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Could one of the items that you want to place in the Caravan be inaccessible? Placed behind a forbidden door or in a walled off room?
Has an item that you want to place in the Caravan been moved since you ordered the form up and now is being carried by another pawn or dropped on the floor outside of a relevant stockpile.
Go through the gear tabs of all animals and pawns in the caravan to see if any item is missing and if so, is the missing item registered on the stockpile summaries on the left screen edge. If it is there, can you order a pawn to access/move it?
Then at some point, they just stopped being able to finish the caravan. I also changed to different days, different destination, different people and animals in the caravan, and all had the same result of the caravan not fully finishing.
I started a new game and this group was able to do caravans, so it wasn't something about the game or mods.
In the end, I deleted that game save and have continued on with other games, which so far have not exhibited this problem again.
Do you use mods, Alpha Animals sometimes breaks caravans and/or raids, as do other mods that attempt to add more caravans or more raids.
I manage to fix it by forcing some of my colonist to load random items on the caravan (right clic on item> load on the cravan). After few items force loaded, the colonist stat to load the remaining items by themselves.
Maybe a clue : last time it works, i "force load" some kibbles that were on a chest
Once gathered as the caravan spot, I then removed any animal that decided to be an ♥♥♥♥♥♥♥, said ♥♥♥♥ you, and zoomed off to eat some ♥♥♥♥♥♥♥ dandelions like there won't be any on the trip (might be mitigated by having kibble or other valid food stockpiles directly around the caravan packing spot, which may explain they forced loading kibble seemed to work). That got my pawns to start loading, and once loaded, I added/re-added any more wanted animals only after the caravan started running off towards the edge of the map. Any animal added then automatically ran over to where everyone else was headed, and once there, off they went. Haven't tested this repeatedly, so good luck to ya if it doesn't work for you.
With hauling this is no problem, the hauler very soon gets bored and selects the *next* hauling task. Caravans unfortunately cannot do this, as your shopping list is absolute. So the jammed pawn tries again, and again, and again.
Meanwhile, he has a bunch of pack animals and other caravaners following him around to assist. So *everyone* gets stalled.
Yes, the simple fix is to draft the jammed person for a second or 5, so that he drops the current haul/pack task. This allows the competing person to complete that task, resolving the logjam.
Example... If you have selected a prosthetic arm to load into the caravan, and you have created a medical bill that wants to use that arm, the medical bill will reserve the arm. But the caravan needs to load it. But the arm is still lying in storage, so the caravan cannot give up on it. This will stall the caravan formation until that operation is done or cancelled.
Until they wake up, nobody's moving.
Put the game on pause. Disband your caravan that will not pack/keeps wandering. Unload all animals. Pick one person to go on a trip. Without any entourage or extra inventory. Just pick a destination for that one pawn and that's it.(ignore warnings obviously)
Now manually add animals, pawns and inventory. Now un-pauze. They all should start working like a charm.
Or
Make multiple smaller caravans (1 pawn +1 animal+ inventory) and merge them right outside your colony. That way you flush out the bottleneck. Sometimes even without missing anything or anyone.