Topcon MACHINE CONTROL AG System Five User manual

AG
System Five
Operator’s Manual
MACHINE CONTROL: AG

AG System Five
Operator’s Manual
For the 9256 Control Box
Part Number 7010-0369
Rev. C
©Copyright Topcon 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.

CO#175

P/N 7010-0369 www.topconpositioning.com
i
Table of Contents
Preface .................................................................. v
Terms and Conditions ...................................................... v
Manual Conventions ........................................................ viii
Chapter 1
Introduction and Setup ........................................ 1-1
Overview .......................................................................... 1-2
Care and Preventive Maintenance ................................... 1-2
Getting Acquainted .......................................................... 1-3
Control Box ............................................................... 1-3
Laser Receiver ........................................................... 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 Mode ............................................... 2-7
Elevation Offset Button and Elev/Avg Button ................ 2-7

Table of Contents
Topcon AG System Five Operator’s Manual
ii
Using the Elevation Offset Button ............................ 2-7
Using the Elev/Avg Button ....................................... 2-8
View Current Elevation ...................................... 2-8
View Average Elevation ..................................... 2-9
Clear Average Elevation ..................................... 2-9
Elevation/Slope Button .................................................... 2-10
Setting the Elevation Mode ....................................... 2-10
Setting the Slope Mode ............................................. 2-10
Search/Survey Button ...................................................... 2-10
Using the Search Function ........................................ 2-11
Using the Survey Function ........................................ 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
Valve Offset .............................................................. 2-22
Averaging .................................................................. 2-25
Elevation Deadband .................................................. 2-26
Slope Deadband ......................................................... 2-28
Beeper Alarm ............................................................ 2-29
Units .......................................................................... 2-31
Test ............................................................................ 2-32
Elevation Offsets (Setpoints) ..................................... 2-34
Record ....................................................................... 2-35
Timed Outputs ........................................................... 2-36

Table of Contents
P/N 7010-0369 www.topconpositioning.com
iii
Chapter 3
Laser Setup ........................................................... 3-1
Laser Placement ............................................................... 3-2
Small Project Laser Transmitter Placement .............. 3-3
Large Project Laser Transmitter Placement .............. 3-4
Laser Transmitter Calibration .......................................... 3-5
Laser Axis Alignment ...................................................... 3-7
Automatic Alignment ................................................ 3-7
Manual Alignment .................................................... 3-8
Conditions Affecting the 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
Calculating the Average Fall ..................................... 4-7
Calculating the Slopes ............................................... 4-8
Irregularly Shaped Fields .......................................... 4-8
Steeply Sloped Fields ................................................ 4-9
Serpentine Survey ............................................................ 4-10

Table of Contents
Topcon AG System Five Operator’s Manual
iv
Chapter 5
Land-leveling ........................................................ 5-1
Automatic 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

P/N 7010-0369 www.topconpositioning.com
v
Preface
This manual has been developed to provide the operator with
information necessary to operate and maintain the TOPCON
machine control lasers. Proper service and use is important to the
reliable operation of the equipment. The procedures described
herein are effective methods for performing service and operation
of this system.
NOTICE
Please read these Terms and Conditions
carefully.
Terms and Conditions
USE – Please study this manual carefully. The benefits this product
provides 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 TPS’ express written consent and may only use
such information for the care and operation of your product. The
information and data in this Manual are a valuable asset of TPS and
are developed by the expenditure of considerable work, time and
money, and are the result of original selection, coordination and
arrangement by TPS.

Preface
Topcon AG System Five Operator’s Manual
vi
TRADEMARKS – System Five™, RT-5Sa™, Topcon® and
Topcon Positioning Systems™ are trademarks or registered
trademarks of TPS. Windows® is a registered trademark of
Microsoft Corporation. Product and company names mentioned
herein may be trademarks of their respective owners.
DISCLAIMER OF WARRANTY – EXCEPT FOR ANY
WARRANTIES IN AN APPENDIX OR A WARRANTY CARD
ACCOMPANYING THE PRODUCT, THIS MANUAL AND THE
PRODUCTS ARE PROVIDED “AS-IS.” THERE ARE NO
OTHER WARRANTIES. TPS DISCLAIMS ANY IMPLIED
WARRANTY OF MERCHANTABILITY OR FITNESS FOR
ANY PARTICULAR USE OR PURPOSE. TPS AND ITS
DISTRIBUTORS SHALL NOT BE LIABLE FOR TECHNICAL
OR EDITORIAL ERRORS 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 CONNECTION WITH
OBTAINING SUBSTITUTE PRODUCTS OR SOFTWARE,
CLAIMS BY OTHERS, INCONVENIENCE, OR ANY OTHER
COSTS. IN ANY EVENT, TPS SHALL HAVE NO LIABILITY
FOR DAMAGES OR OTHERWISE TO YOU OR ANY OTHER
PERSON OR ENTITY IN EXCESS OF THE PURCHASE PRICE
FOR THE PRODUCT.
WEBSITE and OTHER STATEMENTS – No statement
contained at the TPS website (or any other website) or in any other
advertisements or TPS literature or made by an employee or
independent contractor of TPS modifies these Terms and

Terms and Conditions
P/N 7010-0369 www.topconpositioning.com
vii
Conditions (including the Software license, warranty and limitation
of liability).
SAFETY – Improper use of the Product can lead to injury to
persons or property and/or malfunction of the product. The product
should only be repaired by authorized TPS warranty service
centers. Users should review and heed the safety warnings in
Manual.
MISCELLANEOUS – The above Terms and Conditions may be
amended, modified, superseded, 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 notice.
Comments, suggestions, and questions about TOPCON products
are welcomed. Contact your local TOPCON representative or a
representative at our corporate facility.
TOPCON POSITIONING SYSTEMS, Inc.
5758 W. Las Positas Blvd.
Pleasanton, CA 94588
925 / 460 1300
925 / 460 1315 FAX

Preface
Topcon AG System Five Operator’s Manual
viii
Manual Conventions
This manual uses the following conventions:
Example Description
Auto Press, hold, or turn this button or knob.
TIP
Supplementary information that can help you
configure, maintain, or set up 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
UNDER NO CIRCUMSTANCES SHOULD THIS ACTION
BE PERFORMED.

Chapter 1
P/N 7010-0369 www.topconpositioning.com
1-1
Introduction 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
123 4
MANUAL
AUTO
S
ystem
F
ive

Introduction and Setup
Topcon AG System Five Operator’s Manual
1-2
Overview
The System Five™ Control Box can be connected to a grade sensor,
such as a laser receiver to control elevation, as well as a slope
sensor to control the inclination or slope of an implement. The
Control Box receives signals from the sensor and determines
whether the implement is above, below, or at the desired grade. If a
grade correction is needed, the Control Box sends a signal to the
control valve, raising or lowering the implement until it is on-grade.
The operator always has full control over the system, allowing
automatic or manual control. Changes in grade can also be 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
exposed to the elements.
• Some moisture on the Control Box and its components is
acceptable during working conditions. Do not spray water or
use high pressure steam cleaner hoses directly on cables and
components.
• Use protective connector caps on cables when not using the
System Five for a period of time. Water accumulating on the
connectors can cause electrical shorts.
Refer to your laser’s Operator’s Manual for care of the laser
transmitter and sensor.

Getting Acquainted
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1-3
Getting Acquainted
The System Five has three components: Control Box, Laser
Receiver, and a TM-1 Electric Mast.
Control Box
The Control Box (Figure 1-2) is the operator’s interface to
System Five™. After receiving signals from the sensors (Laser
Receiver and/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
5758W. Las Positas Blvd. Pleasanton
CA94588 Madein USA
AUTO
SURVEY
SET
(MENU)
S
ystem
F
ive
S
ystem
F
ive
Front
Back
Bottom

Introduction and Setup
Topcon AG System Five Operator’s Manual
1-4
Laser Receiver
The Laser Receiver (Figure 1-3) is an elevation control sensor.
It measures and controls the elevation 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

System Five Setup
P/N 7010-0369 www.topconpositioning.com
1-5
System Five Setup
The System Five has several components that attach to each other
using cables. The cables allow communication between the Sensor,
the Control Box, and the Hydraulic Valves. When the Sensor
detects a change in slope or elevation, it sends a signal to the
Control Box, which then sends a pre-programmed, instructive
signal to the Hydraulic 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
+-
P
ower/Valve
Cable
Coil Cord
TM-1 Mas
t
TRACTOR COMPONENTS SCRAPER COMPONENTS
HydraulicValve
ConnectedTo
Control Box
Or
Laser Mast
To Control Box
To TM-1 Mast
9256 Control Box LS-B2 Laser
Receiver
Valve Cable
AUTO AUTO
Five
System
Five
System

Introduction and Setup
Topcon AG System 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 Kno
b
S
lide Laser Receiver
D
own onto Mast
1
2

System 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
T
M-1
LS-B2
Attach Coil Cor
d
To Laser Receiv
er
And Mast

Introduction and Setup
Topcon AG System Five Operator’s Manual
1-8
3. Attach the cord to the snap hook, then pull it snug and wrap it
around the shock mount (Figure 1-8). This ensures that 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