Topcon Motorgrader User manual

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POSITIONING SYSTEMS
Motorgrader System Five
Operator’s Manual
For the 9164 Control Box
Part Number 7010-0344
Rev. E
©Copyright Topcon Positioning Systems
March, 2007
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.

ECO#2955

P/N 7010-0344
TOC
i
Table of Contents
Preface .................................................................. v
Chapter 1
System Overview .................................................. 1-1
Control Box ..................................................................... 1-3
Remote “Smart” Knobs ................................................... 1-4
Sonic Tracker II ............................................................... 1-5
Laser Tracker and Trackerjack ........................................ 1-6
Blade Slope Sensor .......................................................... 1-7
Rotation Sensor ................................................................ 1-8
Mainfall Sensor ................................................................ 1-9
Hydraulic Manifold Assembly ........................................ 1-10
Carrying Case .................................................................. 1-11
Chapter 2
Operation .............................................................. 2-1
Control Box ..................................................................... 2-1
Control Box Front Panel Switches and Controls ...... 2-2
The LCD (Liquid Crystal Display) ..................... 2-3
Left and Right Grade Adjustment LEDs ............ 2-4
Left and Right Automatic Operation Indicators . 2-5
Left and Right Grade Adjustment Knobs ........... 2-5
Grade Adjustment Direction Arrows .................. 2-6
Power Switch ...................................................... 2-6
Function Buttons ................................................. 2-7
Control Box Operation .............................................. 2-7
Basic Operation .................................................. 2-7
Control Mode ...................................................... 2-8
Remote “Smart” Knobs ...................................... 2-13
3DMC Mode ....................................................... 2-16
Setup Mode ......................................................... 2-16
Sonic Tracker II ............................................................... 2-20

Table of Contents
Motorgrader System Five Operator’s Manual
ii
Laser Control .................................................................... 2-30
Slope Control .................................................................... 2-33
Chapter 3
Calibration ............................................................ 3-1
Calibrate Rotation ............................................................ 3-2
Calibrate Mainfall ............................................................ 3-3
Calibrate Blade ................................................................. 3-5
Blade Wear Calibration (Trim) ........................................ 3-7
Adjust Valve Offsets ........................................................ 3-10
Automatic Adjusment ................................................ 3-10
Manual Adjusment ..................................................... 3-11
External Switches ............................................................. 3-12
Chapter 4
Getting Ready to Grade ....................................... 4-1
Control Box Setup ............................................................ 4-1
Checking Cross Slope (Trim Calibration) ........................ 4-2
Sonic Tracker Setup ......................................................... 4-3
Setting the Reference Number ......................................... 4-9
Laser Receiver Setup ........................................................ 4-12
Using Set Points ............................................................... 4-18
Chapter 5
Grading Applications .......................................... 5-1
Sonic Stringline ................................................................ 5-1
Setting Up a Sonic Stringline .................................... 5-1
Setting Stringline to Projected Slope ......................... 5-7
Making a Grade Verification Lath ............................. 5-10
Verifying Grade ......................................................... 5-11
Laser Grade Checking System ................................... 5-12
Grading a Road Using a Stringline .................................. 5-15
Grading a City Street ........................................................ 5-31
Grading from Curbs ......................................................... 5-36
Grading From Curbs Placed at Different Elevations ....... 5-39
Road Widening and Shoulders ......................................... 5-44
Grading On Curves ........................................................... 5-46
Grading Slope Transitions ................................................ 5-48

Table of Contents
P/N 7010-0344 iii
Chapter 6
Maintenance .......................................................... 6-1
Preventative Maintenance & Daily Care ......................... 6-1
Transducer Cleaning (Sonic Tracker II) .......................... 6-2
Transducer Replacement Procedure (Sonic Tracker II) .. 6-3
Sonic Tracker II Transducer Replacement ................ 6-3
Rotation Sensor Cleaning and Lubrication ...................... 6-7
Cleaning the Rotation Sensor .................................... 6-7
Lubricating the Rotation Sensor ................................ 6-9
Chapter 7
Troubleshooting ................................................... 7-1
System Test Mode ........................................................... 7-1
Accessing the System Test .............................................. 7-2
Slope Sensor Test ............................................................ 7-3
Troubleshooting ............................................................... 7-7
Mainfall Sensor Test ........................................................ 7-8
Rotation Sensor Test ........................................................ 7-10
Appendix A
Safety Information ................................................ A-1
General 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

Table of Contents
Motorgrader System Five Operator’s Manual
Notes:
iv

P/N 7010-0344
Preface
v
Preface
This manual has been developed to provide the grader operator with
information necessary to operate and maintain the TOPCON System
Five. 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.
The sections provided in this manual include information necessary
for the correct operation, care and trouble- shooting of your TOPCON
System Five. Also contained in this manual is a selection of
WARNINGS, CAUTIONS, and NOTICES you should become
familiar with to safely operate the system.
Each symbol represents a particular level of danger:
WARNING
WARNING
Represents a procedure or operation that, if not strictly
followed, can cause serious damage to the equipment,
and/or serious injury or death to the person performing
the operation.
CAUTION
CAUTION
Represents a procedure or operation that, if not
followed correctly, can result in serious damage to the
equipment or personal injury.
NOTICE
NOTICE
Represents a procedure that, if not performed correctly,
can adversely effect the performance of the equipment.

Preface
Motorgrader System Five Operator’s Manual
vi
Please study this manual carefully. The benefits this product provides
can be greatly influenced by your applications knowledge. 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.
7400 National Drive
Livermore, CA 94551
Phone: [phone]
Fax: [phone]

P/N 7010-0344
Chapter 1
1-1
System Overview
Your TOPCON Grader Control System Five™ is a versatile tool that
combines Elevation and Cross Slope Control into a package powerful
enough for your most demanding jobs, yet convenient enough to use
everyday. In fact, System Five is so easy to learn that your benefits
will start immediately:
•Increase Production
Make faster and fewer cuts. No extra passes to check grade.
•Control Material
Consistent grade along the entire job, not just at the hubs,
means no filling grade variations with costly base or paving
materials.
•Save Engineering Costs
Reduced hubs and staking, waiting on bluetops, and
inspection time.
Your System Five includes a Control Box, one/two Sonic Trackers
II's, a Slope, Rotation, and Mainfall Sensor, and a Hydraulic Manifold
Assembly. Smart Knobs, cables and mounting hardware are also
included. Optional Trackerjack Systems may be added to System
Five.

System Overview
Motorgrader System Five Operator’s Manual
1-2
Figure 1-1.
1. Control Box 2. Laser Tracker & Trackerjack 3. Smart Knobs
TM
4. Sonic Tracker II
TM
5. Slope Sensor 6. Rotation Sensor 7. Manifold Sensor 8. Hydraulic Manifold Assembly
12
3
5
6
4
78
System
Five

Control Box
P/N 7010-0344 1-3
Control Box
The Control Box is the operator's interface to System Five. It easily
attaches to its mounting bracket with one clamp, and at the end of the
day can be quickly removed for storage. The control box connects to
the Remote "Smart" Knobs™ and the machine power system with
one small connector, and connects to the other system components
with one large connector.
Figure 1-2.

System Overview
Motorgrader System Five Operator’s Manual
1-4
Remote “Smart” Knobs
The Remote “Smart” Knobs™ mount on the grader's control levers
for easy access. The knobs allow the operator to perform several
Control Box functions while keeping his hands where they belong -
on the levers.
Figure 1-3.
LEFT KNOB RIGHT KNOB
Raise
Auto Manual
Lower
Survey
Swap
Raise
Auto
Manual
Lower
Set Point
Survey

Sonic Tracker II
P/N 7010-0344 1-5
Sonic Tracker II
The Sonic Tracker II measures and controls the elevations of the
moldboard. A transducer, located in the bottom of the Sonic Tracker
II™, generates sound pulses like a speaker and listens for returned
echoes like a microphone. The Tracker measures the distance, and
controls grade from a physical grade reference, such as a curb,
stringline, or existing road surface.
The Sonic Tracker II attaches to the system through one quick
connect cable and attaches to the machine with a single bolt. At the
end of the day, Sonic Tracker II should be removed for proper storage
in the carrying case.
Figure 1-4.
S
onic
T
racker
II
SOUND
PULSES

System Overview
Motorgrader System Five Operator’s Manual
1-6
Laser Tracker and Trackerjack
The Laser Tracker works by receiving a signal from a rotating laser
and sends that signal to the Control Box. Use the same coil cord from
the Sonic Tracker II to power up the Laser Tracker.
The Trackerjack attaches to the laser receiver and then mounts onto a
vibration pole. Use the coil cord from the Sonic Tracker II to power
up the Laser Tracker/Trackerjack System.
The Laser Trackerjack should be removed at the end of each day and
stored in its carrying case. A vibration pole storage bracket can be
attached to the back of the grader for use when the Trackerjack
system is not needed.
Figure 1-5.
1 2 3 4
OPTIONAL
LS-B
2

Blade Slope Sensor
P/N 7010-0344 1-7
Blade Slope Sensor
The Blade Slope Sensor measures the slope of the cutting edge. It has
a precision electronic level sensor within it that functions like a
carpenter's level. It then relays that information to the Control Box.
The Blade Slope Sensor will measure slopes from +20% to -20%.
There is an option for a steep slope sensor that will measure up to +/-
100% slope.
The Blade Slope Sensor is sealed and once attached to the
motorgrader should not be removed.
Figure 1-6.

System Overview
Motorgrader System Five Operator’s Manual
1-8
Rotation Sensor
The Rotation Sensor continuously monitors the rotation angle of the
blade. This enables the operator to rotate the blade at any time, and
System Five will continue to maintain the desired cross slope.
The Rotation Sensor is a sealed unit and contains no adjustments.
Once attached to the machine it should not be removed, other than for
periodic maintenance (refer to Maintenance Section of this manual).
Figure 1-7.

Mainfall Sensor
P/N 7010-0344 1-9
Mainfall Sensor
The Mainfall Sensor uses the same type of precision electronic device
that is used by the Blade Slope Sensor. It mounts under the Hydraulic
Manifold Assembly and measures the slope of the machine in the
direction of machine travel.
The Mainfall Sensor is a sealed unit and contains no manual
adjustments. Once attached to the machine, it should not be removed.
Figure 1-8.

System Overview
Motorgrader System Five Operator’s Manual
1-10
Hydraulic Manifold Assembly
The Hydraulic Manifold Assembly is connected into the grader blade
lift cylinders. It acts like the manual valves the operator controls by
hand, automatically raising or lowering the blade to produce desired
grade.
The Hydraulic Manifold Assembly is a sealed unit and contains no
adjustments. Once attached to the machine, it should not be removed.
Figure 1-9.