Leica Geosystems iCON grade iGG Series User manual

Leica iCON grade iGGx
Installation Manual
Version 2.0
HITCHDOC HE1597_R0; INSTALL MANUAL, LEICA iGGx

Introduction, iCON grade2
Introduction
Purchase Congratulations on your purchase of a iCON grade control panel. The iCON
grade control panel is an ideal tool for increasing productivity in all
aspects of the construction earthmoving industry.
To use the product in a permitted manner, please refer to the detailed
safety directions in the User Manual. The User Manual forms part of this
manual and must be read in conjunction with this manual.
Legal, Safety & Environmental Issues / Symbols
Legal Copyright
Without prior permission in writing by Leica Geosystems AG (Switzerland),
this document shall not be reproduced as a whole or in part, by mechan-
ical, photographic, electronic, or other means (including into or transmis-
sion in machine-readable form); stored in any retrieval system; used for
any purpose other than that/those for which it is intended; nor made
accessible or communicated in any form to any third party not expressly
authorized by Leica Geosystems AG to have access thereto.
Liability
This document is strictly for the use of qualified service engineers with
the requisite technical skills. Only persons who have successfully
completed the appropriate service training provided by Leica Geosystems
AG and are in the employ of a company in the Leica Geosystems Group or
of an agency, distributor, or service workshop duly authorized by Leica
Geosystems AG have the status of qualified service engineer. Leica
Geosystems AG accepts no liability whatever for direct or indirect damage
that may occur due to the unauthorized or improper use or interpretation
of this document by any person who is not a qualified service engineer in
accordance with the above definition.
Safety / Environ-
ment
Service technicians have the following obligations:
• To understand and follow the safety information and instructions on
the product and in the user manual.
• To be familiar with local regulations relating to industrial and non-
industrial accident prevention in the knowledge that these regula-
tions are up to date.
• To inform Leica Geosystems AG immediately in writing if the equip-
ment becomes unsafe.
• Dispose of the equipment and its components in accordance with the
regulations in force in your country.

3iCON grade, Introduction
Service Safety Hints
User manual The user manual also contains important safety notices. Please read the
user manual thoroughly before switching on the instrument for the first
time.
The iCON grade User Manual contains important safety directions. Refer
to the chapter “Safety Directions” in the User Manual for further informa-
tion.
To ensure safety when using the system, please also observe the direc-
tions and instructions contained in the User Manual and Safety Handbook
issued by the Machine manufacturer.
Introduction This handbook is only for use by Leica Geosystems-trained service
personnel. It is no substitute for attendance at an appropriate training
course. The reader is assumed to be familiar with the user manual
supplied with each instrument. Before starting to study the present hand-
book, the service technician must be able to use the instrument in accord-
ance with the user manual.
Opening or
Dismantling of
Instruments
Opening or dismantling of an Instrument may only be attempted in clean,
dust-free rooms and only by suitably trained technicians. With this
measure, malfunctioning of the instrument caused by dust or other
contamination may be prevented. In addition, ESD-precaution must
strictly be observed when-ever instruments with electronic components
are opened or dismantled.
Symbols
Listing of symbols
and their meaning
The symbols used in this manual have the following meanings:
Type Description
Danger Indicates an imminently hazardous situation which, if
not avoided, will result in death or serious injury.
Warning Indicates a potentially hazardous situation or an
unintended use which, if not avoided, could result in
death or serious injury.
Caution Indicates a potentially hazardous situation or an
unintended use which, if not avoided, may result in
minor or moderate injury and/or appreciable mate-
rial, financial and environmental damage.
Important paragraphs which must be adhered to in
practice as they enable the product to be used in a
technically correct and efficient manner.

Introduction, iCON grade4
General Installation Information
Warning This product may be installed on building and construction machinery only
by an appropriately trained and qualified specialist.
Caution Installing near mechanically moving machine components may damage
the product.
Precautions:
Deflect the mechanically moving machine components as far as possible
and define a safe installation zone.
Warning Unauthorized modification of machines by mounting the product may
alter the function and safety of the machine.
Precautions:
Follow the instructions of the machine manufacturer. If no appropriate
instruction is available, ask machine manufacturer for instructions before
mounting the product.
Prior to installation of an hydraulic system for automatic control of a
machine, the installer has to collect data about the type, model, serial
number, whether it is open center, closed center, load sense or pilot
controlled hydraulic system. Refer also to the machines manufacturer’s
user manual or marketing material to get the information and also refer
the Leica Geosystems Machine database to collect information on known
machines.
For hydraulic hoses it is important to find a suitable place for the hydraulic
valve on the machine and measure the hose length between the connec-
tions on the cylinders and hydraulic valve providing sufficient length.
Identify the type of hydraulic connections on the machine such as JIC or
ORFS-Fittings.
Only personal that have been trained and authorised by Leica Geosystems
are allowed to perform hydraulic, mechanical or electrical installations on
machines.

5iCON grade, Table of Contents
Table of Contents
In this manual Chapter Page
1 System Overview 7
2 System Installation 8
2.1 iCON grade Control Panel 8
2.2 System Components 9
2.2.1 Installation on 12 Volt Machines 11
2.3 Slope Sensor mounting 13
2.3.1 Slope sensor mounting 13
2.4 Junction Box 16
2.4.1 MJB1301 Junction Box 16
2.4.2 Updating the Junction Box Firmware 19
2.5 Cross Slope Sensor 20
2.6 Rotation Sensor 21
2.7 Setting up dual GNSS 24
2.8 Elevation Sensors 29
2.8.1 Installing the Elevation Sensors 29
2.8.2 Installing the L-Bar 30
2.8.3 Installing the Manual/Power Mast 31
2.8.4 Mounting of Laser Collars 35
3 Calibrating the System 36
3.1 Installation Wizard 36
3.2 Automatic Calibration of Machine Hydraulics 48
3.3 Manual Calibration of Machine Hydraulics 52
3.4 Mast calibration 56
3.5 Calibrating the Rotation Sensor 63
3.6 Calibrating the Cross Slope Sensor 65
3.7 Installation and Configuration of MLB1300 Lightbars 66
3.8 Machine-joystick behaviour 67
3.9 Configuration of Auto / Manual Switches 68
3.10 Hydraulic Override with External Switch 69
3.11 CAN Joystick 70
3.12 Calibrating Mast Height Offset 71
4 Deadband and Gain 72
5 Wirings 74
5.1 System Diagram Grader 74
5.2 Junction Box Connectors 78
5.3 Cables 79
6 How to Upgrade the Firmware 81
7 Spare Parts & Accessories 84

Table of Contents, iCON grade6

7iCON grade, System Overview
1 System Overview
Overview Grader A Leica iCON grade system for grader can be equipped in various ways.
Below you will find an example of one of the ways:
a) Power mast/manual mast; Laser receiver on mast
b) Junction box
c) Hydraulic valve
d) iCON grade Control panel iCP32, Cradle MMB1300
e) Multi switch
f) Sonic tracker
g) Rotation sensor
h) Cross slope sensor
a
hfg
d
e
bc

8iCON grade, System Installation
2 System Installation
2.1 iCON grade Control Panel
Programming the
panel
Programming the control panel is done through a standard serial port.
The serial port is located under the wire cover on the MMB1300.
Cradle with wire cover removed
The programming is performed using a graphical upload program, called
“hmcprogrammer.exe” together with three .dll files. They can be down-
loaded, packed together with a short user guide, in a .zip file from the
home page together with the firmware update files.
The .zip file should be unpacked in a known folder on the PC, for example
use c:\update\hmcprog\.
See chapter "How to Upgrade the Firmware" for further instructions.
1 +12V out
2VCAN2
3GND
4CAN2LOW
5CAN2HIGH
6VCAN
7GND
8CANLOW
9CANHIGH
10 JB-xx Sleep
11 Rx
12 TX
13 GND
14 Vout (SW)
15 Right -
16 Right +
17 Right Auto
18 Left -
19 Left +
20 Left Auto
21 Serial port RS232
1 11
12
13
14
15
16
17
18
19
202
3
4
5
6
7
8
9
10
21

9iCON grade, System Installation
2.2 System Components
Power Cable 1. The power cable should be run through the machine and connected
either to the machine side of the battery isolation master switch or
directly to the battery.
2. Connect the positive (red) leads of the power cable to the positive
terminal.
3. Connect the negative (black) leads of the power cable to a suitable
grounding lug on the chassis of the machine.
Cradle voltage range = 10 - 28 V
No battery disconnected:
Positive battery disconnected:

10iCON grade, System Installation
Negative battery disconnected:

11iCON grade, System Installation
2.2.1 Installation on 12 Volt Machines
Description A converter is required for full support of 12 Volt machines. The MDC1300
Power Converter will scale the power up to 24 V to support the MMB1300
Cradle. This converter is installed between the Junction Box (MJB1300 or
MJB1301) and the Cradle (MMB1300) as described in the images below.
MDC1300 on a 2D
system
Below you will find a diagram describing how the MDC1300 is installed on
a 2D system:
2P 2P
Battery
Switch
Chassis
-
+
Fuse
To machine
12V
Battery
2P
764866
MSC1303
Cable
Junction Box
-> cradle, 5 m
761061
Cable CAN
extension
M12, 5 m
767145
MSC1320 Power Cable
MIL2S, fused, 8.0 m
817711
MDC1300,
12 to 24V
Power converter
764839
MJB1301
Junction Box
Grader
764910
MMB 1300
Cradle for
control panel
817816
MSC1383
Cable 5 m
MDC1300 to JB

12iCON grade, System Installation
MDC1300 on a 3D
system
Below you will find a diagram describing how the MDC1300 is installed on
a 3D system:
2P 2P
2P
Battery
Switch
Chassis
-
+
Fuse
To machine
12V
Battery
iCG8x
iCON gps 80
764910
MMB 1300
Cradle for
control panel
767145
MSC1320 Power Cable
MIL2S, fused, 8.0 m
761061
Cable CAN
extension
M12, 5 m
764
MSC
Ca
Junct
-> crad
Cable CAN
M12 F/F
817711
MDC1300,
12 to 24V
Power converter
817816
MSC1383
Cable 5 m
MDC1300 to JB
Optional Cable Lenght M12
Optional Extension Cables M12
770406 Cable straight M12, 0.3 m
763275 Cable straight M12, 0.5 m
770407 Cable straight M12, 1.0 m
761062 Cable straight M12, 2.0 m
764865 Cable straight M12, 3.5 m
761063 Cable straight M12, 5.0 m
761057 Cable straight M12, 7.5 m
761058 Cable straight M12, 10 m
761061 Cable extension M12, 5 m
Op
tional Cable Len
g
ht M12
Op
tional Extension Cables M12
7
70406 Cable strai
g
ht M12, 0.3 m
7
63275 Cable straight M12, 0.5 m
7
70407 Cable stra
ig
ht M12, 1.0 m
7
61062 Cable straight M12, 2.0 m
7
64865 Cable strai
g
ht M12, 3.5 m
7
61063 Cable straight M12, 5.0 m
7
61057 Cable strai
g
ht M12, 7.5 m
7
61058 Cable strai
g
ht M12, 10 m
7
61061 Cable extens
i
on M12
,
5
m
764839
MJB1301
Junction Box
Grader

13iCON grade, System Installation
2.3 Slope Sensor mounting
2.3.1 Slope sensor mounting
Mounting the
sensor
It’s important to take care when installing sensors that measure a slope.
If they are not aligned with the axel that they are supposed to measure
they will have an error in the measurement, and that will result in inaccu-
racy in the final grade.
This chapter will discuss the things that need to be focus on when
mounting sensors that measure a slope.
The sensors in question are:
• Cross slope sensor (single & dual)
• Mast slope sensor
• Main fall sensor (junction box)
•Rotationsensor
Calibration offset It is always a recomm ended to have the calibration offset as close to 0.0%
as possible.
When mounting a cross slope sensor on a blade it should be mounted
level when the blade is level.
If the sensor is mounted with a large calibration offset it will cause a
misreading of the slope when the machine is driving up or down hill, or
the mast is tilted. This misreading will end up as a height error in the auto-
matic grading.
Sensor alignment Because the sensor only can measure the slope in one direction it’s
necessary to make sure the sensor is mounted parallel to the direction
that you want to measure the slope.
The mainfall sensor is designed to measure if a grader is driving up or
down hill, but if the junction box is mounted so that it’s pointing to the
side it will not measure the right mainfall. Therefore it’s important to
mount the junction box so that it’s parallel with the gooseneck.
Junction box mounted parallel with
the gooseneck.
Junction box not mounted parallel
with the gooseneck.

14iCON grade, System Installation
When installing the cross slope or mast slope sensor it’s a good idea to
first take a good look at the machine and blade to see if there is a
feature/part of the blade assembly that is either parallel or perpendicular
to the blade edge. If this is the case then that feature/part can be used
as a reference when mounting the sensor. An example of this can be seen
in figure below where the two “walls” that the sensor is mounted in
between looks to be designed so that they are perpendicular to the blade
edge.
When mounting the rotation sensor, it’s important to get the mounting
plate centred on the swivel. If the mounting plate is placed off centre it
will rotate in an oval shaped curve instead of a perfect circle shaped
curve. This will course an error in the measured rotation.
Mounting the mast
slope sensor
To install the junction box, complete the following steps:
1. Place the machine on a flat and level surface.
2. Place the blade on the ground and tilt the blade so that the mast is
vertical (often the blade is tilted all the way back).
3. The mast tilt sensor needs to be mounted on the part that tilts with
the blade, but not the part that is side shifted. This would be the
Sensor mounted perpendicular to
the blade edge.
Mounting plate centred on the
swivel.

15iCON grade, System Installation
orange part in figure below. The sensor should be mounted with the
connector facing forwards and the label facing to the left.
4. When the mast is vertical, the mast tilt sensor should be mounted so
that it’s horizontal. Ideally the sensor should be mounted with an
offset of less than 1.5%. The figure below shows the mounting
backed welded in place.
5. Run the cable from the mast tilt sensor to a CAN Junction Box, and
place the CAN Junction Box, somewhere near the rotation sensor.
6. Connect the cable from the cross slope sensor to the CAN Junction
Box, and connect a cable from the CAN Junction Box, to the rotation
sensor.
Sensor mounted on the part that tilts with the blade.

16iCON grade, System Installation
2.4 Junction Box
2.4.1 MJB1301 Junction Box
Junction box for
Grader
The junction box for grader is used for connecting the slope and elevation
sensors on the machine. It also contains the electronics for driving the
hydraulic valves. The mainfall sensor, which is integrated in the junction
box, is intended to measure the grader's slope in its driving direction.
The junction box for Dozer does not have any leveling sensor.
The junction box consists of two parts:
•Junctionbox
• Mounting bracket for junction box
The junction box for Grader is normally mounted on top or below the
gooseneck.
For mounting the junction box underneath the gooseneck there is a
special upside-down mounting bracket.
The picture shows the junction box mounted on top of the gooseneck just
in front of the swivel table.
Standard mounting bracket Upside-down mounting bracket

17iCON grade, System Installation
Installation of the
junction box for
Grader
To install the junction box, complete the following steps:
1. Place the grader on a level surface.
2. Find a suitable place on top of the gooseneck to mount the bracket.
Please make sure that the swivel table cannot come into contact with the
junction box, even in the case of extreme movements.
3. Before the mounting bracket is fastened to the gooseneck, check that
the placement of the junction box and its bracket are as level as
possible (± 5.0%).
4. Weld the mounting bracket on to the gooseneck.
Warning Before starting to weld, check that the machines battery is disconnected
and that any electronic systems are removed. Contact your dealer, if
necessary.
5. Install the junction box with the help of the screws enclosed with the
mounting kit and make sure to observe the mounting direction.
Appropriate stickers mark the moving direction <-, LEFT SENSOR and
RIGHT SENSOR.
6. Connect all cables to the junction box. See picture on page 18 for an
overview where to connect the different cables.

18iCON grade, System Installation
7. The cable to the rotation/cross slope sensor can be installed behind
the gooseneck side cover or on some graders even inside the goose-
neck.
Junction box Grader connectors
Con 1 Left and right hydraulic
output
Con 6 Sensor Connector Right
You can connect a Laser
Sensor, Sonic Tracker or
Electric Mast, free of choice
Con 2 Sensor Connector Left
You can connect a Laser
Sensor, Sonic Tracker or
Electric Mast, free of choice
Con 7 Sensor Connector Right
You can connect a Laser
Sensor, Sonic Tracker or
Electric Mast, free of choice
Con 3 Sensor Connector Left
You can connect a Laser
Sensor, Sonic Tracker or
Electric Mast, free of choice
Con 8 Sideshift hydraulic output
Con 4 Connection of Rotation and
Cross Slope sensor
Con 9 Connection of Control Box
Con 5 AUX Output - Extra Valve
output
Con 10 Power connection

19iCON grade, System Installation
2.4.2 Updating the Junction Box Firmware
Programming
MJB1301
Programming the MJB1301 is done through a standard serial port and the
upload kit. The upload kit uses a 9V battery to work.
The programming is performed using a graphical upload program, called
“hmcprogrammer.exe” together with three .dll files. They can be down-
loaded, packed together with a short user guide, in a .zip file from the
home page together with the firmware update files.
The .zip file should be unpacked in a known folder on the PC, for example
use c:\update\hmcprog\.
See chapter "6 How to Upgrade the Firmware" for further instructions.
MJB1301
Upload kit
Battery location

20iCON grade, System Installation
2.5 Cross Slope Sensor
Cross slope sensor The blade slope sensor consists of the following components:
• Single Cross Slope Sensor
•Mountingbracketwithscrews
Install the sensor To install the sensor, complete the following steps:
1. Level the blade using a sprit level.
2. Place the bracket into the pocket at the rear of the circle and tack
weld in place. Align the plate parallel to the blade.
Warning Before starting to weld, check that the machines battery is disconnected
and that any electronic systems are removed. (Contact your dealer, if
necessary.)
Warning The alignment of the cross slope sensor is very critical to the accuracy of
the slope. Tack weld the bracket lightly at first so as to be able to move
the bracket when checking measurements.
Please also refer to the section " Sensor alignment" in this chapter.
3. The bracket must also be mounted so that the sensor, when installed,
will not come into contact with the mainframe when the cylinders are
retracted and the circle is rotated.
4. When the position of the bracket has been checked and, if necessary,
adjusted, then securely weld the bracket into the pocket.
5. Bolt the cross slope sensor to the bracket.
6. Connect the M12 connector to the sensor, and drag the cable up to
the hydra swivel were the rotation sensor is going to be mounted.
Make sure that the cable will not be damaged by the movement of the
blade or the circle.
7. Fasten the cable with cable ties.
Suggested placement of the cross slope sensor