SAFEMINE STANDARD

OPERATORING PROCEDURE
CAT 797F HAUL TRUCK

Contents

Components................................................................................................................ 3
 SAFEmine Equipment....................................................................................... 3
Installation Equipment....................................................................................... 6
System Diagram................................................................................................ 7
Installation................................................................................................................... 8
Main Component Location................................................................................. 8
QC250.................................................................................................... 8

Remote Display...................................................................................... 8

Antenna.................................................................................................. 8

Radar...................................................................................................... 9

Cable Routing.................................................................................................. 10
Power................................................................................................... 10

Reverse Sense..................................................................................... 11

Antenna................................................................................................ 11

Radar.................................................................................................... 11

Maintenance recommendations..............................................................................12
Power............................................................................................................... 12
Moxa................................................................................................................ 12
Configuration Measurements.................................................................................. 13
Antenna Position.............................................................................................. 13
Vehicle Measurements.................................................................................... 14
Radar Measurements...................................................................................... 15
Troubleshooting........................................................................................................ 15
Approvals.................................................................................................................. 16
Components
SAFEmine Equipment

Description Name Qty

CAS/TRACK MainUnit
using Wi-Fi, with I/Os and
GNSS receiver QC250 1

LED Display RS232

Male M8 connector.

QD200 1

Long LED Display Cable

(RS232)
Connects to QD200 or RS232
and can be used with any
MainUnit QC2xx.
QD222 1
Cable length 5m (16'), M8
connector on both ends (1
male, 1 female), PUR jacket.

LED Display Bracket

Suitable for mounting the
QD200 LED Display. QD227 1

Triple GNSS/RF/Wi-Fi
Antenna
Through Hole Mount (TH),
with cables.
Cable length approx 20cm QF056 1
(8''), incl. connectors.
Suited for Wi-Fi CAS/TRACK
MainUnits with GNSS
receiver, e.g. QC250.

MainUnit Isolation Bracket

with Magnet
Suited for all MainUnits QL177 1
QC2xx.
Dimensions approx. 110 x 80
x 6mm (4.3" x 3.15" x 0.2").

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 MainUnit Power Cable
Suited for all MainUnits
QC2xx.
Cable length approx. 2m QM104 1
(6.5'), PUR jacket, 3 Amp
rated, M12 connector on one
end, other end open (cut).

Y-Cable RS232 for QD200 &

QD204 when used with
QC250 & QC240.
Overall length 20cm (8''),
symmetrical.
QM106 1
PUR jacket, M12 female on
one end, M12 male and M8
female on other ends.

TrackingRadar Sensor
Detect static and moving
objects up to 30m.
Fully compatible with all QR310 3
QC2xx.
Enclosure size 144 x 128 x
71mm3 (5.7"x 5" x 0.8")
IP67.

TrackingRadar Y-Cable
Radar Y Cable Deutsch DT QR320 1
m/f/f 20cm 7.9".

TrackingRadar Extension
Cable (5m/16')
Radar Cable Extension
Deutsch DT m/f 5m (16'). QR322 1

TrackingRadar Extension
Cable (10m/32')
Radar Cable Extension
Deutsch DT m/f 10m (32'). QR323 1

TrackingRadar Extension
Cable (20m/65')
Radar Cable Extension
Deutsch DT m/f 20m (65'). QR324 1

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 CAN Bridge Cable
CAN Y-Cable from MainUnit
to Radar cable. Includes one
dust plug. QS413 1

CAN Terminator Harness

One required on each end of
the CAN bus.
QS421 1

Serial Extender
Makes 3 serial links
(RS232)
available, connects to CAN
bus of any QC2xx. Requires
QS422. QS430 1

Y-Cable CAN, without

Termination
required for serial extender
if radar are used. Cable
length 2x 10 cm (2x4''). PUR
jacket, M12 female on
oneend, M12 male and M8 QS422 1
male on
other.

Serial Device Server

Moxa NPORT 5110A.
Translation
from serial to Ethernet.

Supplied by
Site
1

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 Serial Device Server Cable
for
Moxa Nport 5110A.

QS434 1

Installation Equipment

Description QTY
Braided sleeve 30 ft
Coupling, PVC 20mm 1
Fuse Holder ATC WaterProof InLine 32V RD 2
Fuse Holder ATC WaterProof InLine 32V BL 1
Fuse, 3A, Blade ATC 3
Terminal Ring Interface Cable Ground 4
Conn,Crimp Term Butt splc 18-22AWG Pink 5
Conn,Crimp Term Butt splc 16-18AWG Blue 5
Cable Shielded 2 Cond 16AWG strand 30 ft
Single Core Wire - Blue 10 ft
410 SS Hex Head Self Drilling Screw 4
Screw Flat Head M4 x 10 S/S 4
CABLE, LMR195 - 3/16 Flex 100 ft
Conn, SMA Male crimp 2
Conn, SMA Female crimp 2
Conn, RP Male crimp 1
Conn, RP Female crimp 1
Conduit, Corrugated Flex Nylon Split 30 ft
Harnessflex End Fitting Assembly 1
Bag Conduit Clamps and Screws 1

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System Diagram

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Installation
Main Component Location
QC250
The QC250 is located in the rear plastic panel on the right hand side vertical wall. It is attached to
the plastic isolation plate (QL177).

Figure 1: QC250 Mounting Location

Remote Display
The remote display (QD200) is attached to the top of the dash in the center of the cab. It uses the
provided L bracket with integrated tamper proof base (QD207).

Antenna
The antenna is mounted to a mast on the front left of the haul truck. It must be mounted in clear
view of the sky and must not be blocked below the truck headache bed. The plastic washer must
be installed on the bottom of the plate to isolate the antenna from the chassis. The coax cables
exiting the bottom of the antenna are a weak point and must be properly protected using the
plastic conduit and adaptor.

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 Figure 2: Antenna Mounting

Radar
Three radars are installed on each haul truck; two in the front and one in rear. The rear radar is
installed on the rear axle next to the camera. The rear radar is slightly tilted down (approx. 5
degrees) to pick up personnel and light vehicles. The two front radars are mounted in the center
below the existing CAT radars. The front radars are able to slightly tilt up to avoid false alarms
when the front end drops due to bumps while driving.

Figure 3: Rear Radar Mounting Location

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 Figure 4: Front Radar Mounting Location

Cable Routing
Power
The power cable (QM104) runs from the Main Unit (QC250) , to the rear of the fuse panel in the
same compartment. The color of the power cable is white; the color for ground is brown. Both
power and ground have an inline fuse holder with a 3 amp fuse.

Figure 5: Power Wire

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Reverse Sense
The reverse wire is ran from the main unit to the rear alarm relay in the same fuse panel that main
unit power is drawn from. The color of the reverse wire is blue.

Antenna
The antenna cables are ran out the right side of the cab through an access panel. The cables dip
down under the walk way and to the front of the vehicle. They are ran across the front to the front
left corner of the vehicle and ran up the mast to the antenna.

Radar
The rear radar cable (QR324) is ran out the left of the cab where the antenna cables exit and
follows the rear camera cable. It crosses under the engine and follows straight out the back over
the rear axle.

The front radars cable also exit the cab in the same location and follows the antenna cables
forward. Then it is ran down the front vertical support. At the base a Dustch plug can be
disconnected in the event of the radiator being removed.

Figure 6: Cable Entry Point

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Maintenance recommendations
Power
The system is powered according to a Cat mechanic’s recommendations and no extra
precautions are needed to lock-out the vehicle

Moxa
Instructions to configure a moxa can be found in the document
HxM_AN_Device_Server_3_0(CAS_QC2_160427).pdf available at request to Hexagon Mining
and supplied at the go-live.

The configuration settings text file ‘CortezMoxaSettings’.txt that must be uploaded to any new
moxa was provided at Go-Live to the Radioshop technicians

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Configuration Measurements
Antenna Position
The antenna position must be correctly measured and the following diagram can be used as a
reference.

The left front corner of the vehicle is always the reference point were the vehicles measurements
are taken from.

Reference point for all

measurements: front
left of the vehicle

antennaaft:
Measurement from centre
of antenna to the very front
of the vehicle (in meters).

SAFEmine Antenna

antennaright:
Measurement from centre
of antenna to the left side
of the vehicle (in meters).

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 antennaup:
SAFEmine Antenna Measurement from antenna
position on vehicle to the ground
(in meters).

Vehicle Measurements

While measuring the antenna positions verify also the vehicles physical dimensions.

Note down the vehicles:

 Height (in meters): this is the maximum vehicle height (if a bucket is fitted measure the
height to the top of the bucket).

 Driving Height: this is the height of the vehicle when driving (if a bucket is fitted bucket
would be down).

 Length (in meters): from front to rear including extended bumpers.

 Width (in meters): to the widest points of the vehicle (usually mirror to mirror).

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Radar Measurements
The positions of radars should be recorded the same as for antenna measurements, this means
the reference point is front left For the SAFEmine CAS system to be able to interpret correctly the
data received from the TrackingRadar sensors, it is not only necessary to know their position on
the vehicle (like for the antenna), but also their individual orientation, i.e. where they are facing.

In order to describe the orientation of a radar sensor two new parameters were added in addition
to the position parameters known from the antenna parameters. These two parameters define the
facing orientation of each sensor*:

 rad<ID>_yaw: Angle formed between the forward direction of the vehicle and the facing
direction of the radar.
 rad<ID>_pitch: Angle upwards to the sky or downwards to the ground from the leveled
horizontal direction.

Troubleshooting
See document TroubleShooting_3.0.

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Approvals

This document contains the proposed equipment mounting positions and signal connections. It
has been prepared for the Barrick Cortez Hills organization so they have advance notice of the
proposed installation and an opportunity to agree or propose preferred alternatives once the
various parties have been consulted. This document is to be read and signed by the designated
personnel and returned to Leica Geosystems before any installation activity can commence.

Position of Signatory: Superintendent, Operations Barrick Cortez Hills

Name: …………………………………………………………………
Signature: ……………………………………………………………..
Company Name: …………………………………………………….Date…………………..
Comments: …………………………………………………………………………………………………
………………………………………………………………………………………………………………...
Position of Signatory: Manager, Safety Barrick Cortez Hills
Name: …………………………………………………………………
Signature: ……………………………………………………………..
Company Name: …………………………………………………….Date…………………..
Comments: …………………………………………………………………………………………………
………………………………………………………………………………………………………………...
Position of Signatory: FMS, Project Manager Barrick Cortez Hills
Name: …………………………………………………………………
Signature: ……………………………………………………………..
Company Name: …………………………………………………….Date…………………..
Comments: …………………………………………………………………………………………………
………………………………………………………………………………………………………………...
Leica Sign Off:
Name: …………………………………………………………………
Signature: ……………………………………………………………..
Company Name: Leica Geosystems……….……………….Date…………………..
Comments: …………………………………………………………………………………………………
………………………………………………………………………………………………………………...

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Hexagon Mining is the only company to solve surface and underground challenges by integrating design,
planning, and operations technologies for safer, more productive mines. Headquartered in Tucson, Arizona,
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