Topcon MACHINE CONTROL AG System Five Operator'S Manual Download | Manualshive

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Chapter 1

P/N 7010-0369

www.topconpositioning.com

1-1

I

ntroduction and

Setup

Topcon’s AG System Five™ (Figure 1-1) is a complete control
system allowing both survey and automatic operation of a scraper
or other implement. The System Five includes the Control Box,
Laser Receiver, and a TM-1 Electric Mast.

Figure 1-1. AG System Five Components

The heart of the System Five is the Control Box. The Control Box
functions can be set for particular jobs, used to take surveys, or for
automatic leveling control.

1 2 3 4

(MENU)

AUTO

SURVEY

SET

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Summary of Contents for MACHINE CONTROL AG System Five

Page 1: ...AG System Five Operator s Manual MACHINE CONTROL AG ...

Page 2: ......

Page 3: ...con Positioning Systems September 2003 All contents in this manual are copyrighted by Topcon All rights reserved The information contained herein may not be used accessed copied stored displayed sold modified published or distributed or otherwise reproduced without express written consent from Topcon ...

Page 4: ...CO 175 ...

Page 5: ...eiver 1 4 TM 1 Telescoping Mast 1 4 System Five Setup 1 5 End of Day Maintenance and Care 1 10 Chapter 2 Control Box Usage 2 1 Control Box 2 2 LCD Display 2 3 Light Sensor for Grade Adjustment Arrows 2 3 Power Switch 2 3 Grade Adjustment Direction Arrows 2 4 Grade Adjustment Knob 2 4 Grade Adjustment LEDs 2 5 Function Indicator LEDs 2 6 Set Menu Button 2 6 Using the Set Mode 2 6 Using the Menu Mod...

Page 6: ...unction 2 11 Auto Manual Button 2 11 Using the Auto Manual Mode 2 11 Using the Survey Mode 2 12 Manual Record 2 12 Auto Record 2 12 Average Elevation 2 13 Making Selections in the Performance Menu 2 13 Jog Button 2 13 Determining Timed Valve Output Values 2 14 Pressing the Raise Jog Button 2 14 Pressing the Lower Jog Button 2 15 Performance Menu 2 15 Gain Elevation 2 19 Gain Slope Control 2 20 Val...

Page 7: ... Laser Transmitter 3 11 Laser Drift 3 12 Atmospheric Laser Bending 3 13 Setting Grade Reference Points 3 14 Other Factors Affecting Quality 3 16 Wind 3 16 Dust 3 16 Fog 3 17 Curvature of the Earth 3 17 Laser Accuracy and Repeatability 3 18 Chapter 4 Surveying 4 1 Overview 4 1 Survey Preparation 4 2 Laser Transmitter Setup 4 3 Initial Elevation Reference Selection 4 4 Perimeter Survey 4 5 Calculati...

Page 8: ...tic Land leveling 5 1 Second and Succeeding Day Setups 5 2 Chapter 6 Troubleshooting 6 1 Control Box Problems 6 2 Appendix A Safety Precautions A 1 Appendix B Limited Warranty B 1 Electronic and Mechanical Components B 1 Return and Repair B 1 Warranty Disclaimer B 1 Service Information B 2 Index ...

Page 9: ...ides can be greatly influenced by your applications knowledge COPYRIGHT All information contained in this Manual is the intellectual property of and copyrighted material of TPS All rights are reserved You may not use access copy store display create derivative works of sell modify publish distribute or allow any third party access to any graphics content information or data in this Manual without ...

Page 10: ...RS OR OMISSIONS CONTAINED HEREIN NOR FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES RESULTING FROM THE FURNISHING PERFORMANCE OR USE OF THIS MATERIAL OR THE PRODUCT SUCH DISCLAIMED DAMAGES INCLUDE BUT ARE NOT LIMITED TO LOSS OF TIME LOSS OR DESTRUCTION OF DATA LOSS OF PROFIT SAVINGS OR REVENUE OR LOSS OF THE PRODUCT S USE IN ADDITION TPS IS NOT RESPONSIBLE OR LIABLE FOR DAMAGES OR COSTS INCURRED IN CONNE...

Page 11: ...eded or canceled at any time by TPS The above Terms and Conditions will be governed by and construed in accordance with the laws of the State of California without reference to conflict of laws All information illustrations and applications contained herein are based on the latest available information at the time of publication TOPCON reserves the right to make product changes at any time without...

Page 12: ...p a system NOTICE Supplementary information that can have an affect on system operation system performance measurements personal safety CAUTION Notification that an action has the potential to adversely affect system operation system performance data integrity or personal health WARNING Notification that an action will result in system damage loss of data loss of warranty or personal injury DANGER...

Page 13: ...peration of a scraper or other implement The System Five includes the Control Box Laser Receiver and a TM 1 Electric Mast Figure 1 1 AG System Five Components The heart of the System Five is the Control Box The Control Box functions can be set for particular jobs used to take surveys or for automatic leveling control 1 2 3 4 MENU AUTO SURVEY SET 1 2 3 4 MANUAL AUTO System Five ...

Page 14: ...e dialed in from the Control Box as well as many other operational and performance functions Care and Preventive Maintenance In general you should follow these guidelines Always clean and thoroughly dry the removable components before storing them in carrying cases Use a clean soft cloth moistened with a neutral detergent or water Keep carrying cases clean and dry Do not leave them open and expose...

Page 15: ...nd or Slope Sensor the Control Box determines if grade or slope corrections are necessary If a change in grade or slope is required the Control Box sends a signal to the valve controlling the scraper to raise or lower it thus maintaining correct grade Figure 1 2 Control Box The Control Box connects to the TM 1 Mast hydraulic valves and scraper through electrical cables P N S N 57 58 W La s Po sita...

Page 16: ...ion of the scraper When it receives a signal from a rotating laser it sends a signal to the control box through connecting cables Figure 1 3 Laser Receiver TM 1 Telescoping Mast The TM 1 Telescoping Mast Figure 1 4 is installed on the machine s scraper blade and provides a fast accurate and rugged mounting platform for the laser receiver Figure 1 4 TM 1 Telescoping Mast 1 2 3 4 ...

Page 17: ...c Valves Once the valves receive the signal they raise or lower the implement according to the setup of the Control Box After mounting the several System Five components to the implement use the following procedure to get started System Five Figure 1 5 shows a generalized connection diagram for the tractor and scraper components Figure 1 5 AG System Five Setup POWER Power Valve Cable Coil Cord TM ...

Page 18: ...ystem Five Operator s Manual 1 6 1 Attach the Laser Receiver to the TM 1 mast Figure 1 6 Figure 1 6 Attaching Laser Receiver to TM 1 Mast MOUNTING KNOB MOUNTING BRACKET LS B2 Tighten Mounting Knob Slide Laser Receiver Down onto Mast 1 2 ...

Page 19: ... Five Setup P N 7010 0369 www topconpositioning com 1 7 2 Connect the coil cord to the Laser Receiver and mast Figure 1 7 Figure 1 7 Connecting Coil Cord TM 1 LS B2 Attach Coil Cord To Laser Receiver And Mast ...

Page 20: ...t the force of the moving cord is not on the connectors Figure 1 8 Attaching Coil Cord to Snap Hook and Wrapping it Around Shock Mount 4 If needed check the hydraulic valve connection Depending on your setup the hydraulic valve will connect to either the Control Box with the power cable or the mast The hydraulic valve cable should already be attached to the mast FRONT BACK 1 2 3 4 ...

Page 21: ...ntrol Box to a mounting bracket Figure 1 9 Figure 1 9 Mounting Control Box 6 Connect the cables to the Control Box Figure 1 10 Figure 1 10 Connecting Cables to Control Box AUTO SURVEY SET M ENU System Five Sample mounting bracket Power and or Hydraulic Valve Laser Receiver mast ...

Page 22: ...ng the System Five for land leveling End of Day Maintenance and Care At the end of the day performing general maintenance and storing mobile parts will help to keep your System Five in top condition Insert cables into appropriate storage connectors after removing the Control Box Remove the Control Box and the Laser Receiver and dust with a dry or damp non abrasive soft cloth see Care and Preventiv...

Page 23: ... the Control Box sends a signal to the valve raising or lowering it to the correct height Control box functions provide simple ways to apply settings change functions view and record elevation information and allow automatic or manual control This chapter describes The buttons knobs and switches on the Control Box How to change settings access information and take readings using the various button...

Page 24: ...LCD display 2 Light sensor for grade adjustment arrows 3 Power switch 4 Grade adjustment direction arrows 5 Grade adjustment knob 6 Grade adjustment LEDs 7 Function indicator LEDs 8 Set Menu button 9 Elevation offset and Elev Avg button 10 Slope Elevation button 11 Survey Search button 12 Auto Manual button 13 Jog button Five System AUTO SURVEY SET MENU 1 2 3 13 12 11 9 5 6 8 4 10 SUR CON ELEV AVG...

Page 25: ...ght Sensor for Grade Adjustment Arrows The light sensor monitors ambient light increasing the intensity of the grade arrows in bright sunlight and dimming the grade arrows for nighttime operation The light sensor is located above the power switch Power Switch The power switch Figure 2 3 for the System Five Control Box turns it on and off Figure 2 3 Power Switch ON OFF ...

Page 26: ...4 light up in red to indicate the direction you should turn the knob to reach on grade Figure 2 4 Grade Adjustment Direction Arrows Grade Adjustment Knob The grade adjustment knob Figure 2 5 makes measured adjustments to elevation and slope settings or cycles through menu options Figure 2 5 Grade Adjustment Knob Rotate Knob Counterclockwise To Reach Grade Rotate Knob Clockwise To Reach Grade Five ...

Page 27: ...rol LED Display LED Elevation Description Slowly blinking yellow down arrow Out of range beyond 28 above grade Solid yellow down arrow Above grade between 05 and 28 Blinking yellow down arrow Above grade between 02 and 05 Blinking yellow down arrow w green bar Within 02 of grade Blinking green bar On grade Blinking red up arrow w green bar Within 02 of grade Blinking red up arrow Below grade betwe...

Page 28: ...ode used to change the reference number viewed on the display to a desired value Menu Mode used to access the performance menu Figure 2 7 Set Menu Button Using the Set Mode The Set mode is used to change the reference number viewed on the display to a desired value The reference number is used to set the elevation or slope display number 1 Press and hold the Set Menu button 2 Dial in the desired v...

Page 29: ...ffset button Survey Mode acts as an Elevation Average button Figure 2 8 Elevation Offset and Elev Avg Button Using the Elevation Offset Button The Elevation Offset button toggles the display to the next offset if two or three different offsets have been set in the Performance Menu For example if the job requires three different elevation settings one for the Field elevation another 1 higher than t...

Page 30: ...ime you press the Offset button for one second the grade setting moves to the next Offset 5 50 to 6 50 to 5 00 To change an elevation setting turn the Grade Adjustment Knob changing one setting does not effect other settings Using the Elev Avg Button In Survey Mode this button toggles the LCD to view the current elevation reference number view the current calculated average elevation or clear the ...

Page 31: ...ng the Survey Mode on page 2 12 for information on taking points Clear Average Elevation To clear the average elevation 1 Press the ELEV AVG button to display the average elevation Figure 2 10 Figure 2 10 Viewing and Clearing Average Elevation 2 Press the ELEV AVG button again and hold it for three seconds a beep sounds and CLR displays After the three seconds displays indicating the average has b...

Page 32: ...ting the Slope Mode If the Control Box is connected to a slope sensor the desired cross slope can be dialed in for automatic control 1 Press the Slope Elevation button the yellow LED next to the Cross Slope Symbol illuminates 2 Turn the Grade Adjustment Knob until you get the desired cross slope Search Survey Button The search survey Figure 2 12 button is used to search and lock on grade or contin...

Page 33: ...ng the Survey Function Hold the Survey Search button for three seconds to enable the Survey mode The laser receiver electric mast continuously tracks the laser beam while surveying the jobsite Auto Manual Button The auto manual button Figure 2 13 has three functions In Control Mode acts as an auto manual selection button In Survey Mode acts as an on off selection button for recording elevation rea...

Page 34: ...x Auto button The Auto LED begins to blink but the Control Box is still in its current mode 2 While the Auto LED blinks use the remote Auto Manual button to set the Control Box to Auto or Manual The Auto LED remains steady for automatic control or turns off for manual control Using the Survey Mode When using the Survey mode the Control Box can record elevation numbers either manually or automatica...

Page 35: ... average elevation as the survey progresses While surveying simply press the ELEV AVG button to switch between current and average elevations Making Selections in the Performance Menu When using the Performance Menu use the Auto Manual button to select settings and functions for the System Five Control Box See Performance Menu on page 2 15 for information on the different menus available Jog Butto...

Page 36: ...to the Control Box for the Lower Timed Output The Timed Output feature can also be used to combine the Auto Manual function and Jog Raise Lower function in one button Set the Timed Output to 0 1 second for raise and or lower Pressing the raise button shifts the system to manual Pressing the lower button shifts the system to auto This allows the Timed Output function to switch to manual when just r...

Page 37: ...ires Once the sensor detects a laser signal the system returns to normal automatic control Performance Menu Performance menu settings allow the System Five to be modified for operator or performance enhancement A combination of buttons and the Adjustment knob control and display menu settings NOTICE For some machine configurations not all menu selections are accessible Table 2 2 describes the Cont...

Page 38: ...follow for a description of each menu Averaging 1 100 1 Elevation Deadband 1 30 mm 3 mm 01 ft 6 mm 02 ft Slope Deadband 025 75 0 075 Beeper on off off Unit ft cm ft Test open short pass no setting Set Points 1 3 1 Record on off on Timed Outputs 0 0 10 0 0 0 Table 2 2 Performance Menu Settings Continued Menu LED Symbol Range Factory Setting ...

Page 39: ...ion Arrows flash Figure 2 15 Figure 2 15 Setting Control Box to Performance Menu Settings 2 Rotate the Grade Adjustment Knob to scroll through the Performance Menu selections unit beeper test etc located on the LCD Figure 2 16 Figure 2 16 Scrolling Through Performance Menu Selections 3 Press the Auto button to select a menu Five System AUTO SURVEY SET MENU Five System AUTO SURVEY SET MENU ...

Page 40: ...ection Figure 2 17 Figure 2 17 Scrolling Through Menu Options 5 Press the Auto button again to store the value option Figure 2 18 Figure 2 18 Storing Menu Option To access other Menu settings turn the Grade Adjustment Knob To exit the Performance Menu press the Set Menu button Five System AUTO SURVEY SET MENU Five System AUTO SURVEY SET MENU ...

Page 41: ...ster hydraulic response increase the gain value For slower hydraulic response decrease the gain The objective is to set the gain so the scraper reacts to the change in grade quickly but without overshooting the new elevation 1 Rotate the Grade Adjustment Knob to access the Gain Menu for elevation 2 Press the Auto button to select the Gain Elevation gAn menu Figure 2 19 Figure 2 19 Selecting Gain E...

Page 42: ...Menu button to exit Gain Slope Control This setting determines the speed at which the System Five allows the instrument to adjust to a change in slope The gain can be adjusted from a setting of 1 to 100 For faster hydraulic response increase the gain value For slower hydraulic response decrease the gain value The objective is to set the gain so the instrument reacts to the change in grade quickly ...

Page 43: ...l Menu 3 Turn the Grade Adjustment Knob to select the desired value Figure 2 22 Figure 2 22 Selecting Gain Menu Option 4 Press the Auto button to store the value and return to the Performance Menu 5 Rotate the Grade Adjustment Knob to access anther item on the Performance Menu Or press the Set Menu button to exit Five System AUTO SURVEY SET MENU Five System AUTO SURVEY SET MENU ...

Page 44: ...ccess the Valve Offset menu 2 Press the Auto button to select the Valve Offset OFS menu Figure 2 23 Figure 2 23 Selecting Valve Offset Menu This automatically activates the value screen for Raise The Raise Grade Correction Arrow illuminates and the Control Box begins to send a raise correction signal to the valve 3 Turn the Grade Adjustment Knob counter clockwise decreasing the Valve Offset value ...

Page 45: ...n to store the Raise Offset Value Figure 2 25 Figure 2 25 Storing Raise Offset Value Pressing the Auto button also switches the box to Lower Offset The Lower Grade Correction Arrow illuminates and the Control Box begins to send a lower correction signal to the valve Five System AUTO SURVEY SET MENU Five System AUTO SURVEY SET MENU ...

Page 46: ...2 26 Figure 2 26 Changing Valve Lower Offset Value 6 Press the Auto button to store the Lower Offset Value 7 Press the Auto button to return to the Performance Menu 8 Rotate the Grade Adjustment Knob to access anther item on the Performance Menu Or press the Set Menu button to exit NOTICE The jog raise lower button is always active during valve calibration If a cylinder bottoms out you can use the...

Page 47: ...urements For normal job conditions a lower value is preferred When gusty winds cause erratic grade lights increase the averaging value The value range is 1 to 100 1 Rotate the Grade Adjustment Knob to access the Averaging Menu 2 Press the Auto button to select the Averaging AVG menu Figure 2 27 Figure 2 27 Selecting Averaging Menu Five System AUTO SURVEY SET MENU ...

Page 48: ...to access anther item on the Performance Menu Or press the Set Menu button to exit Elevation Deadband Deadband is the area of the working window that is displayed as on grade While the elevation reference is within the deadband the machines s valves remain idle closed The wider the deadband on grade area the more an elevation reference can move up or down without initiating a correction 1 Rotate t...

Page 49: ...e 2 29 Figure 2 29 Selecting Elevation Deadband Menu 3 Turn the Grade Adjustment Knob to select the desired value typically 6mm 0 02 Figure 2 30 Figure 2 30 Selecting Elevation Deadband Menu Option NOTICE The numeric value seen on the display is in millimeters 3mm 01 Five System AUTO SURVEY SET MENU Five System AUTO SURVEY SET MENU ...

Page 50: ...s the area of the working window that is displayed as on grade While the slope reference is within the deadband the machines s valves remain idle closed The wider the deadband on grade area the more a slope reference can move up or down without initiating a correction 1 Rotate the Grade Adjustment Knob to access the slope Deadband Menu 2 Press the Auto button to select the Slope Deadband db menu F...

Page 51: ...de Adjustment Knob to access anther item on the Performance Menu Or press the Set Menu button to exit Beeper Alarm In Automatic Control Mode the beeper emits a single beep when the laser receiver loses the laser beam such as when the laser beam is blocked by dust In Survey Mode the beeper beeps each time a reading is taken to calculate an average To turn on the Beeper function 1 Rotate the Grade A...

Page 52: ...urn the Grade Adjustment Knob to turn the beeper ON or OFF Figure 2 34 Figure 2 34 Selecting Beeper Alarm Menu Option 4 Press the Auto button to store the choice and return to the Performance Menu 5 Rotate the Grade Adjustment Knob to access anther item on the Performance Menu Or press the Set Menu button to exit Five System AUTO SURVEY SET MENU Five System AUTO SURVEY SET MENU ...

Page 53: ...ths or centimeters 1 Rotate the Grade Adjustment Knob to access the Units Menu 2 Press the Auto button to select the Units unt menu Figure 2 35 Figure 2 35 Selecting Units Menu 3 Turn the Grade Adjustment Knob to select the desired units measurement Figure 2 36 Figure 2 36 Selecting Units Menu Option Five System AUTO SURVEY SET MENU Five System AUTO SURVEY SET MENU ...

Page 54: ...n the Performance Menu Or press the Set Menu button to exit Test This tests the valve for shorts and disconnected valves It tests the raise valve first and then lower valve 1 Rotate the Grade Adjustment Knob to access the Test Menu 2 Press the Auto button to select the Test tSt mode menu Figure 2 37 on page 2 33 Table 2 3 Unit Measurement Descriptions Measurement Display Description Numerical Disp...

Page 55: ... display will read Pass if the lower valves test out OK If there is a problem the display will read Open or Short NOTICE This function always display OPEN when using Danfoss valve output or when connected to a tractor s existing proportional control valves Table 2 4 summarizes the Test solutions Table 2 4 Test Solutions Test Display Description Good Valve Valve NOT connected OR Danfoss valve outpu...

Page 56: ...e number of active elevation offsets or setpoints 1 Rotate the Grade Adjustment Knob to access the Elevation Offsets Setpoints Menu 2 Press the Auto button to select the Offsets SPt menu Figure 2 38 Figure 2 38 Selecting Elevation Offsets Setpoints Menu 3 Rotate the Grade Adjustment Knob to select the desired number of active offsets 1 3 4 Press the Auto button to return to the Performance Menu Va...

Page 57: ...levation each time you press the Auto button Auto Record The Control Box continuously records elevation readings once per second after pressing the Auto button Press the Auto button to pause taking readings Then press the Auto button again to resume Auto Record 1 Rotate the Grade Adjustment Knob to access the Record Menu 2 Press the Auto button to select the Record rEC menu Figure 2 39 Figure 2 39...

Page 58: ...Menu Or press the Set Menu button to exit Timed Outputs See Jog Button on page 2 13 for further information about timed outputs 1 Rotate the Grade Adjustment Knob to access the timed Outputs Menu 2 Press the Auto button to select the Timed Outputs to menu Figure 2 40 Figure 2 40 Selecting Timed Outputs Menu Five System AUTO SURVEY SET MENU ...

Page 59: ...ts Current Setting 3 Rotate the Grade Adjustment Knob to set the desired time in seconds Figure 2 42 The up arrow light illuminates Figure 2 42 Selecting New Raise Timed Outputs Setting 4 Press the Auto button The down arrow light illuminates and the LCD displays the existing Lower Timed Output setting Figure 2 43 on page 2 38 Five System AUTO SURVEY SET MENU Five System AUTO SURVEY SET MENU ...

Page 60: ...in seconds The down arrow illuminates Figure 2 44 Figure 2 44 Selecting New Lower Timed Outputs Setting 6 Press the Auto button to set the Timed Outputs and return to the Performance Menu 7 Rotate the Grade Adjustment Knob to access another item on the Performance Menu Or press the Set Menu button to exit Five System AUTO SURVEY SET MENU Five System AUTO SURVEY SET MENU ...

Page 61: ...alibrated or is misaligned the cost in time and money to fix any one of these problems can cause delays in completing a project NOTICE Place the laser transmitter as recommended to ensure its availability NOTICE Check the laser calibration daily to ensure correct grade control NOTICE Align the laser to ensure correct slope NOTICE Ensure that the laser grade axis matches the direction of slope on t...

Page 62: ...ing factors affect grade at long distances Accuracy of individual laser instruments Ground vibration from machinery working near the laser transmitter Calibration error Curvature of the earth Laser movement from blowing wind Atmospheric conditions 2 Keep the laser transmitter as low as possible Keeping the laser transmitter low where you can reach it will make setup and grade changing much easier ...

Page 63: ... Project Laser Transmitter Placement On small projects the laser transmitter can be placed off the working area Figure 3 1 The working distance from your laser will indicate the type of project small or large Figure 3 1 Laser Transmitter Placement Small Project 1000 ...

Page 64: ...r of the project to maximize the area you can grade and minimize the distance from the laser Figure 3 2 The working distance from your laser will indicate the type of project large or small Figure 3 2 Laser Transmitter Placement Larger Project You may need to grade one section of the project then move the laser to finish other sections 1000 1000 ...

Page 65: ...ents as necessary 1 Set the laser on a tripod about 150 to 200 45 to 60 meters from the laser sensor and turn on the laser s power switch Confirm that grades are set to 0 slope and the laser is in automatic level mode 2 Set the laser sensor to fine correction mode if applicable 3 Raise or lower the sensor to get an on grade signal a solid tone Figure 3 3 Record or mark the position on the grade ro...

Page 66: ... X axis points toward the grade rod Figure 3 4 Figure 3 4 Rotate Laser 5 Raise or lower the sensor to get an on grade signal Figure 3 5 Record or mark the position on the grade rod X2 Figure 3 5 Note Laser Sensor s Second Position About 200ft If Less Than 02 No Calibration Necessary See Notice Below Graphic ...

Page 67: ...is Alignment When setting up the laser to grade a pad or an area with slope correct laser alignment is critical The laser transmitter must be aligned so that the laser slope is parallel to the desired slope of your project Even slight rotation errors can cause significant error in the elevation of the cross slope axis The steeper the slope the more error you will have with an incorrectly aligned l...

Page 68: ...nment follow these steps to correctly align the axis of your laser 1 Locate or place two hubs parallel to the slope of the project The hubs should be approximately 300 apart or completely across the project on small jobs 2 Place the laser transmitter over one hub and dial in 0 slope on both axis 3 Align the laser by sight pointing in toward the second hub 4 Place the grade rod on the second hub an...

Page 69: ...ition Figure 3 7 Figure 3 7 Laser and Grade Rod Positioning 6 Dial the slope into the laser transmitter on the axis facing away from the detector Leave the slope on the axis facing the detector at 0 If the laser is aligned properly the grade on the 0 axis will not change at the second hub and the detector will still have and on grade signal Figure 3 8 on page 3 10 ...

Page 70: ...Laser Setup Topcon AG System Five Operator s Manual 3 10 If you do not have an on grade signal rotate the laser until you get the on grade signal Figure 3 8 Larger Slope Set ...

Page 71: ...tions that can affect the transmitter also affect the grade or quality of work Once finish grade control reference points are in place see Setting Grade Reference Points on page 3 14 continue to verify these points throughout the leveling process Succeeding day setups or conditions throughout the day such as laser transmitter drift atmospheric conditions wind and other factors can affect the accur...

Page 72: ...ach axis If grade increases on one side of the laser and decreases on the other side or the scraper cuts on one end of the project and fills on the other end the laser beam has drifted and is at an incorrect position Figure 3 10 Figure 3 10 Laser Drift To minimize problems associated with drift Topcon has developed lasers with leveling systems that eliminate or greatly reduce laser drift The RT 5S...

Page 73: ...se drift in some lasers detecting atmospheric bending as well as drift can help reduce or eliminate grading problems Excluding laser drift if the implement cuts or fills on all ends of the field the laser is bent due to atmospheric bend Figure 3 11 Figure 3 11 Beam Bending Due to Atmospheric Conditions Atmospheric beam bending can be an inconsistent increasing error the farther away from the trans...

Page 74: ...meters from the transmitter or near the ends of the field for small projects Figure 3 12 Figure 3 12 Set Grade References If you suspect laser drift atmospheric bending or some other problem use a grade rod on the benchmark hubs or the implement on the finish grade spots to measure the error In most cases and with little or no drift you can compensate for the small changes that occur from atmosphe...

Page 75: ...roughout the night the beam will most likely stay in that position until early morning or until the wind mixes the layers of air In this case set the Control Box to compensate for this error NOTICE Changing grade to match one end of the field to compensate for drift will cause double the error on the opposite side of the laser field Therefore only change grade on one side of the laser if working o...

Page 76: ...s are sometimes difficult to get stable especially in hard dirt Wiggle the trailer until all legs are secure and have even pressure on the ground Minimize the working distance from the laser transmitter Use multiple lasers if needed Increase the Averaging function on the System Five Control Box If the implement then begins to porpoise i e leaving long waves lower the Averaging setting See Averagin...

Page 77: ...rth are the same Unless grading at extreme distances the errors generated from the curvature of the earth are undetectable If leveling huge fields use multiple transmitter setups due to the limitation of the laser distance Since each laser transmitter levels itself using gravity the total field distance will not cause compounding errors Table 3 1 shows the error s due to the earth s curvature at d...

Page 78: ...leveling instrument A circle is divided into 360 A degree is divided into 60 arc minutes An arc minute is divided into 60 arc seconds Table 3 2 shows how arc seconds relate to elevation at a distance Table 3 2 Arc Seconds vs Feet Meters At 100 30m At 500 152m At 1000 305m 1 arc second 0005 00015m 0024 00073m 0048 00146m 5 arc seconds 0024 00073m 012 00366m 024 00732m 10 arc seconds 0048 00146m 024...

Page 79: ...levation of the field provide information on the high and low points of the field and thus the cut and fill levels for those points When in survey mode Topcon s TM 1 mast moves the laser receiver up and down until the receiver locates locks onto and tracks the laser beam If the receiver loses the beam for more than 20 seconds the TM 1 mast automatically moves the receiver to search for locate and ...

Page 80: ...n using the automatic record feature the control box records elevations in one second intervals See Using the Survey Mode on page 2 12 for setting the Control Box for recording elevations Survey Preparation Before you begin an elevation survey you need to Have pen and paper available Setup the laser transmitter Detect the beam Enter an initial reference elevation See the following sections for sur...

Page 81: ...s on setting up the laser Once your laser is set up and rotating position the scraper within approximately 50 of the laser and lower the scraper so it rests on the ground Press the Survey button to search for and lock onto the beam See Using the Search Function on page 2 11 and Using the Survey Function on page 2 11 for more information TIP To maximize the amount of adjustment while surveying posi...

Page 82: ... hold the Set button 2 Rotate the Grade Adjustment Knob to dial in the initial elevation reference Both the Grade Correction Indicator lights and the Double arrows will be lit 3 Release the Set button and the Control Box saves the setting 4 If needed press the Survey Search button to have the receiver search for and lock onto the laser transmitter Now you are ready to begin surveying a field 1 Adj...

Page 83: ...meter survey to calculate the actual field slope Then set the best fit slope into the transmitter perform a serpentine survey then level the field 1 To calculate the percentage of slope get an average elevation reading at each side of the field Figure 4 3 Figure 4 3 Measure Elevation on Opposite Sides of Field 2 Knowing the distance between the elevation readings calculate the percentage of slope ...

Page 84: ...consistencies at the field s edges perform the survey 50 to 100 in from the perimeter 1 Set your laser transmitter to 0 slope 2 With the Control Box set to Survey mode press the Auto button to begin recording elevations 3 Drive the entire length of one side for example side A in Figure 4 5 4 At the end of side A press the Auto button to stop recording elevations 5 Press the ELEV AVG button to view...

Page 85: ...age Fall Calculate the Average Fall AF in both the North South direction sides A and C and in the East West direction sides D and B Use this equation where AE is average elevation and AF is average fall Using the example numbers from Figure 4 6 the equations look like this for the North South average fall for the West East average fall M A N U A L A U T O S y s t e m F i v e N AE 5 15 A E 5 0 0 L ...

Page 86: ...aped Fields For irregularly shaped fields survey the largest square or rectangle possible for a perimeter survey Opposite sides must be parallel to each other regardless of the shape of the field this is very important for calculating the percentage of slope The following example Figure 4 7 demonstrates how to survey the perimeter of an irregularly shaped field Figure 4 7 Perimeter Survey Examples...

Page 87: ...reading on each axis at 100 or a known distance from the transmitter Figure 4 8 Figure 4 8 Measure Elevation on Opposite Sides of Field 2 Calculate the slope as for a complete perimeter survey see Calculating the Slopes on page 4 8 fall north to south approximate slope north to south 3 Dial the approximate slope into the transmitter then complete the perimeter survey as usual If the calculated slo...

Page 88: ...lected from a serpentine survey allows you to find the field s average elevation and to create a cut and fill map The cut and fill map allows you to plan your land leveling operation for more efficient and higher quality results Figure 4 9 Serpentine Survey Reveals Highs and Lows In the serpentine survey cross from one field border to the other then turn around and return continuing until you have...

Page 89: ...hod you are most comfortable with or follow the steps below 1 Enter the desired field slope or the calculated slope into the laser transmitter This slope determines the slope of the field when finished land leveling 2 With the Control Box in Survey mode press and hold the ELEV AVG button for three seconds to clear any previous readings 3 Begin driving the field in a serpentine pattern with the scr...

Page 90: ...while crossing the field Figure 4 11 Once you complete the survey create a cut fill map to help with land leveling Figure 4 12 on page 4 13 Figure 4 11 Survey Map 6 When you have completed the serpentine survey press the Auto button to stop recording elevations 7 Press the ELEV AVG button to view the field s average elevation and record the number 8 After completing the survey establish an elevati...

Page 91: ...f the ground was tight during the survey lower grade from 0 02 to 0 05 For loose ground like after disking allow 0 05 to 0 10 see Chapter 5 for more information In the following example Figure 4 12 the average elevation is 5 58 Adjusted for soil compaction of 03 the adjusted average elevation becomes 5 55 Looking at the cut fill map anything above 5 55 will be a cut and anything below 5 55 will be...

Page 92: ...Surveying Topcon AG System Five Operator s Manual 4 14 Notes ...

Page 93: ...eference on page 5 3 If you have just finished the survey and the laser is still in place follow the steps below for automatic land leveling 1 Press the Survey button to switch the Control Box from Survey mode to Control mode 2 Use the Grade Adjustment Knob to dial in your field s average elevation into the control box LCD display Adjust the average elevation to allow for soil compaction The level...

Page 94: ... using one of the following methods Level a small section of the field 50 x50 to finish grade Use a grade rod to setup a benchmark hub If the height of the transmitter remains the same ensure the Control Box uses the same elevation setting number from the previous day If the height of the transmitter changes use the finish grade or benchmark hub as a reference for succeeding day setups Amount of D...

Page 95: ...y Figure 5 2 Figure 5 2 Starting from Previous Day s Finish 2 Set up the laser with correct slopes at any height 3 Press Survey to lock the receiver on grade Figure 5 3 Figure 5 3 Adjusting Receiver to get On grade Signal Place the Cutting Edge on the Finished Grade Cut from the Previous Day 1 2 3 4 MANUAL AUTO System Five AREAOFDETAIL Allow Receiver to Search Up or Down Until On Grade Displays 1 ...

Page 96: ...reference number since the laser transmitter and TM 1 mast have move Set the LCD display to read the previously used reference number TIP You can run several machines at once from a single laser reference Simply use a finished grade pass as your elevation reference during set up The setup procedure for each machine is the same as described above ...

Page 97: ...ter will help you diagnose and solve some common problems you may encounter with your Control Box Before contacting your local Topcon Distributor try the following Check that all cables are securely and properly connected to the various components of the System Five control box TM 1 mast laser receiver valves sensor etc Disconnect cables and inspect them for damage or contamination Clean all conne...

Page 98: ...k the power cable fuse Replace if necessary Check that all cables are properly and securely connected to the System Five Box Disconnect cables and inspect them for damage or contamination Clean all connections with an electrical contact cleaner Problem Control Box LCD displays Error Causes Solutions The Control Box cannot communicate with the laser receiver When turning on the Control Box watch th...

Page 99: ...nstable secure the laser Check Deadband in Performance Menu is not less than 6mm Increase Averaging using the Performance Menu Problem The valve is driving the hydraulic cylinder too far and overshooting grade Causes Solutions Valve Offset in Control Box are set too high Lower the Valve Offset value until the sensor no longer overshoots grade See Valve Offset on page 2 22 for more information For ...

Page 100: ...utions Valve offsets in Control Box are set too low Raise the Valve Offset Value until the sensor is driven to grade See Valve Offset on page 2 22 for more information For Servo and Solenoid valves raise the value by 2 to 5 numbers then check hydraulic performance For Proportional valves raise the value by 10 to 15 numbers then check hydraulic performance ...

Page 101: ...craper blade and rippers should be grounded before working on or around the machine 3 Do not attach Topcon components while the engine is running 4 Protect yourself at all times and wear protective clothing when working on or near hydraulic lines Hydraulic lines can be under extreme pressure even when the machine is off Topcon cannot anticipate all possible circumstances that could result in a haz...

Page 102: ...llow moisture to get inside the case Moisture trapped in the case can adversely affect components CAUTION DO NOT stare into the laser beam or view the beam directly with optical equipment WARNING Improper operation lubrication maintenance or repair of this product can be dangerous and could result in injury or death WARNING Relieve all pressure in the hydraulic lines before disconnecting or removi...

Page 103: ...npositioning com A 3 WARNING Do not weld near hydraulic lines or on any equipment when in operation WARNING Be aware of overhead power and telephone lines Do not drive under power and telephone lines with the mast pole raised ...

Page 104: ...Safety Precautions Topcon AG System Five Operator s Manual A 4 Notes ...

Page 105: ...iods any of the above items found defective may be shipped to TOPCON for repair TOPCON will promptly repair the defective item at no charge and ship it back to you Calibration of components labor and travel expenses incurred for in field removal and replacement of components are not covered under this warranty policy Damage to components due to negligence abuse or improper use is NOT covered under...

Page 106: ...advised of the possibility of such damages Service Information Service assistance can be provided by contacting your local TOPCON dealer or by calling the Corporate Service Center Phone 800 443 4567 8 a m to 5 p m Pacific Time Monday through Friday FAX 925 460 1329 Travel charges will be applied for any on site service whether warranty or non warranty in nature ...

Page 107: ...ch for 2 11 4 3 Beeper beam loss 2 29 jog switch 2 14 2 15 lower 2 15 raise 2 14 taking readings 2 29 Benchmarks 3 14 C Calculate average elevation 2 9 2 13 4 12 average fall 4 7 slopes 4 8 Calibrate transmitter 3 5 field adjustment 3 7 Calibration error 3 7 field adjustment 3 7 Compact soil 5 1 Control mode auto manual button 2 11 automatic land leveling 5 1 elev avg button 2 7 elevation offset b...

Page 108: ...apart 3 8 locate 3 8 J Jog button 2 14 2 15 lower 2 15 raise 2 14 timed outputs 2 14 L Land leveling automatic 5 1 Laser alignment 3 7 calibrate 3 5 height 3 2 location advice 3 2 placement 3 2 3 4 3 8 LED 2 15 function indicators 2 6 grade adjustment 2 5 symbols 2 15 Leveling optics drift 3 12 Location 3 2 3 4 large project 3 4 small project 3 3 working distance 3 2 working height 3 2 M Manual co...

Page 109: ...ltiple 2 7 points 3 14 S Serpentine survey 4 10 4 12 cut and fill map 4 10 Setpoints 2 7 2 34 Slope mode 2 10 reference deadband 2 28 Slope Mode 2 10 Soil compaction 5 1 Survey 4 2 4 13 button 2 10 irregular shaped fields 4 8 mode 2 12 2 35 auto manual button 2 11 beeper 2 29 elev avg button 2 7 elevation offset button 2 7 LED 2 6 Survey map 4 12 T Timed outputs 2 14 Transmitter drift 3 12 setup 4...

Page 110: ...Index Topcon AG System Five Operator s Manual Index Notes ...

Page 111: ......

Page 112: ...Topcon Positioning Systems Inc Phone 800 443 4567 www topcon com 2003 Topcon Corporation All rights reserved No unauthorized duplication P N 7010 0369 Rev C Printed in U S A 8 02 100 TOPCON ...

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