office TMAC Port =	12345	16020
   $ Default Minestar Address =	Minestar Gateway PC IP Address>	Cat MineStar System server IP Address>
   $ Default Minestar Port =	16020	16020
   $ Position Time Interval =		300
   $ Position Distance Interval =		1000

2. Reboot the on-board software to apply the new settings.

   Note: Once the change has been applied by rebooting the on-board software, communications between METSmanager and the machine will not function properly. From this point, the management of the machine has transferred to Cat MineStar System.

Transferring Files to a Display Module

This section describes the general procedure for transferring files.

Use the following methods to transfer files from the office (or a portable PC) to the machine:

• Cat MineStar System

• File Transfer Protocol (FTP)

• USB memory module

• HyperTerminal (not used on G610 display module)

Note: The recommended method for selecting files is to use FTP server for new sites and Cat MineStar System for upgrading existing sites.

Transferring Files Using Cat MineStar System

Cat MineStar System was designed to handle the transfer of files to the display module. In most cases, Cat MineStar System can transfer files to the display module. However, in certain circumstances FTP, the USB, or HyperTerminal may be needed to transfer files.

Transferring Files Using an FTP Client

A File Transfer Protocol (FTP) client can be used to transfer files to the display module. Caterpillar supplies Cat FTP server as part of the on-board software installation.

Note: Other FTP clients may be used, but are not supported and may not work with the software.

Menu - Opens the main menu

To use Windows Explorer to transfer files using FTP, complete these steps:

1. Open the on-board software on the machine.

2. Decide into which folder the file is to be transferred.

3. Verify that Cat FTP Server is running on the machine.

   1. Start the on-board software.

   2. In the main menu, open "Diagnostics" > "File transfers".

   3. Verify that the "FTP Status" is "Up".

4. Open Windows Explorer on the PC or portable PC and enter ftp://<IP address of machine>/. For example, "ftp://10.3.16.191".

   The contents of the memory of the display module can now be viewed.

5. Navigate to "ftp://<IP address of machine>/<path of folder>".

6. Open a second instance of Windows Explorer.

7. Navigate to the current location of the file.

8. Copy the file into the location from Step 5.

Transferring Files Using a USB

To transfer files using a USB, complete these steps:

1. Attach the USB memory module and keyboard to the G610 display module or the appropriate harness.

2. In the "Start" menu, select the USB memory module.

3. Copy the files to transfer.

4. Open a second instance of "Windows Explorer".

5. Navigate to the required location and paste the files.

6. Close any windows or applications that are using the USB memory module.

7. Remove the USB memory module from the USB plug.

Transferring Files Using HyperTerminal

Hyperterminal cannot be used to transfer files to a G610 display module.

HyperTerminal is used to transfer files to a D3:C4 Nav 10.4 monitor display. A PC or portable PC connected to the serial port of the D3:C4 Nav 10.4 monitor display is required to use HyperTerminal.

Detailed instructions for sending and receiving files using HyperTerminal are given below.

If running Windows 7, Hyperterminal could be used through the Windows XP Virtual PC. If Hyperterminal is not preinstalled ("Start" > "All Programs" > "Windows Virtual PC" > "Windows Virtual PC"), the program can be downloaded at http://www.microsoft.com/windows/virtual-pc/download.aspx. Follow the instructions to install Windows XP mode, Windows Virtual PC, and Windows XP Mode Update before using Hyperterminal.

Sending files from a PC or portable PC using HyperTerminal

While on the machine, perform the following steps to set up HyperTerminal to transfer files:

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Illustration 47	g03382653
Hyperterminal Setup

1. Connect the 291-1504 Wiring Harness .

   1. Connect one end to the service connector of the 290-1917 Front Harness As on the monitor display.

   2. Connect the opposite end of the wiring harness to the serial communication port of the computer.

2. Connect the 291-1503 Wiring Harness .

   1. Connect one end to the keyboard connector of the 290-1917 Front Harness As.

   2. Connect the opposite end of the wiring harness to the PS2 connector on the 324-3358 Keyboard.

3. On the PC, select "Start" >"Programs" > "Accessories".

   Note: Do not select "Send" until instructed to do so.

4. Select "Communications" >"HyperTerminal" to launch HyperTerminal.

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Illustration 48	g03382655

5. In the "Connect using:" drop-down. select the communication port that the cable was connected to in Step 1.b.

6. Select the "OK" button.

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Illustration 49	g03382656

7. Set up a new connection using the following settings:
   • Baud Rate = "115200"

   • Data Bits = "8"

   • Parity = "None"

   • Stop Bits = "1"

   • Flow Control = "None"

   Refer to Illustration 49.

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Illustration 50	g03382657

8. From the main "HyperTerminal" window, open the "Transfer" drop-down menu. Refer to Illustration 50.

9. Select "Send File...".

10. In the "Send File" window, select the "Browse" button and navigate to the "C:\Program Files\Caterpillar\" directory.

11. Select the required file.

12. Select the "Open" button.

Receiving files from Hyperterminal

Note: This procedure uses the keyboard that is connected to the D3:C4 Nav 10.4 monitor display to receive files from Hyperterminal.

1. Hold down the "ALT" key and select "F4".

   This action closes CAESultra. You may need to perform this process multiple times to shut down CAESultra properly.

2. Hold down the "ALT" key and select the "Tab" button.

   This action cycles through any other programs that are running on the display module. If another program is running, then hold down the "ALT" key and select "F4".

3. Repeat Step 2 until no programs are running on the display module.

4. Press the "Windows" key on the keyboard to launch the "Start" menu.

   Note: If the keyboard does not have a "Windows" button, hold down the "Ctrl" key and select the "Esc" key. This action will also bring up the "Start Menu".

5. Select "Programs" > "HyperComm1" and enter any 3-digit area code.

6. Select the "OK" button.

7. Select the "Transfer" menu.

8. Select "Receive File".

9. Select the "d:\" as the destination.

10. Select the "Receive" button.

11. On the computer, select "Send".

12. After the files have been transferred to the display module, open Windows Explorer on the display module.

Using the Upgrades Folder

This section describes creating and using the Terrain Upgrades folder.

To create the upgrade folder, complete these steps:

1. Run the upgrade executable, TerrainUpgrade.5.0.xxx.exe, on an office PC.

2. Accept the license agreement and select a location to install the software.

   The default location for the installer software is C:\Terrain Upgrade\Version 5.0.xxx.xxxxx. The software requires at least 10.6 MB of space.

The upgrade executable unpacks a second executable, TerrainInstaller.5.0.xxx.exe. This install executable is used for a new install and for an upgrade install.

Because you have already accepted the license agreement, you can copy "TerrainInstaller.5.0.xxx.exe" to the USB memory module so the installer executable is easier to use in the field.

Entering Machine Dimensions

This section describes the general procedure for entering machine dimensions.

With Terrain and CAESultra, installers can input the dimensions of the machine using either of the following methods:

• Enter the values in the MCU now.

• Enter the values in the MCU at a later stage.

The process for entering machine dimensions varies slightly as follows for single and dual antenna machines:

Single - Single antenna machine dimensions are entered in the MCU.

Dual - Some dual antenna machine dimensions are entered in the MCU, but most are entered during the calibration process. The calibration process is described in the relevant machine install instructions.

Entering Machine Dimensions using the MCU

Menu - Opens the main menu

To enter machine dimensions using the MCU, complete these steps:

1. Open the MCU.

2. Select the machine name.

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Illustration 51	g03384249

3. Select Machine > Machine Dimensions and enter the dimensions for the machine.

4. In the main menu, select "File" > "Send to Cat MineStar System" to send the new machine configuration file.

5. If no additional steps are required, restart the on-board software.

Entering Machine Dimensions On-board

Note: Not available in v5.0. In v 5.0, the on-board software sends the new file to the office software. The office software does not send the new file on to the MCU. To resolve this known issue, enter the machine dimensions into the MCU rather than in the on-board software.

To enter single antenna machine dimensions into the on-board software, complete these steps:

1. Connect a keyboard to the display module.

2. Configure the on-board software to a point where a mach_cfg.txt file is received from the office.

3. Reboot the on-board software.

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Illustration 52	g03382658
Note: Entering machine dimensions on-board is not available in v5.0.

4. In the on-board software, open "System" > "Select" > "Dimesions".

   A machine-specific screen like Illustration 52 appears.

5. Enter values into the relevant fields.

6. Select "OK".

   A mach_cfg.txt file containing the new machine dimensions is sent to the office. The MCU receives the file and adds the contents from the file to a new mach_cfg.txt file.

   If the installer returns to the dialog before completing the following steps, the values will be the existing values before the dimensions were updated. The on-board software will continue to provide guidance to these values until the following steps have occurred:

7. Open the MCU.

   The "Machine" > "Machine Dimensions" field will update with the new values entered in the on-board software. The status of the machine will change to yellow.

8. In the MCU, go to File >Send to Cat MineStar System to send the new configuration file.

   Note: Steps 7 and 8 are required to maintain a synchronized revision number. The synchronized number allows the configuration to be put back to a previously archived version by Cat MineStar System.

9. Reboot the on-board software to use the new dimensions.

   Note: The new dimensions are not used for guidance or data recording by the on-board software until the software reboots with the new configuration file from the office.

If the values required for the machine dimensions are not known, the default values can be used. The validation process allows a machine configuration with the default machine dimension values to be sent to the machine.

Writing Changes to the Disk

When settings are changed in TightVNC that must remain after the display module restarts, run the write executable file to write the changes to the disk.

To write changes to the disk, complete these steps:

1. Attach a keyboard to the display module.

2. Open the following folder:

   D:\CAES\exe

3. Highlight the "WriteChangesToDisk.exe" file and press "Enter" on the keyboard.

   A window indicating that the changes have been committed to the drive flashes briefly on the screen.

Using the Screen Configuration Utility

Use the Screen Configuration Utility (SCU) to configure windows and screens in the on-board software. Each version of the on-board software uses the SCU with the same version number as Terrain. Therefore, multiple versions of SCU may be present on a PC or portable PC.

SCU is not upgraded. Instead, each new version is downloaded.

Configuring the Screens

To configure screens for the on-board software, complete these steps:

1. Ensure that the most recent version of Cat MineStar System office software from the office installer is installed.

   If performing a custom install, make sure to select "CAESultra Screen Configuration Utility".

2. Open the following data directory:

   C:\catmstar\CAESultra_Screen_Configure

3. Open the appropriate folder for the version of the on-board software you wish to configure.

4. Run the executable file. For example, run the following file:

   TerrainScreenConfigInstaller.5.0.xxx.exe

5. Follow the instructions in the install wizard.

6. Create the recommended desktop icon and apply the "Fix Window Borders for Terrain" fix.

   The Screen Configuration Utility shortcut appears on the desktop and the install process is finished. The software stores the SCU files to a folder similar to the following:

   C:\Users\[name]\AppData\Local\TerrainScreen Config\ 5.0.316.16156

   The SCU master and machine configuration files are stored in this folder along with the user guide.

   A different directory is available for each version of Terrain/ CAESultra that has ever been installed with the office software.

   Earlier versions store the SCU in the following folder:

   c:\\CAESultra_Configure_4.x

Running the SCU

To run the latest SCU, complete these steps:

1. Open the following folder:

   C:\catmstar\CAESultra_Screen_Configure

2. Double click "TerrainScreenConfigInstaller.5.0.xxx.exe" to run the installer.

3. Accept the default settings and create a desktop icon.

4. Double-click the desktop icon to start SCU.

5. Select a default configuration or use the new configuration icon (top left) to open a screen.

6. Edit or create screens and windows as required.

7. Save and send the new configuration file to the machine.

For detailed instruction on using the SCU, locate and create a shortcut to the "Screen Configuration Utility User Guide.pdf" that is found in the following folder:

C:\Users\{ComputerUser}\AppData\Local\Terrain ScreenConfig\"5.0.xxx.xxxxx"

Configuring Satellite Receivers

This section describes the procedures for configuring satellite receivers including:

• Configuring the ports

• Using Configuration Toolbox

• Configuring application files

• Upgrading MCG Flash

• MS Controller

Note: Within this document the terms application file, app file, and "appfile" are synonymous.

Specific application files (app files) are used to configure satellite receivers. App files ensure that the receivers provide accurate information to the on-board software.

The app file sets the following:

• Coordinate system

• Local site adjustment

• Receiver inputs

• Receiver outputs

Configuring the Ports

The on-board software enables communication using the "GPS Port" and the parameters shown in Table 10.

Table 10

"GPS Port" Parameters
Parameter	Value
GPS Port Baud	38400
GPS Port Data Bits	8
GPS Port Parity	None
GPS Port Stop Bits	1

Note: For both the display module and the receiver to communicate, the "GPS Port" parameters must be the same in both devices. Do not change the parameters unless you are a very experienced user.

On the G610 display module, the on-board software communicates automatically over a CAN bus. However for machines using the MS990 receiver in a mining application, read ""Setting up a G610 Display Module for an MS990 Receiver" ".

Using Configuration Toolbox

This section describes the general procedure for using Configuration Toolbox.

Configuration Toolbox (CToolbox) is used to produce the application files (app files) that are used with MS series receivers.

The following installers for CToolbox have been provided in this version:

ConfigurationToolbox_v6_9_0_5 FullInstall.exe - This installer includes geoid files allowing sites to select from a range of geoids. Sites that are required to provide positions with respect to a geoid should install this file.

ConfigurationToolbox_v6_9_0_5 NoGeoidInstall.exe - This installer is the same as the previous installer but without the geoid files. This version is provided for sites that are not concerned with the use of geoids and would prefer to conserve disk space.

Installing CToolbox

To install CToolbox, complete these steps:

1. Insert the Terrain USB memory module.

2. Launch the <USB drive>.

3. Select the "Caterpillar" > "04 Utilities" > "Trimble" > "CToolbox GPS Receiver Configuration Utility" folder.

4. Select either of the installers and follow the directions on the screen.

5. To run the CToolbox software, navigate to "Start" > "All Programs" > "Trimble" > "Configuration Toolbox" > "Configuration Toolbox".

CToolbox Documentation

The CToolbox software contains a Help file that provides instruction for using the CToolbox software.

The USB memory module contains the User Guide, Release Notes, support notes, and a system schematic.

Configuring Receiver Application Files

Use the Configuration Toolbox (CToolbox) software to configure receiver application files (app files) for GNSS receivers.

ReferenceRefer to ""CToolbox (Configuration Toolbox)" " for instruction to install the CToolbox software.

Sample app files are available from the Terrain USB memory module and from the Cat MineStar System directory of sample files.

ReferenceFor instructions on obtaining the sample app files in Cat MineStar System, refer to Systems Operation, RENR9562, "Cat MineStar System Office Software", "Configuring GPS Application Files".

The following sample app files are available for the listed machines:

1ANT.cfg - All single antenna machines

2ANT.cfg - Dual antenna excavators and dual antenna front shovels only

Note: Do not use an app file configured for dual antenna machines on a single antenna machine.

ReferenceRefer to Systems Operation, KENR8277, "Application Files" for configuration information for single antenna, dual antenna, and third-party position receivers.

Other than the coordinate system, the sample app files contain the minimum required settings to use the on-board software.

Before either of these files can be used by the satellite receivers mounted on the machines, configure the app files, in particular the coordinate system.

To configure the app file, complete these steps:

1. Open the CToolbox utility by navigating to "Start" > "All Programs" > "Trimble" > "Configuration Toolbox" > "Configuration Toolbox".

2. Open either of the sample app files.

3. In the "Contents" pane, scroll down to and highlight the "Coordinate System" option.

4. Select one of the following actions:

   "Select" - Select to choose the desired coordinate system from a predefined list. The list is accessed through the "Select Coordinate System Type " wizard.

   "Import From DC" - Select to import a coordinate system. The system is defined by a local coordinate system stored in a Trimble *.dc file.

5. Respond to the prompts provided by the dialogs until the coordinate system selection is complete.

6. Check that "Coordinate System" in the CToolbox has been populated with the desired settings.

7. Select "Save" to update the app file with the coordinate system.

   Note: App files can be renamed to any name with eight characters or less.

8. Repeat the process for the other app file, if required.

Send the app file using one of the following actions:

• Use Cat MineStar System to send the final version of the app file to the machine. Refer to the "Cat MineStar System Install and Administration Manual" for this procedure.

• Send the app file to the display module using one of the transfer methods. Methods are described in ""Transferring Files to a Display Module" ". Place the app file in d:\Caes\temp.

ReferenceFor more information regarding outputs and transmission frequencies, refer to the MCU Help file, "Application Files (GNSS Receiver) - Reference" or to Systems Operation, KENR8277, "Cat^® Terrain for Grading and Loading" in the "Application Files" section.

Upgrading MCG Flash

This section describes the general procedure for upgrading and using MCG Flash.

MCG Flash is used to configure IP radios and satellite receivers that are supplied with Terrain and CAESultra. MCG Flash replaces WNCT for IP sites. The MCG Flash installer can be found on the Terrain v5.0 USB memory module.

To upgrade MCG Flash, complete these steps:

1. Insert the USB memory module.

2. Launch the <USB drive>.

3. Select the "Caterpilar" > "04 Utilities" > "Trimble" > "MCG Flash" folder.

4. Select "MCG Flash.exe".

5. Once "MCG Flash.exe" launches, follow the directions on the screen.

6. Check for newer versions of the utilities and install any utilities that are required.

ReferenceRefer to Special Instruction, REHS2585, "MCG Flash User Guide" or to the Help file in the MCG Flash documentation for instruction on using the MCG Flash software.

MS Controller

This section describes the general procedure for installing MS Controller.

MS Controller allows installers and support personnel to check the configuration or behavior of a GPS/GNSS receiver. The MS Controller software provides a real-time interface to an MS series receiver to validate the operation of the receiver. A version of the MS Controller is installed with the on-board software.

MS Controller on the display module

MS Controller has been updated for the G610 display module to communicate with the receiver by using either serial or CAN ports.

To open MS Controller on the display module, select "D:\CAES\exe" and run the type of controller that is required.

MSControllerCAES.exe - Communicate using a serial port.

MSControllerCAES_CAN.exe - Communicate over a CAN bus.

Note: Sites using METSmanager office software must use a serial port. Sites using Cat MineStar System office software can use either serial or CAN.

Installing MS Controller on a PC

A separate copy of MS Controller can be installed on a PC.

The MS Controller installer can be found on the Terrain v5.0 USB memory module.

To install MS Controller on a PC, complete these steps:

1. Insert the Terrain v5.0 USB memory module.

2. Launch the <USB drive>.

3. Select the "Caterpillar" > "04 Utilities" > "MS Controller" folder.

4. Copy "MSControllerCAES.exe" or "MSControllerCAES_CAN.exe" to a location on the PC.

To run the MS Controller software on a PC or on the display module, complete these steps:

1. Close Terrain.

2. Verify that PCAN-USB or ValueCAN drivers are loaded.

3. Navigate to "MSControllerCAES.exe".

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Illustration 53	g03419871

4. Highlight the executable file and press "Enter" on the keyboard.

   MSController opens.

Finding MSController Documents

The MSController is described in the "MS980 Operation Manual" on the Terrain USB memory module.

To obtain the MS980 Operation Manual, complete these steps:

1. Insert the Terrain USB memory module.

2. Launch the <USB drive>.

3. Select the "Caterpillar" > "03 Firmware" > "Documentation" > "Receiver Manauls" > "MS980" folder.

4. Copy the "MS980 Operation Manual 59016-00-ENG.pdf" file to a location on the PC.

5. Read all of the release notes from v1.38A to the most recent release.

Installing MSController is the last step in configuring the satellite receiver to communicate with the on-board software. Use MSController to check the behavior of the receiver.

Checking Measure-up and Calibration

The calibration data for single antenna and dual antenna machines must be checked after the initial calibration. The check will show that the measure-up is correct and that the sensor, if used, has been calibrated properly.

Users may also wish to recalibrate a machine at certain stages of the work flow.

The following checks and recalibration procedures are discussed in the sections below.

• Check single antenna machines.

• Check dual antenna machines.

• Recalibrate surface miners and terrain levelers using a digital level.

• Recalibrate other machine types in the field.

• Perform benching as required.

Checking Measure-up and Calibration on Single Antenna Machines

These instructions are for installers and apply to dozers, loaders, surface miners, and terrain levelers, with or without sensors attached.

Position Debug - Opens the "Positions" window

Menu - Opens the main menu

To check the machine position, measure-up, and sensor calibration, complete these steps:

1. Ensure the following prior to beginning this procedure:
   • The machine software is working.

   • The security is up to date in the mach_cfg.txt file.

   • The dimensions and sensor calibration are complete.

2. Drive the machine without deviating for at least 5 m and stop in the check position.

   This action ensures that the calculated heading is valid for the machine position that is being checked.

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Illustration 54	g03382660
"Positions" window

3. Open the "Positions" window using one of the following methods:

   Position Debug - Select the button.

   Main menu - Select "Diagnostics" > "Position".

4. Choose information about the desired position type such as the "Blade" position. This position is the center of the blade on the ground.

5. Annotate the position.

6. Mark the ground clearly under the point of interest. Project the point of interest to the ground and mark the ground. Keep the surface miner or terrain leveler level. Do not lower the blade.

7. Drive away from the point.

8. Survey the point.

9. Compare the surveyed position to the position from the Diagnostic File.

10. Recalibrate if there is a difference between the positions.

11. Re-enter into the MCU.

12. Resend the mach_cfg.txt file. The position is updated.

13. Reboot the on-board software.

Checking Measure-up and Calibration on Dual Antenna Machines

These instructions are for installers and apply to dual antenna machines.

Position Update - Updates the machine position and the current digital point position

Menu - Opens the main menu

To check the machine position, measure-up, and sensor calibration, complete these steps:

1. Do not move the machine.

2. Turn on the on-board software, guidance, and sensors.

3. Position the bucket tip stretched on the ground.

4. In the main menu, open "Diagnostics" > "Linkages".

5. Select one of the following methods:

   Position Update - Select the button.

   Main Menu - Select "System" > "Update Position".

6. Mark, or note, the bucket tip position. This position is the center of the bucket tip on the ground.

7. Survey the bucket tip while the bucket is still on the ground.

8. Compare the survey results to data in the Diagnostic File.

9. Bring the bucket in close to the machine body and repeat the measurement.

10. Determine If there is a difference between the survey results and the Diagnostic File data.

    If there is a difference, diagnose the exact fault by repeating the check at each linkage point.

Recalibrating the Sensor Using a Digital Level

Sensor recalibration is part of the regular maintenance of surface miners and terrain levelers. The recalibration using a digital level includes the following steps:

• Modifying the machine configuration file

• Calibrating the sensor

• Measuring the sensor offset

• Entering the sensor offsets

Modifying the Machine Configuration File

To modify the machine configuration file, complete these steps:

1. In the MCU, select Machine > Sensors. The relevant "Use <sensor name> Sensor" settings appear in the right-hand pane.

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Illustration 55	g03382661

2. Select the "Use Rolls Sensor" checkbox to enable this function. Select the "460" sensor type from the "Type" drop-down box. Leave the "Offset" value set to zero at this stage.

3. Select the "Use Pitch Sensor" checkbox to enable this function.

4. Select the "460" sensor type from the "Type" drop-down box.

5. Select the "Pitch Sensor Offset " checkbox to enable this function.

6. Leave the "Offset" value set to zero at this stage.

7. Select "File".

8. Select "Send to MineStar".

9. Restart the on-board software.

Calibrating the Pitch and Roll Angle Sensor

The calibration in this section makes the following assumptions:

Illustration 56	g03382662

Installed pitch and roll angle sensor

• All of the hardware for the system has been installed.

• The pitch and roll angle sensor has been mounted with the connector towards the rear of the machine, as shown in Illustration 56.

Use a calibrated digital level (part number not specified) to calibrate the 312-0755 Angle Sensor .

Most digital levels provide readings as positive values. In the calibration procedure for the angle sensor, provide the direction of the digital level value. Provide the value in the form of a negative or a positive value.

For purposes of this calibration, a positive digital level value occurs when the left-hand side of the level is down. In other words, the reading is positive if the left-hand side of the level must be lifted to reach 0 (level). The reading is negative if the right-hand side of the level must be lifted to reach 0 (level).

Digital levels usually provide arrows both left and right of the digital level value. If the arrow on the left-hand side of the digital value points upwards, then the left-hand side of the level is down. The value of the digital level is positive.

Illustration 57	g03382663
Typical digital level

The image in Illustration 57 indicates a negative reading of 9.2 because:

• The right side of the level must be lifted to reach 0 (level).

• The left arrow is pointing down and the right arrow is pointing up.

To calibrate the pitch and roll angle sensor, complete these steps:

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Illustration 58	g03382664

1. Read the pitch of the machine.

   Observe the digital level from the right side of the machine. The back of the machine should be on your left and the front of the machine should be on your right. The digital level should be in front of you. Refer to Illustration 58.

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Illustration 59	g03382665

2. Read the roll of the machine.

   Observe the digital level from the front of the machine. The digital level should be in front of you as you look towards the back of the machine. Refer to Illustration 59.

Measuring the Sensor Offset

Menu - Opens the main menu

To measure the sensor offset, complete these steps:

1. Ensure that a new mach_cfg.txt file has been created in the office, sent to the machine, and activated.

2. Move the machine onto a level surface or level the machine, if possible.

3. Open the main menu, and select "Diagnostics" > "Sensors" to open the "Sensor Values" window.

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Illustration 60	g03382980
"Sensor Values" window

4. Locate the "Pitch" and "Roll" readings of the angle sensor.

   There are a total of three readings for pitch and three readings for roll labeled as follows:

   • "Value"

   • "Unfiltered"

   • "Raw"

5. Record the "Raw" "Pitch" and "Roll" values.

   Angle Sensor Pitch ____________________

   Angle Sensor Roll ____________________

6. Using a calibrated digital level, place the digital level on the machine to measure the machine pitch accurately.

   Record the digital level value for pitch. Ensure that the sign of the value is correct based on the instructions for reading the digital level.

   Machine Pitch ____________________

7. Using a calibrated digital level, place the digital level on the machine to measure the machine roll accurately.

   Record the digital level value for roll. Ensure that the sign of the value is correct based on the instructions for reading the digital level.

   Machine Roll ____________________

8. Calculate the Pitch Offset using the following formula:

   Ptich Offset = (Machine Pitch) - (Angle Sensor Pitch)

   Pitch Offset ____________________

9. Calculate the Roll Offset using the following formula:

   Roll Offset = (Machine Roll) - (Angle Sensor Roll)

   Example:

   Machine Roll: -2

   Angle Sensor Roll: -3

   Roll Offset = (-2) - (-3)

   Roll Offset = 1

   Roll Offset ____________________

Entering the Sensor Offsets

To enter the sensor offsets, complete these steps:

1. In the MCU select Machine > Sensors. The relevant "Use <sensor name> Sensor" settings appear in the right-hand pane.

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Illustration 61	g03382669

2. Enter the calculated Pitch Offset into the "Offset" field of the "Pitch Sensor Offset" setting.

3. Enter the calculated Roll Offset into the "Offset" field of the "Use Roll Sensor" setting.

4. Select "File".

5. Select "Send to Cat MineStar".

6. Restart the on-board software.

Recalibrating a Sensor in the Field

Menu - Opens the main menu

Sometimes the operator of a machine other than a surface miner or terrain leveler must recalibrate a sensor in the field.

In this case, the office and operator work together to update offset values by completing the following steps:

1. The operator obtains the following two values for sensor offset.

   Original - Obtain the original value of the offset by opening the main menu and selecting "Diagnostics" > "Sensor"

   New - Obtain the new value of the offset by following the procedure as described in Special Instruction, REHS5169, "Installation of the Pitch and Roll Angle Sensor for Cat^® Terrain", "Calibrating a Sensor"

2. The operator provides the two values (original and new) to the office and says whether the values are pitch or roll sensor values.

3. The office calculates the average of the two values. This value is the new "Offset" (for roll) or "Pitch Sensor Offset" (for pitch).

   1. If the new offset value differs from the original offset value, the office enters the offset into the MCU. For more information, read ""Entering the Sensor Offsets" ". The office sends out a new mach_cfg.txt file. The operator reboots the machine.

   2. If the offset value does not differ from the original offset value, no change is needed.

4. Finally, the operator checks the Profile window to ensure that the pitch/roll sensor and the direction of the machine are now correct.

Benching an Excavator

Benching is the process by which the machine uses a surveyed and physically solid point on site to set a position exactly. Benching is most often used for excavators where the excavator places the bucket on a solid bench post with a known height.

To bench an excavator, complete these steps:

1. Drive the wheels onto marked positions on the ground.

2. Place the bucket tip on the survey benchmark.

3. Check Northing, Easting, and Elevation against the known surveyed positions.

4. Compare original and bench positions and recalibrate if necessary.

Configuring Cat Productivity Reporting Tools

Note: These instructions were last updated in 2011.

These instructions assume that the Cat Productivity Reporting Tools have been installed by the Cat MineStar System installer. The configuration instructions described here are for users who wish to use the reporting tools for Terrain for grading and loading data.

From the "Start" menu, select "All Programs" > "Caterpillar" > "Cat Tools".

Each tool has a dedicated subdirectory with the following contents:

• Shortcut to the tool

• User guide with same contents as "Help" system

• Revision history

• Uninstall executable file

The Cat Reports tool also has complimentary guides for the reports that are available in the tool.

For information on installing and using the Cat Productivity Reporting tools, users should consult the "Help" system or the "User Guide". These sources provide specific information necessary for configuring the CAT Tools for Terrain for grading and loading installations.

Configure the Cat Tools to use Terrain for grading and loading data in the following order:

• Cat 2DB

• Cat Configurator

• Cat Editor

• Cat Reports

Cat 2DB Service

Cat 2DB Service - Stops Cat 2DB

To configure Cat 2DB Service, complete these steps:

1. Right-click on the "Cat 2DB Service" icon.

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Illustration 62	g03382670

2. Select the "Stop Cat 2DB" option and then select the "OK" button.

   Note: Do not start the Cat 2DB Service until instructed in a future step.

3. Right-click on the "Cat 2DB Service" icon a second time.

4. Select the "Configuration" option.

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Illustration 63	g03382671

5. Select the "DSN" pull-down arrow, scroll down the list, and select the "XE" option from the list.

6. Enter the Client PC "Username" and "Password".

7. Click on the "Test Connection" button.

   If the test is successful, the "Connection Successful" message will be displayed and you can continue to Step 8. If the test results in an "Unable to connect" message, then review the configuration in Step 5 and 6.

8. Select "OK"

Executing a Script in CAT 2DB

Table 11 lists the scripts that are available in CAES v4.0. Execute the scripts that are listed for the relevant scenario.

Table 11

Scenario	Scripts to execute
Installing CAT 2DB with Oracle database for the first time	Application V1.2.0 - (Oracle) Installation CAES v4.0.0 - (Oracle) Installation
Upgrading an existing installation of CAT 2DB with Oracle database	Application V1.2.0 - (Oracle) Upgrade for Application V1.0.1 CAES v4.0.0 - (Oracle) Update
Installing CAT 2DB with MS SQL Server database for the first time	Application V1.2.0 - (Microsoft SQL Server) Installation CAES v4.0.0 - (Microsoft SQL Server) Installation

Note: Execute the scripts in the listed order.

To execute a script in Cat 2DB, complete these steps:

1. Right-click on the "Cat 2DB Service" icon. This icon is in the lower right corner of the monitor within the Windows system tray.

2. Select the "DB Script Executor" option.

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Illustration 64	g03382672

3. In the "Action" window, select the script to execute.

4. Select the "Execute Action" button. If prompted to confirm, select the "Yes" button and then wait for the script to execute.

5. Repeat the steps for any additional scripts.

Configuring Folder Pairs

The following folders must be defined in Cat 2DB:

Source Folder - This folder is the location where productivity files are stored before being processed and the data within that is added to the database.

Processed Files Folder - Once processed, the productivity files are moved to this folder so that the files are not handled again.

Note: Numerous folder pairs that can be defined so that collating productivity files into one location before processing is not required.

Cat 2DB Service - Use this icon to stop Cat 2DB.

To configure the folder pairs, complete these steps:

1. Right click on the "Cat 2DB Service" icon.

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2. Select the "Configuration" option.

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3. Select the "Folder" tab.

4. Change the "File pattern" option from "*.*" to "*.prod".

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5. Select the "Add Folder Pair" button.

6. Under the "Production Folder" area, select the "Browse" button.

7. Select the location where productivity files are stored, for example:
   • C:\Program Files\Caterpillar\METSmanager DATA\metsdata\00020\product\2010\

8. Select the "OK" button.

9. Under the "Production Folder" area, select the "Browse" button.

10. Select the location where productivity files are to be stored once processed, for example:
    • C:\Program Files\Caterpillar\METSmanager DATA\metsdata\00020\product\2010\Archive

11. Select the "OK" button.

12. On the "Folder Pairs" window, select the "OK" button.

13. Repeat Step 5 through Step 12 for every location where productivity files are stored.

14. Once all of the folder pairs have been added on the "Cat 2DB Configuration" window, select the "OK" button.

Installing Cat 2DB on a Different Server to the Database

The Cat 2DB service may be installed on a different server from the database. In this situation, configure the CAT 2DB service to run under a user that has access to all required services on the remote server.

To install Cat 2DB on a different server, complete these steps:

1. Click "Start" > "Control Panel" > "Administrative Tools" > "Services".

2. Right-click on "Cat 2DB Service" and select "Properties".

3. Click the "Log On" tab.

4. Click "This account", and then enter an appropriate username and password.

5. Click "Apply".

6. Click "OK".

7. Close the "Services" dialog.

Cat Configurator

Once the Cat Productivity Reporting Tools are installed, a roster and a schedule must be created.

Create the schedule in the Cat Configurator before any data is loaded into the database. If this action does not occur, users will notice that Cat Reports will not produce reports that are populated with the required information.

Problems may occur once the term of the roster and the schedule has completed. To avoid this effect, create a roster and a schedule that continues for 10 years.

Setting Up Cat Configurator

To set up Cat Configurator, complete these steps:

1. Select "Start" > "Programs" > "Caterpillar" > "Cat Configurator".

2. Select and launch "Cat Configurator".

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3. Go to "File" menu and select "Connect to Database".

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4. Enter the Client PC "User:" and "Password:".

5. Select "OK".

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6. Go to "Schemas" > "CAES" > "Scheduling" and double click on "Crew".

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7. Select the "Crew Add" button.

8. Type in "Crew A" and then select the "OK" button.

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9. Close the "CAES: Schedule Crew Editor" window and select "Yes" to save the changes.

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10. Go to "Schemas" > "CAES" > "Scheduling" and double click on "Roster".

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11. Change the "Shift Length" to "24:00".

12. Select "Crew A" from the "Crew List".

13. Select the right arrow button.

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14. Select the "Save Roster" button.

15. Type in "Roster A" and select the "OK" button.

16. Select the "Exit" button on the "CAES: Roster Editor" window.

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17. Go to "Schemas" > "CAES" > "Scheduling" and double click on "Schedule".

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18. Select "Roster A" from the "Roster" drop-down menu.

19. Select the "From:" date and time.

    Note: The starting date should be the same as the oldest productivity file that the site is converting. This period is normally 6 months to a year of data.

20. Select the "To:" date and time.

    Note: The ending date should be a date at least 10 years in the future. This action ensures that another schedule will not need to be created in the future.

21. Select the "OK" button.

22. Select the "Exit" button on the "CAES: Scheduler" window.

23. Close the "Cat Configurator" window.

Loading Productivity Files into the Database

Now that the folders pairs and the schedules have been defined, users can begin uploading productivity information into the database.

To load productivity files into the database, complete these steps:

Note: If the next two steps are not done, then the conversion of the data will not begin.

1. Right click on the "Cat 2DB Service" icon. This icon is in the lower right corner of your monitor within the Windows system tray.

2. Select the "Start Cat 2DB" option and then select the "OK" button.

   Note: The more machines or years that you convert, the longer the conversion and upload process will take to complete. The conversions will slow down the computer response time depending on the speed of your CPU.

Cat Editor

Setting Up Cat Editor

Cat Editor is used to enter scale weights into the CAES database. Before weights can be entered, set up Cat Editor.

To set up Cat Editor, complete these steps:

1. Select "Start" > "Programs" > "Caterpillar" > "Cat Editor".

2. Select and launch CAT Editor.

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3. Go to the "File" menu and select "Connect to Database".

4. Enter the Client PC "User" and "Password".

5. Select "OK".

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6. Go to the "Tools" menu and select "Options...".

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7. Go to the "Units" tab and change the "Volume Unit:" to the unit that is used on the site, such as m³ (cubic meters) or yd³ (cubic yards).

8. Select the "OK" button.

9. Close the "Cat Editor" window.

Cat Reports

Setting Up Cat Reports

The Cat Reports are used to view data from the CAES database. Before data can be viewed, set up Cat Reports.

To set up Cat Reports, complete these steps:

1. Select "Start" > "Programs" > "Caterpillar" > "Cat Reports".

2. Select and launch the Cat Reports program.

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3. Go to "Tools" menu and select "Options...".

4. On the "Database" tab, select the "DSN" drop-down arrow, scroll down the list, and select the "XE" option.

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5. Enter the Client PC "Username" and "Password".

6. Select the "Database Type" drop-down arrow, then scroll down the list and select the "ORACLE" option.

7. Click on the "Test Connection" button.

   "Connection Successful" - The test is successful. Continue to Step 8.

   "Unable to connect" - Refer to Step 4 through Step 6 to ensure that all of the values are configured correctly.

8. Select "OK".

9. Select the "Units" tab.

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10. Change the "Local Units:" to the default units that are used by the site such as "Metric", "US Feet", or "US Survey Feet".

    Note: Leave the "Database Units:" set to "Metric". The database stores all of the values in a metric format. The reports will not show the correct value if you change this value.

11. Select "OK".

    Note: The "CAES Advanced Reports" settings are stored in the following file:

    C:\Program Files\Caterpillar\Cat Reports\ Adv_Report_Info.cfg

    Note: If users want to return to the default settings, then delete this file before installing the CAES Office Suite.

    Note: To modify the "Site name" that is shown in the CAES reports, open this file with Mircrosoft Notepad.

12. Close the "Cat Reports" window.

Firmware Matrix

Table 12

Terrain On-board Software
Application	Version
BIOS version G610	v29
Terrain for Grading and Loading CAESultra Resource DLL - All languages	5.0.358
G610 version of XPe operating system	1.04
Terrain Installer	TerrainInstaller.5.0.xxx.exe

Table 13

CAES Office Software Versions
Application	Version
CAT2 DB6 CAT DB Configurator CAT Editor CAT Reports	6.6.0
Cat MIneStar Office Task List Manager Task List Server MCU Server MCU Client	1.2
Terrain Mobile Installer	TerrainMobile.5.0.xxx.exe

Table 14

Utilities
Application	Version
CGStestSuite.62 GNSS	v0.72
Configuration Toolbox	6.9.0.5
Easy IP DNS	1.2 B1.0.0.64
MCG Flash	1.1.8.3
MSControllerCAES (on-board)	MSControllerCAES (v5.0.xxx)
TerrainDemo Installer	TerrainDemo. 5.0.xxx.exe

Table 15

Firmware for Receivers
Device	Version
MS840	1.58
MS860
MS980 (application / monitor)	1.62/1.10
MS990 (application / monitor)	4.49/3.21
MS992 (application / monitor) Single and Dual	4.65/3.21

Table 16

Annunciators
Device	Comment
Alarm	Mandatory for Detect

Table 17

Firmware for Angle Sensors
Device	Version
AS450	1.10 or 2.29
AS460

Current Documentation

Table 18

Title	v5.0 Media
"Cat® Terrain Systems Operation"	KENR8277
"Cat® Terrain Operation and Maintenance"	SEBU8822
"Replacement of the Position and Inclination Sensors for Cat® Terrain"	REHS3698

Table 19

Title	v4.5 Media
"Cat® Terrain Systems Operation"	UENR2509
"Cat® Terrain Operation and Maintenance"	SEBU88814
"MS9xx Hardware Update for Cat® Terrain"	REHS7226
"Replacement of the Position and Inclination Sensors for Cat® Terrain"	REHS7232

Table 20

Title	v4.0 Media
"Configuration Toolbox User Guide"	RENR7548 (1)
"MCGFlash User Guide"	REHS2585

( 1 )

Will be replaced by KENR9006

End User License Agreements

ReferenceRefer to Special Instruction, REHS7395, "End User License Agreements for CAES and Terrain" for End User License Agreements related to software usage.