Topcon X-63 Use and care manual

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POSITIONING SYSTEMS
X63/X62
Excavator Indicate System
Installation and Calibration
Manual
Part Number 7010-0697
Rev C
©Copyright Topcon Positioning Systems, Inc.
February, 2012
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#000061
Terms and Conditions
Thank you for buying this Topcon product. This manual has been prepared to assist
you with the care and operation of the product and its use is subject to these Terms
and Conditions and those more fully set forth in the Operator’s/User’s Manual.
Usage and Safety
This product is designed for use by professionals. Always use safety precautions
when operating this or any Topcon product.
Copyrights
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.
Trademarks
X63, X62, 3DMC, MC-R3, GX-60, TS-1, MC-A1, Topcon, and Topcon Positioning
Systems are trademarks or registered trademarks of TPS. Windows and the Windows
CE icon are registered trademarks of Microsoft Corporation.
Other product and company names mentioned herein may be trademarks of their
respective owners.
Disclaimer of Warranty
EXCEPT FOR SUCH WARRANTIES AND LICENSES PROVIDED WITH THE PRODUCT,
THIS MANUAL AND THE PRODUCT ARE PROVIDED “AS-IS”. TOPCON 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.
Please see the Operator’s/User’s Manual for detailed information on warranties and
the license agreement which may apply to the Product.
License Agreement
Use of any computer programs or software supplied by Topcon or downloaded from
the Topcon website in connection with the Product implies acceptance of the Terms
and Conditions here and in the Operator’s/User’s Manual.
Please see the Operator’s/User’s Manual for detailed information on warranties and
the license agreement which may apply to the Product.

P/N 7010-0697
TOC
i
Table of Contents
Introduction ............................................................ 1-1
X63 3D Excavator Indicate System ..................................... 1-2
X62 2D Excavator Indicate System ..................................... 1-5
TS-1 Sensor Installation ........................................ 2-1
TS-1 Sensor Orientation ...................................................... 2-2
Body Sensor Mounting ........................................................ 2-4
Boom Sensor Mounting ....................................................... 2-5
Secondary Boom Sensor Mounting (Optional) ................... 2-6
Stick Sensor Mounting ........................................................ 2-7
Bucket Sensor Mounting ..................................................... 2-8
Dog-bone Sensor Mounting (Optional) ............................... 2-9
Tilt Bucket Sensor Mounting (Optional) ............................. 2-11
Machine Calibration ............................................... 3-1
Measuring Machine Lengths ............................................... 3-2
Entering Sensor Information ................................................ 3-5
Calibrating the Sensors ........................................................ 3-9
Body Sensor Calibration ............................................... 3-9
Boom Sensor Calibration .............................................. 3-11
Secondary Boom Sensor Calibration (Optional) ........... 3-14
Stick Sensor Calibration ................................................ 3-15
Bucket Sensor Calibration ............................................. 3-18
Bucket Edge Calibration ......................................... 3-20
Multiple Bucket Calibration .......................................... 3-22
Bucket Edge Calibration ......................................... 3-24
Dog-bone Sensor Calibration ........................................ 3-26
Bucket Edge Calibration ......................................... 3-29
Tilt Bucket Calibration .................................................. 3-31
Bucket Edge Calibration ......................................... 3-33
CAN Termination ................................................................ 3-35

Table of Contents
X63/X62 Installation and Calibration Manual
ii
Sensor Filtering ................................................................... 3-35
Verifying X63/X62 Setup ......................................... 4-1
Verifying Range of Motion ................................................. 4-1
Verifying Elevation Accuracy ............................................. 4-2
Verifying Main Antenna to Boom Length .......................... 4-5
Verifying Aux Antenna to Boom Length ............................ 4-7
Verifying the Main Antenna ............................................... 4-12
Verifying Main Antenna Height ......................................... 4-16
Verifying Aux Antenna Height ........................................... 4-17
Verifying Boom Pivot Height ............................................. 4-17
LS-B10W Laser Receiver Setup ............................ 5-1
LS-B10W Mounting ............................................................ 5-1
LS-B10W Calibration ........................................................ 5-3
LS-B10W Test ..................................................................... 5-5
Full System Test ..................................................... 6-1
Testing Machine Element Sensors for Accuracy ................ 6-1
Testing Machine Body Sensor for Accuracy ...................... 6-4

P/N 7010-0697
Chapter 1
1-1
Introduction
This manual discusses how to install and calibrate the X63 GPS
excavator indicate system for 3D control and the X62 excavator
indicate system for 2D control.
The TS-1 tilt sensors (9174-0000) used in the Topcon excavator
systems measure the pitch and roll angle of various machine elements
(Figure 1-1). Each sensor accurately measures a gravity-referenced
angle of the body, boom, stick and bucket, sending this angle data to
the GX-60 Display (9169-0000) to provide precise grade. Each sensor
is configured and calibrated for its specific location on the excavator.
The body sensor functionality is unique as it measures both pitch and
roll (cross slope) of the machine.

Introduction
X63/X62 Installation and Calibration Manual
1-2
X63
3D Excavator Indicate System
Topcon’s X63 excavator indicate system contains the TS-1 tilt
sensors, GX-60 Display, MC-R3 Controller, and two GPS antennas
for 3-dimensional control of the machine.
Figure 1-1. TS-1 Tilt Sensors on Excavator
Bucket
Sensor
LS-B10W
LS-B10W
Laser Receiver
Laser Receiver
Body
Sensor
Boom
Boom
Sensor
Sensor
Boom
Sensor
Stick
Stick
Sensor
Sensor
Stick
Sensor

X63
P/N 7010-0697 1-3
Sitting in the cab facing forward, the sensor angles are 0° straight
ahead (horizontal), +90° straight up, and -90° directly down
(Figure 1-2).
Figure 1-2. Angle Convention Used For TS-1 Sensors
The Main and Auxiliary antennas provide positional and heading
information.
• Main antenna – determines 3D machine position.
• Aux antenna – determines heading using relative position.
Using the TS-1 sensors, the 3D position of the bucket is projected
from the Main antenna.
Figure 1-3. TS-1 Positional and Heading References
0
+90
-90
Main Ant
Position
Aux Ant
provides
heading
Project position from
Main Ant to bucket teeth

Introduction
X63/X62 Installation and Calibration Manual
1-4
Figure 1-4 shows the basic cabling connections for the X63/X62
system. When installing components, use the Topcon supplied fuse or
fused power from the machine of the same rating.
Figure 1-4. Basic Cable Connections for X63
NOTICE
System ground must be connected to the frame side
of the ground disconnect switch, not directly to the
negative battery terminal.
ATTACH TO
UPPER CONNECTOR
AUX GPS
ANTENNA
MAIN GPS
ANTENNA
TS-1 TILT SENSORS
BODY BOOM STICK BUCKET
40-PIN
CONNECTOR "A"
-
+
VOLTAGE SUPPLY
(SWITCHED OR
UNSWITCHED IS
ACCEPTABLE)
GROUND TO CHASSIS
15 AMP
IN-LINE FUSE
REQUIRED
MC-R3 CONTROLLER
GX-60 DISPLAY
SENSOR
TERMINATOR

X62
P/N 7010-0697 1-5
X62
2D Excavator Indicate System
The TS-1 tilt sensors, the GX-60 Display, and the LS-B10W Laser
Receiver make up the 2D excavator indicate system. The LS-B10W
adds a laser height reference to the X62 system and is calibrated for
its location on the stick of the excavator.
Figure 1-5. TS-1 Tilt Sensors and LS-B10W on Excavator
Figure 1-4 on page 1-4 shows the basic cabling connections for the
X62 system. When installing components, use the Topcon supplied
fuse or fused power from the machine of the same rating.
NOTICE
System ground must be connected to the frame side
of the ground disconnect switch, not directly to the
negative battery terminal.
Dogbone
Sensor
LS-B10W
Laser Receiver
Body
Sensor
Boom
Boom
Sensor
Sensor
Boom
Sensor
Stick
Stick
Sensor
Sensor
Stick
Sensor

Introduction
X63/X62 Installation and Calibration Manual
1-6
Figure 1-6. Basic Cable Connections for X62
TS-1 TILT SENSORS
BODY BOOM STICK BUCKET
LS-B10W
LASER RECEIVER
AND BRACKET
POWER
+ -
SENSOR
TERMINATOR

P/N 7010-0697
Chapter 2
2-1
TS-1 Sensor
Installation
Each TS-1 sensor contains a 3-axis 360° sensor element which must
be configured depending on the mounting position. The TS-1 tilt
sensors can be mounted in many orientations as long as they are
parallel to the axis being measured (Figure 2-1). Locate surfaces that
protect the sensor from physical damage and are convenient for cable
routing. When the position of the sensor is at zero degrees
(horizontal), make a note of the direction of the arrow marker on the
sensor name plate. This direction is needed during calibration. The
calibration process uses 3DMC to enter direction, orientation, and
other sensor variables.
TIP
When mounting the tilt sensors, begin with the
bucket to help simplify cable routing.

TS-1 Sensor Installation
X63/X62 Installation and Calibration Manual
2-2
TS-1 Sensor Orientation
Figure 2-1. TS-1 Arrow Marker Location and Direction
Table 2-1 indicates arrow marker direction options once the mounting
surface has been selected. These directions assume the mounting
surface is at zero degrees.
Table 2-1. Marker Direction Options
Mounting Surface Marker Direction Options
Back Right Up
Down Forward Right
Forward Right Up
Left Up Forward
Right Forward Up
Up Forward Right
Direction
of Travel
Left
Forward
Back
Down
Right
Up
Back
Arrow Marker

TS-1 Sensor Orientation
P/N 7010-0697 2-3
TIP
Mounting each tilt sensor within +/- 20° of the pivot
centerline is a good practice. Though not necessary
for system performance, squaring the sensors to
each part of the machine makes for a cleaner
looking installation.
NOTICE
All tilt sensor orientation is determined when the
sensor is horizontal (zero degrees). The orientation
of each tilt sensor is entered in 3DMC.

TS-1 Sensor Installation
X63/X62 Installation and Calibration Manual
2-4
Body Sensor Mounting
For the body sensor, locate a convenient surface parallel to the boom
pivot. The recommended mounting location is up, on top of the body,
with the arrow pointing forward toward the direction of travel
(Figure 2-2)
Figure 2-2. Body Sensor Mounting
Boom Pivot
Body Sensor
Mount Body Sensor
Parallel to Boom Pivot

Boom Sensor Mounting
P/N 7010-0697 2-5
Figure 2-3. Body Sensor Mounting Examples
Boom Sensor Mounting
For the boom sensor, locate a convenient surface parallel to the boom
center. The recommended mounting location is up (on the top of the
boom) with the arrow pointing forward toward the direction of travel
(Figure 2-4 on page 2-6).
If mounting on the side of the boom, because many booms will taper
out at the boom pivot, be sure to place the sensor at a location away
from the boom pivot.
NOTICE
Placing the boom sensor on a tapered section will
cause calculation errors.
Up Mounting
(Recommended)
Side

TS-1 Sensor Installation
X63/X62 Installation and Calibration Manual
2-6
Figure 2-4. Boom Sensor Mounting
Secondary Boom Sensor
Mounting (Optional)
See the previous section “Boom Sensor Mounting” on page 2-5 for
secondary boom sensor mounting locations.
CL
Correct
Up Location
(Recommended)
CL
Correct
Side Location
CL
Incorrect Taper Location
Direction of Travel

Stick Sensor Mounting
P/N 7010-0697 2-7
Stick Sensor Mounting
Locate a convenient surface to mount the sensor. Mounting the TS-1
close to the top of the stick will help prevent damage during digging.
The recommended mounting location is on the left side of the stick
with the arrow pointing forward toward the direction of travel, when
the stick is extended (Figure 2-5 on page 2-7).
If mounting the TS-1 on the front of the stick, make sure the sensor is
parallel to the stick-to-bucket centerline (Figure 2-5 on page 2-7).
Figure 2-5. Stick Sensor Mounting
Correct Front
Location
Correct Side
Location
(Recommended)
Incorrect Incorrect

TS-1 Sensor Installation
X63/X62 Installation and Calibration Manual
2-8
Bucket Sensor Mounting
The bucket sensor is the most challenging sensor to mount to keep the
sensor and cables protected.
The recommended location of the sensor is on the left side of the
bucket with the arrow pointing forward, toward the direction of
travel.
When mounting the bucket sensor, keep the following in mind
(Figure 2-6 on page 2-9):
• Position the bucket at zero degrees before mounting the sensor.
• Sensor orientation (Up/Forward, etc.) references the position of
the bucket at zero degrees.
NOTICE
Fabrication of a sensor guard and cable protection is
required to minimize damage.
Because this varies widely, such specific protection
is not included in the Topcon kit and must be
supplied by the installer.
NOTICE
When using a quick-release bucket, mount the
sensor to the quick-release, not the bucket.