Procedure for Installing and Configuring Cat® MineStar Onboard for Supervisor and Accessory Vehicles {7605, 7610, 7620} Caterpillar

Machine Control and Guidance Products

CAT FLEET ONBRD (S/N: FT41-UP)

CATDETECT-PROXIAWAIV (S/N: PA41-UP)

Introduction

This Special Instruction contains necessary information for Installing and configuring Cat^® MineStar Onboard for Supervisor and Accessory Vehicles.

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

Safety Section

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

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

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

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

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

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Personal injury or death can result from improper assembly procedures. Do not attempt any assembly until you have read and understand the assembly instructions.

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Accidental engine starting can cause injury or death to personnel working on the equipment. To avoid accidental engine starting, disconnect the battery cable from the negative (−) battery terminal. Completely tape all metal surfaces of the disconnected battery cable end in order to prevent contact with other metal surfaces which could activate the engine electrical system. Place a Do Not Operate tag at the Start/Stop switch location to inform personnel that the equipment is being worked on.

Required Parts

Note: The 492-0395 Wiring Kit contains components for a 12 V system. The timer module, and main relay are not rated for 24 V service. For 24 V service, the 453-4118 Module, and 3E-5239 Relay As should be substituted.

The required parts are listed in Table 1 to Table 4. Table 1 lists the base kit. Table 2 lists the generic display mounting kit. Table 3 and Table 4 list the model specific mounting kits. Only kits listed in Table 1 and Table 2 or kits listed in Table 1, Table 3, and Table 4 will be required to install the system.

Note: Select one of the following two Display Mounting Kits. If the 492-0396 Display Mounting Kit is used, one of the base brackets will be required depending on model.

Customer Supplied Components

The following components must be supplied by the customer prior to the installation of the system:

• Power source

• Ethernet based radio

• Ethernet cable

• GNSS reference station

• Site calibration file

• IP address list containing the following:

- MineStar Office IP and Port

- Display IP address, subnet, and default gateway

- GPS receiver IP address, subnet, and default gateway

- Radio IP address when applicable

Wireless Connectivity for Machine Communication

All third-party radios interacting with a Fleet on-board installation must be capable of filtering network traffic or have a managed switch to allow or block data flow.

Power Supply

This system and the components listed are installed on vehicles and machines capable of providing regulated supply of 14.4V and at least 5 A.

Ethernet Based Radio

A third-party Ethernet based radio must be installed on the machine. The radio provides network connectivity on the sites broadband wireless network. Also, the IP data radio is required to receive GNSS corrections from a reference station. The radio must be installed in accordance with the integrators instructions.

Ethernet Cables

Ethernet cables of CAT5E or TIA/EIA 568B standard or newer will be required. The Ethernet cables are required for connecting the Cat^® Ethernet adapter to a customer provided Ethernet based radio.

GNSS Reference Station

Operation of Caterpillar technology systems requires the continuous availability of GNSS RTK corrections. The infrastructure plan of the customers site must be reviewed and approved by the Caterpillar dealer. The reference station must be able to remove tracking of individual satellites. Also, the GNSS reference station must support the option to output corrections in the following formats:

• CMR (RTK)

• CMR+ (RTK)

• CMRx (RTK)

• RTCM

Note: The following RTCM versions are used: v2.1, v2.2, v2.3, and v3.0 (RTK, DGPS, or RTK+DGPS)

Note: For full positioning requirements, refer to Special Instruction, REHS8823, "Site Positioning Requirements for Cat^® MineStar System Products".

Site Calibration File

A site calibration file must be supplied to the dealer by the mine site. The site calibration file converts GPS coordinates into local mine coordinates. Caterpillar recommends that a licensed surveyor, under contract, perform the site calibration. The site calibration file must be available in the Trimble .dc file format, or the .cfg file format for use on equipment that has GNSS receivers.

Preparation Prior to Installation

This section will outline the following information:

• Special tools and resources that are required for the installation.

• Determining the mounting location for the components.

• Grounding practices for the components.

Required Tools for Installation

Ensure that the following list of special tools and resources are available prior to installation:

• Hex tool

• Metric Wrench and Socket Set

• Standard Wrench and Socket Set

• Drill and Drill bit set

• Hole cutter

• Wire cutter and stripping tool

• Crimping tool for RJ45

Note: The hole cutter and drill may not be required depending on vehicle and installation. They will be used to create the exit for the antenna cable to the exterior of the vehicle, if one is not available.

Determining the Mounting Locations

• Antenna (GNSS) must be mounted free from obstructions and have visibility to the sky.

• Monitor and display group that will be installed in the machine cab on the pedestal option.

• Electrical circuit connection.

• Harness and cables that will interconnect the components.

Mounting Location for the Monitor Display Group

The monitor display group must be mounted in a location that will not interfere with the existing equipment in the cab. If necessary, relocate the existing equipment.

Note: The monitor display group must not interface with any movement of the operator.

Ensure that the monitor display group does not cause any of the following conditions:

• Interface with the operators direct view or the operators view in the mirrors.

• Interface with the ability to enter the cab or exit the cab from the operators seat or the buddy seat.

• Expose the operator or the person in the buddy seat to potential of additional injury from impact during machine collisions, or rollovers.

• Interface with the operation of the machine controls. The machine controls include the following components: the gear selector, the retarder, and the steering wheel.

• Interface with operator comfort. Operator comfort includes the rest positions for the arm and the leg.

• Block or cover up any warning films.

Inspecting the Machine

Perform the inspection of the vehicle to identify the best mounting location for each component. Verify that the selected location will meet the following conditions:

• The installation will not interface with the ability of the operator to view from the cab.

• The installation will not block any mirrors.

• The components will not block the entry or the exit of the operator.

• The components will not interface with the operation of the other equipment.

• The cables will not extend beyond the electrical specifications.

Procedure for Installing Display Mounting, and Mounting 459-2220 Electronic Control Gp

Install either the 492-0396 Display Mounting Kit or the 451-3759 Display Mounting Kit and mount the 459-2220 Electronic Control Gp.

Procedure for Installing 492-0396 Display Mounting Kit

To install the 492-0396 Display Mounting Kit, use the following procedure:

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Illustration 1	g06013982
(1) 487-7882 Support ( 203.2 mm (8 inch)) (2) 487-7882 Support ( 304.8 mm (12 inch)) (3) 488-5337 Adapter (4) 488-5338 Bracket (5) 487-7879 Bracket (6) 487-7880 Bracket (7) 495-1077 Bracket As (GMC 1500)

1. Following the instructions provided with the base bracket, install one of the following:

   • 488-5338 Bracket

   • 487-7879 Bracket

   • 487-7880 Bracket

   • 495-1077 Bracket As (GMC 1500)

2. Add 487-7878 Spacer as needed to compensate possible gaps between the floor, and the base bracket.

3. Bolt the 488-5337 Adapter to the base bracket with the hardware provided with the adapter.

4. Bolt the 487-7882 Support to the 488-5337 Adapter. Assemble the 487-7882 Support to the 487-7882 Support with the hardware provided.

5. Connect the 450-0297 Bracket As to the ball mounting socket with four 8T-4753 Screws.

6. Connect the 459-2220 Electronic Control Gp to the 450-0297 Bracket As using four 6V-5683 Bolts, and four 114-6658 Washers.

Procedure for Installing 451-3759 Display Mounting Kit

To install the 451-3759 Display Mounting Kit, use the following procedure:

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Illustration 2	g06013986
451-3759 Display Mounting Kit (8) 114-6658 Washer & 6V-5683 Bolt (9) 450-0297 Bracket As (10) 8T-4753 Screw (11) 329-2679 Clamp (12) 329-2680 Base (13) 450-0297 Bracket As (14) 329-2682 Bracket As (15) 8T-4189 Bolt & 8T-4224 Hard Washer

1. Attach one 329-2680 Base to the 329-2682 Bracket As using four 8T-4753 Screws.

2. Mount the 329-2680 Base of the 329-2682 Bracket As assembled in step 1 to the cab interior using two 8T-4189 Bolts, and two 8T-4224 Hard Washers. Ensure that the mounting location will support the load of the display with consideration of forces and motion.

3. Attach the 329-2680 Base to the 450-0297 Bracket As using four 8T-4753 Screws.

4. Mount the display to the bracket assembled in step 3 using the 114-6658 Washer, and 6V-5683 Bolt.

5. Connect the two bracket bases using the 329-2679 Clamp.

Installation Procedure

The system consists of the following:

Wiring Kit:

• Display

• GPS Receiver and Antenna

• Main Power Relay for System

• Shut down timer module

• Harnessing

• Hardware

Display Mounting Kit:

• Display Mounting

Base Bracket:

• Base Bracket for model-specific mounting

Perform the following procedure for Installing MineStar Onboard for Supervisor and Accessory Vehicles:

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Illustration 3	g06014012
Electrical component mounting (16) 371-7044 Satellite Receiver Gp (17) 489-1584 Timer (18) 115-1615 Relay As (19) 419-5974 Adapter As (20) 3E-3370 Connector Receptacle As (21) 8T-4137 Bolt, 8T-4121 Hard Washer, and 9R-2613 Weld Boss, or 8T-4133 Nut (optional) (22) 490-5042 Bracket (23) 480-5752 Wiring Harness

1. Identify the appropriate mounting locations for the following components:

   • Display mounting structure

   • Electrical Component Mounting plate

   • GPS Antenna

   • Customer supplied radio

2. Mount the 490-5042 Bracket using four 8T-4137 Bolts, four 8T-4121 Hard Washers, and four 9R-2613 Weld Boss, or 8T-4133 Nut depending on location selected.

3. Install the display mounting as shown in Illustration 3 by performing the following:

   1. Mount the 371-7044 Satellite Receiver Gp (16) to the 490-5042 Bracket (22) using four 6V-7357 Bolts, four 9X-8267 Washers, and four 6V-8225 Nuts.

   2. Mount the 489-1584 Timer (17) to the 490-5042 Bracket (22) using four 7X-2533 Bolts, and four 9X-8267 Washers, and 6V-8225 Nuts.

   3. Mount the 115-1615 Relay As (18) to the 490-5042 Bracket (22) using the 5C-9553 Bolt, 9X-8267 Washer and 6V-8225 Nut.

   4. Mount the 419-5974 Adapter As (19) to the 490-5042 Bracket (22) using the 3S-2093 Cable Strap.

   5. Mount the 3E-3370 Connector Receptacle As (20) to the 490-5042 Bracket (22) using the 3S-2093 Cable Strap.
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   Illustration 4	g06014014
   480-5752 Wiring Harness (24) Display Ethernet 1 (25) Display Ethernet 2 (26) Display power (27) Key switch power (28) Ground (29) Battery power (30) Power for Radio or customer attachment (31) Ethernet to switch or radio (32) Main power relay (33) Timer module (34) MS352

4. Connect the 480-5752 Wiring Harness to the components installed. Refer to Illustration 4.

5. Make the power connections of the 480-5752 Wiring Harness.

   1. Verify that the batter power is isolated.

   2. Connect the ring terminal of the long lead labeled "KEYSWITCH" to a switched power source.

   3. Connect the ring terminal lead labeled "GND" to an appropriate ground source.

   4. Connect the ring terminal of the lead labeled "UNSWITCHED PWR" to an unswitched power source.

6. After all connections have been made, power the vehicle, turn the keyswitch to the ON position.

   1. Verify that the display powers ON, after the splash screen is displayed. The display will go to a black screen, if no configuration has been loaded.

   2. Verify that the power LED on the 371-7044 Satellite Receiver Gp illuminates.

   3. Ensure that when the keyswitch is moved to the OFF position, the components power OFF.

7. The 419-5974 Adapter As is available for the connection of the system to the wi-fi radio. Prior to making this connection, the configuration steps of this manual must be completed. After the configuration is complete, connect the customer provided Ethernet cable to from the wi-fi radio to this adapter.

Note: Before connecting to the customer radio, follow the configuration section of this manual.

Note: The timer module provides power to system for up to 60 seconds after key OFF. This component must be unplugged to fully isolate the system when servicing.

Wiring Schematic

Illustration 5	g06174132

Procedure for Mounting 372-4806 Antenna

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Illustration 6	g06002229
372-4806 Antenna

1. Mount the 371-2200 Mounting Bracket using four 8T-4138 Bolts, four 9X-8256 Washers, and 6V-8225 Nuts.

   Note: If a permanent mount is not available, the 492-0394 Support included can be used.

2. Mount the 372-4806 Antenna to the 371-2200 Mounting Bracket using the hardware provided with the antenna.

3. Connect the 424-0876 Cable As to the antenna. Then connect to the 424-0877 Cable As, and route towards the receiver.

Configuration Procedure

Perform the following procedure for configuring the MineStar Onboard for Supervisor and Accessory Vehicles:

Procedure for Flashing the Display

1. Connect to the display receiver by connecting an Ethernet cable to the Ethernet harness adapter or by connecting the service flashing harness to back of the display.

2. Connect to the display by using Caterpillar Electronic Technician (Cat ET) Win Flash through an "Ethernet Direct Connection" selectable in Cat ET preferences.

3. After connecting to the display, select the file to be flashed, and begin flashing the display.

4. If prompted newer OS maybe installed.

   Note: Never interrupt flashing as this will result in display failure.

   Note: The display will reboot twice during the flash process, if OS is updated. This may take up to 10 minutes.

5. The flash process will progress as follows:

   • New OS is transferred to display, when applicable.

   • Old OS is erased, when applicable.

   • Display reboots to complete OS installation.

   • New application file is transferred.

   • Display reboot.

   • Application launched and software installation complete.

6. After the display launches the application, the initial configuration will be displayed. Configure the display with the MineStar IP and Port and a static IP address, subnet, and Gateway.

7. The display may restart to accept these changes. After the restart, a Topeconfig.txt file needs to be loaded with the "$Use NMEA GPS Input" key present to enable further configuration. Refer "Procedure for Loading Configuration" to proceed with the configuration of the system.

Procedure for Loading Configurations

1. After the software has been updated, load the Topeconfig.txt file, and the Topewincfg.txt file. This will need to be done using a third-party FTP tool.

   1. Access the file structure using an FTP tool

   2. The user name is aquila

   3. The password is cold

   4. Transfer the Topeconfig.txt file to the \Storage\ folder

   5. Transfer the Topewincfg.txt file to the \Storage\config\ folder

2. Ensure that the key "$ Use NMEA GPS Input" has been added to the Topeconfig.txt file in addition to the base G407 keys.

   • $ Softpanel Startup Command =\Storage\TopeButtonPanel.exe -h=$Handle

   • $ Screen Size X =690

   • $ Screen Size Y =480

   • $ Use NMEA GPS Input

3. Ensure that the Topewincfg.txt has been adjusted accordingly or the baseline Light Vehicle config is in use.

4. Restart the display.

Procedure for Configuring Direct Connection to the MS352 GPS Receiver

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Illustration 7	g06001718

1. Access the developers menu by either selecting the tool bar button ($ Tools x =12) or pressing the areas of the screen in the order shown in the Illustration 7 to access the menu.

2. Go to "Options" > "Initial Configuration" after accessing the menu.

3. Once the initial configuration menu is displayed, enter the MineStar Office address and port, the display static IP, subnet, and gateway, and press connection test. The display may restart to accept any changes. If this occurs, repeat step 1 to access the initial configuration after the reboot and rerun the connection test. Once the connection test is complete, press "save".

4. Select the option for a direct connection to the GPS receiver and enter the GPS receiver address that will be programmed into the receiver in the next step. Press "save", when complete.

Procedure for Configuring GPS Receiver with A Static Address

Note: To configure the MS352 receiver, need a predetermined set of IP addresses for the onboard components (G407, receiver, and radio as required), Cat 5e or greater Ethernet cable, the sites GPS receiver application file, and the sites.dc file. You may also need PC admin rights to perform these tasks. Consult your IT department for additional details.

Note: Refer to Systems Operation, UENR4696, "Cat^® Detect and Cat^® MineStar System Onboard Configuration for the MS352 Satellite Receiver" for additional information about the MS352 GPS receiver.

1. Connect to the GPS receiver by connecting an Ethernet cable to the Ethernet Harness adapter if not previously completed in the Section "Procedure for Flashing the Display".

2. Ensure that the system is not connected to the network.

3. Disable PC wireless and any VPN connections through the "Network and Sharing Center of the PC" using a service PC.

4. Configure the service PC to have a static IP address of 169.254.1.0 and a subnet of 255.255.254.0. No gateway will be needed.
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   Illustration 8	g06002136
   Default Ethernet access

5. Using a command prompt ping 169.254.1.0. This is the factory IP address of the MS352 receiver.
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   Illustration 9	g06002138
   Default config

6. After a successful ping, open a web browser and enter the factory IP address (http://169.254.1.0) of the GPS receiver. The default user name is "admin" and the password is "password" for the MS352.
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   Illustration 10	g06002139
   Ethernet config

7. Configure a static IP into the GPS receiver by accessing "Network Configuration" > "Ethernet".

   1. Set the IP Setup to "Static".

   2. Enter the MS352 predetermined site IP address. This should be controlled by the site champion or the network administrator.

   3. Enter the Netmask address.

   4. Enter the Gateway address.

   5. Select "Change Configuration".

      Note: The IP address of the MS352 receiver has now changed. Remove the static IP assigned to the service IP and access the MS352 receiver through the network for the remainder of the configuration.

Procedure for Accessing Receiver through the Site Network

1. Disconnect the Ethernet cable that is used to access the display and receiver, and connect the system to the Wi-Fi radio.

2. Ensure that you can access the receiver through the network by opening a command prompt and pinging the receiver.

   Note: To access the GPS receiver through the sites network, PC must be connected to the site network.

3. Enter the address of the GPS receiver into a web browser.

4. When the prompt appears, enter the default user name and password of "admin" and "password".

5. Once the page opens continue to configure the receiver as described below.

Procedure for Loading the application and .dc file

Using the "Menu" on left-hand side of the web page, complete the following:

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Illustration 11	g06002148
Load application file

1. Go to "Receiver Configuration" > "Application Files" of the receivers menu.

2. In the "Operation" drop-down, select "Upload File" and browser to the application file required.

3. Select "OK".

4. Return to "Receiver Configuration" > "Application Files" of the receivers menu.
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   Illustration 12	g06002159
   Application files

5. In the "Operation" drop-down, select "Start Now" with the file name of the application file loaded. The application file will now be displayed in the "Executing Application File Name" dialog.

6. Select "OK".

7. Return to "Receiver Configuration" > "Application Files" of the receivers menu.

8. Select "Upload & Apply Project and Calibration File". Browse to the .dc file and select "OK".

9. Now, with a GPS antenna connected, verify that the receiver is calculating positions by selecting "Receiver Status" from the main menu and accessing the "Positions" tab.
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   Illustration 13	g06002165
   Positions

10. If positions are not displayed, review the previous steps, check cable connections, and antenna visibility to the sky.

Procedure for Configuring Direct Connection to G407 Display

Note: Misconfiguration of GPS module can result in GPS receiver entering monitor mode. This will render GPS module inoperable. Never configure NEMA to output over any port other than what is listed below.

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Illustration 14	g06014017
I/O configuration

1. Select "I/O configuration" of the main receiver menu and configure the UDP port for corrections and the TCP/IP port for iDesk communications with the display.

   1. Double-click the "UDP" under the type column and enter 3784 for the port value. This is the port that will receive corrections from the base station.

   2. Double-click the "TCP/IP" and enter the port number of 15555.

   3. In the same menu window, locate the "NEMA" section, and set "GST" to "1 Hz" and "PJK" to "5 Hz".

   4. In the "Variations from standard" section of the same page, check the "Report extended information in NEMA GGA and RMC strings" and the "Report GST message always as GPGST" check boxes.

   5. Select "OK".
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      Illustration 15	g06117688
      I/O configuration

   6. Verify that GPS receiver positions are available to the display by accessing the developers menu and viewing the GPS diagnostics window.