Cat® Site Positioning Commissioning Procedure {7605, 7610, 7620} Caterpillar

Machine Control and Guidance Products

CMD FOR HAULING (S/N: CM41-UP; CM51-UP; AT61-UP)

Off-Highway Truck/Tractor

789D (S/N: SPD1-UP)

793F (S/N: D3T1-UP; RBT1-UP)

797F (S/N: LAJ1-UP; LTZ1-UP)

Introduction

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

The purpose of this Special Instruction is to assist a qualified technician in assessing the successful integration of third-party Site Positioning Equipment with the Cat^® MineStar System. Site Positioning consists of the following (1) Global Navigation Satellite System (GNSS) Base Station, (2) Truth Positioning System (TPS), (3) GNSS Site Calibration (.dc file).

Note: Caterpillar Inc. does not distribute or sell Site Positioning equipment. Technical support, training, and best practices utilized for installation, operation, maintenance, and troubleshooting of the Site Positioning hardware should be provided by the respective dealer of that equipment.

This document will be divided into two sections isolating checkouts at an initial installation of Site Positioning with Cat^® MineStar System versus subsequent changes to site positioning at a Cat MineStar System site.

Important Safety Information

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

A person must be alert to potential hazards. This person must 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 of a potential hazard.

Therefore, the warnings in this publication and the warnings that are on the product are not all inclusive. Avoid using a tool, a procedure, a work method, or operating technique that is not recommended by Caterpillar. If used, ensure the safety of the operating personnel and others.

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Do not operate or work on this machine unless you have read and understand the instructions and warnings in the Operation and Maintenance Manuals. Failure to follow the instructions or heed the warnings could result in injury or death. Contact your Cat dealer for replacement manuals. Proper care is your responsibility.

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Electrocution Hazard! Keep the machine and attachments a safe distance from electrical power. Stay clear 3 m (10 ft) plus twice the line insulator length. Read and understand the instructions and warnings in the Operation and Maintenance Manual. Failure to follow the instructions and warnings will cause serious injury or death

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Accidental engine starting can cause injury or death to personnel working on the equipment. To avoid accidental engine starting, turn the battery disconnect switch to the OFF position. Remove the key for the battery disconnect switch. Use a secure padlock in order to lock the battery compartment access door. Place a Do Not Operate tag at the Start/Stop switch location to inform personnel that the equipment is being worked on.

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Personal injury or death can result from sudden machine movement. Sudden movement of the machine can cause injury to persons on or near the machine. Prevent possible injury by performing the procedure that follows before working on the machine. Move the machine to a smooth horizontal location. Move away from working machines and personnel and lower the implement to the ground. Permit only one operator on the machine. Keep all other personnel away from machine or in view of the operator. Engage the parking brake. Stop the engine. Move the hydraulic control levers to all positions to release the pressure in the hydraulic system.

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Personal injury or death can occur if personnel are trapped between the wheel and the frame. The steering system is hydraulically controlled and wheels can crush personnel during movement. Use caution when working between the wheels and the frame. If the wheels must be turned, ensure that all personnel are clear of the machine before any movement.

Illustration 1	g00037860

Use steps and handholds whenever you mount the machine. Use steps and handholds whenever you dismount the machine. Before you mount the machine, clean the step and the handholds. Inspect the step and handholds. Make all necessary repairs.

Face the machine whenever you mount the machine and whenever you dismount the machine. Maintain a three-point contact with the step and with handholds.

Note: Three-point contact can be both feet and one hand or a single foot and two hands.

Do not mount a moving machine. Do not dismount a moving machine. Never jump off the machine. Do not try to mount the machine when you carry tools or supplies. Do not try to dismount the machine when you are carrying tools or supplies. Use a hand line to pull equipment onto the platform. Do not use any controls as handholds when you enter the cab or when you exit the cab.

Perquisites

The following procedures assume that all parties involved possess the appropriate approvals, skills, health and safety practices, documentation, Personal Protection Equipment (PPE), and tools to perform these actions.

A site must have a local site co-ordinate system established before installing and/or integrating Site Positioning Hardware. This local site coordinate system should not change throughout the life of the mine site.

Note: If the local site coordinate system changes, it will be required that the Cat MineStar System mine model is recreated to match the new local site coordinate system. If the Cat MineStar System mine model does not match the local site coordinate system as perceived by the various Cat MineStar System on-board systems, then the Cat MineStar System may experience unpredictable errors that could have safety implications.

Note: Changes to Site Positioning could cause the various Cat MineStar System on-board systems to perceive a different local site coordinate system than what was intended. The Cat MineStar System mine model is required to match the local site coordinate system.

Note: Written verification from the mine site confirming the above requirements have been met, must be received prior to beginning this checklist. The requirements checklist must be completed, signed, and received by Caterpillar.

Note: The exact process to complete this verification depends on the manufacturer and model used in the application. See manufacturer documentation for more detailed procedures.

Requirements

The following procedure should be completed before site positioning:

1. Establish mine site coordinate system that meets the local regional survey standards utilizing the services of local qualified licensed surveyors.

2. Install and configure the GNSS Base Station utilizing the services of a qualified GNSS Base Station expert.

3. Program the GNSS Base Station Reference Location with accurate latitude, longitude, and height of the GNSS Base Station antenna position in WGS84 coordinates.

   • The WGS84 latitude, longitude, height of the Base Station antenna are provided by a local qualified licensed surveyor utilizing regional survey standards.

   • The accuracy of the WGS84 latitude, longitude, height of the Base Station antenna position are validated at the mine site before being programmed into the Base Station Reference Location.

   Note: Caterpillar does not possess the expertise to validate the accuracy of the mine site provided, position of the Base Station antenna sufficiently.

4. Configure the GNSS Base Station to provide GNSS corrections to Cat MineStar System on-board systems and the TPS receiver utilizing the services of a qualified GNSS Base Station expert.

5. Create GNSS Site Calibration (.dc file).

   • The GNSS Site Calibration must meet the requirements described in the Site Positioning Requirements doc.

   • The GNSS Site Calibration (.dc file) can be created utilizing the now operational site GNSS Base Station.

   • The accuracy of the GNSS Site Calibration (.dc file) is validated at the mine site (utilizing licensed surveyors) before it is provided for installation on the TPS receiver or any on-board Cat MineStar system.

   • The accuracy of the GNSS Site Calibration is validated for all areas of the mine site where the Cat MineStar System on-board systems is operating.

   Note: Caterpillar does not possess the expertise to validate the accuracy of the GNSS Site Calibration (.dc file) sufficiently.

6. Install and configure the TPS receiver and antenna utilizing the services of a qualified GNSS Base Station expert.

   • Configure the TPS receiver to send the required position messages to the Cat MineStar System server.

   • Configure the TPS receiver to utilize GNSS corrections provided by the GNSS Base Station.

   • Configure the TPS receiver to utilize the local GNSS Site Calibration (.dc file).

7. Program the TPS antenna location into the Cat MineStar System server in Local Mine Site Coordinates (easting, northing, elevation).

   • The local site easting, northing, and elevation of the TPS antenna must be provided by a local qualified licensed surveyor utilizing regional survey standards, but not by the TPS receiver for this step.

   • The accuracy of the local site easting, northing, and elevation of the TPS antenna position is validated at the mine site before programmed into Cat MineStar System.

   Note: Caterpillar does not possess the expertise to validate the accuracy of the mine site provided position of the TPS antenna sufficiently.

   Note: If this step is not followed correctly the checkout may result in false validation.

8. Install the local GNSS Site Calibration (.dc file) (if applicable) and load the GNSS Site Calibration (.dc file) on all necessary Cat MineStar System on-board systems utilizing a qualified technician.

New Installation

The purpose of this checklist is to assist a qualified technician in assessing the successful integration of third-party Site Positioning Equipment with the Caterpillar MineStar System for a new site installation where no Cat MineStar System mine model has yet been created.

This procedure will assess the successful integration of the GNSS Base Station, TPS receiver, and GNSS Site Calibration (.dc file) with the Cat MineStar System.

Note: This procedure will not verify the Cat MineStar System mine model versus the Cat MineStar System on-board systems since the mine model does not yet exist.

Note: This procedure must be completed before any portion of the Cat MineStar System mine model is created complete before any Cat MineStar System on-board system commissioning activities.

Re-Installation or Update

For a change to Site Positioning at an existing Cat MineStar System Installation.

The purpose of this checklist is to assist a qualified technician in assessing changes made to an initial successful integration of third-party Site Positioning Equipment with the Caterpillar MineStar System.

This procedure will assess the successful integration of the GNSS Base Station, TPS receiver, and GNSS Site Calibration (.dc file) with the Cat MineStar System.

This procedure will perform a course sanity check of the Cat MineStar System mine model versus the Cat MineStar System on-board systems position reporting.

This procedure must be completed if any of the following changes occur:

1. Changes to the physical location of the Base Station Antenna.

2. Changes to the configuration of the GNSS Base Station other than those related to I/O or network configuration.

3. Changes to the physical location of the TPS Antenna.

4. Changes to the configuration of the TPS receiver other than those related to I/O or network configuration.

5. Changes to the TPS antenna location programmed into Cat MineStar System.

6. Changes to the GNSS Site Calibration (.dc file).

Site Positioning Appendix

NMEA Messages

National Marine Electronics Association (NMEA) is a combined electrical and data specification for communication between electronic devices including Global Positioning System (GPS) receivers. It is defined and controlled by the U.S. National Marine Electronics Association. The NMEA standard uses a simple ASCII, serial communications protocol to define how data is transmitted in a sentence from one speaker to multiple listeners at a time. By using intermediate expanders, a speaker can have a unidirectional conversation with a nearly unlimited number of listeners. Using multiplexers, multiple sensors can talk to a single computer port.

General application layer protocol rules

The general application layer protocol rules are given below:

• The starting character of each message is a dollar sign.

• The next five characters identify the speaker (two characters) and the type of message (three characters).

• All data fields that follow are comma-delimited.

• <CR> <LF> ends the message.

Example of an NMEA string in Cat MineStar System

Example for an NMEA string is shown in Illustration 2.

Illustration 2	g06050360

NMEA Messages in Cat MineStar System

There are three areas of the screen to review from the Infrastructure Assistance window under the General tab.

1. Verify that the TPS entered X, Y, and Z coordinates match the coordinates obtained from the mine site survey within 1 cm (0.4 inch).

2. View the Deviation field to ensure the NMEA (northing, easting, and elevation) coordinates reported in the Truth Positioning Latest Message string are within tolerance (< 5 cm (2.0 inch)), when compared to the coordinates displayed for the TPS entered Coordinates.

   The deviation field displays immediate reference whether the coordinates reported are within tolerance of the coordinates programmed into Cat MineStar System for the TPS. Details on the deviations may be derived from comparing the PJK NMEA string to the entered TPS Coordinates.

   To quickly orient your view to pertinent information in the NMEA strings, look for the letter "N" about midway through Positioning Latest Message or the Truth Positioning Latest Deviation Message.

   • Directly before the letter "N" is the coordinate information for "E" (East). This action compares with the "X"coordinate in the Position section near the top of the screen. This is the latitude (easting) reported for the TPS receiver.

   • Directly after the letter "N" is the coordinate information for "N" (North). This action compares with the "Y" coordinate in the Position section near the top of the screen. This is the longitude (northing) reported for the TPS receiver.

   • Directly after the letters "GHT" the height data is listed. This action compares with the "Z" coordinate in the Position section near the top of the screen. This is the elevation (height) reported for the TPS receiver.

   To more accurately check for deviation, use the following formula:

   = sqrt((PJK northing - TPS entered northing)^2 + ( PJK easting - TPS entered easting)^2 + (PJK elevation - TPS entered elevation)^2).

Verify Boundaries

1. Start the machine and drive approximately 20 m (65.6 ft) to obtain an accurate heading and position.

2. Park machine, apply parking brake and place wheel chock blocks. Do not turn off the machine.

   Note: If machine is turned off, it may lose heading and position. This procedure will need to be restarted.

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   Illustration 3	g06050380
   Site Editor Window

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   Illustration 4	g06050395
   Site Editor Window

3. In Cat MineStar System office software, open the "Site Editor" window.

   Select "Machine Tracking", click "Site Editor"

   Select: "Create Rectangle"

   Then select: "Create Zone"

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   Illustration 5	g06050453
   Plan view n

4. Move cursor on the Plan view to the general area where the zone is to be placed, then click to set the zone location:

   Name zone "machine_X_virtual_size".

   Note: X represents the machine number. (For example, "machine_52_virtual_size").

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   Illustration 6	g06050403
   Plan view (zoomed)

5. Zoom in to a level where the zone can be created the exact size and shape of the body boundary then drag the corners of the zone to the exact corners of the body boundary.

   1. Double-click the new zone to open the "Zone Editor".

   2. Press the "Apply" button in the "Zone Editor window".

      Note: The body boundary is indicated on the Plan view as a red dashed line around the machine.

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   Illustration 7	g06050408

6. Physically mark the location of the projected 4 corners of the machine (use stakes, cones, or other similar device to mark the corners of the machine on the ground). These points are shown in the illustration 7 as green dots.

7. Move the machine to a position away from the marked points (approximately 20 to30 m (65.6 to 98.4 ft)). Park and apply parking brake. Then take precautions not to disturb the marked corner locations.

   Note: The machine can be turned OFF now.

   Note: Obtain survey coordinates for the marked four corners of the machine body area.

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   Illustration 8	g06050380
   Site Editor Window

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   Illustration 9	g06050395
   Site Editor Window

8. In Cat MineStar System office software, open the "Site Editor" window.

   Select "Machine Tracking", click "Site Editor"

   Select: "Create Rectangle"

   Then select: "Create Zone"

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   Illustration 10	g06050453
   Plan view

9. Move cursor on the Plan view to the general area where the zone is to be placed, then "click" to set the zone location:

   Name zone "machine_X_virtual_size".

   Note: "X" represents the machine number. (For example, "machine_52_virtual_size").

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   Illustration 11	g06050418
   Zone Editor Window

10. Double-click the new zone to open the "Zone Editor".

    1. On the "General" tab, set the "Zone Display Color".

    2. Ensure that all options are unchecked.

11. Next click the "Polygon" tab.

    1. Set Unit: Centimeter.

       Note: Only whole numbers are allowed.

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       Illustration 12	g06050432
       Zone Editor Window - Polygon Tab

    2. Set corners for the zone to match the survey points taken earlier.
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       Illustration 13	g06050439
       Zone Editor Window

    3. Press the "Apply" button in the "Zone Editor" window.
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    Illustration 14	g06050463
    Site Monitor Window

12. In Cat MineStar System office software, open the "Site Monitor" window.

    Select "Machine Tracking", click "Site Monitor" then Locate the new zone.

    Now verify that the "machine_X_virtual_size" zone completely covers the "machine_X_actual_size" zone.