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Motorgrader System Five 9164 Control Box

1. 5 1 Setting Stringline to Projected Slope 5 7 Making a Grade Verification Lath 5 10 Metitymg Grade ees 5 11 Laser Grade Checking System ss 5 12 Grading a Road Using a Stringline 5 15 Grading a City Street esient eant eiee 5 31 Grading from Curbs esee 5 36 Grading From Curbs Placed at Different Elevations 5 39 Road Widening and Shoulders 5 44 Grading On Curves sese 5 46 Grading Slope Transitions eene 5 48 ii Motorgrader System Five Operator s Manual Table of Contents Chapter 6 Maintenance isis cep iic nane aliu ck rk rat oa aru 6 1 Preventative Maintenance amp 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 esee 6 7 Lubricating the Rotation Sensor 6 9 Chapter 7 Troubleshooting eee 7 1 System Test Mode eee 7 1 Accessing the System Test esee 7 2 Slope Sensor Test eee 7 3 Troubleshooting E Ep t e eee 7 7 Mainfall Sensor Test
2. Figure 5 1 Setting Up a Sonic Stringline On a typical project hubs or laths offset from the edge of the road provide the grade information for the operator This information needs to be transferred from the ground to the operator This is commonly done by a grade setter using a hand level a 4 man crew pulling a string across the road and marking cuts placing blue tops or hubs at finished grade or some other similar method In any of these methods the operator has grade information at the stakes every 25 or 50 feet P N 7010 0344 5 1 Grading Applications Sonic Stringline provides an inexpensive easy to set up continuous reference that takes the best advantage of the non contacting feature of the Sonic Tracker II By taking a few minutes to set up a stringline the Tracker can transfer grade to the operator 39 times per second And not just at the stakes but along the entire road section The stringline also becomes a great visual reference for the job Any mistakes in a hub elevation can be quickly spotted by just sighting down the string Available From Your Topcon Dealer TOPCON Part Description 7020 0101 Sonic Stringline 1000 Roll 7020 0121 Sonic Grade Clips Box of 100 7000 1026 Cut Fill Offset Tape Feet Tenths 7000 1027 Cut Fill Offset Tape Metric 9210 1013 Stringline Laser Bracket fonen NOTICE Although Topcon s Sonic Tracker will work with many sizes and types of stringline for best r
3. esee 7 8 Rotation Sensor Test eese 7 10 Appendix A Safety Information ess A 1 General Precautions eeeeeseeeeeeeen enne A 1 Appendix B Limited Warranty eere B 1 Electronic and Mechanical Components B 1 Return and Repair eeeeeeeeeeeeen ee B 1 Warranty Disclaimer eeeeeeeeeeeee B 1 Service Information eere B 2 P N 7010 0344 iii Table of Contents Notes iv Motorgrader System Five Operator s Manual Preface 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 pus WARNING Represents a procedure or operation that if not strictly followed can caus
4. VIEW FROM BEHIND GRADER Figure 5 51 5 34 Motorgrader System Five Operator s Manual Grading a City Street For best results stay about 6 inches in from the paint marks on the rough in passes to avoid material spilling onto the curb grade Continue to grade the street across the centerline Grade the opposite sidewalk curb and street section and the project is complete SONIC SONIC STRINGLINE STRINGLINE a 2 0 SLOPE SONIC SONIC STRINGLINE STRINGLINE SONIC STRINGLINE SONIC STRINGLINE Figure 5 52 P N 7010 0344 5 35 Grading Applications Grading from Curbs When grading a street from curbs work the material across the street in the same manner as shown in the previous section The Completed Objective CURB 2 0 2 0 CURB SLOPE SLOPE Y y A7 2 17 2 BELOW EDGE BELOW EDGE OF CURB OF CURB Figure 5 53 Refer to the chapter Getting Ready to Grade and position the Tracker to cut from a curb Dial in the slope and desired depth of cut and begin grading from the curb Be sure the grade checker verifies the grade the first 25 50 feet Remember it is always best to start with the grade high then trim down on the next pass 2 0 SLOPE VIEW FROM BEHIND GRADER Figure 5 54 5 36 Motorgrader System Five Operator s Manual Grading from Curbs Carry the material across the cent
5. Sonic Tracker II If the Tracker sees an obstruction closer than the reference signal such as a grade pin the sound waves do not take as long to come back and the stop watch is stopped much sooner The Tracker is out of the Working Window and no On Grade correction signals will be applied STOPWATCH SLOW BLINKING MM CORRECTION SIGNALS STRINGLINE REFERENCE DESIRED GRADE Figure 2 34 P N 7010 0344 2 27 Operation When setting up the Tracker over a grade reference the size of the Sonic Cone or the footprint needs to be considered As an example at about 2 feet from the tracker you will have a footprint or cone of about 6 inches As the Tracker is positioned closer to the grade reference the working footprint decreases in size As the Tracker is moving farther away from the grade reference the sonic footprint or cone will increase in size SONIC FOOTPRINT 2 0 Figure 2 35 2 28 Motorgrader System Five Operator s Manual Sonic Tracker II The Tracker has a total working range of 14 inches to 55 inches 41 inches of adjustment This allows the Tracker to be set over a stringline or choker on one pass then match grade on the next pass without moving the tracker The Tracker is not more accurate when set closer to the grade reference The job application should determine the position of the Tracker For example as a rule of thumb when using a stringline reference keep the Tracker about
6. TOPCON System Five 9164 Control Box Operator s Manual TOPCON 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 TOC Table of Contents lilio MITTEN S V Chapter 1 System Overview eere 1 1 Control BOK duet ere ep e edet egal 1 3 Remote Smart Knobs eee 1 4 Sonic Tracker IL i eee ete eee pee 1 5 Laser Tracker and Trackerjack ssss 1 6 Blade Slope Sensor essent 1 7 Rotation Sensor 552223 nuni od pepe 1 8 Mainfall Sensor nocni anina Deere 1 9 Hydraulic Manifold Assembly esses 1 10 Carrying Case 2 eoe eee 1 11 Chapter 2 Operati useisrisielaran dieux en ie Eai r eredi In ER 2 1 Control Box utente mes 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
7. bounce off of any physical reference and are reflected back to the Tracker The Tracker measures the time it takes for the sound wave to return to the Tracker Knowing the speed of sound the Tracker accurately calculates the exact distance to the grade reference The Tracker can use any physical grade reference such as a stringline curb or existing surface STOPWATCH S Vos 4 Figure 2 28 P N 7010 0344 2 21 Operation Working Window Since the Sonic Tracker II is mounted to the mold board as it raises or lowers the tracker measures exactly how far above or below the desired grade reference it is Built into the Tracker is an operational zone or Working Window 2 feet above and below the grade reference The grade lights on the Sonic Tracker and Control Box continuously display this grade information to the operator 4 SLOW BLINKING UP ARROW 4 SOLID UP ARROW BLINKING UP ARROW E BLINKING UP ARROW ON G RADE 4 ONG RADE lt a _ BLINKING DOWN ARROW ON G RADE 2 __ BLINKING DOWN ARROW Y SOLID DOWN ARROW 4 SLOW BLINKING DOWN ARROW NO CORRECTION COARSE FINE MADE CORRECTION CORRECTION OUT OF AUTOMATIC AUTOMATIC WORKING WI NDOW Figure 2 29 2 22 Motorgrader System Five Operator s Manual Sonic Tracker II On the grader the Sonic Tracker II will be positioned above the grade reference Its job is to maintain th
8. it is always best to start with the grade high then trim down on the next pass GAIN 1 D ser 1 95 MENU J trim J Li pm 2 0 CONTROL MODE LEFT SONIC STRINGLINE t r VIEW FROM BEHIND GRADER SONIC STRINGLINE Figure 5 46 Once the sidewalk grade has been cut and verified mark the edge of the sidewalk with spray paint to make it visible for the operator SONIC STRINGLINE LEFT SONIC MARK LEFT EDGE STRINGLINE OF SIDEWALK WITH SPRAY t lt Figure 5 47 Motorgrader System Five Operator s Manual 9 32 Grading a City Street Next use the sidewalk grade as a reference to cut the curb grade Dial in the desired grade and slope MENU TRIM 5 x LEFT SONIC STRINGLINE b y VIEW FROM BEHIND GRADER Figure 5 48 For best results stay about 6 inches in from the paint marks on the rough in passes to avoid material spilling onto the sidewalk grade ROUGH IN PASS Figure 5 49 P N 7010 0344 5 33 Grading Applications Once the curb grade has been cut and verified mark the edge of street with spray paint to make it visible for the operator LEFT SONIC MARK EDGE STRINGLINE OF STREET WITH SPRAY my Figure 5 50 Use the curb grade as a reference to cut the street grade Dial in thedesired grade and slope LEFT SONIC e STRINGLINE
9. 22 5 18 Motorgrader System Five Operator s Manual Grading a Road Using a Stringline Be sure to check the grade several times in the first 50 feet Depending on how accurate the Tracker and the stringline offset from the edge of the road were zeroed out the grade may not be exactly 1 70 feet below the stringline However the grade will be consistently a few hundreths high or low By checking the grade and knowing how high or low the grade is being cut adjustments can be made to get the desired grade Figure 5 23 After grading the first pass along the edge of the road make a pass to move the material away Just dial the Tracker to 0 00 to match the previous pass and the cross slope system will continuing to cut the slope up toward the centerline Figure 5 24 P N 7010 0344 5 19 Grading Applications VIEW F ROM BEHIND G RADER SONIC STRINGLINE Figure 5 25 gt NOTICE For the examples in this manual the right Tracker is always used On the job the blade can be rotated and the Tracker or slope can be used on either side depending on what is best for that particular job This avoids backing up to use the Tracker only on one side CUT GRADE TO MATCH THE PREVIOUS PASS Figure 5 26 5 20 Motorgrader System Five Operator s Manual Grading a Road Using a Stringline Now go back to the stringline and make another pass dialing in an additional cut Since th
10. 76 P N 7010 0344 5 47 Grading Applications Grading Slope Transitions Jobs with varying slopes are easily accomplished by dialing the desired slope into the Control Box as you are grading With the Smart Knob switches this can be done while keeping your hands on the control levers The key to making this job easy is to mark the stations with he Cross Slope so the operator can see the slope at least one station ahead Making the slope on a plastic coated paper plate and stapling the plate to the witness lath is one simple solution Each time you press the Smart Knob button the slope changes by 0 1 This will produce a smooth transitions as you are grading Figure 5 77 5 48 Motorgrader System Five Operator s Manual Chapter 6 Maintenance This section contains information regarding preventative maintenance and daily care of System Five Also included are 1 Cleaning procedures for the Sonic Tracker II Transducer 2 Replacement procedures for the Sonic Tracker II Transducer Preventative Maintenance amp Daily Care A good preventative maintenance and daily care routine will prevent many problems before they occur The most important part of daily care for System Five is to clean it and keep it free of debris and to thoroughly dry removable components Sonic Tracker II the Control Box and cables before storing them in the Carrying Case In addition the following procedures will ensure
11. Adjustment Direction Arrows 2 6 Power SWitch i e PR BG 2 6 Function Buttons seen 2 7 Control Box Operation eee 2 7 Basic Operation esee 2 7 Control Mod m eeunenn a nee 2 8 Remote Smart Knobs esse 2 13 3DMCMO9d inem ERO 2 16 Setup Mode notte 2 16 Sonic Tracker IL 2 ote RS etn 2 20 P N 7010 0344 i Table of Contents Teaser Controls ies en doa el cete ete cete 2 30 Slope Controll 2 doce adhere t in 2 33 Chapter 3 Calibration e E 3 1 Calibrate Rotation sissies eh eee 3 2 Calibrate Mainfall seen 3 3 Calibrate Blad ss eb oe ttt ans 3 5 Blade Wear Calibration Trim esses 3 7 Adjust Valve Offsets sess 3 10 Automatic Adjusment sesseeeeeeeee 3 10 Manual Adjusment eese 3 11 External Switches nete eee a 3 12 Chapter 4 Getting Ready to Grade 4 1 Control Box Setup nacio usmoe io Ho s 4 1 Checking Cross Slope Trim Calibration 4 2 Sonic Tracker Setup iiion eene 4 3 Setting the Reference Number eese 4 9 Laser Receiver Setup cete eos 4 12 Using Set Points eee erit tes 4 18 Chapter 5 Grading Applications 5 1 Sonic StringIm e isc eee ee a el ee erat pene 5 1 Setting Up a Sonic Stringline
12. 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 this warranty Warranty Disclaimer The above warranties are in lieu of all other warranties whether expressed or implied including all warranties or merchantability or fitness for a particular purpose In no event will Topcon Laser Systems Inc or its Representative be liable for lost profits or other consequential damages arising from the purchase or use of TOPCON s components or any performance hereunder or any claims P N 7010 0344 B 1 Limited Warranty of negligence even if TOPCON has been 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 B 2 Motorgrader System Five Operator s Manual TOPCON Topcon Positioning Systems Inc 7400 National Drive Livermore CA 94551 U S A Phone 925 245 8300 Fax 925 245 8583 www topcon com 2007 Topcon Positioning Systems Inc All rights reserved No unauthorized duplication P N 7010 0344 Rev E Printed in U
13. Left and Right Automatic Operation Indicators 4 Left and Right Grade Adjustment Knob 5 Power Switch 6 Function Buttons Figure 2 1 2 2 Motorgrader System Five Operator s Manual Control Box The LCD Liquid Crystal Display The LCD allows the operator to view text and graphic symbols that represent elevation or slope settings that System Five is currently maintaining for the left and right sides of the motorgrader System Five in Control Mode during operation LEFT RIGHT Figure 2 2 A Slope Control B Sonic Control Figure 2 3 2 0 cross slope has been selected for the left side The blade symbol shows that the 2 0 slope is going down The Sonic Tracker symbol indicates that Sonic Control has been selected for the right side Figure 2 4 P N 7010 0344 2 3 Operation Left and Right Grade Adjustment LEDs opeJ6 mojaq z puokeg apes6 wojeq z puo eq abu jo NO mone dn pai Bupjuilq MoS Z 8 ueeeq epeJb wojeg Z 8 S0 ueemjeq epes6 wojeg mouse dn pai prios ML 9 95z uoo eq epeJ6 mojag S0 8 Zo ueeweg epeJ6 mojeg mone dn pas Buug epeJD jo Z ULM epe4 jo 20 UIA Jeq ueaJD woure dn pas Buryuyg opeJjb uo apei6 uo Jeq ueaJ6 Buryuig epeJD jo Z ULM epeJD jo Z0 UUM Jeq ueaJD woure umop Mojja Buryuig 9519 952 ueemjeq epeJb e oqv G0 9 Z0 Usemjeq epeib e oqy MOE UMOP MO 9A Bulyulg WZ 8 usem
14. it works for both applications without having to move the Tracker Figure 4 4 4 4 Motorgrader System Five Operator s Manual Sonic Tracker Setup The closest the Tracker can be set to the grade reference is 14 inches 14 0 MINIMUM DISTANCE Figure 4 5 The farthest the Tracker can be set from the grade reference is 55 inches 8 55 0 MAXIMUM DISTANCE Figure 4 6 P N 7010 0344 4 5 Getting Ready to Grade When tracking a stringline keep the Tracker about 24 inches above the string At 24 inches the Sonic Footprint is about 6 inches in diameter so keeping the Tracker over the string is easy Just keep the moldboard at the edge of the road where it should be and the Tracker should be over the stringline a A 18 0 to 30 0 RECOMMENDED DISTANCE w STRINGLINE REFERENCE m EDGE OF ROAD TO STRINGLINE Figure 4 7 4 6 Motorgrader System Five Operator s Manual Sonic Tracker Setup When tracking an existing road position the Tracker 14 30 inches This will leave enough distance to adjust the Working Window to On Grade when the blade is moved over to match the first pass 14 0 to 30 0 RECOMMENDED DISTANCE EXISTING ROAD Figure 4 8 When tracking next to a barrier wall lower the Tracker to reduce the size of the Sonic Footprint Position the Tracker so it just picks up the edge of the road and does not hit the side of the bar
15. laser detector and the cut fill lath or folding rule At the edge of the road finished grade is the same as the stringline hike up Any cuts or fills are immediately measured on the lath or folding rule Figure 5 15 Grade can be inspected at the 1 4 crown centerline or any desired distance Just measure the distance from the edge of the road and calculate the desired finished grade using the formula RISE RISE Figure 5 16 P N 7010 0344 5 13 Grading Applications The Laser Grade Checking System can be used to check grade on the opposite side of the road and to even verify that the hub or stringline on the opposite side is correct Figure 5 17 To check grade at additional stations just pick up the laser and move it Because of the consistent grade cut by System Five you will find you do not need to inspect grade at every station but you should spot check grade at several stations Figure 5 18 5 14 Motorgrader System Five Operator s Manual Grading a Road Using a Stringline Grading a Road Using a Stringline In this example a Sonic Stringline has been set 2 0 above the desired finished sub grade Desired cross slope is 2 0 SONIC STRINGLINE 2 0 2 0 SLOPE 7 SLOPE Y a i SS 2 0 BELOW SONIC STRINGLINE Figure 5 19 Conen NOTICE Before grading always make sure the Cross Slope System is ca
16. may need to be more frequent if operating in excessively dusty or gritty materials Cleaning the Rotation Sensor The following procedures detail the disassembly of the rotation Sensor for cleaning 1 Place the moldboard perpendicular to the frame of the grader and lower the cutting edge to the ground 2 Remove the four screws securing the two halves of the retaining ring and remove the retaining rings REMOVE FOUR 4 SCREWS AND TWO HALVES OF RETAINER Figure 6 7 P N 7010 0344 6 7 Maintenance 3 Now remove the shoulder screw washer and jam nut from the Rotation Sensor arm REMOVE SHOULDER SCREW WASHER AND JAM NUT FROM L BRACKET Figure 6 8 4 Carefully lift the Rotation Sensor from its base plate GENTLY LIFT ROTATION SENSOR FROM BASE PLATE AND WIPE SURFACES CLEAN Figure 6 9 Conen NOTICE DO NOT force or pry the Rotation Sensor from the base plate The Rotation Sensor pin may bend or break 5 Use a clean rag and thoroughly clean the base plate and bottom of the Rotation Sensor 6 8 Motorgrader System Five Operator s Manual Rotation Sensor Cleaning and Lubrication Lubricating the Rotation Sensor 1 Pack the base plate reservoir and pin cavity with fresh grease PACK SENSOR CHANNEL AND PIN SLOT WITH FRESH GREASE Figure 6 10 2 Place the Rotation Sensor back on the base plate Make sure the rotation pin seats firml in the pin cavity it will only
17. the centerline paint marks Figure 5 36 Once centerline has been cut carry the slope toward the edge at the road RIGHT SONIC STRINGLINE 2 0 1 SLOPE VIEW FROM BEHIND GRADER Figure 5 37 P N 7010 0344 5 27 Grading Applications If a Sonic Stringline has been set on the opposite side cut the road just as you did on the first side RIGHT SONIC STRINGLINE l 2 0 2 0 1 U o SLOPE l SLOPE LEFT SONIC VIEW FROM BEHIND GRADER STRINGLINE Figure 5 38 If there is no stringline on the opposite side the grade previously cut by System Five can be used as a reference for the Tracker In this case rotate the blade so that the cross slope is controlling the leading edge of the blade at the edge of the road and the tracker is controlling grade on the trailing edge TOP VIEW OF GRADER SLOPE CONTROL EDGE OF ROAD SONIC CONTROL Figure 5 39 5 28 Motorgrader System Five Operator s Manual Grading a Road Using a Stringline To accomplish this the Tracker will need to be repositioned so the sound waves will not pick up the window at the end of the blade Set the blade on a smooth previously graded pass so that the cutting edge is just touching the ground i _ EMI Ql Figure 5 40 Slide the L bar out and rotate it forward to a position where the Tracker will not pick up
18. the correct cross slope 2 0 Slope Curbline Figure 2 43 P N 7010 0344 2 35 Operation Notes 2 36 Motorgrader System Five Operator s Manual Chapter 3 Calibration CALIBRATION ADJUST LED BRIGHTNESS SET POINTS SYSTEM TEST MEASUREMENT UNIT BEEPER CHECK HOURMETERS Figure 3 1 Why do you need to calibrate Although System Five does not usually require maintenance or adjustment the grader it is attached to does All the moving parts on your grader wear at different rates In order for System Five to work correctly it has to be told what changes have occurred on your grader All the Calibration Settings are stored in the Control Box memory The Control Box will not loose the Calibration Settings when turned off or stored for long periods There are 6 calibration selections Rotation Sensor Mainfall Sensor Blade Slope Sensor Blade Wear trim Adjust Valve Offsets External Switch CALIBRATE ROTATION ADJUST VALVE OFFSETS CALIBRATE MAINFALL EXTERNAL SWITCHES CALIBRATE BLADE BLADE WEAR CAL TRIM Figure 3 2 P N 7010 0344 3 1 Calibration Calibrate Rotation The Cross Slope System cuts the desired slope perpendicular to the draw bar or A frame assembly The Rotation Sensor which measures the blade angle of rotation must be calibrated so it knows when the blade is perpendicular or at 0 degrees
19. the left hand side of the blade raises slowly 3 Repeat on the right hand side for both the Raise and Lower Offsets Press the ENTER button and the values will be saved e NOTICE Pressing EXIT does not save values Ex J raise J Lower cios J LRAISE J Lower ENTER 303 265 HT ow ODEON Figure 3 13 P N 7010 0344 3 11 Calibration External Switches The External Switch Menu allows the operator to use their Remote Switch OR SmartKnobs SMARTKNOB 12C SIMPLE SWITCH AUTO SELECT Figure 3 14 SmartKnob Selects program to operate the SmartKnob Simple Switch Selects program to operate the Simple Switch System Four Type Switches Auto Select Automatically determines which device SmartKnob or Simple Switch is connect to System Five System The appropriate program is then selected to operate the device 3 12 Motorgrader System Five Operator s Manual Chapter 4 Getting Ready to Grade Control Box Setup To prevent theft or vandalism the Control Box has been designed for quick removal at the end of the day To install the Control Box just bolt it on with the hand knob and connect the two quick disconnect electrical connectors Figure 4 1 When you power up System Five it will automatically come on to Control Mode with the settings just as you had them the last time the box was used The Slope Calibration and Elevation Reference Setting are stored in
20. the windrow Be sure to swivel the Tracker bracket so the Tracker is plumb The Tracker may end up only 18 inches or so off the ground which is OK for this application Figure 5 41 P N 7010 0344 5 29 Grading Applications Set the Tracker to on grade and grade the pass along the edge of the road Sonic Tracker II RIGHT SONIC STRINGLINE 2 0 l SLOPE 1 VIEW FROM BEHIND GRADER Figure 5 43 5 30 Motorgrader System Five Operator s Manual Grading a City Street After the windrow is picked up Sonic Control on both sides may be used to make a final clean up pass after the scraper or loader Figure 5 44 Grading a City Street This section reviews how to cut sidewalk curb and street grade as well as cutting a crowned street from existing curb Street design varies greatly so use this as an example and make adjustments for your job LEFT RIGHT SIDEWALK SIDEWALK LEFT RIGHT LEFT RIGHT CURB sTREETGRADE STREETGRADE CURB 2 0 ER 20x 205 uei 42 0 store 28 qux x4 o ioe mol gt 58 4 i Sa a lo 43 5 gt 1 5 ma gt 15 ma 35 Figure 5 45 For best results set Sonic Stringline to use as a reference for the sidewalk grade Using Sonic Tracker and Slope Control dial in the desired grade and slope Be sure the grade checker verifies the grade P N 7010 0344 5 31 Grading Applications being cut in the first 25 50 feet Remember
21. trouble free operation 1 Keep the Carrying Case clean and dry Do not leave it open and exposed to the elements Clean and dry all components prior to placing them into the Carrying Case 2 Be sure protective connector caps provided on the Mainfall Sensor are in place when the cables are not in use Water accumulating on the connectors can cause electrical shorts 3 Donotuse high pressure spray water steam cleaner hoses directly on cables and components The components can be used in the rain or light spraying 4 Checkthe Sonic Tracker II Transducer daily to make sure the Filter Foam and Transducer are clean and free of debris If the Filter Foam is clogged with dirt replace it If the Transducer appears to be covered with debris and performance is being affected see Sonic Tracker II in Chapter 2 Operation clean or P N 7010 0344 6 1 Maintenance replace Sonic Tracker II Transducer using the steps listed later in this chapter Transducer Cleaning Sonic Tracker II a gt NOTICE 5 This procedure is not meant to be a regular maintenance procedure Cleaning of the Transducer should only be performed when Transducer contamination is suspected or evident Over cleaning of the transducer will result in shortened Transducer life and or water damage to the Sonic Tracker Hold the Sonic Tracker II in an UPRIGHT position this will prevent moisture from inadvert ently entering the Sonic Tracker Mix a mild detergent
22. with water and place the mixture in a spray bottle use Simple Green where available With the Sonic Tracker II upright thoroughly spray the Transducer with the detergent solution Once the Transducer has been sprayed with the detergent fill the spray bottle with clean water and rinse any residual detergent off of the Transducer Allow to thoroughly dry If the ability of the Sonic Tracker II to see a sonic stringline continues to be impared the transducer may be damaged and needs replaced 6 2 Motorgrader System Five Operator s Manual Transducer Replacement Procedure Sonic Tracker II Transducer Replacement Procedure Sonic Tracker II gt NOTICE If the Sonic Tracker II is experiencing erratic or inconsistent readings Transducer contamination should be considered first before assuming any other type of failure The most common sign of Transducer contamination is the ability of the Sonic Tracker II to see the ground but not a Sonic Stringline Sonic Tracker Ill Transducer Replacement 1 Remove and discard the Filter Foam a new Filter Foam is provided in the Transducer Replacement Kit Figure 6 1 2 Remove the four screws and the black Retaining Ring There are four replacement screws supplied in the Transducer Replacement Kit but it is advisable to use the original screws and keep the four supplied in the kit for replacements in the event one or more are lost Remove and discard the O Ring a
23. 2 feet above the string This will give the operator about 6 inches of lateral movement to keep the Tracker over the string When tracking a curb you may want to lower the Tracker to keep it over the lip of the curb and avoid the Tracker from seeing the top or face of the curb No Figure 2 36 P N 7010 0344 2 29 Operation Laser Control For Laser Control a laser transmitter is used to produce a plane of light which becomes the grade control reference for the job site The laser receiver will control the blade to cut grade parallel to the laser beam reference When the laser beam is in the center of the receiver it indicates an On Grade signal Figure 2 37 2 30 Motorgrader System Five Operator s Manual Laser Control As the blade is raised the beam of light hits the Laser Receiver below the center and a lower signal is indicated Figure 2 38 P N 7010 0344 2 31 Operation As the blade is lowered the beam of light hits the Laser Receiver above the center a raise signal is indicated Figure 2 39 2 32 Motorgrader System Five Operator s Manual Slope Control Slope Control System Five uses 3 sensors to measure and cut the desired slope perpendicular to the edge of the road Blade Slope Sensor A blade slope sensor is mounted to the back of the circle It contains an electronic level vial which acts as a precision carpenters level As the blade is raised or lo
24. 36 feet rise at centerline 36 RISE el ee 2O 20 It 36 00 Figure 5 59 If the curbs are at different elevations a 36 feet rise at centerline will produce incorrect slopes 1 7 Figure 5 60 P N 7010 0344 5 39 Grading Applications When System Five is used to cut a true 2 0 slope the crown of the street will not be at the centerline NEW CENTERLINE AT 2 0 GRADE CUT 2 0 2 0 ORIGINAL CENTERLINE Figure 5 61 The curb elevations can be easily spot checked using a fast leveling RL HB rotating laser Set the laser at the lip of one curb then use the detector and a folding rule to take a reading on the he other curb Spot check every 25 50 feet by just moving the laser Figure 5 62 5 40 Motorgrader System Five Operator s Manual Grading From Curbs Placed at Different Elevations To cut grade from uneven curbs there are two suggested methods Method 1 Using Sonic Tracker and Cross Slope cut grade from one curb highest curb if known and carry grade past centerline Figure 5 63 Use Sonic Tracker and Cross Slope to match the centerline grade Figure 5 64 P N 7010 0344 5 41 Grading Applications Use Sonic Tracker and Cross Slope to cut grade from the opposite curb m Figure 5 65
25. 5 24 Motorgrader System Five Operator s Manual Grading a Road Using a Stringline Position the grade to make the pass by setting the edge of the moldboard so it is about 1 1 2 2 feet past the centerline To keep the material from spilling out from the leading edge rotate the moldboard to a fairly steep angle Figure 5 33 Change the direction of the cross slope and switch the cross slope to Automatic Control Then manually lower the leading edge until the cutting edge just touches the finished grade at the centerline VIEW FROM BEHIND GRADER T is 2 0 MANUALLY LOWER UNTIL AUTOMATIC CUTTING EDGE TOUCHES CROSS SLOPE FINISHED GRADE Figure 5 34 P N 7010 0344 5 25 Grading Applications Press the red buttons on the Smart Knobs to get the Sonic Tracker to On Grade Since the Tracker is tracking the ground sloping down the opposite side the reference number will not be 0 00 Switch to Automatic Control and continue grading Verify the grade and make small adjustments as necessary Figure 5 35 5 26 Motorgrader System Five Operator s Manual Grading a Road Using a Stringline While grading it is important to drive straight to keep the Tracker positioned over the same path on the opposite slope Steering left or right will cause the Tracker to ride up or ride down the slope causing an elevation error at the centerline Keep the front tire at the same position referencing
26. 7 5 Troubleshooting If you cannot calculate slope 1 Place cutting edge lightly on the ground and read the slope value on the screen MAINFALL 2 796 ROTATION 5 SLOPE 1 0 SYSTEM TEST Figure 7 6 2 Turn machine around and lightly place cutting edge in the exact same place The slope value should be in the opposite direction and within 2 of the previous number MAINFALL 2 796 ROTATION 5 SLOPE 1 1 SYSTEM TEST Figure 7 7 7 6 Motorgrader System Five Operator s Manual Troubleshooting Conen NOTICE It is important to set the blade on the ground with the same amount of pressure in both directions Troubleshooting When ERROR is displayed the Blade Slope Sensor information is not communicating with the Control Box This does not necessarily mean that the sensor is defective A damaged cable may be disrupting the information The following procedure will help you locate the problem If the Mainfall Sensor also reads ERROR go to the Mainfall Troubleshooting first KNOB MAINFALL 2 7 KNOB VALVE PASS ROTATION 5 VALVE PASS LASER ERROR SLOPE ERROR LASER 0 SONIC 2 58 SONIC ERROR SYSTEM TEST Figure 7 8 Turn the Control Box off 2 At the Mainfall Sensor disconnect the cable from the Control Box 3 Connect the Control Box cable directly into the Blade Slope Sensor You will need to unbolt the Blade Senso
27. Auto Mode Do not leave switch in Automatic when not in use 2 Swap Left Knob Only Swap performs two functions at once it reverses the sensor functions being used from one side of the machine to the other Slope Sensor the direction of fall is reversed 9 14 Motorgrader System Five Operator s Manual Control Box Sonic Tracker switches the side of the machine controlling elevation This is commonly used when turning the machine around at the end of a pass Hold switch in for 1 second and swap occurs A single beep tone is heard when swap occurs menu J ser J Le U Le 7 Ltr Coan J LEFT SIDE SMART KNOB HOLD FOR 1 SECOND menu Tn J 5 CH J Le 4 ser Lean Figure 2 20 NOTICE Although swap will switch elevation amp slope from left to right side it does not change the elevation grade setting used previously on that side If the current elevation setting on the left side is 0 0 FT pressing Swap will NOT change the right elevation setting to 0 0 FT P N 7010 0344 2 15 Operation Set Points Right Knob Only Set Points will allow the operator to preset up to 3 different elevation and slope settings This is most commonly used when the job application requires multiple settings from one pass to another Each time the Set Point Switch is toggled the Control Box will switch to the
28. Manual Calibrate Blade Calibrate Blade The Blade Slope Sensor bolted to the back of the machine s circle assembly measures the slope of the cutting edge Cutting edge wear is the reason for Blade Sensor Calibration To perform the Blade Slope Sensor Calibration 1 Place the cutting edge of the blade firmly on the ground and mark the location This is position 1 Push the NEXT button 2 Wait 5 seconds until you hear a single beep Place cutting edge firmly on ground and mark location POSITION 1 VIEW F ROM F RONT OF G RADER Figure 3 7 P N 7010 0344 3 5 Calibration 3 Turn the machine around 180 degrees and line up the blade on the previous mark The blade can be rotated or side shifted to make cutting edge match This is position 2 Push the ENTER button 4 Wait 5 seconds until you hear a double beep and the calibration is complete Turn around and place cutting edge on same location lo ras Oe Annamaa LIL UJ 1 LT VIEW F ROM BEHIND G RADER Figure 3 8 a3 NOTICE This is a rough Blade Sensor Calibration and only needs to be performed when the system is installed or if the Slope Sensor has been removed After this calibration has been completed always perform the Blade Wear Trim Calibraton as your are cutting grade to make a fine calibration adjustment 3 6 Motorgrader System Five Operator s Manual Blade Wear Calibra
29. O NOT attach System FiveD brackets or hose connections while the grader is running 4 DO NOT allow any System Five component to limit the visibility of the operator 5 Use Ty wraps supplied with System Five to keep hoses and wires secured and away from possible wear or pinch points 6 Useeye protection when welding cutting or grinding is being done on the machine 7 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 turned off P N 7010 0344 A 1 Safety Information pus WARNING Relieve all pressure in the hydraulic lines before disconnecting or removing any lines fittings or related components If injury does occur seek medical assistance immediately Avoid direct exposure to your eyes when using laser control A CAUTION DO NOT stare into the laser beam or view the beam directly with optical equipment 9 Use appropriate welding precautions and practices when welding After welding all affected areas should be painted with a rust inhibitor x NOTICE Disconnect all Topcon system electrical cables prior to welding on the machine pus WARNING DO NOT weld near hydraulic lines or on any equipment when in operation D NOTICE All mounting bracket welds must be secure and strong to prevent the sensor equipment from vibrating excessively or from becoming detached at the weld during oper
30. S A 03 07 500
31. System Five Operator s Manual Road Widening and Shoulders Using Sonic Tracker and cross slope dial in the desired depth and slope 2 0 SLOPE Figure 5 72 If the barrier wall is placed so close to the edge at the road that the existing surface can not be tracked set up a Sonic Stringline EXISTING SURFACE SONIC STRING Figure 5 73 P N 7010 0344 5 45 Grading Applications In some cases the existing surface may not be usable as the grade reference Set up a Sonic Stringline as shown above or use short pins welded to a plate to set the stringline SONIC STRING EXISTING SURFACE Figure 5 74 Grading On Curves The Cross Slope System always cuts the desired slope perpendicular to the graders draw bar assembly of the A frame When grading corners or curves articulate the grader to keep the draw bar assembly perpendicular to the direction of slope og Figure 5 75 5 46 Motorgrader System Five Operator s Manual Grading On Curves When articulating the grader for special applications side shift the circle assembly so the draw bar assembly is perpendicular to the direction of slope Because the Mainfall Sensor is not measuring in the direction of travel there may be a small error in the slope cut After roughing in straighten the grader to make a correct finish pass or just adjust the slope dialed in until the correct slope is being cut Figure 5
32. To perform Calibration Settings refer to the Calibration Chapter in this manual Set Points Allows operator to decide how many sets of preset values will be stored in the box 1 2 or 3 See Set Points Section of Manual Enter number of 2 set points desired Figure 2 22 Measurement Unit 1 Using the right hand knob either select FEET or METERS 2 Press the ENTER button MEASURE UNIT Figure 2 23 P N 7010 0344 2 17 Operation Check Hourmeters This screen informs how many hours the box has been on and how many hours that it has been operating in the Automatic Mode There are also user resettable hour meters These can be reset to 0 0 by pressing the RESET button When finished press the EXIT button 23 9 HOURS ON 0 0 14 6 HOURS AUTO 0 0 CHECK HOUR METERS Figure 2 24 Adjust LED Brightness 1 Press button above BACKLIGHT BRIGHT to brighten up the backlight of the display 2 Press button above BACKLIGHT DIM to dim the backlight of the display 3 Turn the right hand knob to increase decrease the brightness of LED s on the faceplate of the box 4 Press the ENTER button to save the settings BACKLIGHT BACKLIGHT BRIGHT DIM THESE CONTROL THIS KNOB ADJUST THE BACKLIGHT THE LED BRIGHTNESS ADJUST LED BRIGHTNE Figure 2 25 2 18 Motorgrader System Five Operator s Manual Control Box System Test This is a diagnostic test for all of the components tha
33. Use Sonic Tracker and Sonic Tracker to match grade and finish the street Figure 5 66 Method 2 For this method blue tops will need to be set at the centerline of the street Using Sonic Tracker and Cross Slope cut grade from one curb i a a q Figure 5 67 5 42 Motorgrader System Five Operator s Manual Grading From Curbs Placed at Different Elevations Manually cut centerline grade from the blue tops and use cross slope on the trailing edge leaving the windrow on this side of the street MANUAL OPERATION m E Eo _ Figure 5 68 Use Sonic Tracker and Cross Slope to match the centerline grade Figure 5 69 Use Sonic Tracker and Cross Slope to cut grade from the opposite curb Figure 5 70 P N 7010 0344 5 43 Grading Applications Use Sonic Tracker and Sonic Tracker to match grade and finish the street Figure 5 71 Road Widening and Shoulders The Sonic Tracker and Cross Slope System can be used to cut grade from an existing road surface for lane extensions or shoulders If a barrier wall is being used make sure the base of the barrier is at least 2 3 inches from the edge The Sonic Tracker needs to be positioned so it is just picking up the edge of the road but be sure it will not pick up the base of the barrier well See Tracker set up in Chapter Getting Ready to Grade 5 44 Motorgrader
34. ase become wet If the case does become wet remove the components and dry it out P N 7010 0344 1 11 System Overview Notes 1 12 Motorgrader System Five Operator s Manual Chapter 2 Operation This chapter reviews System Five s components and explains the function of each oor NOTICE When operating in rainy weather or in wet conditions the Control Box Sonic Tracker II s and cables must be thoroughly dried BEFORE placing them in the Carrying Case at the end of the day Any moisture left on the Control Box Sonic Tracker II s and or cables when being put into the Carrying Case can cause condensation on the inside of the components which may severely affect accurate operation during the next grading session Control Box The Control Box is the main operator control interface for System Five It has several purposes One is to inform the operator of the system s performance It also receives information from the sensors processes the information and sends out correction signals to the grader s hydraulic system when required P N 7010 0344 2 1 Operation Control Box Front Panel Switches and Controls The operator can control and monitor grading using the switches and displays located on the front panel of the Control Box The function of each is as follows o JAAA 1 LCD Display 2 Left and Right Grade Adjustment LED s 3
35. ation A 2 Motorgrader System Five Operator s Manual General Precautions a gt NOTICE Keep the Carrying Case dry at all times DO NOT allow moisture to get inside the case Moisture trapped in the case can adversely affect components If moisture does enter the Carrying Case leave it open and alllow it to thoroughly dry before storing any components 10 To prevent vandalism or theft do not leave removable Topcon components Control Boxes Sonic Tracket IIs and cables on the machine at night Remove the components each evening and store appropriately in the Carrying Case P N 7010 0344 A 3 Safety Information Notes A 4 Motorgrader System Five Operator s Manual Appendix B Limited Warranty Electronic and Mechanical Components TOPCON warrants that the electronic components manufactured by TOPCON shall be free of defects in materials and workmanship for a period of one year from the original date of shipment to the dealer TOPCON warrants that all valves hoses cables and mechanical parts manufactured by TOPCON shall be free of defects in materials and workmanship for a period of 90 days from the date of installation Return and Repair During the respective warranty periods 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
36. crease from 0 degrees to 45 degrees in a smooth transition f the numbers jump erratically as the circle is being rotated then the Rotation Sensor is not working properly If the numbers do not change as the circle is being rotated remove the Rotation Sensor and check to make sure the pin has not fallen out V ROTATE BLADE 45 EXIT J ENTER KNOB MAINFALL KNOB VALVE ROTATION 45 VALVE LASER SLOPE LASER SYSTEM TEST Figure 7 15 7 12 Motorgrader System Five Operator s Manual Rotation Sensor Test 5 Rotate the circle back clockwise continuously and smoothly to a 45 degree angle The values next to rotation should decrease from 45 degrees to a 45 degrees angle in a smooth transition If they do not refer to the procedures in step 4 45 EXIT ENTER KNOB MAINFALL KNOB VALVE ROTATION 45 VALVE LASER SLOPE LASER SYSTEM TEST Figure 7 16 6 The Rotation Sensor Test can also be used to indicate whether servicing of the circle hose tray or guide rods is required Rotate the circle counterclockwise until chisel mark on the circle lines up with the A frame CHISEL MARK then Re align the chisel mark with the A Frame Figure 7 17 P N 7010 0344 7 13 Troubleshooting a gt NOTICE If you go past the chisel mark repeat the procedure beginning with the blade rotated 1 foot clockwise beyond the chisel mark If the value is wi
37. e exact distance from the tracker to the grade reference keeping the Tracker On Grade If the Tracker is On Grade the cutting edge will be at the desired grade STOPWATCH On Grade REFERENCE DESIRED GRADE Figure 2 30 P N 7010 0344 2 23 Operation If the moldboard and the Tracker II start to raise the stop watch will be stopped at a longer time The Tracker and Control Box will indicate a down correction arrow and lower hydraulic valve corrections will be applied to bring the Tracker back to On Grade STOPWATCH On Grade GRADE REFERENCE DESIRED GRADE T Figure 2 31 2 24 Motorgrader System Five Operator s Manual Sonic Tracker II If the moldboard and Tracker are lowered the stop watch will be stopped at a shorter time The Tracker and Control Box will indicate a raise correction arrow and raise hydraulic valve corrections will be applied to bring the Tracker back to On Grade STOPWATCH On Grade ey GRADE REFERENCE DESIRED Figure 2 32 P N 7010 0344 2 25 Operation If the Tracker is side shifted off a stringline the Tracker s stopwatch indicates a long time for the sound waves to come back The Tracker is out of the Working Window and no On Grade correction signals will be applied STOPWATCH On Grade SLOW BLINKING CORRECTION SIGNALS STRINGLINE REFERENCE DESIRED GRADE Figure 2 33 2 26 Motorgrader System Five Operator s Manual
38. e last pass was cut at 1 70 feet dialing to 1 80 would produce a 10 foot cut With the cross slope system maintaining a 2 0 slope the ENTIRE moldboard will be cutting 10 foot Machine and material conditions will determine how much cut is made in each pass SLOPE I i STRINGLINE Figure 5 27 P N 7010 0344 5 21 Grading Applications Continue to make additional passes until you reach desired grade 2 0 fll 0 00 VIEW FROM BEHIND GRADER SONIC STRINGLINE 2 0 SLOPE gt 209 2 00 VIEW FROM BEHIND GRADER SLOPE i STRINGLINE Figure 5 28 5 22 Motorgrader System Five Operator s Manual Grading a Road Using a Stringline I I I Figure 5 29 Once to grade carry the material on this side of the road at least 1 1 2 2 feet past the centerline Figure 5 30 P N 7010 0344 5 23 Grading Applications Once grade has been cut and verified at the centerline mark the centerline with spray paint to make it visible for the operator WINDROW PUSHED NERLINE 1 1 2 OR MORE AT 25 INTERVALS PAST CENTERLINE MARK CENTERLINE WITH SPRAY CAN 2 096 2 096 SLOPR oag SLOPE c a Figure 5 31 Finished grade can be carried over the centerline by tracking the pass on the opposite side 2 096 SLOPE jun dem VIEW F ROM BEHIND G RADER Figure 5 32
39. e sensor test before conducting Rotation Sensor Test EXIT ENTER KNOB MAINFALL 1 0 KNOB VALVE PASS ROTATION ERROR VALVE PASS LASER ERROR SLOPE ERROR LASER 0 SONIC 2 58 SONIC ERROR SYSTEM TEST Figure 7 12 7 10 Motorgrader System Five Operator s Manual Rotation Sensor Test To check if the sensor is working properly 1 Manually rotate the circle counterclockwise approximately 1 foot 2 Slowly rotate the circle back until the chisel mark is in line with the A frame and stop TOP VIEW OF A FRAME A FRAME A FRAME CIRCLE CIRCLE CHISEL Manually rotate the circle Re align the chisel mark counter clockwise 1 with the A Frame Figure 7 13 gt NOTICE If you go past the chisel mark repeat the procedure beginning with the circle rotated 1 foot beyond the chisel mark P N 7010 0344 7 11 Troubleshooting 3 The value next to rotation should display 0 degrees If it does not read 0 degrees recalibrate the Rotation Sensor in its current position and re enter the System Test Mode EXIT J ENTER J KNOB MAINFALL KNOB VALVE ROTATION o VALVE LASER SLOPE LASER SYSTEM TEST Figure 7 14 4 Proceed by rotating the circle counterclockwise continuously and smoothly to about a 45 degree angle the right side of the blade should be approximately 1 foot from the front tire The value next to Rotation should display the in
40. e serious damage to the equipment and or serious injury or death to the person performing the operation cim CAUTION Represents a procedure or operation that if not followed correctly can result in serious damage to the equipment or personal injury a gt NOTICE Represents a procedure that if not performed correctly can adversely effect the performance of the equipment P N 7010 0344 V Preface 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 925 245 8300 Fax 925 245 8583 vi Motorgrader System Five Operator s Manual Chapter 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 N
41. e the knob clock wise to reach grade Figure 2 8 Power Switch Push the switch to turn the box on or off 2 6 Motorgrader System Five Operator s Manual Control Box Function Buttons When pushed these buttons activate the function shown on the screen directly below Control Box Operation menu J raw J 7 2 LA J Le 4 ser J eaN oo 0 0 Ea Figure 2 9 Basic Operation Turn the Control Box on by pressing the On Off switch It will always power up in the Control Mode The adjustments and settings will appear just as they were left the last time the box was shut off In order to work in the 3DMC or Setup Mode press the function button directly above the Menu display MAIN MENU Figure 2 10 P N 7010 0344 2 7 Operation Control Mode LEFT RIGHT I Figure 2 11 Menu Eu Pressing the Menu button will allow the operator to go to the Main Menu This enables the operator to choose between Control 3DMC and Setup Modes Elevation Slope Setting PENES Pressing the Elevation Slope button will change the left or right sides of the LCD from Elevation Mode to Slope Mode and vice versa Figure 2 12 2 8 Motorgrader System Five Operator s Manual Control Box menu J ser J 24 C J Le 4 trim J GAN 9 o CONTROL MODE mw J Lait Lt J le TRIM GAIN o 2 0 ILA Figure 2 13 Slope Directi
42. erline and then cut the opposite side of the street MENU J trim Lai Es m 2 0 2 096 SLOPE n OR Yoo 17 2 BELOW EDGE OF CURB Figure 5 55 MENU TRIM JL i J l 4 SET GAIN 2 0 p 0 12 LEFT RIGHT CURB 2 0 8 2 0 CURB SLOPE SLOPE i i Y y aT 2 BELOW EDGE OF CURB Figure 5 56 P N 7010 0344 5 37 Grading Applications RIGHT 2 0 o6 CURB SLOPE SLOPE lt gt Y n 17 27 BELOW EDGE OF CURB Figure 5 57 After the windrow has been picked up make a final clean up pass using a Sonic Tracker on each side to complete the project Figure 5 58 5 38 Motorgrader System Five Operator s Manual Grading From Curbs Placed at Different Elevations Grading From Curbs Placed at Different Elevations In some cases the curbs may be poured at different elevations across the street Even though the curb was poured out of tolerance it may have passed inspection and the grading needs to be cut from the incorrect curbs If the curbs are at different elevations it is impossible to grade a typical design slope on both sides of the street Depending upon the severity of the error in the curbs standard grading practices if System Five may have to be adjusted to meet the job requirement A cross section design of a 36 feet wide street a 2 0 slope will produce a
43. esults we recommend 1 8 inch diameter nylon stringline If the Tracker will track the ground but will not track a 1 8 inch diameter stringline clean or replace the transducer 5 2 Motorgrader System Five Operator s Manual Sonic Stringline 1 Place the Sonic Grade Clips on stakes and drive the stakes approximately 6 to 8 inches away from but in line with the hubs Do Not disturb the hubs Figure 5 2 P N 7010 0344 5 3 Grading Applications 2 Using an anchor pin at each end roll out the Sonic Stringline the length of the working area and pull the stringline tight 3 After the stringline has been pulled tight place it into the fingers of each Sonic Grade Clip Figure 5 3 4 Decide what the Sonic Stringline hike up the distance from Finished Grade to the Sonic Stringline should be in this case 2 feet Make a cut fill lath using a lath and a Topcon Cut Fill Decal 5 4 Motorgrader System Five Operator s Manual Sonic Stringline Measure from the bottom of the lath the desired hike up and make a mark at that point Place the Cut Fill Decal on the lath with 0 on the point you marked LATH ra pa 20 SET 0 ON DECAL AT 2 0 MARK FROM LATH BOTTOM OF LATH Figure 5 4 5 Next set the cut fill lath on the hub and read the cut or fill from the grade stake next to the hub Adjust the clip up or down until the stringline crosses the cut fill lath at that p
44. et can be attached to the back of the grader for use when the Trackerjack system is not needed OPTIONAL Figure 1 5 1 6 Motorgrader System Five Operator s Manual Blade Slope Sensor 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 o gt 0 0 LQ D store e ae 0 OF 385 173 zi uL A Jus 209 oo CONTROL BOX LCD DISPLAY Figure 1 6 P N 7010 0344 1 7 System Overview 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 1 8 Motorgrader System Five Operator s Manual Mainfall Sensor Mainfall Sensor The Mainfall Sensor uses the same
45. g Grade To verify grade set the Grade Checking Lath on the edge of the graded area so that the level bubble extends over the Sonic Stringline shown below TRINGLINE SON MN 4 FINISHED GRADE FINISHED GRADE APPROX 05 HIGH Figure 5 13 Tilt the Grade Checking Lath until the level bubble is centered Finished Grade is correct when the level just touches the Sonic Stringline P N 7010 0344 5 11 Grading Applications Laser Grade Checking System Once the Sonic Stringline has been set the operator can dial in the desired cross slope and depth of cut and begin grading As he begins grading the grade must be immediately inspected to verify the cut is correct The grade setters job is now to inspect the grade behind the grader and make adjustments if necessary Although this can be done by various methods the Laser Grade Checking System is a quick accurate one person grade checking tool It allows grade to be inspected not just at the edge of the road but all the way across the section at any desired distance Set the laser on the Stringline Laser Bracket and place the bracket on the Sonic Grade Clip The automatic leveling laser will produce a stringline of laser light across the road at the same height as the stringline Figure 5 14 5 12 Motorgrader System Five Operator s Manual Sonic Stringline To inspect grade use the
46. he Transducer assembly with the beveled edges out and the flat surface against the Sonic Tracker II base Line up the holes for the mounting screws the mounting screw holes are set to an irregular pattern This ensures the retaining ring will only lineup with the mounting holes one way P N 7010 0344 6 5 Maintenance 7 Start the mounting screws into the holes and tighten each until firm DO NOT OVER TIGHTEN Use a cross X pattern to tighten screws Figure 6 6 D NOTICE Over tightening may distort the Transducer metallic material and may crack the Retaining Ring Use of the O Ring assures tightness while preventing vibration from loosening the Mounting Screws erro NOTICE DO NOT use Loctite on the mounting screws Loctite will attack the plastic retaining ring 8 Make sure there are no visible wrinkles in the metallic surface inside the Transducer If distortion is evident repeat Steps 5 through 8 9 Place a NEW Filter Foam over the Transducer The Sonic Tracker II is now ready to return to operation 6 6 Motorgrader System Five Operator s Manual Rotation Sensor Cleaning and Lubrication Rotation Sensor Cleaning and Lubrication The Rotation Sensor baseplate should occasionally be cleaned and greased Although the sensor does not need lubrication the grease will keep contaminents from acumulating in the baseplate and binding the sensor a NOTICE Cleaning and lubrication of the Rotation Sensor
47. igure 5 9 On some jobs it may be more practical to secure the stringline directly to the grade stake next to the hub First mark the lath with a 2 or 3 feet hike up or boot above grade just as you would to check grade with an eye level or pulling a string across the street Figure 5 10 5 8 Motorgrader System Five Operator s Manual Sonic Stringline Secure an anchor pin at each end of the stringline and pull the stringline tight At each station staple or ty rap the stringline directly to the witness lath so the stringline is at the desired hike up Figure 5 11 Due to the height of some stakes the Tracker may need to be raised or the tops of those stakes may need to be cut off Once finished grade can be cut P N 7010 0344 5 9 Grading Applications Making a Grade Verification Lath Verifying grade requires measuring depth of cut from the Sonic Stringline Because the hubs are offset from the edge of road and the Sonic Stringline is a predetermined hike up above Finished Grade a simple tool called a Grade Checking Lath can be constructed This can be easily done using lath a level bubble and simple hand tools In this example assume that the hub offset from the edge of road is 1 5 feet and that the hike up is 2 0 feet Construct a Grade Checking Lath as shown below Figure 5 12 5 10 Motorgrader System Five Operator s Manual Sonic Stringline Verifyin
48. jeq apei e oqy 8 90 ueewjeq epej6 e oqy MOE UMOP MOJI pilos apes6 e oge z puoKeg ddO1S OH LNOO AdOT1S NOILLVA apei6 e oge z puo eq eDuei jo NO uasovu HASV1 8 OINOS NOI V 3 T3 v v v Y ZN A A a4 LLI 14a MOE UMOP ojo Buruq MOS NOILOV G31 Figure 2 5 Motorgrader System Five Operator s Manual 2 4 Control Box Left and Right Automatic Operation Indicators These LED s illuminate with the word Auto when the Right and or Left Auto Manual switch Smart Knobs are used to switch System Five to Automatic Operation Left and Right Grade Adjustment Knobs These knobs are used to make measured adjustments to the cross slope or elevation settings Adjusts the grade height when Elevation Control is selected Turning the knob clockwise increases the depth of cut or lowers the cutting edge menu J ser J Lev C Le 79 TRM J can o G CONTROL MODE we ser Cz E G3 Cre Cen Figure 2 6 P N 7010 0344 2 5 Operation Adjusts the percentage of slope when cross slope control is selected me T Ziv 2 I4 TRIM GAIN CONTROL MODE Figure 2 7 Grade Adjustment Direction Arrows These red arrows light up around the Grade Adjustment Knob to indicate the direction the knob should be rotated to reach On Grade Rotate the knob counter clockwise to reach grade Rotat
49. just the rod for cut fill or known elevation of the reference hub Figure 4 20 4 14 Motorgrader System Five Operator s Manual Laser Receiver Setup Set both sides of the cutting edge on the ground and raise or lower the receiver to get an On Grade signal This can be done by just pushing the two red buttons on the Smart Knobs and the Trackerjack will search up and down the vibration pole and lock onto the laser beam Figure 4 21 Switch to Automatic and grade a short pass Figure 4 22 Using the grade rod with detector check the grade Cut behind the machine Figure 4 23 P N 7010 0344 4 15 Getting Ready to Grade 1 Setting the reference number to a known elevation This is typically used for jobs with flat or dead level surfaces For example if the cutting edge is at a known sea level elevation of 325 65 feet for example then set the display to read 5 65 feet In this case the operator can just dial in a desired elevation This is great when cutting multiple pads at different elevations Push the SET button turn the knob to read 5 65 feet the push ENTER Figure 4 24 4 16 Motorgrader System Five Operator s Manual Laser Receiver Setup 2 Setting the reference number to 0 00 This is typically used for jobs with slope although it can be used on flat pads as well If the cutting edge is 15 feet above fi
50. librated and the Tracker reference number has been zeroed out See Chapter Getting Ready to Grade P N 7010 0344 5 15 Grading Applications When beginning to cut grade it is likely that the rough subgrade is several inches above grade To start set the cutting edge down on the existing grade with the Tracker positioned over the stringline VIEW F ROM BEHIND G RADER Figure 5 20 5 16 Motorgrader System Five Operator s Manual Grading a Road Using a Stringline Press both red buttons on the Smart Knob to set the Tracker to On Grade The Control Box will then read the depth of cut below the stringline at that location In this example the display indicates that the cutting edge is 1 65 feet below the stringline Since the desired depth is 2 00 feet the grade is 35 feet high at this location Sonic Tracker II Figure 5 21 P N 7010 0344 5 17 Grading Applications Begin grading then immediately switch to automatic control You can make grade adjustments using the Smart Knob which will keep your hands on the controls You may want to dial in a small amount of cut as you make this first pioneering pass Depending upon the material conditions and amount of cut along the road Came ea 25 o 1 79 CUT GRADE 1 70 BELOW THE SONIC STRINGLINE 2 095 WINDROW SLOPE VIEW FROM BEHIND GRADER Figure 5
51. low the operator to perform several Control Box functions while keeping his hands where they belong on the levers LEFT KNOB RIGHT KNOB Manual Manual Set Point Figure 1 3 1 4 Motorgrader System Five Operator s Manual Sonic Tracker II Sonic Tracker Il 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 P N 7010 0344 1 5 System Overview 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 brack
52. new O Ring is supplied with the Transducer Replacement kit P N 7010 0344 6 3 Maintenance Figure 6 2 gt NOTICE Always remove and discard used O Rings Used O Rings will be distorted and may loose there elasticity due to weather or exposure to diesel fumes 3 The Transducer can now be gently pulled out Use a SMALL pair of dikes to gently cut the Ty Wrap then remove the small wire connectors from their tabs gt NOTICE When cutting the Ty Wrap be careful not to cut or damage the wires CAREFULLY REMOVE WIRE CONNECTORS CUT TY WRAP Figure 6 3 6 4 Motorgrader System Five Operator s Manual Transducer Replacement Procedure Sonic Tracker II 4 Place the wire connectors of the new Transducer firmly on their tabs the gray wire connector is placed on the elevated tab Place the Ty Wrap in the slot next to the elevated gray wire tab tighten and trim DO NOT pinch the wires TRIM EXCESS PLACE NEW TY WRAP AROUND WIRES AND TIGHTEN CAREFULLY PLACE WIRE CONNECTORS ON TABS Figure 6 4 5 Feed the wires back up into the Sonic Tracker II and seat the Transducer into place the two wire tabs have to sit down into the extra deep area of the recess Place the new O ring around the Transducer and seat firmly between the Transducer and the Sonic Tracker II Transducer recess TRANSDUCER WIRE CONNECTOR PINS Figure 6 5 6 Place the black Retaining Ring over t
53. next Set Point The Control Box will automatically remember the settings just as you left them before you switched to the next set point Refer to the Set Points section within this manual 3DMC Mode 3DMC stands for 3 Dimensional Machine Control 3D MC is a revolutionary new automated machine control system that allows a contractor to guide an earthmoving machine directly from the digital data supplied by engineering firms For the first time ever a grading contractor can perform site grading work directly from design information This system greatly reduces the need for costly stakeout work Understanding of this system grows with experience More experience and understanding makes judging how much survey staking to eliminate from a project easier while still providing professional accurate grading Setup Mode Setup Mode is used for Calibration System Setup and advanced features of System Five ENTER Setup CALIBRATION ADJUST LED BRIGHTNESS SET POINTS SYSTEM TEST MEASUREMENT UNIT BEEPER CHECK HOURMETERS MACHINE SETUP Figure 2 21 2 16 Motorgrader System Five Operator s Manual Control Box Calibration Why do you need to calibrate Although System Five does not usually require maintenance or adjustment the grader it is attached to does All the moving parts on your grader wear at different rates In order for System Five to work correctly it has to be told what changes have occurred on your grader
54. nish grade then set the display to read 15 feet The operator can then dial in a desired height above grade while roughing in then dial down to 0 00 for finish grade Push the SET button turn the knob to read 0 15 feet the push ENTER Figure 4 25 P N 7010 0344 4 17 Getting Ready to Grade Using Set Points Set Points will allow the operator to preset up to 3 different elevation and slope settings This is most commonly used when the job application requires multiple settings from one pass to another Each time the Set Point Switch is toggled the Control Box will switch to the next Set Point The Control Box will automatically remember the settings just as you left them before you switched Refer to the Set Points section within this manual To set up System Five to use Set Points go to the Set Up Mode and select Set Points Push ENTER to access Set Points CALIBRATION ADJUST LED BRIGHTNESS SET POINTS SYSTEM TEST MEASUREMENT UNIT BEEPER CHECK HOURMETERS Figure 4 26 Turn the right Control Box knob to enter the number of set points desired for your job application Enter number of Set Points desired Figure 4 27 4 18 Motorgrader System Five Operator s Manual Using Set Points After returning to Control Mode the center of the LCD will display the number of Set Points entered and which one is currently being used CONTROL MODE Figure 4 28 To switch t
55. o a different Set Point push the Set Point switch on the right hand Smart Knob inward for one second a beep is heard System Five will now display and operate on these new settings As an example of how Set Points might be used let s look at a simple job application using two Set Points For this pass the right side is set to Sonic Tracker Control to cut 1 90 below the stringline The left side is set for a 2 0 slope going up to the centerline CONTROL MODE Figure 4 29 P N 7010 0344 4 19 Getting Ready to Grade CUT GRADE 1 90 BELOW THE SONIC STRINGLINE VIEW FROM BEHIND GRADER Figure 4 30 4 20 Motorgrader System Five Operator s Manual Using Set Points For the next pass the right side needs to be set to match the previous pass Push the Set Point switch and then dial the Sonic Tracker II to 0 00 while keeping the cross slope at and the cross slope to 2 0 MATCH THE PREVIOUS PASS VIEW FROM BEHIND GRADER V RIGHT SIDE SMART KNOB HOLD FOR 1 SECOND Figure 4 31 P N 7010 0344 4 21 Getting Ready to Grade Once set each time the Set Points switch is toggled the Control Box will return to the last values entered on that screen AAAA Figure 4 32 4 22 Motorgrader System Five Operator s Manual Chapter 5 Grading Applications Sonic Stringline
56. o 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 P N 7010 0344 1 1 System Overview KEY q ING P em ND ADS Laser Tracker amp Trackerjack Smart Knobs Hydraulic Manifold Assembly Sonic Tracker II Slope Sensor Rotation Sensor Manifold Sensor Control Box 1 2 3 4 5 6 7 8 Figure 1 1 1 2 Motorgrader System Five Operator s Manual Control Box 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 P N 7010 0344 1 3 System Overview Remote Smart Knobs The Remote Smart Knobs mount on the grader s control levers for easy access The knobs al
57. o speed up or slow down the hydraulic response or gain of System Five Gain adjustments can be made on the fly in Automatic Control If the blade seems to be moving too slow and the lights take too long to reach grade increase the Gain Setting Number which will cause the hydraulics to respond quicker f the blade is moving too fast and the lights are skipping through On Grade decrease the gain There is a separate adjustment setting for Elevation Mode and Slope Mode Making an adjustment for Elevation Mode or Slope Mode on the left side also changes the adjustment for that mode on the right side Figure 2 17 2 12 Motorgrader System Five Operator s Manual Control Box Once Gain adjustments have been complete push ENTER TURN THIS KNOB TO TURN THIS KNOB TO ADJUST ELEVATION GAIN ADJUST CROSS SLOPE GAIN Figure 2 18 Remote Smart Knobs LEFT RIGHT Auto Manual Manual Auto Poi NY Set Point us X Lower Raise Survey Survey Figure 2 19 Raise and Lower These buttons will make measured adjustments to the slope or elevation setting Each time one of the buttons is pressed the slope elevation will change by one step Theoutside button will P N 7010 0344 2 13 Operation raise the moldboard and the inside button will lower the moldboard They perform the same function as the Grade Adjustment Knobs located on the face of the Control Box and allow the opera
58. o that it s magnetic pickup sensor is above the magnet on the bottom of the vibration pole Once the sensor is above the magnet the operator can not accidentally lower the Trackerjack off the pole using the grade adjustment knob on the Control Box Another magnet at the top of the vibration pole acts as an upper limit keeping the Trackerjack from climbing off the top of the pole Position the L Bar horizontally so that the Laser Trackerjack is near the end of the moldboard Position the vibration pole vertically so the Trackerjack is at an optimum height for the job application It is always best to keep the Laser Transmitter and Trackerjack as low as possible For most jobs position the vibration pole so the receiver is just above the machine frame when the Trackerjack is at the lowest position Figure 4 18 P N 7010 0344 4 13 Getting Ready to Grade For jobs with multiple elevations the vibration pole and Trackerjack can be adjusted as needed providing over 9 feet of elevation adjustment Figure 4 19 For Laser Trackerjack application it is best to set the reference number so that when the cutting edge is at Finished Grade the reference number is either set to a known elevation or set to 0 00 To set the reference number first set up the Laser Transmitter for the job application Then place the grade rod on the reference hub and move the detector up or down to lock on the laser beam Ad
59. oint A cut of 25 feet pf 2 pre en f Russi 22 pb ff o 09m n Pd Figure 5 5 P N 7010 0344 5 5 Grading Applications The stringline is now set to 2 feet above finished grade 2 0 OFFSET Figure 5 6 Repeat this process at each station before starting to grade Figure 5 7 5 6 Motorgrader System Five Operator s Manual Sonic Stringline Setting Stringline to Projected Slope Jobs with slope transitions or super elevations must have the stringline set to the projected slope Failure to do this will produce an elevation error at the edge of the road as the slope is changed To set the stringline to the projected slope first set up the string at the desired hike up as shown in the previous pages Next raise or lower the stringline to compensate for the slope and the distance from edge of the road to the stringline RISE RUN If the road is rising away from the stringline the stringline will need to be lowered If the road is sloping down from the stringline the stringline will need to be raised This adjustment is needed at each station Example 2 0 Cross Slope with 2 feet offset 2 0 SLOPE X 2 00 OFFSET 04 PROJECTED SLOPE 2 0 OFFSET Figure 5 8 P N 7010 0344 5 7 Grading Applications Example 3 0 Cross Slope with 2 feet offset 3 0 SLOPE X 2 00 OFFSET 06 2 0 OFFSET F
60. on Cte Pressing the Slope Direction button will change the direction of the slope regardless of what side slope is being used The blade indicator shows the direction of slope MENU SET J Cz na TRIM GAIN 9 o CONTROL MODE Figure 2 14 P N 7010 0344 2 9 Operation Trim Slope Control Only Pressing the Trim button will allow the operator to adjust or trim the Blade Slope Sensor Calibration in order to compensate for the blade s cutting edge wear This adjustment can be done on the fly in automatic cross slope operation This calibration should be performed as the cutting edge wears When operating in harsh material conditions the slope calibration should be checked more often Refer to the Trim Calibration section within this manual TURN T HE G RADE KNOB TO G ETT HE BLADE TOM ATCH Figure 2 15 2 10 Motorgrader System Five Operator s Manual Control Box Set Elevation Control Only Use J Pressing the Set button will allow the operator to set the elevation grade reference number to any value desired This does not change the elevation it only changes the reference number displayed on the Control Box Refer to Setting Reference Number section within this manual a TRIM GAIN Figure 2 16 P N 7010 0344 2 11 Operation GAIN e Gain Pressing the Gain button will allow the operator t
61. r and hold it near the Mainfall Sensor to get the cable to reach 4 Turn the Control Box On and enter the System Test Mode If ERROR continues to be displayed your Blade Slope Sensor may have failed If ERROR is no longer displayed the Blade Slope Sensor is not damaged and there is a cable failure Continue with the rest of the tests to locate the damaged cable 5 Turn the Control Box Off and reconnect the cable to the Mainfall Sensor P N 7010 0344 7 7 Troubleshooting 6 At the Rotation Sensor disconnect the cable from the Mainfall Sensor and connect it to the Blade Slope Sensor by passing the Rotation Sensor 7 Turn the Control Box On again and enter the System Test Mode If ERROR is displayed the Mainfall to Rotation Sensor Cable is damaged If ERROR is NOT displayed then the failure is located in the Rotation to Blade Slope Sensor Cable If a Blade Slope Sensor or cable failure has occured contact your Topcon Dealer or Topcon s Service Department Mainfall Sensor Test The Mainfall reading in the center of the screen is the calibrated value of the Mainfall Sensor To check if sensor is working properly EXIT J ENTER J KNOB MAINFALL 1 0 KNOB VALVE ROTATION VALVE Figure 7 9 7 8 Motorgrader System Five Operator s Manual Mainfall Sensor Test Mark the midpoint between the two rear tires Note the slope displayed for the Mainfall 3 Turn the g
62. racker on the other side Figure 4 15 4 10 Motorgrader System Five Operator s Manual Setting the Reference Number When setting the Tracker reference number be aware of cutting edge wear common at the edges of the blade Setting to 0 00 with the tip of the blade on the ground would cause the blade to undercut farther in from the edge For best results switch to Automatic and grade a short pass Look about 18 inches in from the end of the blade to verify whether the cutting edge is matching Make grade adjustments as needed to get the cutting edge to match perfectly and then reset the number to 0 00 It is usually better to set the blade to 01 foot or 02 foot high Error Induced by Cutting Ege Wear Match Surface 18 0 in from Edge Figure 4 16 P N 7010 0344 4 11 Getting Ready to Grade Laser Receiver Setup Trackerjack and Vibration Pole installation and positioning Bolt the vibration pole to the L Bar and visually check to get the L Bar and vibration pole plumb To attach the Trackerjack turn on the Control Box and attach the coil cord to the Trackerjack Place the Trackerjack on the vibration pole so the four wheels slide into the slots at the bottom of the pole Push the manual raise button on the Trackerjack to raise it up the pole Magnetic Sensor Figure 4 17 4 12 Motorgrader System Five Operator s Manual Laser Receiver Setup Raise the Trackerjack s
63. rader around placing the front tires directly over the previous rear tire midpoint marking 4 TheLCD should display the same slope as in step 1 but in the opposite direction EXIT ENTER KNOB MAINFALL 1 0 KNOB VALVE ROTATION VALVE Figure 7 10 If two different slopes are displayed If the second slope displayed is different from the first recalibrate the Mainfall Sensor and perform the test one more time If the slopes displayed continue to be different your Mainfall Sensor is not working properly P N 7010 0344 7 9 Troubleshooting If the Error symbol is displayed If the Mainfall shows ERROR but the Slope shows a value the Mainfall is not functioning If both Mainfall and Slope show ERROR the problem is in the Control Box or the Control Box to the Mainfall Cable EXIT ENTER KNOB MAINFALL ERROR KNOB VALVE PASS ROTATION 5 VALVE PASS LASER ERROR SLOPE 1 5 LASER 0 SONIC 2 58 SONIC ERROR SYSTEM TEST Figure 7 11 Rotation Sensor Test Unlike the two previous sensor test procedures the Rotation Sensor Test displays in degrees of rotation rather than percentage of slope gt NOTICE The Rotation Sensor information is communicated to the Control Box from the Slope Sensor If the Slope Sensor or Slope Sensor Cable is defective the Rotation Sensor will also indicate ERROR If both are indicating error proceed to slop
64. rier wall The concrete is porous enough to reflect sound waves and give a false reading even though it is vertical 14 0 to 18 0 RECOMMENDED DISTANCE CONCRETE BARRIER EXISTING ROAD Figure 4 9 P N 7010 0344 4 7 Getting Ready to Grade When tracking a curb lower the tracker so it is just picking up the lip of the curb This will keep it from picking up the top of curb or obstructions in the gutter Figure 4 10 14 0 to 18 0 RECOMMENDED DISTANCE Figure 4 11 4 8 Motorgrader System Five Operator s Manual Setting the Reference Number Setting the Reference Number For most Sonic Tracker applications it is best to set the reference number so when the cutting edge is matching a pass the number reads 0 00 In this case the blade is not cutting or filling so it makes sense that the number reads 0 00 To set the reference number 1 Manually place the blade so the cutting edge is just resting on smooth ground Figure 4 12 2 Press both red buttons on the Smart Knob to lock the Tracker On Grade Sonic Tracker II Figure 4 13 P N 7010 0344 4 9 Getting Ready to Grade 3 Press the Set button EXIT ZERO ENTER Figure 4 14 4 Press the Zero button The Control Box will set the reference number to zero beep twice and then return to the Control Mode Repeat these steps for the Sonic T
65. ross Slope System EXIT J ENTER J TURN T HE G RADE o KNOB TO G ETT HE 2 O o BLADE TOM ATCH o Figure 4 2 4 2 Motorgrader System Five Operator s Manual Sonic Tracker Setup Sonic Tracker Setup When installing and positioning the Sonic Tracker II first connect the coil cord to the Tracker Bolt the Tracker to the bracket and visually check to get the L Bar and Tracker plumb Make one wrap of the coil cord around the L Bar This will act as a strain relief for the connector on the Tracker Be sure the coil cord snap hook is in place and secure Figure 4 3 P N 7010 0344 4 3 Getting Ready to Grade Position the L Bar horizontally so the Tracker will be over the reference for the jobsite For example when tracking a stringline that is offset from the edge of the road set the end of the moldboard at the edge of the road and slide the L Bar so the Tracker is over the stringline When tracking a curb keep the L Bar in close to keep the Tracker over the lip of the curb Raise or lower the Tracker bracket to position it at a proper height above the grade reference Although the Tracker can be set as close as 14 inches and as far as 55 inches from the grade reference consider the job application for the best set up When tracking multiple references for example elevated string on one pass then matching grade on the next pass consider the Tracker position so
66. seat correctly one way MAKE SURE ROTATION PIN IS ALIGNED CORRECTLY PLACE ROTATION SENSOR ON BASE PLATE Figure 6 11 P N 7010 0344 6 9 Maintenance 3 Place the two halves of the retaining rings on the base plate with the screw holes aligned and replace the four screws Tighten until firm PLACE BOTH HALVES OF RETAINER RING ON ROTATION SENSOR BASE AND RE INSTALL SCREWS Figure 6 12 4 Realign the Rotation Sensor arm with the L bracket and replace the shoulder screw washer and jam nut Tighten until firm ROTATE SENSOR UNTIL ARM LINES UP WITH L BRACKET AND INSTALL SHOULDER SCREW WASHER AND JAM NUT Figure 6 13 Before returning the Rotation Sensor to work the Rotation Sensor must be re calibrated Follow the procedures in the Calibration Rotation section of this manual 6 10 Motorgrader System Five Operator s Manual Chapter 7 Troubleshooting System Test Mode The System Test is a troubleshooting guide built into System Five that provides you with a method for detecting and isolating a problem with a cable or system component The following sections will explain how to use the System Test features in order to locate where a problem exists while in the field D NOTICE Before assuming sensor failure check that all cables are firmly attached to their sensors Also check that the connectors are clean and free of debris that might interrupt signal communications between
67. sensors P N 7010 0344 7 1 Troubleshooting Accessing the System Test 1 Press Setup from Main Menu Use the grade knob to select System Test 3 Press the button above ENTER EXIT J ENTER KNOB MAINFALL 2 7 KNOB VALVE PASS ROTATION 5 VALVE PASS LASER ERROR SLOPE 1 5 LASER 0 SONIC 2 58 SONIC ERROR SYSTEM TEST ADJUST GAIN CHECK HOURMETERS CALIBRATION ADJUST LED BRIGHTNESS SET POINTS SYSTEM TEST MEASUREMENT UNIT BEEPER Figure 7 1 In System Test Mode the LCD will display System Five s component readings The readings on the left side of the display are for the components on the left side of the grader The reading on the right side of the display are for components on the right side of the grader The Cross Slope System Sensor readings are displayed in the center of the LCD Each component should have a number or indicator next to it showing that it is communicating to the Control Box If a component has ERROR displayed that indicates it is not communicating to the Contol Box This problem could be a defective component or a defective cable attached to the component 7 2 Motorgrader System Five Operator s Manual Slope Sensor Test Slope Sensor Test The slope reading in the center of the screen is the calibrated value of the Blade Slope Sensor To check if the sensor is working properly 1 Slowly raise the right side of the blade The slope value
68. should increase smoothly and continuously MAINFALL 2 796 ROTATION 5 SLOPE 4 5 SYSTEM TEST Figure 7 2 P N 7010 0344 7 3 Troubleshooting 2 Slowly lower the right side of the blade The slope value should decrease smoothly and continuously If your slope sensor is responding this way proceed to next step MAINFALL 2 7 ROTATION 5 SLOPE 3 7 SYSTEM TEST Figure 7 3 Your Slope Sensor is not working properly if The numbers increase or decrease erratically as the blade is smoothly raised and lowered The number displayed continues to change even though you have stopped moving the blade If your Slope Sensor is responding this way contact your local Topcon dealer 7 4 Motorgrader System Five Operator s Manual Slope Sensor Test To check if Slope Sensor is measuring accurately 1 Using a laser smart Level or Auto Level calculate the slope of the ground If you do not have an instrument to calculate slope proceed to step 6 t8 E CL 1 SLOPE Figure 7 4 2 Place the cutting edge lightly on the ground in the same direction you measured the slope The value displayed on the screen should be within 2 of the calculated slope MAINFALL 2 7 ROTATION 5 SLOPE 1 2 SYSTEM TEST Figure 7 5 P N 7010 0344
69. t make up the system The Control Box will indicate if the device is in use and if it is properly working Refer to Troubleshooting section KNOB 910 MAINFALL 1 6 KNOB 910 VALVE PASS ROTATION 0 VALVE PASS LASER 0 SLOPE 0 2 LASER ERROR SONIC ERROR SONIC 3 12 YSTEM TEST Figure 2 26 Beeper Press the ENTER button to toggle between the beeper being ON or OFF When the beeper is turned on a short beep will sound when System Five gets an out of range signal from the Sonic or Laser Sensor P N 7010 0344 2 19 Operation Sonic Tracker Il The Sonic Tracker II measures and controls the elevations of the moldboard A transducer located in the bottom of the Tracker 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 Tracker should be removed for proper storage in the carrying case E Figure 2 27 2 20 Motorgrader System Five Operator s Manual Sonic Tracker II The Sonic Tracker II measures the distance to a physical grader reference by sending out sound pulses 39 times per second As soon as the Tracker sends out a sound wave it starts a stop watch The sound waves go down
70. the Control Box Except for possible cutting edge wear and changes in Sonic Tracker or Laser Trackerjack set up you may not need to make any calibration or adjustments for many weeks or months In most cases you can turn on the box and begin grading P N 7010 0344 4 1 Getting Ready to Grade Checking Cross Slope Trim Calibration Before using the Cross Slope System check to make sure there has not been excessive cutting edge wear from previous use This takes less than 5 minutes and is completed right on the jobsite 1 Switch the Cross Slope to either the left or right side and grade a smooth finish pass at about 50 feet long in Automatic Control The slope you dial in does not matter for calibration but it is best to dial in a slope that will closely match the area you are grading so you will not have to cut too much If the ground is fairly rough you may need to back up and grade 2 or 3 passes until you cut a smooth finish pass Turn the machine around push the switch to reverse the slope and begin to grade slowly over the previous pass with either side in Automatic Slowly lower the blade and observe to see if the cutting edge matches the previous pass If the cutting edge matches no adjustment is needed If the cutting edge does not match Push the Trim button then turn the Grade Adjustment Knob to get it to match Push ENTER and the Blade Trim Calibration is complete You are now ready to begin grading with the C
71. thin 1 or 2 degrees of 0 then rotation is accurately compensated and no repairs are needed MAINFALL ROTATION 2 SLOPE SYSTEM TEST Figure 7 18 If the value is more than beyond 2 degrees then the problem is one or more of the following ENTER MAINFALL ROTATION 5 SLOPE Figure 7 19 Excess slop in the pin between the grader s hydraulic swivel and the hose tray Hose tray is bent and the guide rods are no longer attached to the circle The hole where guide rod is attached to circle is worn so the guide rod is no longer held tight Guide rods are weak and have too much flex These are physical wear areas that must be repaired for System Five to cut accurate cross slope 7 14 Motorgrader System Five Operator s Manual Appendix A Safety Information It is your responsibility to be completely familiar with the cautions described in this System Five Manual These messages advise against the use of specific methods or procedures which can result in personal injury damage to the equipment or unsafe operating conditions Remember most accidents are caused by failure to observe basic safety precautions General Precautions 1 Read and become familiar with the grader manufacturer s operations manual including safety information before installing or using your TOPCON System Five 2 Use extreme caution on the jobsite Working around heavy construction equipment can be dangerous 3 D
72. tion Trim Blade Wear Calibration Trim The Blade Wear Calibration allows the operator to make an adjustment for cutting edge wear This calibration adjustment is performed while cutting grade right on the job and can be completed in less than 5 minutes This will insure a perfect calibration and verifies System Five is cutting exactly the way it is supposed to To perform the Blade Wear Calibration 1 Switch either left side or right side to Automatic Control and grade a smooth finish pass at least 50 feet long The of slope dialed in does not matter but it is best to dial in a slope that will closely match the area being graded If the ground is fairly rough back up and grade 2 or 3 passes until a smooth finish pass is cut Press the NEXT button TURN ONE SIDE TO AUTO AND GRADE A SMOOTH FINISH PASS pd Ze BLADE WEAR CAL TRIM P N 7010 0344 3 7 Calibration 2 Turn machine around 180 degrees and position blade over previous pass With one side in automatic slowly lower the blade and observe to see if the cutting edge matches the previous pass Press the NEXT button TURN AROUND AND STOP OVER PREVIOUS PASS IN AUTO CHECK IF CUTTING EDGE MATCHES Figure 3 10 3 8 Motorgrader System Five Operator s Manual Blade Wear Calibration Trim 3 If the cutting edge matches no adjustment is needed Press the ENTER button If the cutting edge does not match turn the right grade adjustment knob
73. to get it to match Press the ENTER button and the Blade Trim Calibration is complete Figure 3 11 After pushing the ENTER button the cutting edge and will raise or lower half the distance you just dialed in to get it to match P N 7010 0344 3 9 Calibration Adjust Valve Offsets Allows the operator to adjust the hydraulic valve offsets automatically or manually Valve Offsets set the minimum hydraulic correction needed to return to grade This is not a speed adjustment Automatic Adjusment 1 Raise the moldboard so that both sides are a few inches above the ground 2 Push the Auto Offsets button System Five will automatically perform the Valve Calibration first with left hand raise and then lower then repeating with the right hand side 3 Once all four adjustments are completed press the ENTER button and the values will be saved LOWER RAISE ENTER 265 303 RIGHT AD I VALVE OFFSET 304 Figure 3 12 3 10 Motorgrader System Five Operator s Manual Adjust Valve Offsets Manual Adjusment If the operator wants to make an adjustment or just verify that the Valve Offset Values are correct a Manual Valve Offset Calibration can be performed 1 Press the Raise button on the left hand side Rotate left hand knob raising or lowering the Raise Offsets 2 Press the Lower button on the left hand side Rotate left hand knob raising or lowering the Lower Offsets until
74. to the A frame assembly Wear or damage to the machine s hose tray or guide rods are the reason for occassional Rotation Sensor Calibration To perform the Rotation Sensor Calibration Rotate blade to chisel marks Figure 3 3 1 Rotate the blade to the chisel marks on the A frame assembly provided by installer 2 Push the ENTER button and the Rotation Sensor Calibration is completed Figure 3 4 9 2 Motorgrader System Five Operator s Manual Calibrate Mainfall Calibrate Mainfall The Main Slope Mainfall Sensor bolted to the frame of the machine measures the slope of machine travel up hill and down Tire wear is the primary reason for occasional Mainfall Sensor Calibration To perform the Mainfall Sensor Calibration 1 Raise the moldboard so that both sides are a few inches above the ground position the machine on a smooth even surface and mark the front tire locations Push the NEXT button 2 Wait 5 seconds until you hear a single beep Position machine on smooth ground and mark tire location ALIBRATE MAINFALL Figure 3 5 P N 7010 0344 3 3 Calibration 3 Turn the machine around 180 degrees and line up the center of rear tires on previous tire mark Push the ENTER button 4 Wait 5 seconds until you hear a double beep and the calibration is complete Turn machine around over previous marks ALIBRATE MAINFALL Figure 3 6 9 4 Motorgrader System Five Operator s
75. tor s hands to never leave the blade levers Survey Survey is used to quickly lock on grade The Sonic Sensor will lock on the stringline curb or any other physical reference The Laser Trackerjack will search up and down and lock on the laser beam The Slope Control System will lock on to and display the slope the moldboard is setting on To activate Survey Mode hold both the Raise and Lower Buttons for one second until a double beep is heard The Slope Control System can also be set to Indicate Mode In this mode the operator manually cuts grade and the Control Box continuously displays the slope he is cutting It also shows the readings of the Blade Slope Sensor Mainfall Sensor and Rotation Sensor This screen enables the operator to quickly check that all the sensors are functioning To activate the Slope Indicate Mode first switch Slope Control to Manual Then hold both the Raise and Lower Smart Knob buttons for three seconds until a second double beep is heard To switch back out of Indicate Mode push either the Raise or Lower button or just switch to Automatic Control Auto Manual Allows operator to switch the blade between Automatic and Manual Push the switch outward for Automatic Control If both sides of the motorgrader are in slope mode then only one Auto indicator LED will illuminate consistantly when System Five is switched to Automatic Operation The other LED will flash this indicates that side is NOT in
76. 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 P N 7010 0344 1 9 System Overview 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 1 10 Motorgrader System Five Operator s Manual Carrying Case Carrying Case A Carrying Case is provided with each System Five The Carrying Case is lined and includes pre cut sections for each Sonic Tracker II and the Control Box A cut out section is also provided for storing coil cords At the end of the day always wipe down each of the components and place them and the coil cords in the appropriate sections for storage This will ensure the continued integrity of these components and will protect them from vandalism or theft Figure 1 10 D NOTICE Keep the Carrying Case dry and store in a dry location Never let the interior of the Carrying C
77. wered the Blade Slope Sensor continuously measures the slope of the cutting edge and sends the slope information to the Control Box ii o oa 0 0 CONTROL MODE menu J Ltr J 7 9 J C A ser Jeans t 0 9 2 0 4 0 0 Figure 2 40 P N 7010 0344 2 33 Operation Rotation Sensor A Rotation Sensor is mounted on the hydraulic swivel in the center of the circle It measures the rotation angle of the moldboard Since the desired slope is perpendicular to the edge of the road the rotation sensor measures the blade rotation angle to compensate to get the correct cross slope 2 0 Slope turb ne L Figure 2 41 Mainfall Sensor Mounted to the frame of the machine is the Mainfall Sensor It has an electronic level vial just like the Blade Slope Sensor The Mainfall Sensor measures the slope of the machine going up hill or down When the blade is rotated the mainfall prevents the leading edge from undercutting when going uphill and the trailing edge from undercutting when going downhill Figure 2 42 2 34 Motorgrader System Five Operator s Manual Slope Control The operator just dials in the desired slope of the project and the system will cut the desired slope perpendicular to the edge of the road regardless of the blade angle or going up or down hills The operator can rotate the blade on the fly and System Five will automatically compensate to cut

Motorgrader System Five 9164 Control Box

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