Trimble GCS900 Operator's Manual

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Operator's Manual

Trimble®GCS900 Grade Control System for

Excavators

Version 12.10 Revision A Part Number 65129-03-ENG July 2011

Contact Information

Trimble Engineering and Construction Division 5475 Kellenburger Road Dayton, Ohio 45424-1099 USA 800-538-7800 (toll free in USA) +1-937-245-5600 Phone +1-937-233-9004 Fax www.trimble.com

© 2000–2011, Caterpillar Trimble Control Technologies LLC. All rights reserved. Trimble, the Globe & Triangle logo, GCSFlex, CC SFlex, and SiteVision are trademarks of Trimble Navigation Limited, registered in the United States and other countries. PROTECTED UNDER U.S. PATENTS: 5,107,932; 5,375,663; 6,691,437; 7,307,710; 7,246,456; 7,139,662; 5,987,379; 6,324,455; 6,253,160; 4,888,890; 5,235,511; 4,924,374. SiteNet, CMR and CMR+ are trademarks of Trimble Navigation Limited. For STL support, the software uses the STLPort adaptation of the Moscow Center for SPARC Technology S tandard Template Library. Copyright © 1994 Hewlett-Packard Company, C opyright © 1996, 97 Silicon Graphics Computer Systems, Inc., Copyright © 1997 Moscow Center for SPARC Technology, Copyright © 1999, 2000 Boris Fomitchev. Microsoft, Windows, and Windows NT are trademarks or registered trademarks of Microsoft Corporation in the United States and/or other countries. Wi-Fi is a trademark of the Wi-Fi Alliance, registered in the United States and other countries. WPA and WPA2 are trademarks of the Wi-Fi Alliance. Developed under a License of the European Union and the European Space Agency. Portions of the software are copyright © 2003 Open Design Alliance. All rights reserved. All other trademarks are the property of their respective owners.

Release Notice

This is the July2011 release (Revision A) of the GCS900 Grade Control System for ExcavatorsOperator's Manual, part number 6512903-ENG. It applies to version 12.10 of the GCS900 Grade Control System software. The following limited warranties give you specific legal rights. You may have others, which vary from state/jurisdiction to state/jurisdiction.

Trimble Navigation Limited

END-USER LICENSE AGREE MENT

IMPORTANT, READ CAREFULLY. THIS END USER LICENSE AGREEMENT ("AGREEMENT") IS A LEGAL AGREEMENT BETWEEN YOU AND CATERPILLAR TRIMBLE CONTROL TECHNOLOGIES LLC ("CTCT") and applies to the computer software provided by CTCT with the GCS900 or AccuGrade system (the "Product") purchased by you (whether built into hardware circuitry as firmware, embedded in flash memory or a PCMCIA card, or stored on magnetic or other media), or provided as a stand-alone computer software product, and includes any accompanying printed materials and any "online" or electronic documentation ("Software"). The Software also includes any CTCT software (including, without limitation, upgrades and updates) relating to the Product that is furnished by Trimble Navigation Limited (“Trimble”) or its dealers (including, without limitation, CTCT software downloaded from Trimble's or its dealers' website(s)) unless accompanied by different license terms and conditions that will govern its use. BY CLICKING ''YES" OR "I ACCEPT" IN THE ACCEP TANCE BOX, OR BY INSTALLING, COPYING OR OTHERWISE USING THE S OFTWARE, YOU AGREE TO BE BOUND BY THE TERMS OF THIS AGREEMENT. IF YOU DO NOT AGREE TO THE TERMS OF THIS AGREEMENT, DO NOT USE THE PRODUCT

OR COPY THE SOFTWARE.INSTEAD PROMPTLY RETURN THE UNUSED SOFTWARE AND ACCOMPANYING P RODUCT TO THE PLACE FROM WHICH YOU OBTAINED THEM FOR A FULL REFUND. 1 SOFTWAREP RODUCT LICENSE

1.1 License Grant. Subject to this Agreement, CTCT grants you a limited, non-exclusive, non-sublicensable right to use one (1) copy of the Software in a machine-readable form on the Product. Such use is limited to use with the Product for which it was intended and into which it was embedded. You may use the installation S oftware from a computer solely to download the S oftware to one Product. In no event shall the installation Software be used to download the S oftware onto more than one Product without securing a separate license. A license for the Software may not be shared or used concurrently on different computers or Products.

1.2 Other Rights and Limitations. (1) You may not copy, modify, make derivative works of, rent, lease, sell, distribute or transfer the S oftware, in whole or in part, except as otherwise expressly authorized under this Agreement, and you agree to use all commercially reasonable efforts to prevent its unauthorized use and disclosure. (2) The Software contains valuable trade secrets proprietary to CTCT and its licensors. You shall not, nor allow any third party to copy, decompile, disassemble or otherwise reverse engineer the Software, or attempt to do so, provided, however, that to the extent any applicable mandatory laws (such as, for example, national laws implementing EC Directive 91/250 on the Legal Protection of Computer Programs) give you the right to perform any of the aforementioned activities without CTCT's consent in order to gain certain information about the Software for purposes specified in the respective statutes (i.e., interoperability), you hereby agree that, before exercising any such rights, you shall first request such information from C TCT in writing detailing the purpose for which you need the information. Only if and after CTCT, at its sole discretion, partly or completely denies your request, may you exercise such statutory rights. (3) This S oftware is licensed as a single product. You may not separate its component parts for use on more than one Product. (4) You may not rent, lease, or lend, the Software separate from the Product for which it was intended. (5) No service bureau work, multiple-user license or time-sharing arrangement is permitted. For purposes of this Agreement "service bureau work” shall be deemed to include, without limitation, use of the Software to process or to generate output data for the benefit of, or for purposes of rendering services to any third party over the Internet or other communications network. (6) You may permanently transfer all of your rights under this Agreement only as part of a permanent sale or transfer of the Product for which it was intended, provided you retain no copies, you transfer all of the Software (including all component parts, the media and printed materials, any upgrades, and this Agreement) and the recipient agrees to the terms of this Agreement. If the Software portion is an upgrade, any transfer must include all prior versions of the Software. (7) You acknowledge that the Software and underlying technology may be subject to the export administration regulations of the United States Government relating to the export of technical data and products. This Agreement is subject to, and you agree to comply with, any laws, regulations, orders or other restrictions on the export of the Software from the United S tates which may be imposed by the United States Government or agencies thereof. (8) At the request of CTCT, you agree to cooperate with CTCT to track the number of Products using Software at your site(s) to ensure compliance with the license grant and installation restrictions in this Agreement.

1.3 Termination. You may terminate this Agreement by ceasing all use of the Software. Without prejudice as to any other rights, CTCT may terminate this Agreement without notice if you fail to comply with the

2 GCS900GradeControlSystem for Excavators Operator's Manual

terms and conditions of this Agreement. In either event, you must destroy all copies of the Software and all of its component parts, and provide an affidavit to C TCT stating that you have done the same.

1.4 Copyright. All title and copyrights in and to the Software (including but not limited to any images, photographs, animations, video, audio, music, and text incorporated into the Software), the accompanying printed materials, and any copies of the S oftware are owned by CTCT and its licensors. You shall not remove, cover or alter any of CTCTs patent, copyright or trademark notices placed upon, embedded in or displayed by the Software or on its packaging and related materials.

1.5 U.S. Government Restricted Rights. The Software is provided with “RESTRICTED RIGHTS”. Use, duplication, or disclosure by the United States Government is subject to restrictions as set forth in this Agreement, and as provided in DFARS 227.7202-1(a) and 227.72023(a)(1995), DFARS 252.227-7013(c)(1)(ii) (OCT 1988), FAR

12.212(a) (1995), FAR 52.227-19, or FAR 52.227-14(ALT III), as applicable. 2 LIMITED WARRANTY

2.1 Limited Warranty. CTCT warrants that the Software will perform substantially in accordance with the accompanying written materials for a period of one (1) year from the date of receipt. This limited warranty gives you specific legal rights, you may have others, which vary from state/jurisdiction to state/jurisdiction.

2.2 Customer Remedies. CTCT's and its licensors' entire liability, and your sole remedy, with respect to the Software shall be either, at CTCT's option, (a) repair or replacement of the S oftware, or (b) return of the license fee paid for any Software that does not meet CTCT's limited warranty. This limited warranty is void if failure of the Software has resulted from (1) accident, abuse, or misapplication; (2) alteration or modification of the Software without CTCT’s prior written authorization; (3) interaction with software or hardware not supplied by CTCT or Trimble; (4) improper, inadequate or unauthorized installation, maintenance, or storage of the Software or Product; or (5) if you violate the terms of this Agreement. Any replacement Software will be warranted for the remainder of the original warranty period or thirty (30) days, whichever is longer.

2.3 NO OTHER WARRANTIES. TO THE MAXIMUM EXTENT PERMITTED BY APPLICABLE LAW, C TCT AND ITS LICENSORS DISCLAIM ALL OTHER WARRANTIES AND CONDITIONS, EITHER EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED TO, IMPLIED WARRANTIES AND CONDITIONS OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, TITLE, AND NON INFRINGEMENT WITH REGARD TO THE SOFTWARE AND THE PROVISION OF OR FAILURE TO PROVIDE S UPPORT SERVICES. THE ABOVE LIMITED WARRANTY DOES NOT APPLY TO ERROR CORRECTIONS, UPDATES OR UPGRADES OF THE SOFTWARE AFTER EXPIRATION OF THE LIMITED WARRANTY PERIOD, WHICH ARE PROVIDED "AS IS" AND WITHOUT WARRANTY. BECAUSE THE S OFTWARE IS INHERENTLY C OMPLEX AND MAY NOT BE COMPLETELY FREE OF NONCONFORMITIES, DEFECTS OR ERRORS , YOU ARE ADVISED TO VERIFY YOUR WORK. CTCT DOES NOT WARRANT THE RESULTS OBTAINED THROUGH USE OF THE SOFTWARE, OR THAT THE SOFTWARE WILL OPERATE ERROR F REE OR UNINTERRUPTED, WILL MEET YOUR NEEDS OR EXPECTATIONS, OR THAT ALL NONCONFORMITIES CAN OR WILL BE CORRECTED. TO THE EXTENT ALLOWED BY APPLICABLE LAW, IMPLIED WARRANTIES AND CONDITIONS ON THE SOFTWARE ARE LIMITED TO ONE (1) YEAR. YOU MAY HAVE OTHER LEGAL RIGHTS WHICH VARY FROM S TATE/JURISDICTION TO STATE/JURISDICTION.

2.4 LIMITATION OF LIABILITY. CTCT'S ENTIRE LIABILITY UNDER ANY PROVISION OF THIS AGREEMENT SHALL B E

LIMITED TO THE GREATER OF THE AMOUNT PAID B Y YOU FOR THE SOFTWARE LICENSE OR U.S. $25.00. TO THE MAXIMUM EXTENT P ERMITTED BY APPLICABLE LAW, IN NO EVENT SHALL CTCT OR ITS LICENSORS BE LIABLE F OR ANY SPECIAL, INCIDENTAL, INDIRECT OR CONSEQUENTIAL DAMAGES WHATSOEVER (INCLUDING, WITHOUT LIMITATION, DAMAGES FOR LOSS OF BUSINESS PROFITS, BUSINESS INTERRUPTION, LOSS OF BUSINESS INFORMATION, OR ANY OTHER PECUNIARY LOSS) ARISING OUT OF THE USE OR INABILITY TO USE THE S OFTWARE, OR THE P ROVISION OF OR FAILURE TO PROVIDE S UPPORT SERVICES, EVEN IF CTCT HAS BEEN ADVISED OF THE POSSIBILITY OF SUCH DAMAGES. BECAUSE SOME STATES AND JURISDICTIONS DO NOT ALLOW THE EXCLUSION OR LIMITATION OF LIABILITY FOR CONSEQUENTIAL OR INCIDENTAL DAMAGES, THE ABOVE LIMITATION MAY NOT APPLY TO YOU. 3 GENERAL

3.1 This Agreement shall be governed by the laws of the State of Ohio and applicable United S tates Federal law without reference to “conflict of laws" principles or provisions. The United Nations Convention on Contracts for the International Sale of Goods will not apply to this Agreement. Jurisdiction and venue of any dispute or court action arising from or related to this Agreement or the Software shall lie exclusively in or be transferred to the courts of the Montgomery County, Ohio, and/or the United States District Court for Ohio. You hereby consent and agree not to contest, such jurisdiction, venue and governing law.

3.2 Notwithstanding Section 3.1, if you acquired the Product in Canada, this Agreement is governed by the laws of the Province of Ontario, Canada. In such case each of the parties to this Agreement irrevocably attorns to the jurisdiction of the courts of the P rovince of Ontario and further agrees to commence any litigation that may arise under this Agreement in the courts located in the Judicial District of York, Province of Ontario.

3.3 Official Language. The official language of this Agreement and of any documents relating thereto is English. For purposes of interpretation, or in the event of a conflict between English and versions of this Agreement or related documents in any other language, the English language version shall be controlling.

Product Warranty Information

For applicable product warranty information, please refer to the Warranty Card included with this product, or consult your dealer.

Notices

Class B Statement – Notice to Users. This equipment has been tested and found to comply with the limits for a Class B digital device, pursuant to Part 15 of the FCC rules. These limits are designed to provide reasonable protection against harmful interference in a residential installation. This equipment generates, uses, and can radiate radio frequency energy and, if not installed and used in accordance with the instructions, may cause harmful interference to radio communication. However, there is no guarantee that interference will not occur in a particular installation. If this equipment does cause harmful interference to radio or television reception, which can be determined by turning the equipment off and on, the user is encouraged to try to correct the interference by one or more of the following measures:

- Reorient or relocate the receiving antenna.

- Increase the separation between the equipment and the receiver.

- Connect the equipment into an outlet on a circuit different from that to which the receiver is connected.

- Consult the dealer or an experienced radio/TV technician for help.

GCS900GradeControlSystem for Excavators Operator's Manual 3

Changes and modifications not expressly approved by the manufacturer or registrant of this equipment can void your authority to operate this equipment under F ederal Communications Commission rules.

Canada

This digital apparatus does not exceed the Class B limits for radio noise emissions from digital apparatus as set out in the radio interference regulations of the C anadian Department of Communications. Le présent appareil numérique n’émet pas de bruits radioélectriques dépassant les limites applicables aux appareils numériques de Classe B prescrites dans le règlement sur le brouillage radioélectrique édicté par le Ministère des Communications du Canada.

Europe

This product has been tested and found to comply with the requirements for a Class B device pursuant to European Council Directive 89/336/EEC on EMC, thereby satisfying the requirements for CE Marking and sale within the European Economic Area (EEA). Contains Infineon radio module ROK 104001. These requirements are designed to provide reasonable protection against harmful interference when the equipment is operated in a residential or commercial environment.

Australia and New Zealand

This product conforms with the regulatory requirements of the Australian Communications Authority (ACA) EMC framework, thus satisfying the requirements for C-Tick Marking and sale within Australia and New Zealand.

Taiwa n – Battery Rec yc ling Requirements

The product contains a removable Lithium-ion battery. Taiwanese regulations require that waste batteries are recycled.

Notice to Our European Union Customers

For product recycling instructions and more information, please go to www.trimble.com/environment/summary.html. Recycling in Europe: To recycle Trimble WEEE (Waste Electrical and Electronic Equipment, products that run on electrical power.), Call + 31 497 53 24 30, and ask for the "WEEE Associate". Or, mail a request for recycling instructions to: Trimble Europe BV c/o Menlo Worldwide Logistics Meerheide 45 5521 DZ Eersel, NL

4 GCS900GradeControlSystem for Excavators Operator's Manual

Safety Information

Most accidents that involve product operation, maintenance and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills and tools to perform these functions properly.

Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result in injury or death.

Do not operate or perform any lubrication, maintenance or repair on this product, until you have read and understood the operation, lubrication, maintenance and repair information.

Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons.

The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as “DANGER”, “WARNING” or “CAUTION”. The Safety Alert “WARNING” label is shown below.

WARNING — This alert warns of a potential hazard which, if not avoided, can cause severe

injury.

The meaning of this safety alert symbol is as follows:

Attention! Become Alert! Your Safety is Involved.

The message that appears under the warning explains the hazard and can be either written or pictorially presented.

Operations that may cause product damage are identified by “NOTICE” labels on the product and in this publication.

Trimble® cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in this publication and on the product are, therefore, not all inclusive. If a tool, procedure, work method or operating technique that is not specifically recommended by Trimble is used, you must satisfy yourself that it is safe for you and for others. You should also ensure that the product will not be damaged or be made unsafe by the operation, lubrication, maintenance or repair procedures that you choose.

The information, specifications, and illustrations in this publication are on the basis of information that was available at the time that the publication was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service that is

GCS900GradeControlSystem for Excavators Operator's Manual 5

Safety Information

Safety (Laser)

given to the product. Obtain the complete and most current information before you start any job. Dealers have the most current information available.

The IEC and the United States Government Center of Devices for Radiology Health

(CDRH) has classified this laser as a Class II laser product. The maximum radiant

power output of this laser is less than 5 milliwatts.

Refer to the operator's manual of the laser transmitter for installation and operating instructions.

The laser that is supplied with the GCS900 - Laser System complies with all applicable portions of “Title 21” of the “Code of Federal Regulations, Department of Health and Human Services, Food and Drug Administration, Federal Register, Volume 50, Number 161, 20 August 1985”.

This laser complies with “OSHA Standards Act, Section 1518.54” for use without eye protection. Eye protection is not required or recommended. The following safetyrules should be observed:

l Never look into a laser beam or point the beam into the eyes of other people.

Set the laser at a height that prevents the beam from flashing directly into people's eyes.

l Do not remove any warning signs from the laser.

l Use of this product by personnel that are not trained on this product may result

in exposure to hazardous laser light.

l If initial service requires the removal of the outer protective cover, removal of

the cover must be performed by trained personnel.

Crushing Prevention and Cutting Prevention

Support the equipment properly when you work beneath the equipment. Do not depend on the hydraulic cylinders to hold up the equipment. An attachment can fall if a control is moved, or if a hydraulic line breaks.

Unless you are instructed otherwise, never attempt adjustments while the machine is moving. Also, never attempt adjustments while the engine is running.

Whenever there are attachment control linkages, the clearance in the linkage area will increase or the clearance in the linkage area will decrease with movement of the attachment. Stay clear of all rotating and moving parts.

Keep objects away from moving fan blades. The fan blade will throw objects or cut objects. Do not use a kinked wire cable or a frayed wire cable.

Wear gloves when you handle wire cable. When you strike a retainer pin with force, the retainer pin can fly out. The loose retainer pin can injure personnel. Make sure that the area is clear of people when you strike a retainer pin.

6 GCS900GradeControlSystem for Excavators Operator's Manual

In order to avoid injury to your eyes, wear protective glasses when you strike a retainer pin.

Chips or other debris can fly off objects when you strike the objects. Make sure that no one can be injured by flying debris before striking any object.

Operation

Clear all personnel from the machine and from the area.

Clear all obstacles from the machine's path. Beware of hazards (wires, ditches, etc).

Be sure that all windows are clean.

Secure the doors and the windows in the open position or in the shut position.

Adjust the rear mirrors (if equipped) for the best visibility close to the machine.

Make sure that the horn, the travel alarm (if equipped), and all other warning devices are working properly.

Fasten the seat belt securely.

Safety Information

Warm up the engine and the hydraulic oil before operating the machine.

Only operate the machine while you are in a seat.

The seat belt must be fastened while you operate the machine. Only operate the controls while the engine is running.

While you operate the machine slowly in an open area, check for proper operation of all controls and all protective devices. Before you move the machine, you must make sure that no one will be endangered.

Do not allow riders on the machine unless the machine has the following equipment:

l Additional seat

l Additional seat belt

l Rollover Protective Structure (ROPS)

Note any needed repairs during machine operation. Report any needed repairs.

Avoid any conditions that can lead to tipping the machine. The machine can tip when you work on hills, on banks and on slopes. Also, the machine can tip when you cross ditches, ridges or other unexpected obstructions.

Avoid operating the machine across the slope. When possible, operate the machine up the slopes and down the slopes.

Maintain control of the machine.

Do not overload the machine beyond the machine capacity.

Be sure that the hitches and the towing devices are adequate.

Never straddle a wire cable. Never allow other personnel to straddle a wire cable.

GCS900GradeControlSystem for Excavators Operator's Manual 7

Safety Information

Warnings

Before you maneuver the machine, make sure that no personnel are between the machine and the trailing equipment.

Always keep the Rollover Protective Structure (ROPS) installed during machine operation.

Monitor the location of components that are mounted to the blade. Ensure that the components do not come into contact with other parts of the machine during operation.

WARNING — When replacement parts are required for this product Trimble recommends

using Trimble replacement parts or parts with equivalent specifications including, but not limited to, physical dimensions, type, strength and material. Failure to heed this warning can lead to premature failures, product damage, personal injury or death.

WARNING — If you create a ramp or other work platform that is too steep, machines and

vehicles using the ramp or platform could become difficult to control. This could result in harm to the operator, to others, or damage to the machine. To ensure your safety and the safety of others, find out what the maximum slope for your site is and make sure you do not exceed it.

WARNING — Do not operate or work on this machine unless you have read and understand

the instructions and warnings in the system manual. Failure to follow the instructions or heed

warnings could result in injury or death. Contact your dealer for replacement manuals.

Proper care is your responsibility.

WARNING — If the machine’s direction is locked, for example if it is locked in the forward

direction, the distance to avoidance zones will be calculated incorrectly when you are driving in the opposite direction, resulting in unreliable avoidance zone warnings. Entering an avoidance zone could cause personal injury or damage to the machine. Always be aware of nearby avoidance zones when operating a machine with direction lock on.

WARNING — In order to prevent personal injury during installation and removal of a GPS

receiver or a UTS target, use an approved access system in order to reach the mounting locations of the GPS receiver or UTS target at the top of the mast.

WARNING — Do not stare into the laser beam when the laser transmitter is operating. For

more information, refer to the documentation that came with your laser.

WARNING — Falling Hazard. Do not climb onto the machine in order to access the GPS

receiver or UTS target. Climbing on the machine could result in a fall which could cause serious injury or death. Use the raise and lower mechanism to access the GPS receiver or UTS target for all required maintenance and service.

8 GCS900GradeControlSystem for Excavators Operator's Manual

Contents

Safety Information 5

1 About This Manual 13

1.1 Scope and audience 14

1.2 Trimble training classes and technical assistance 14

1.3 To learn more about Trimble 14

1.4 Your comments 14

2 Using the Control Box and Lightbars 15

2.1 Introduction 16

2.2 Control box basics 16

2.2.1 Power key 17

2.2.2 System memory and the USB flash drive 17

2.2.3 Transferring data to and from the control box 18

2.3 Working with control box information 21

2.3.1 Working with menus and dialogs 22

2.3.2 Working with guidance screens 27

2.3.3 Guidance views 32

2.4 Understanding lightbar information 34

2.4.1 External lightbars 34

2.4.2 Internal lightbars 35

2.4.3 3D excavator lightbar behaviour 35

2.4.4 2D excavator lightbar behavior 38

2.5 3D remote switch 39

2.6 System beeper 39

3 Preparing to Work 41

3.1 Introduction 42

3.2 Power up checks 42

3.2.1 Lightbar power up 42

3.2.2 Control box power up 43

3.3 Software option keys 44

3.3.1 Option key structure 44

3.3.2 Software support 44

3.3.3 Troubleshooting option keys 44

3.4 Work preparation checks 45

3.4.1 Machine settings 46

3.4.2 Switching guidance modes 47

3.4.3 Main screen views 47

3.4.4 Display brightness 49

GCS900GradeControlSystem for Excavators Operator's Manual 9

Contents

3.4.5 Keypad backlight brightness 49

3.4.6 Lightbar brightness 50

3.4.7 Display settings 50

3.4.8 Lightbar tolerances 51

3.4.9 Set depth and slope increment values 53

3.4.10 Checking bucket wear 53

3.5 Configuring the machine radio 54

3.6 Wi-Fi networking 57

3.6.1 About cellular modems 57

3.6.2 About Wi-Fi networking 57

3.6.3 SNRx20 radio modem status indicators 57

3.6.4 Managing Wi-Fi networks 58

3.6.5 Connecting to a Wi-Fi network 58

3.7 Exchanging files with a Connected Community filespace 59

3.7.1 Initiating Connected Community file exchange from the machine 59

3.7.2 Connected Community file synchronization 60

3.7.3 Troubleshooting Connected Community file exchange 60

3.8 Selecting an excavator bucket 61

3.9 Selecting a 3D vertical guidance method 62

3.10 Selecting a Depth and Slope vertical guidance method 63

4 Using 2D Depth And Slope Guidance in the Field 65

4.1 Introduction 66

4.2 Setting the focus point 66

4.3 Selecting or creating a guidance model 66

4.3.1 Selecting a vertical guidance method 67

4.3.2 Depth and Slope system softkeys 68

4.3.3 Depth and slope models 68

4.3.4 Depth dual slope models 71

4.3.5 Profile models 75

4.4 Establishing an elevation reference 77

4.4.1 Using the bucket focus as the reference elevation 78

4.4.2 Using a laser plane as the reference elevation 78

4.5 Working with Depth and Slope guidance 79

4.5.1 Transferring a benchmark reference elevation 80

4.5.2 Using the bucket position to measure site features 82

5 Using 3D Guidance in the Field 85

5.1 Introduction 86

5.2 Preparing 3D sensors 86

5.2.1 Starting the UTS system 87

5.2.2 Benching a UTS target 89

5.2.3 Setting the UTS accuracy level 90

5.2.4 Initializing single-3D excavator orientation 91

5.2.5 Setting GPS accuracy mode 92

10 GCS900GradeControlSystem for Excavators Operator's Manual

Conttents

5.2.6 GPS geoid grid support 92

5.3 Checking 3D cutting edge guidance 93

5.4 Loading or creating a design 94

5.4.1 Loading a design 94

5.4.2 Creating a design 97

5.5 Working with 3D guidance 103

5.5.1 Setting the working surface lift and/or vertical offset 104

5.5.2 Selecting horizontal alignment 105

5.5.3 Selecting focus for horizontal guidance 107

5.5.4 Setting horizontal offset 108

5.5.5 3D remote switch support 108

5.5.6 Reacquiring UTS lock 109

5.5.7 Re-initializing orientation after moving the machine 109

5.5.8 Clearing the UTS benched elevation 109

5.5.9 Turning off UTS guidance 110

6 Using Mapping/Recording in the Field 111

6.1 Introduction 112

6.2 Automatic mapping 112

6.2.1 Fixed mapping rules 112

6.2.2 Machine mapping rules 112

6.3 Loading or creating a map 113

6.3.1 Creating a map file 113

6.3.2 Loading a map file 114

6.4 Configuring Mapping/Recording 114

6.5 Using Mapping/Recording 115

6.5.1 Mapping/Recording states 115

6.5.2 Plan view mapping types 116

6.6 Minimum height mapping 117

6.7 Point recording 117

7 Troubleshooting in the Field 119

7.1 Introduction 120

7.2 General troubleshooting 120

7.3 Running system diagnostics 120

7.3.1 UTS diagnostics 122

7.3.2 GPS diagnostics and satellite monitoring 126

7.4 Troubleshooting flashing warning messages 130

7.4.1 General warning messages 131

7.4.2 UTS warning messages 132

7.4.3 GPS warning messages 134

7.4.4 Excavator warning messages 137

7.5 Troubleshooting error messages 138

7.5.1 Software support option errors 138

7.5.2 Avoidance zone warnings 139

GCS900GradeControlSystem for Excavators Operator's Manual 11

Contents

7.5.3 Other selected error messages 139

7.6 Troubleshooting system components 145

7.6.1 External lightbar system status indicators 145

7.6.2 GPS receiver status indicators 146

7.6.3 SNRx10 data radio status indicators 147

7.6.4 SNR900, SNR450, and SiteNet 450 data radio indicators 148

7.6.5 MT900 machine target status indicators 148

7.6.6 Excavator arm sensor error indication 149

7.7 Troubleshooting UTS systems 149

7.8 Troubleshooting GPS systems 151

7.9 Before you contact your dealer 152

Index 155

12 GCS900GradeControlSystem for Excavators Operator's Manual

C H A P T E R

1About This Manual

In this chapter:

n Scope and audience

n Trimble training classes and

technical assistance

n To learn more about Trimble

n Your comments

Welcome to the GCS900 Grade Control System for Excavators Operator's Manual. This manual provides procedural information for the day to day operation of the system. The system is designed specifically for earthmoving equipment in the construction industry.

GCS900GradeControlSystem for Excavators Operator's Manual 13

1 About This Manual

1.1 Scope and audience

This manual is intended for personnel who operate the system, including:

l Machine operators

l Dealers

l Installation technicians

l Site supervisors

This manual describes how to use the standard features of the system. To learn about the underlying concepts of the system, refer to the Trimble GCS900 Grade Control System Reference Manual.

For information on how to use features not described in this manual, refer to the Trimble GCS900 Grade Control System Site Supervisor’s Manual.

Even if you have used other machine guidance systems before, Trimble recommends that you spend some time reading this manual to learn about the special features of this product.

Trimble manuals that are related to this product are available in PDF format on the GCS900 Grade Control System release media. To view or print the manuals, use Adobe Reader (provided on the media). Utilities that do not have an accompanying manual have integrated Help.

1.2 Trimble training classes and technical assistance

Contact your dealer for:

l Technical support, information notes, and other technical notes

l Information about:

the support agreement contracts for software and firmware

extended warranty programs for hardware

training classes

1.3 To learn more about Trimble

For an interactive look at Trimble, go to www.trimble.com.

1.4 Your comments

Your feedback about the supporting documentation helps us to improve it with each revision. Email your comments to ReaderFeedback@trimble.com.

14 GCS900GradeControlSystem for Excavators Operator's Manual

C H A P T E R

2Using the Control Box and Lightbars

In this chapter:

n Control box basics

n Working with control box

information

n Understanding lightbar

information

n 3D remote switch

n System beeper

As you work with the GCS900 Grade Control System, you need to set up and control the guidance system and understand the guidance information the system provides.

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2.1 Introduction

The control box is a computer that runs the system software. You control the guidance system with, and are given guidance information by, the following system components:

l the control box and lightbars

l the remote switches, if installed

l the audible alarm, or beeper

This chapter describes, in general terms, how these components are used.

For more information on these components, refer to the GCS900 Grade Control System Reference Manual.

2.2 Control box basics

The control box has a color LCD screen to display guidance and other information, and push button controls to operate the system. In addition, the control box has internal lightbars, and a USB flash drive port for loading and saving machine and display configuration data, and for loading and saving data. See Figure 2.1 and the following table that describes the items in the figure.

Power button

Next key

Zoom-out key

OK key

Figure 2.1 The control box

16 GCS900GradeControlSystem for Excavators Operator's Manual

2 5 8 b

Softkey label area

Zoom-in key

Escape key

USB flash drive port

Softkeys

Beeper

Arrow keys

Menu key

Description Function

LCD screen Displays guidance information

UsingtheControl Box andLightbars 2

Softkey labels See

Softkeys See

Zoom-in key

Zoom-out key

Next key

Menu key

USB flash drive port See

Arrow keys

( )

Zoom in on the machine

Zoom out from the machine

View the next guidance screen or select the next field in a dialog

View the

Pan a guidance view, select an item in a list, or enter data in a field

[ ]

OK key

Escape key

Power key

Beeper

Save changes made in a dialog, and exit the dialog

Exit from a dialog without saving changes, or exit from a menu

See

See 2.6 System beeper

2.3.1 Working with menus and dialogs

Setup Menu – Configuration

2.2.2 System memory and the USB flash drive

2.2.1 Power key

dialog

2.2.1 Power key

The P key turns the control box on and off.

To turn on the control box and the system, press P. After a brief pause, an opening screen appears.

Note – If the system reports that there are upgrade files or other system files on the control box, or that the operating system is out of date, contact your site supervisor immediately.

To turn off the control box and the system, press and hold P for two to three seconds until the control box shuts down. (This delay reduces the risk of you turning off the power accidentally.) You can turn off the system from any screen or dialog.

2.2.2 System memory and the USB flash drive

Files and data are stored on the control box in an area known as system memory. The files and data in system memory are used by the system and there is only limited Site Supervisor access via the control box.

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To access the files and data in system memory, they need to be transferred from the control box onto a USB flash drive. The files and data on the USB flash drive can then be directly accessed from a laptop, an office computer, or SiteVision Office software.

Note – When you insert a USB flash drive into the control box, system operation is temporarily disabled. System operation resumes when the USB flash drive is removed.

The USB flash drive folder structure is:

l At the root directory level is a “Machine Control Data” folder.

l Within the “Machine Control Data” folder are machine specific folders based

on machine names, which contain machine specific data. For example, a “HEX” folder for Hydraulic Excavator.

Note – If folders do not exist when files are transferred to the USB flash drive, the system will create them.

ATTENTION — It is recommended to always use a USB flash drive with a metal surround on the connector. When using a USB flash drive with no metal surround on the connector, the drive can be inserted upside down, and due to the lack of the metal part of the connector, contact can be broken and the file transfer process can be interrupted. See Figure 2.2.

No metal surround on the connector (NOT

recommended)

Figure 2.2 USB flash drive connector examples

2.2.3 Transferring data to and from the control box

1. Start the control box.

2. Insert the USB flash drive into to the control box USB port. The File Transfer

18 GCS900GradeControlSystem for Excavators Operator's Manual

Metal surround on the connector

(recommended)

UsingtheControl Box andLightbars 2

dialog appears.

Transferring files to the USB flash drive

Note – If a file or folder to be transferred already has an item with a matching file name, but different contents on the USB flash drive, the destination item will be renamed to a backup name generated by appending the item’s last-modified date to its file name.

1. Press To USB.

Only files that have been generated or modified on the control box transfer to the “Machine Control Data” folder on the USB flash drive and are written to the machine’s sub-folder. The machine’s sub-folder name is the same as the machine name set on the control box.

The following table describes the action that is applied to each file type during a file transfer to the USB flash drive.

File type Copy Move

Design files

Map design files

Program log files

ZSnap and .gif files

Production .tag files (when 2-way data communication IS NOT enabled)

Production .tag files (when 2-way data communication IS enabled)

Points .csv files

RemoteBase.txt file

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Note – A copy action copies the file and leaves the original file on the control box. A move action copies the file and deletes the original file from the control box.

A progress bar appears, showing the progress of the data transfer.

To exit, press \ or remove the USB flash drive.

Transferring files from the USB flash drive

Two types of file transfer from the USBflash drive are available:

l Add from USB

l Overwrite from USB

Add from USB

Note – If a file or folder to be transferred already has an item with a matching file name, but different contents on the display, the destination item will be renamed to a backup name generated by appending the item’s last-modified date to its file name. Files and folders matching this backup naming convention, generated by a previous “to USB” operation, will NOT be transferred from the USB flash drive to the display.

1. Press Add from USB.

Data in the “\Machine Control Data\MachineName” folder and sub-folders, and the “\Machine Control Data\All” folder of the USB flash drive transfers to the control box.

A progress bar appears, showing the progress of the data transfer.

To exit, press \ or remove the USB flash drive.

Overwrite from USB

Note – Use with caution, as this transfer deletes all existing files from the control box.

1. Press Overwrite from USB. The following actions occur:

a. A warning is displayed. Read the warning message carefully and only

press \ if you are sure you want to continue.

b. The control box is backed up. All current files on the control box are saved

to a backup folder on the USB flash drive. Your site supervisor can restore from backup.

c. The entire data content is deleted from the control box.

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UsingtheControl Box andLightbars 2

d. Data in the “\Machine Control Data\MachineName” folder and sub-

folders, and the “\Machine Control Data\All” folder is transferred from the USB flash drive to the control box.

A progress bar appears, showing the progress of the data transfer.

To exit, press \ or remove the USB flash drive.

Data transfer error messages

When transferring data, a warning message appears when there is insufficient space on either the control box or the USB flash drive.

Control box storage capacities

Available control box file storage capacities are:

l CB450 - 450 MB

l CB460 - 3.5 GB

Data transfer suspend and resume

If the USB flash drive is removed from the control box, or if the = key is pressed during a file transfer operation, the file transfer is suspended and will resume when:

l the USB flash drive is re-inserted into the control box, and/or

l the relevant softkey is pressed to resume the last file transfer operation

2.3 Working with control box information

When you work with the control box, you use a mix of keys, softkeys, menus, dialogs, and guidance screens. The availability of many of these items is determined by the following factors:

l The sensors installed on the machine. For example, some configuration screens

are only available when particular sensors are installed.

l The guidance configuration of the system. Your selection of guidance method

affects the guidance information available on the display and the guidance configuration options you get.

l The operator configuration of the system. The menus and screens selected for

you by your site supervisor affect the setup information you can view and modify.

Note – This manual only covers the menu options that are available to operators by default.

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Any configuration and guidance options not covered in this manual are described in the GCS900 Grade Control System Site Supervisor’s Manual.

2.3.1 Working with menus and dialogs

Before you can begin work, you must enter configuration and set-up information into the system, and view the current system state, by using screens called menus and dialogs. Menus let you select a dialog. Dialogs let you specify set-up and configuration information, or view information about the state of system components.

Softkeys and softkey labels

Softkeys are the six physical keys immediately to the right of the screen. The function of these physical keys depends on the information displayed and is identified by the softkey label beside the key. See Figure 2.3 for an example.

Softkey labels are graphical “keys” that appear down the side of the screen.

The following tables list the softkey labels that display on the guidance screens of the control box with a brief description of each softkey's functionality.

Generic softkey icons

CB4x0 icon Functionality

Direction: Unknown

Direction

Direction: Forward

open the

Direction: Reverse

open the

GPS

UTS

dialog.

Direction

- Press to open the

dialog.

- Direction of motion is unknown. Press to open the

- Direction of motion is calculated to be forwards. Press to

- Direction of motion is calculated to be in reverse. Press to

dialog.

GPS

dialog.

UTS

22 GCS900GradeControlSystem for Excavators Operator's Manual

Excavator softkey icons

CB4x0 icon Functionality

UsingtheControl Box andLightbars 2

Bucket Tip: Center

focus to the right side of the bucket.

Bucket Tip: Left

focus to the center of the bucket.

Bucket Tip: Right

focus to the left side of the bucket.

H. Offset

V. Offset

Map recording softkey icons

CB4x0 icon Functionality

Reset Map

displayed in Manager Mode.

- Focus is on the center of the bucket. Press to change the

- Focus is on the left side of the bucket. Press to change the

- Focus is on the right side of the bucket. Press to change the

- Press to open the

Horizontal Offset

Vertical Offset

Reset Map

dialog. (3D only)

dialog. By default, this softkey is only

dialog. (3D only)

Mapping: Auto

working. Press to change map recording to theOnmode.

Mapping: On

data.

Mapping: Off

mode.

Auto

- Map data is recorded when the machine is considered to be

- Map data is recording continuously. Press to stop recording map

- Map data is not recording. Press to change map recording to the

Record Point - Record a point, when point recording is active.

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2D Depth and Slope excavator softkey icons

Table 2.1 — Softkey icons

Icon Description

Touch point

Accept laser strike

Depth memory

Slope memory

Depth dual slope memory

Select profile

Flip profile

Select profile origin

Bench

Bench rotation

The text on a softkey label can show the following details:

l A description of the operation that is performed when you press the softkey

once.

l The setting that is currently selected. The text on the softkey label changes

when you press the softkey to switch between options. The top line of the softkey label ends with a colon (:) and the bottom line shows the current option or setting.

The icon on a softkey label can show the following details:

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UsingtheControl Box andLightbars 2

l A graphical representation of the operation that is performed when you press

the softkey once.

l The setting that is currently selected. The icon on the softkey label changes

when you press the softkey to switch between options.

l Softkeys that have a fold on the bottom right corner support press and hold

functionality to directly access the associated operation.

For example, the softkey labels Bucket Tip: Center, Bucket Tip: Left and Bucket Tip:

Right (1) show the side of the bucket that is selected for horizontal guidance on 3D

systems.

Softkey labels

Figure 2.3 Example softkey labels on a guidance

screen

Some softkey labels appear in more than one screen, in which case the function of the softkey they identify is always the same.

As a softkey’s function relates to particular screens or dialogs, that functionality is only available when the appropriate screen or dialog appears. For example the New

Level function is available only when the Select Design File screen appears, as that

function relates only to that screen.

If a softkey has no function in a screen or dialog, the softkey label is blank.

By convention, this manual refers to a softkey/function combination by softkey label.

Menus

Menus let you choose another menu or dialog from a list. To move up or down the list of menu items use the ] or [ keys. Once you highlight the item you want to view, press \ to select it. See Figure 2.4 for an example.

To leave a menu without making a selection, press =.

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2 Usingthe ControlBox andLightbars

Highlighted menu item

Figure 2.4 Example menu

Dialogs

Dialogs let you enter data into the system. Dialogs can contain any of the following items:

l Text fields. Text fields let you enter text information, such as the name of a

machine. Once you select a field, you can enter data into it. A selected field appears as white text on a blue background.

l Number fields. Number fields let you enter numerical values, such as the

height of a benchmark. Once you select a field, you can enter data into it. A selected field appears as white text on a blue background.

l Lists. Lists let you select a single item from a list of items, such as a list of

machine settings files.

l Check lists. Check lists let you select one or more items, or no items, from a

list of items, such as a list of sensors.

l Yes/No fields. Yes/No fields let you enable and disable particular features.

l Information to help you make your selection.

To move between fields in a dialog, press N.

To enter data into a text or number field, use the arrow keys as follows:

Press ] or [ to scroll through the upper case alphabet (A through Z), numbers (0 through 9), the decimal point (.), the negative sign (–), the positive sign (+), a space ( ), and back to A.

Note – Available values depend on the type of field that is selected. For example, the only values available for number fields are 0 through 9, the decimal point (.), –, and +.

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UsingtheControl Box andLightbars 2

When you change a character in a field, the keys start stepping from the existing character.

) steps to the next character to the right.

In fields that allow spaces, press) twice to insert a space.

( steps back one character to the left. This deletes the character in the space

to the left.

To select an item from a list, press ] or [ to highlight the item you want to select, and press \.

To leave the dialog without saving the new data or selection, press =. If you have made changes to a dialog setting, and you choose to exit without saving those changes, the following warning appears:

To confirm that you want to abandon the changes you have made to the dialog, press

2.3.2 Working with guidance screens

While you work, you read guidance information from the system using guidance screens.

Guidance screens display a mix of text and graphics that give you information such as the slope or elevation of the cutting edge or the position of the machine.

Depending on the configuration of the system, as setup by your site supervisor, you can view varying numbers of guidance screens:

l Plan view

l Terrain

l Pass count

l Cut/Fill pass count

l Radio coverage

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l Cross-section view

l Profile view

l Split screen (profile and cross-section) view

l Level (bubble) view

l Text view 1

l Text view 2

To move between guidance screens, press N.

The availability of each screen, and the information the screen contains, changes with the following configuration items:

l The sensors installed on the machine

l The guidance configuration of the system

l The operator configuration of the system

l The type of design currently loaded

Guidance screen components

Figure 2.5 shows the main components of the guidance screens:

Guidance view area

Guidance settings status

bar

Figure 2.5 Guidance screen components

Optional text i nformation

area

The three main areas of a guidance screen are:

l The guidance view area. The guidance view area displays the machine

relative to the surface being worked. There is no guidance view area in the text screens.

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l The optional text information area. The text information area lets you view

user-selectable information. In the text screen guidance views, the text information area uses the guidance view area.

If there are more than three text items selected for display, then the text information area appears down the right side of the screen.

If there is no text information configured for that view, the text information area does not appear.

l The guidance settings status bar. The guidance settings status bar displays

the current sensors and guidance settings being used to generate guidance information. For more information, see Guidance settings, page 30.

Machine icons

The system uses a variety of icons to identify the machine in the guidance views:

l The bucket icon provides information on the bucket slope in cross-section view.

l The cutting edge tip in an icon corresponds exactly to the cutting edge tip of the

machine.

l The bucket edge in an icon corresponds exactly to the bucket cutting edge of

the machine.

l As you move the machine and bucket, the icon mimics the movements on the

screen.

l The red square on the bucket indicates the horizontal guidance point (the

bucket focus), if applicable. The green line on the bucket indicates the vertical guidance point(s).

Note – The position of symbols for other parts, in particular the tracks/wheels or rear corners, are approximate and for indication only.

Table 2.2 — 3D guidance machine type and icon

Machine type Plan View icon Profile View Icon

Excavator

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Machine type Plan View icon Profile View Icon

Excavator with variable angle boom

Table 2.3 — 2D Depth and Slope guidance machine type and icon

Machine type Profile View Icon

Excavator

Excavator with variable angle boom

Guidance settings

To display guidance settings, the system uses a variety of icons to identify the sensors being used to generate guidance information, and text to display numerical values.

3D horizontal guidance

icon

Vertical offset

Figure 2.6 Example guidance setting area for a 3D excavator system

Horizontal offset

Mapping/Recording icon -

set to Auto

Elevation guidance icons

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UsingtheControl Box andLightbars 2

Slope memory icon

Elevation offset

Figure 2.7 Example guidance setting area for a 2D Depth and Slope excavator

system

Table 2.4 — Guidance setting icons used by the system

Guidance setting icon Meaning

Elevation guidance is available.

For Depth and Slope systems, the system has been benched, but the benchmark elevation has not been referenced to a laser plane.

3D horizontal guidance information is being generated.

Use of a laser catcher is enabled i n the installation menu.

Elevation guidance is available. The system has been benched and the benchmark elevation has been referenced to a laser plane.

The system has no bench. The bench data has been cleared. The

Bench Required

Elevation guidance is available. The system is using a laser plane as the elevation reference.

Current slope memory

Laser catcher enabled

3D vertical guidance information is being generated.

flashing message is displayed.

2D elevation guidance

icon

Auto

On

Off

Slope guidance is available.

Note – The icon illustrated indicates positive slope.

Reliable bucket tilt data i s temporarily unavailable, typically due to radial movement of the arm or curling of the bucket.

No avoidance zone guidance is available. (3D only)

Mapping/Recording status.

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Zooming the view

There are four possible ways of zooming a view:

Press + to zoom in on the current view.

Press - to zoom out of the current view.

Press and hold + to zoom the machine.

Press and hold - to zoom out as much as possible.

Tip – The system saves the sizes of the views when you turn off the control box. The views automatically load at their previous size when you next use the system.

2.3.3 Guidance views

Guidance views enable the operator to view the machine guidance in a variety of ways.

Split screen view

The split screen view displays both the profile view and cross-section view in a single screen. Split screen view is useful for monitoring the position of the bucket cutting edge, relative to the guidance surface.

Note – The split screen view replaces both the cross-section and profile views; when the split screen view is available, you cannot view the cross-section and profile views as full screen views.

Level (bubble) view

Level view displays the current pitch and roll of an excavator, and is useful for helping you to level the machine.

Level view displays a level bubble, horizontal and vertical level bars, and an angle measurement. The level bubble provides a visual representation of the current pitch

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and roll information coming from the pitch and roll sensor(s). The Pitch and Roll text items appear in level view by default, and are the only text items available.

The outer ring represents 45°; the inner ring represents 22.5°.

The bubble, the horizontal and vertical level bars, and the text items all update as the machine moves and the pitch and roll readings change.

Figure 2.8 shows the level view for the Depth and Slope excavator system.

Inner ring

Outer ring

Machine roll

Figure 2.8 An example of a level view

Level bubble

Machine pitch

The level bubble units are the same as the cross slope units set in the Units dialog.

When the pitch and/or roll sensor(s) are not connected, or when a value is not available, N/A appears for that value and the bubble does not appear.

Text view 1 and text view 2

The site supervisor configures the text items that display in text view 1 and text view2. The following figure shows an example text view guidance screen.

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2 Usingthe ControlBox andLightbars

Note – Up to 10 text view items can be displayed in full screen view and the text size scales automatically to fit the available screen space.

2.4 Understanding lightbar information

The system uses LED arrays, called lightbars, to provide the operator with guidance information.

Lightbars let you simultaneously view guidance information, the cutting edge, and the surface being worked.

The CB460 control box supports either internal or external lightbars. The characteristics of internal and external lightbars differ as follows.

2.4.1 External lightbars

External lightbars can be installed in the cab, as required to replace the internal lightbars.

Note – External lightbars are only supported on CB430 and CB460 control boxes.

In each external lightbar there are seven sets of LEDs in two colors, as shown below.

Amber LEDs

Figure 2.9 LB400 external lightbar LEDs

Green LEDs

When the cutting edge is within half of the on-grade or on-line tolerance, only the central green LED is lit. When the cutting edge is within the on-grade or on-line tolerance, the central green LED and one other green LED are lit. If any LED, other than a green LED is lit, then the cutting edge is off grade or off line.

When the drum is within half of the on-grade or on-line tolerance, only the central green LED is lit. When the drum is within the on-grade or on-line tolerance, the central green LED and one other green LED are lit. If any LED, other than a green LED is lit, then the drum is off grade or off line.

34 GCS900GradeControlSystem for Excavators Operator's Manual

2.4.2 Internal lightbars

Internal lightbars are built into the control box and can be disabled if not required.

In each internal lightbar there are seven LEDs in two colors, as shown below.

UsingtheControl Box andLightbars 2

Amber LEDs

Figure 2.10 Control box internal lightbar LEDs

When the cutting edge is within the on-grade or on-line tolerance, only the central green LED is lit. If any LED, other than a green LED is lit, then the cutting edge is off grade or off line.

Excavator lightbar behavior depends on the system installed. The following sections describe how Depth and Slope and 3D guidance information is displayed using lightbars.

2.4.3 3D excavator lightbar behaviour

Up to three lightbars can be used with a 3D excavator system. Each lightbar shows different information about the bucket position:

l The left vertical cut/fill lightbar provides corrections for cut and for fill. This

lightbar displays information for the lowest bucket tip relative to the design.

l The horizontal left/right lightbar indicates left and right corrections to the arm

position relative to the horizontal alignment, for the bucket tip that has focus.

l The right vertical reach lightbar indicates extension and retraction corrections

to the arm position relative to the horizontal alignment line, for the bucket tip that has focus.

Green LED

Only one of either the horizontal lightbar or the right vertical lightbar is active at any one time. The system automatically selects which lightbar is activated, based on the excavator’s orientation relative to the selected horizontal alignment.

The left vertical cut/fill lightbar gives guidance to only one bucket tip at a time and indicates guidance to the following points:

l The bucket tip with the smallest Cut value, when both bucket tips are above the

temporary working surface.

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l The bucket tip with the largest Fill value, when both bucket tips are below the

temporary working surface.

l The Fill bucket tip, when one bucket tip is below and one bucket tip is above

the temporary working surface.

Note – For machines fitted with a tilting bucket, the lightbar gives guidance to one bucket tip at a time in the same way as described above.

Tip – Use text items to see the cut/fill values for both bucket tips at the same time.

Left vertical cut/fill lightbar guidance

The cut/fill lightbar on an excavator gives on-grade guidance to the working surface, as shown in Figure 2.11.

Cut/fill lightbar

Figure 2.11 Excavator vertical cut / fill 3D guidance

Horizontal left/right lightbar guidance

Excavators can operate parallel to a horizontal alignment. Horizontal guidance is given by the left/right lightbar once the excavator has turned so that it is parallel to the selected alignment. See Figure 2.12

36 GCS900GradeControlSystem for Excavators Operator's Manual

Lowest tip guidance. One amber LED lit. Cut

down.

UsingtheControl Box andLightbars 2

Left/right lightbar

Figure 2.12 Excavator horizontal left/right 3D guidance

Left/right guidance. One amber LED lit. Steer

left.

Right vertical extend/retract lightbar guidance

An excavator can also work square to (toward) an alignment. The right vertical extend/retract lightbar guidance gives extension guidance to the selected alignment. This is shown in Figure 2.13.

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Extend/retract lightbar

Figure 2.13 Excavator reach 3D guidance

2.4.4 2D excavator lightbar behavior

Note – The horizontal lightbar is not currently used in 2D excavator systems.

Extension guidance. Three amber LEDs lit and

flashing. Retract arm to move bucket in.

Bucket guidance. Green and three amber

LED lit. Lower bucket.

Figure 2.14 Using a 2D excavator’s lightbars

38 GCS900GradeControlSystem for Excavators Operator's Manual

Laser strike guidance. No LEDs lit. No

laser strike.

The left lightbar displays cut/fill information. The cut/fill information is relative to the guidance surface under the bucket.

The right lightbar behaves in the following way when the laser catcher receives laser strikes:

l Green LED lit – laser strike detected in the center of the laser catcher window.

l Green and two amber LEDs lit – laser strike detected close to the center of the

laser catcher window.

l Green and three amber LEDs lit – laser strike detected far from the center of

the laser catcher window.

l No LEDs lit. No laser strike detected.

To set lightbar brightness, see 3.4.6 Lightbar brightness.

2.5 3D remote switch

The 3D excavator system supports the use of a remote switch for:

UsingtheControl Box andLightbars 2

l turning map recording events on and off:

Pass count coverage – On/Off/Auto.

Radio Map – On/Off/Auto.

Terrain – On/Off/Auto.

Cut/Fill Map – On/Off/Auto.

l recording a point.

Configuration of which of these events (if any) is available is managed by your Site Supervisor.

Note – 3D remote switch support is not available when using a 2D Depth and Slope system.

2.6 System beeper

In addition to the display and lightbars, the system also uses an audible alarm, or beeper, to alert you to status changes and other events.

The following table lists the pattern of sounds generated by the beeper, and the events that cause them. By default, the beeper will sound for all the events listed in the table, but alerts for some events may be turned off by your site supervisor.

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Table 2.5 — Beeper patterns

Event Sounds when... Pattern

Inside Avoidance Zone the machine is inside an avoidance zone. Repeated:

150 msec on, 175 msec off, 300 msec on, 175 msec off

Above Grade the bucket is more than the vertical tolerance and less

than four times the vertical tolerance above grade.

On-Grade the bucket is within the vertical tolerance of grade. Continuous:

Below Grade the bucket is more than the vertical tolerance and less

than four times the vertical tolerance below grade.

Approach Avoidance Zone the machine is within the warning distance of an

avoidance zone.

No Avoid the No Avoid message appears. Once only:

Warning Message Appears a warning message appears. Once only:

Warning Message Disappears a warning message automatically disappears. Once only:

GPS Accuracy the GPS accuracy level changes. Once only:

Continuous: 50 msec on, 50 msec off

Continuous: 100 msec on, 100 msec off

Once only: 200 msec on, 200 msec off, 400 msec on

200 msec on

200 msec on, 200 msec off, 200 msec on

200 msec on

UTS Tracking the UTS loses lock on the machine target. Once only:

200 msec on

Laser Alerts a l aser strike is detected in the laser catcher window. Once only:

200 msec on

Key/Switch Beeps a key or a switch is pressed. Once only:

200 msec on

40 GCS900GradeControlSystem for Excavators Operator's Manual

C H A P T E R

3Preparing to Work

In this chapter:

n Power up checks

n Software option keys

n Work preparation checks

n Configuring the machine radio

n Wi-Fi networking

n Exchanging files with a

Connected Community filespace

n Selecting an excavator bucket

n Selecting a 3D vertical guidance

method

n Selecting a Depth and Slope

vertical guidance method

Before you begin work with the GCS900 Grade Control System, you need to check the state of the machine and its system components to ensure the system provides accurate guidance.

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3.1 Introduction

This chapter describes how to check the machine before you turn on the system, what to look for as the system powers up, and how to check the general system setup once the system is running.

3.2 Power up checks

ATTENTION — In cold environments, when you start the machine to warm it up turn on the control box as well.

When you power up the system to begin work, observe the system’s start-up sequence to make sure that all components function correctly. See the following list of basic checks.

Check For more information, see ...

Lightbar power up

Control box power up

3.2.1 Lightbar power up

Observe the lightbars during start-up and make sure that the lightbars work correctly.

To perform the lightbar start-up check:

To turn on the system power, press P on the control box.

2. Immediately observe the pattern of the lightbar LEDs.

The LEDs flash in the following sequence:

LEDs on this lightbar Flash

Cut / fil l Bottom to top

Left / right Left to right

In / out (extend / retract) Top to bottom

All Twice, simultaneously

3.2.1 Lightbar power up

3.2.2 Control box power up

The following problems may occur with internal lightbars:

Problem Action

Lightbars do not illuminate

42 GCS900GradeControlSystem for Excavators Operator's Manual

Use the methods described in 3.2.2 Control box power up to check that the control box has started successfully.

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Problem Action

Use the procedure descri bed in 3.4.6 Lightbar brightness to check that the lightbar brightness is not set too low.

The following problems may occur when you power up the external lightbars:

Problem Action

Lightbars do not illuminate

Lightbars flash in the wrong sequence

3.2.2 Control box power up

Observe the control box after the system has powered up.

You should see a guidance screen, softkeys, and optional text items (if configured).

If the machine has one or more 3D sensors installed and configured, the following items appear:

l A plan view guidance screen.

l The correct machine icon for your machine type.

l A site plan, if the system has a site plan file.

l A design or map, if one was loaded when the system was last powered down.

Use the methods described in 3.2.2 Control box power up to check that the control box has started successfully.

Use the procedure descri bed in 3.4.6 Lightbar brightness to check that the lightbar brightness is not set too low.

Check the system harness between the control box and the lightbars.

The lightbars have probably been install ed incorrectly. Consult your site supervisor.

The following problems may occur when you power up the control box and the system:

Problem Action

Control box does not start Check that the master disconnect switch and machine power switch

are on. Check the ignition switched power cable section of the system harness.

Start-up is interrupted by the “Error loading avoidance zone” error message

Start-up completes but the error message “Some of the required devices are not responding” appears

Start-up completes but the error message The system has detected a discrepancy between a configured

The avoidance zone file is corrupt. Consult your site supervisor.

A device specified during system configuration is missing or not connected. Follow the procedure described in

diagnostics

7.3 Running system

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Problem Action

“Check Machine Dimensions” appears machine dimension, and an observed one, possibly because an

incorrect machine configuration file has been loaded. Consult your site supervisor.

Start-up completes but the wrong machine icon appears on the guidance screen

3.3 Software option keys

The system supports an enhanced option key model based on specific machine types and functionality. For more information contact your dealer.

3.3.1 Option key structure

The machine/functionality option keys control which machines have which levels of functionality. The functionality levels are hierarchical in ascending capability:

l 3D Automatics

l 3D Indicate

l 2D Automatics

Each higher level contains all levels of functionality below it.

3.3.2 Software support

An incorrect machine configuration file has been loaded. Consult your site supervisor.

For new CB450 and CB460 control boxes the software will self-generate the initial 12 months of software support. If no software support date is set then an initial dialog screen will be presented to the operator. The operator can either press softkey 3 to activate 12 months of software support or decide not to do this at that time.

If software support is not activated, the software will function normally for 60 minutes after which time it will cease to calculate machine positions, making the software unusable for machine control. On the next power cycle, if software support is still not set then the same initial screen is presented to the user.

To extend this software support date, 12-month software support extension option keys are available via the Trimble Store.

3.3.3 Troubleshooting option keys

In the absence of a valid option key for at least one machine type, the system displays a persistent Option not Installed flashing message and does not resolve any machine position information.

44 GCS900GradeControlSystem for Excavators Operator's Manual

When a machine settings file is restored that specifies a machine type not supported by the current option key set, the following full screen error message is displayed:

The system lacks the Option Keys necessary to support the configured machine type.

When a machine settings file specifies a supported machine type but includes settings relating to a level of functionality not currently supported, the settings will be loaded but will not be enabled. After the load has completed, the following full screen warning message is displayed:

Not all the settings in the selected machine settings file could be loaded, the system lacks the Option Keys necessary to fully support the specified machine configuration.

After the correct option key is loaded the settings, as described by the loaded machine settings file, should be usable.

3.4 Work preparation checks

As you get ready to begin work, you need to prepare the system for the job. Perform the following work preparation tasks as and when described below.

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Check and set ... When To learn how, see ...

Machine settings As instructed by your site supervisor, or if an error in

machine dimensions is reported

Mode selection

Main screen views As required for the current job and environment

Display brightness Every power-up

Keypad backlight brightness

Lightbar brightness Every power-up

Display settings As instructed by your site supervisor

Lightbar tolerances As instructed by your site supervisor, or when there is a

Bucket wear As instructed by your site supervisor

When you restore machine settings

When devices have been added or removed

When you need to switch between guidance systems

Every power-up

significant change in material or accuracy requirements

3.4.1 Machine settings

3.4.2 Switching guidance modes

3.4.3 Main screen views

3.4.4 Display brightness

3.4.5 Keypad backlight brightness

3.4.6 Lightbar brightness

3.4.7 Display settings

3.4.8 Lightbar tolerances

3.4.10 Checking bucket wear

Note – When excavating underwater, do not submerge the sensors deeper than 20meters (66feet).

Note – Underwater excavation is only supported when using a dedicated underwater solution.

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3.4.1 Machine settings

To ensure accurate guidance, you must use the correct machine settings. Machine settings are typically saved in a machine settings file.

To view your current machine settings:

Press M from any guidance screen.

2. Press Installation.

3. Select Machine Settings.

Press = to exit.

Saved settings include calibration settings for AS300/AS45x sensors.

All saved machine settings are restored, with the following exceptions:

l Calibration settings for AS21 sensors are not saved in a machine settings file,

and are not restored when you restore the settings file.

l To learn more about sensor calibration, refer to the Site Supervisor's manual.

To view your current machine settings, select Machine Settings from the Setup Menu - Installation menu.

To restore a machine settings file:

From any guidance screen, press M.

2. Select Restore Settings. The Restore Settings dialog appears.

3. Select Machine Settings.

4. Select the correct setting file for your machine.

To confirm the settings, press \; to exit without saving the changes, press

Changes take effect immediately.

46 GCS900GradeControlSystem for Excavators Operator's Manual

The following problems may occur when you try to restore machine settings:

Problem Action

Invalid machine settings file The machine settings file is corrupt.

No settings suitable for your machine The machine settings data is incorrect.

3.4.2 Switching guidance modes

You can use a variety of guidance modes even if the sensors required for a particular configuration are not detected.

Use the Mode softkey to switch between systems, as an alternative to using multiple machine settings files:

From any guidance screen, press M. The Mode:<value> softkey indicates the current guidance mode.

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The machine settings are for the wrong machine type.

Consult your site supervisor.

2. If required, press Mode: <value> to switch to a different mode. When a new sensor or device is added to or removed from the machine, the system automatically updates the mode values.

Note – To choose from a list of available systems or to enable / disable specific systems, press and hold Mode: <value>.

3.4.3 Main screen views

The system features a new Configuration Menu item called Main Screen Views.

Main Screen Views allows the user to configure some views on the main screen to

suit the specifics of the current job and environment.

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The following tables describe the functions that can be adjusted using Main Screen Views.

Note – Some of the items listed in the following table may not apply to your system.

Table 3.1 — Main screen views - Plan views

Item Options Description

Rotation Yes / No Yes - Keeps the machine facing up the display.

No - The plan view is drawn north-up.

Auto pan Yes / No Yes - Pans the display to keep the machine

displayed.

No - The plan view will not pan if the machine drives off the display.

Display recorded points

Points only

Points and Names

None

Table 3.2 — Main screen views - Active views

Item Options Description

Only displays the points

Displays the points and point names

Does not display points

Plan (no mapping) Yes / No Yes - A plan view with no mapping content is avail able.

Terrain Yes / No Yes - A plan view with terrain mapping is available.

Cut/Fill Yes / No Yes - A plan view with cut/fill mapping is available.

Pass count Yes / No Yes - A plan view with pass count is available.

Radio coverage Yes / No Yes - A plan view with radio coverage mapping is

available.

Profile Yes / No Yes - A profile view is available.

Cross section Yes / No Yes - A cross section view is available.

Text view 1 Yes / No Yes - A text vi ew is available.

Text view 2 Yes / No Yes - A second text view is available.

Split view Yes / No Yes - A profile and cross section split view is available.

Level view Yes / No Yes - A level bubble view is available.

Table 3.3 — Main screen views - Main Screen Softkeys

Item Options Description

Mapping Softkey

None

Mapping: On/Off/Auto

Reset Maps

Record Point

Configure the function of the main screen view mapping softkey.

Mapping Softkey 2

None

48 GCS900GradeControlSystem for Excavators Operator's Manual

Configure the function of the main screen view mapping 2 softkey.

Note – Compactor systems only.

Item Options Description

Press and Hold

3.4.4 Display brightness

Use the following key combinations to adjust the brightness of the control box display for your working conditions:

To increase the display brightness, hold down M and press +.

To increase the display brightness, hold down M and press -.

Mapping: On/Off/Auto

Reset Maps

Record Point

In-Field Report

None

Record Point

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When Record Point is selected, press and hold

Record Point

Mapping/Recording

Record Point dialog.

to display the

Note – You can also set the display brightness using the Display and Lightbar Brightness dialog from the Setup Menu – Configuration menu.

3.4.5 Keypad backlight brightness

The control box keypad backlight brightness can be adjusted by the operator to suit operating conditions.

To check and adjust the keypad backlight brightness:

From any guidance screen, press M.

2. Select Display and Lightbar Brightness.

3. Press Keypad.

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4. Use one of the following tools to set the lightbar brightness:

Use the arrow keys to increase or decrease the value of the Keypad Backlight Brightness field.

Press Set Maximum to set the value to the maximum of 15.

To confirm the settings, press \; to exit without saving the changes, press

3.4.6 Lightbar brightness

To check and adjust the lightbar brightness for your working conditions:

From any guidance screen, press M.

2. Select Display and Lightbar Brightness. The control box screen of the Display and Lightbar Brightness dialog appears.

3. Press Lightbar.

4. Use one of the following tools to set the lightbar brightness:

Use the arrow keys to increase or decrease the value of the Lightbar brightness field.

Press Set Maximum to set the value to the maximum of 15.

To confirm the settings, press \; to exit without saving the changes, press

3.4.7 Display settings

Note – You do not need to restore machine and/or display settings files every time you start the control box, as the system automatically saves and reloads the settings that were being used before the last shut down.

Use the display configuration that has been created for you. To restore a display settings file:

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From any guidance screen, press M.

2. Select Restore Settings. The Restore Settings dialog appears.

3. Select Display Settings.

4. Select the correct setting file for your use.

To confirm the settings, press \; to exit without saving the changes, press

3.4.8 Lightbar tolerances

Note – In systems that do not have lightbars configured, you should still check the on-grade tolerances for the Cut/Fill text items using the On-Grade Tolerance dialog in the Setup Menu – Configuration menu. The interface is similar to the interface described in this section.

The lightbar tolerances control not only the way the lightbar LEDs are lit, but also how far the cutting edge can be from design before the Off Grade message is displayed.

To check and/or set the tolerance thresholds (scales) for the lightbars:

From any guidance screen, press M.

2. Select Lightbar Scales.

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Figure 3.1 External lightbar scale dialog

Figure 3.2 Internal lightbar scale dialog

3. Press either Vertical or Horizontal to view the current vertical or horizontal tolerance settings respectively.

Note – The tolerances for both horizontal lightbars are set to the same value. When a Depth and Slope guidance method is selected, only the left (cut/fill) lightbar is affected by the settings in the Lightbar Scales dialog.

4. If required, use the following tools to set the off grade distance at which the green LED(s) are lit. The value must be between 0m and 12.5m (41ft):

Edit the Vertical Tolerance or Horizontal Tolerance field directly.

Press Default Set <value> to set the tolerance to the default value.

Press Half Set <value> to set the tolerance to half of the current value.

Press Double Set <value> to set the tolerance to twice the current value.

Note – The remaining threshold values are calculated automatically, and appear in the dialog. The values shown on these softkeys will change, depending on the current tolerance value.

To confirm the settings, press\; to exit without saving the changes, press

52 GCS900GradeControlSystem for Excavators Operator's Manual

Any changes take effect immediately.

3.4.9 Set depth and slope increment values

Depth and Slope excavator systems provide an interface that enables you to set the amount by which depth and slope values are incremented and decremented. These values appear on the increment and decrement softkeys in the Depth Memories and Slope Memories dialogs.

Note – The Depth Memories and Slope Memories dialogs are described in 4.3

Selecting or creating a guidance model.

To set increment/decrement values:

From any guidance screen, press M.

2. Select Increment Adjustment.

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3. To set the vertical offset increment and/or the slope increment:

Edit the Vertical offset increment: or Slope increment: fields directly.

Press Default <value> to set the increment/decrement amount to its default value.

To confirm the settings, press \; to exit without saving the changes, press

3.4.10 Checking bucket wear

You must regularly check the changes in the cutting edge measurements caused by bucket wear, or as instructed by your site supervisor. To check and/or set the bucket wear compensation:

1. Measure the cutting edge height to the bucket wear control point. The bucket wear control point was defined when the bucket was first measured up.

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If the bucket wears unevenly, use an average value. However, guidance will never be better than the range of the differences in cutting edge height.

From any guidance screen, press M.

3. Select Bucket Wear.

4. If required, edit the Length J-J1 field.

Note – If the bucket teeth are longer now than when the bucket was first measured up, enter a negative value.

To confirm the settings, press \; to exit without saving changes, press =.

The changes take effect immediately.

3.5 Configuring the machine radio

The machine radio communicates with the GPS base station radio.

The machine radio communicates with the UTS instrument radio.

The Machine Radio Configuration dialog is available when your system uses one of the following radio modems:

Use this radio ... With ...

SNR2400 A UTS system.

SNR2410 or SNR2420 A UTS or GPS system.

SNR900 or SNR910 A GPS system.

SNR450 or SNRx10 A GPS system.

To open the Machine Radio Configuration dialog:

From any guidance screen, press M. The Setup Menu–Configuration dialog appears.

2. Press Installation. The Setup Menu–Installation dialog appears.

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3. Select Machine Radio Configuration. The Machine Radio Configuration dialog appears, and the system searches for a radio.

Note – For the SNR450 radio-modem it may take some time before a connection is made.

4. Use the arrow keys to enter information into the Machine Radio Configuration dialog. To save the changes, press \; to exit without saving changes, press=.

The Machine Radio Configuration dialog displays different fields, depending on your radio type. Two examples are shown below:

l For a 900MHz radio on a GPS system:

Note – This release of the system requires the use of SiteVision Office 7.4 or later for wireless communications over 900 MHz radios. For more information, refer to the site supervisor's manual.

l For a 2400MHz radio on a UTS system:

The Radio Status field can provide the following messages:

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This message ... Displays when the ...

To configure this radio ...

Not Found

Configuring

Configuration failed

Connected

App <version num.>

System cannot communicate with the radio.

Radio is currently being configured.

Radio configuration failed.

Radio connects to the system.

Radio firmware must be upgraded to the specified versi on.

required

Loader <version num.>

Radio firmware must be upgraded to the specified versi on.

required

System Error

This radio type cannot be

Firmware is not installed correctly.

System connects to an unsupported radio.

configured.

UTS incompatible

GPS incompatible

System connects to a 900MHz radio for use with an SPSx30 UTS.

System connects to an SNR2400 radio for use with a GPS system.

The Machine Radio Configuration dialog enables you to set either the network or channel that both the system and UTS or GPS communicate over. The following table outlines how to configure your machine radio:

Confirm that you have turned on the ...

Enter this into the

Configuration

dialog ...

Machine Radio

Also configure the same ...

SNR900 SNR900 machine radio A network number between 1-40 Network number on the radio-

modem (through the base station radio display)

SNR910 SNR910 machine radio A network number between 1-40 Network number on the radio-

modem (using the base station radio display)

SNR2400, SNR2410 or SNR2420

SiteNet 450, SNRx10 or SNR2420

SNR2400, SNR2410 or SNR2420 machine radio

SiteNet 450, SNRx10 or SNRx20

A channel number between 3160

A network ID between 0 and

255. Default is 1.

A frequency between 0-255. The system configures the same frequency in the machine radio and also programs the radio as a mobile radio

Channel number on the internal UTS radio (using the UTS face plate)

Note – If your site uses both GPS and UTS positioning systems with 900MHz radios, then the GPS radios and each UTS radio must be on a different network.

Note – If you have a dual band SNRx10 radio, make sure that both radio modules are assigned a radio network ID so that you can switch between radio bands if necessary. For more information, see your site supervisor.

56 GCS900GradeControlSystem for Excavators Operator's Manual

The changes take effect immediately. The network number is uploaded to the machine radio, and the machine radio is programmed as a rover radio.

For 900MHz and 2400MHz radios, the network number is stored in the control box. Whenever you start the control box, the control box automatically sets the same network number in the machine radio. For example, if a radio is moved from one machine to another, the control box automatically sets the same radio network that was configured for the previous radio.

3.6 Wi-Fi networking

This release of the system supports the use of two types of Wi-Fi enabled wireless devices:

l the SNRx20 range of modular radio modems

l the SNM940 digital communications module

Wi-Fi networking allows the exchange of data over short distances within a site without the installation of base radios or other major infrastructure.

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3.6.1 About cellular modems

Cellular modems are only available on CB430 control box systems.

A cellular modem is a wireless device that enables the on-machine system to connect to a computer network, such as the Internet, over a cell phone network.

The GCS900 Grade Control System uses the cellular modem to:

l receive VRS and Network RTK corrections

l connect to the Connected Community website

Note – Wireless file exchange does not replicate all the features of the wireless communications feature. For example, you cannot use the file exchange feature to request a snapshot of the display.

3.6.2 About Wi-Fi networking

Wi-Fi networking manages two-way wireless IP data transfer between two or more wireless devices and, optionally, a wired networking infrastructure. Wi-Fi is intended for medium to high speed data transfer over short distances.

3.6.3 SNRx20 radio modem status indicators

These are the same as the SNRx10 indicators. See 7.6.3 SNRx10 data radio status

indicators.

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3.6.4 Managing Wi-Fi networks

To connect to a Wi-Fi network, open the Wi-Fi Network dialog, from the Setup Menu – Installation menu, and select Wi-Fi Network. The known networks are

downloaded from the Wi-Fi device and listed on the control box.

3.6.5 Connecting to a Wi-Fi network

Note – Before you can connect to a Wi-Fi network, the network details and authorization pass phrase must be entered into the list of known networks. For more information, see your site supervisor.

1. From the list of known networks, select the Wi-Fi network you want to join and press \.

2. The system attempts to connect to the selected Wi-Fi network. When the connection process completes, successfully or otherwise, the Setup Menu – Installation menu displays.

3. If the system has connected to the requested network the received Wi-Fi signal strength displays in the status bar (1).

58 GCS900GradeControlSystem for Excavators Operator's Manual

Otherwise, the "disconnected" icon is displayed (2).

3.7 Exchanging files with a Connected Community filespace

This version of the software supports the use of the Trimble®SNM930 cellular modems (CB430 control box systems only) and Trimble®SNM940 cellular modems to exchange files with a customer's file space on the Connected Community website.

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3.7.1 Initiating Connected Community file exchange from the machine

To synchronize the system to the Connected Community:

1. From the Setup Menu - Configuration menu select TCC Synchronization.

2. Press Start to begin the synchronization.

The system logs into the Connected Community server, establishes a connection, and begins file exchange. The status of the file exchange is displayed in the dialog. The progress of the file exchange is displayed on the progress bar.

3. When the exchange is complete the status changes to Synchronization complete. To return to the Setup Menu - Configuration menu, press \ or =.

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3.7.2 Connected Community file synchronization

The system supports both automatic and background synchronization when transferring files between the Connected Community and the system. Background synchronization allows the operator to use the system with file synchronization running in the background.

The system also supports resuming a background file synchronization from the point at which the synchronization may have been interrupted.

Using auto synchronization

Auto synchronization allows you to keep the office and machine files up to date, without manually initiating a TCC Synchronization. To enable auto synchronization, see your site supervisor.

Using background synchronization

1. Start a TCC synchronization.

Press = at any time to return to the system and continue working while the synchronization continues to run in the background. Full system control and guidance is supported, including use of autos.

3. To return to the synchronization dialog, select TCC Synchronization from the Setup Menu - Configuration menu. The current status of the file exchange is displayed.

Stopping and resuming synchronization

From the TCC Synchronization dialog:

l Press Stop to interrupt the file exchange.

l Press Start to resume the file exchange.

3.7.3 Troubleshooting Connected Community file exchange

Use the following table to resolve Connected Community file exchange problems in the field:

Problem Resolution

Is the wireless communications device installed correctly?

Check cables and connectors. See your site supervisor.

60 GCS900GradeControlSystem for Excavators Operator's Manual

Problem Resolution

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Is the wireless communications device configured to connect to your Internet service provider?

Is the system configured to use a wireless communications device?

Is the wireless communications device connected to the Connected Community?

Does the in to the Connected Community server?

TCC Synchronization

dialog log

3.8 Selecting an excavator bucket

For excavators, the bucket model that the system uses to calculate guidance information must match the bucket you use on the job.

To check and/or select an excavator bucket model:

From any guidance screen, press M. The Setup Menu – Configuration menu appears.

2. Select Select Bucket.

See your site supervisor.

See

3.7.1 Initiating Connected Community file

exchange from the machine

3. Select the bucket model you are going to use for the job.

To confirm the settings, press \; to exit without saving the changes, press

Some possible problems that can occur when you try to select an excavator bucket are:

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Problem Action

No bucket models are available The installation of the system has not been completed.

Notify your site supervisor.

There is no bucket model available for the bucket you want to use

Choose another bucket, or ask your site supervisor to define a bucket model for you to use.

3.9 Selecting a 3D vertical guidance method

To check and/or select a vertical guidance method:

From any guidance screen, press M.

2. Select Guidance Method.

3. Press Change Method. A dialog similar to Figure 3.3 appears:

List of available vertical

guidance methods

Figure 3.3 Example of a 3D Vertical Guidance Method

dialog

4. Highlight the vertical guidance method you want to use.

To use in the field, see Chapter 5, Using 3D Guidance in the Field.

Method Description

3D, 1 Point Center One vertical guidance point in the center of the bucket.

3D, 1 Point Focus One vertical guidance point inset 200 mm (8 inches) from the

bucket focus.

3D, 2 Points Tips Two vertical guidance points, inset 200 mm (8 inches) from the

bucket tips.

62 GCS900GradeControlSystem for Excavators Operator's Manual

Brief description of

highlighted vertical guidance method

Tip – Trimble suggests that you use the default 3D, 1 Point Center method, unless you have a good reason to use another Vertical Guidance Method.

To confirm the settings, press \; to exit without saving the changes, press

3.10 Selecting a Depth and Slope vertical guidance method

This is covered in Chapter 4, Using 2D Depth And Slope Guidance in the Field.

To select a Depth andSlope vertical guidance method, see 4.3.1 Selecting a vertical

guidance method.

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64 GCS900GradeControlSystem for Excavators Operator's Manual

the Field

C H A P T E R

4Using 2D Depth And Slope Guidance in

In this chapter:

n Setting the focus point

n Selecting or creating a guidance

model

n Establishing an elevation

reference

n Working with Depth and Slope

guidance

To generate guidance information, the GCS900 Grade Control System measures the cutting edge of the bucket position relative to a physical reference surface or laser plane. These systems are called Depth and Slope, or 2D, guidance methods.

Unlike 3D guidance methods, Depth and Slope guidance methods do not rely on knowing the machine’s three dimensional location. This can make the site infrastructure much easier to set up.

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4 Using2D Depth And Slope Guidance in theField

4.1 Introduction

This chapter describes how to set up Depth and Slope guidance systems, and use them in the field.

For more information about Depth and Slope guidance systems and their sensors, refer to the GCS900 Grade Control System Reference Manual.

4.2 Setting the focus point

The focus point is the point on the bucket used as the reference point when benching. By default, the focus is located at the center of the cutting edge of the bucket.

If you need to change the focus point:

From any guidance screen, press M.

2. Select Bucket Focus: <position>.

3. Select one of the following positions for the focus point:

Left – the focus point is at the left end of the cutting edge of the bucket

Center – the focus point is at the center of the cutting edge of the bucket

Right – the focus point is at the right end of the cutting edge of the bucket

To confirm the settings, press \; to exit without saving the changes, press

4.3 Selecting or creating a guidance model

A guidance method consists of guidance models stored in system memory. Once you have selected a guidance method and created guidance models, you can then use a guidance screen softkey to switch between stored guidance models.

66 GCS900GradeControlSystem for Excavators Operator's Manual

Using2D DepthAnd SlopeGuidancein the Field 4

Guidance models are stored as Depth Memories and Slope Memories and are accessed from the Vertical Guidance Setup dialog. Cab rotation is supported when using a cab rotation sensor.

The system supports the use of the HS410 heading sensor as a cab rotation sensor for 2D excavation. The heading sensor is designed to measure the excavator body sensor relative to the Earth's magnetic field, and incorporates a heading sensing unit.

A guidance method needs to be selected before you can receive cutting edge guidance. You can select a saved guidance method already stored in the system, or you can create a guidance method while you are working in the field.

Available guidance methods are listed in the following table:

Guidance Method

Depth Depth specifies the elevation of the design surface. Positive values of depth

Depth Slope Slope specifies the grade of a design surface. Positive values of slope

Depth Dual Slope

Profile Profiles specify a linked sequence of line segments. The segments must be

Description For more

place the design surface above the benched elevation. If depth is combined with slope, then the depth specifies the elevation of the design surface directly above or below the benching point.

cause the design surface to slope upwards away from the front of the machine. Slope is always used in combination with depth.

Reach and elevation guidance to a dual slope.

Note – Depth Dual Slope is only available when the HS410 cab rotation

sensor is installed and configured.

vertical or less than vertical.

4.3.1 Selecting a vertical guidance method

To check and/or select a vertical guidance method:

From any guidance screen, press M.

2. Select Guidance Method. The Vertical Guidance Method dialog appears.

information, see ...

4.3.3 Depth and slope models

4.3.4 Depth dual slope models

4.3.5 Profile models

3. Press Change Method. A dialog similar to Figure 4.1 appears:

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4 Using2D Depth And Slope Guidance in theField

Brief description of

highlighted guidance method

Figure 4.1 Example of a Vertical Guidance Method

dialog

4. Highlight the vertical guidance method you want to use.

To confirm the settings, press \; to exit without saving the changes, press

= .

4.3.2 Depth and Slope system softkeys

See Table 2.1 on page 24 for a list of the Depth and Slope system softkeys.

4.3.3 Depth and slope models

Depths and slopes are stored on the control box in depth and slope memories respectively. These memories are only accessible when a vertical guidance method has been selected that requires the use of a model from the memory. For example, you can only access slope memory when the Depth Slope vertical guidance method has been selected.

List of available

guidance methods

Selecting a depth or slope model from memory

Depth and slope models are selected from any guidance screen by pressing the

Depth or Slope softkeys respectively. The softkey labels identify the model number

that is selected, and that model’s depth or slope.

There is always at least one depth and one slope model stored in each memory. If there is more than one model of a particular type in memory, then pressing the softkey will select the next model.

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Creating a new depth model

1. From any guidance screen, press and hold Depth.

Note – You can also access Depth Memories by pressing Depth Memories from the Guidance Method dialog.

Press J until the highlight bar moves past the last item in the current list. A new depth model is created, with a depth of zero.

Using2D DepthAnd SlopeGuidancein the Field 4

3. Use any of the following tools to set the depth:

Edit the Depth field directly

Press +0.015 or –0.015 to add or subtract 0.015 m (0.6 inches) to or from the current depth

Note – The actual softkey labels displayed depend on the increment/decrement values that have been set and the units selected for distance. For more information on setting the increment/decrement values, see 3.4.9 Set depth and slope increment values.

Press Set 0.00 to set the depth to zero

To confirm the changes, press \; to exit without saving the changes, press

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Creating a new slope model

1. From any guidance screen, press and hold Slope.

Note – You can also access Slope Memories by pressing Slope Memories from the Guidance Method dialog.

Press J until the highlight bar moves past the last item in the current list. A new slope model is created, with a slope of zero.

3. Use any of the following tools to set the slope:

Edit the Slope field directly

Press +1:100.00 or –1:100.00 to add or subtract the value from the current slope

The actual softkey labels displayed depend on the increment/decrement values that have been set and the units selected for grade. For more information on setting the increment/decrement values, see 3.4.9 Set depth

and slope increment values.

Press Set Level to set the slope to zero

To confirm the changes, press \; to exit without saving the changes, press

Editing a depth or slope model

1. Select a depth or slope model from the Depth Memories or Slope Memories dialog.

2. Edit the model, and save changes, using the tools described in Creating a new

slope model, page 70.

Tip – You can also save changes by pressing I or J. This enables you to edit a

number of designs in succession without leaving the dialog.

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Deleting a depth or slope model

1. Select a depth or slope model from the Depth Memories or Slope Memories dialog.

2. Press Delete.

To confirm the changes, press \; to exit without saving the changes, press

4.3.4 Depth dual slope models

Depth dual slope provides reach and elevation guidance to a dual slope. Cab rotation is supported.

A depth dual slope model is stored on the control box in the depth dual slope memory. You can only access depth dual slope memory when:

l the Depth Dual Slope guidance method has been selected, and

Using2D DepthAnd SlopeGuidancein the Field 4

l the system is configured to use the HS410 cab rotation sensor

Using the HS410 cab rotation sensor

The HS410 cab rotation sensor is designed to measure the excavator body sensor relative to the Earth's magnetic field, and incorporates a heading sensing unit. The system uses the heading sensor to measure the excavator body rotation.

The following photo shows the HS410 cab rotation sensor.

When using the depth dual slope guidance method:

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4 Using2D Depth And Slope Guidance in theField

l the grade icon shows that:

the grade of the slope is in the direction in front of the machine

a positive grade is up and away from the cab

a negative grade is down and away from the cab

l the cross slope icon shows that:

a positive slope is up to the right

a negative slope is down to the right

Selecting a depth dual slope model from memory

A depth dual slope model is selected from any guidance screen by pressing the

Depth Dual Slope softkey.

There is always at least one depth dual slope model stored in each memory. If there is more than one model in memory, press Depth Dual Slope again to select the next model.

Creating a new depth dual slope model

1. From any guidance screen, press and hold Depth Dual Slope.

Note – You can also access Depth Dual Slope Memories from the Guidance Method dialog.

Press J until the highlight bar moves past the last item in the current list. A new depth dual slope model is created.

3. Use any of the following tools to set the grade and cross slope:

Edit the Grade and Cross slope fields directly.

Press +1:100.00 or –1:100.00 to increment or decrement the grade and cross slope values.

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Note – The actual softkey labels displayed depend on the increment/decrement values that have been set and the units selected for distance.

Press Level to level the grade or cross slope values.

To confirm the changes, press \; to exit without saving the changes, press

Bench rotation

Bench rotation benches the machine rotation so the system knows the direction of the main grade slope.

To bench the cab rotation sensor:

1. Press Bench Rotation to initiate the bench rotation.

2. Rotate the machine to face the direction of the grade to be worked and press

\ to accept the bench.

Cab rotation text item

A "Cab Rotation" text item (1) is available when using a cab rotation sensor.

The cab rotation text item:

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4 Using2D Depth And Slope Guidance in theField

l displays the current rotation of the cab up to ±180° around the benched rotation

direction (16° in this example)

l shows a small top-down excavator icon that indicates which side of the rotation

bench direction the excavator is currently on (in this example, clockwise from the benched rotation)

Additional rotation features

When an HS410 is installed and configured, you can:

l rotate the machine to catch a laser strike

l rotate the machine to use the touch point feature when working on slopes.

(single and dual)

Enabling and disabling cab rotation support

To disable the rotation sensor support:

1. From the Setup Menu – Installation dialog, select the Cab Rotation Support.

2. In the Cab Rotation dialog, select:

Yes to use the output from the cab rotation sensor in guidance calculations

No to ignore the output from the cab rotation sensor

Cab rotation sensor troubleshooting

The cab rotation sensor has an LED that indicates power:

l when lit the unit has power at the connector

l when not lit, the unit does not have power at the connector or there is an

internal harness failure in the unit.

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4.3.5 Profile models

Profiles are stored in profile memory. This memory is only accessible when the Profile vertical guidance method has been selected.

Selecting a profile from memory

1. From any guidance screen, press Profile.

Note – You can also access Profile Memories by pressing Select Profile from the Guidance Method dialog.

2. Select the profile you require. The guidance screen re-appears, and the Bench

Required flashing warning message is displayed. For information on benching,

see 4.4 Establishing an elevation reference.

Creating a new profile

1. From any guidance screen, press Profile. The Select Profile dialog appears.

Using2D DepthAnd SlopeGuidancein the Field 4

2. Press Create New. The Profile Definition dialog appears, with the point of origin of the profile displayed as a green point:

3. Use the following tools to create the new profile:

Press Use Bucket to align the current position of the bucket focus to the origin of the profile. Move the bucket so that the bucket focus is at the

origin of the profile you are creating, and press \.

Cross hairs appear in the Profile Definition dialog’s design pane, indicating the current position of the bucket relative to the origin, and the

Use Bucket softkey is replaced with the Point Here softkey.

Once you have aligned the bucket focus with the origin (see previous tool), to add a line segment to the profile press Point Here at any time. A new

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4 Using2D Depth And Slope Guidance in theField

point appears in the Profile Definition dialog’s design pane at the current position of the bucket focus:

The new point defines a new line segment. Both the new point and the new line segment are displayed in red, indicating that the point has edit focus.

To add a line segment to the profile, press New Point. A new point appears in the Profile Definition dialog’s design pane:

Both the new point and the new line segment are displayed in red, indicating that the point has edit focus.

Press the arrow keys on the control box to modify the position of the selected point.

Press ] to move the edit focus forwards or [ to move the edit focus backwards along the profile.

Press Delete Point to delete the point with edit focus.

When you have finished adding segments to the profile, press \, to save the profile. The Profile Name dialog appears:

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5. Do one of the following:

Press \ to accept the supplied name.

Edit the Profile Name field directly, and press \. Profiles must have a unique name, and names cannot contain spaces.

The Select Profile dialog re-appears with the name of the new profile highlighted in the profile list.

Press \ to select the profile. The guidance screen re-appears and the Profile softkey identifies the origin point you are going to bench on, or have already benched on.

Editing a profile

1. From the Select Profile dialog, select the profile to be edited.

2. Press Edit. The Profile Definition dialog appears, with the profile to be edited displayed.

3. Edit the profile, and save changes, using the tools described in Creating a new

profile, page 75.

Deleting a profile

1. From the Select Profile dialog, select the profile to be deleted.

2. Press Delete.

To confirm the changes, press \; to exit without saving the changes, press

4.4 Establishing an elevation reference

Before you begin working, or whenever you move the machine to a new working position, you must establish, or re-establish, your elevation reference. All depths are

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4 Using2D Depth And Slope Guidance in theField

relative to this reference, and all slopes and profiles have their origins at this point.

Until you establish a reference elevation, no guidance information is available, and the Bench Required flashing warning message is displayed.

The system provides two methods for establishing an elevation reference:

l By benching using the elevation of the bucket focus as the reference.

l By using the elevation of a laser plane as the reference.

If using a cab rotation sensor, you must bench the rotation before you bench the elevation. To bench the cab rotation sensor, see Bench rotation, page 73.

Note – The availability of a particular elevation reference will depend on the site infrastructure and the vertical guidance method chosen.

4.4.1 Using the bucket focus as the reference elevation

To bench the system using the elevation of the bucket focus as the reference elevation:

1. Place the machine in a convenient location to work the surface. If using a profile or a slope, orient the machine with the arm parallel to the long section of the profile, or parallel to the mainfall of the slope.

ATTENTION — Benching with the tilt bucket warning indicator displayed may give poor results.

2. If the using a profile, check the orientation and origin of the profile. If required:

Press Flip Profile to reflect the profile about its vertical axis.

Press Profile Origin as often as required to select a different point on the profile as the origin. This point will be at the bucket tip after benching.

These tools are useful if, for example, you want to work the surface from the opposite side.

3. Place the bucket focus on the benchmark, or at the location you want to make the origin of the profile, and press Bench. The bench elevation is accepted as the reference elevation, and all depths will be relative to the bench point.

4.4.2 Using a laser plane as the reference elevation

If you have a depth model selected, check with your site supervisor to make sure the laser plane is level.

If you have a depth and slope model selected, check with your site supervisor to make sure the laser plane has been set up so that the:

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l slope of the laser plane is parallel to the mainfall of the surface

l slope is the same as the slope used on the machine (for example, if the

machine slope is 15% the laser grade must also be 15%)

Note – This feature is not available with profiles.

WARNING — Do not stare into the laser beam when the laser transmitter is operating. For

more information, refer to the documentation that came with your laser.

To use a laser plane as the reference elevation:

1. Place the machine in a convenient location to work the surface. If using a slope model, orient the machine with the arm parallel to the mainfall of the slope.

2. If you have previously benched the system, press and hold Bench to clear the benching information.

Note – If you do not clear the benching information, then the system will continue to use the bench elevation as the reference elevation, rather than the elevation of the laser plane.

3. Raise the boom so that the laser lightbar indicates that the laser catcher is receiving laser strikes. The laser catcher must be reasonably steady in the laser plane. Once the system has detected valid strikes, the Laser softkey appears.

Note – The Laser softkey is displayed while the laser catcher is receiving laser strikes. The system stores the position of the arm at the time valid strikes were detected, and if strikes are lost, the arm position is retained for three seconds (3s.). During this period the Laser softkey continues to be displayed, and can be pressed to accept the valid strike elevation.

4. Press Laser. The laser strike elevation is accepted as the reference elevation, and all depths will be relative to the laser plane. The depth from laser icon

is shown on the status bar.

4.5 Working with Depth and Slope guidance

Common tasks that you must perform when working with Depth and Slope guidance are shown below.

Task When To learn how, see ...

Carry bench data as you move around the site

Whenever you need to change the position of the machine after benching.

4.5.1 Transferring a benchmark reference elevation

Measure site features Whenever you need to measure site features or

store the slope of a site feature in a Slope Memory.

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4.5.2 Using the bucket position to measure site features

4 Using2D Depth And Slope Guidance in theField

4.5.1 Transferring a benchmark reference elevation

As you work you will typically move the machine, so you must re-bench the system after moving. If your original reference elevation was a benchmark, a move to a new working position may mean you are unable to reach the benchmark and still have the cab in the correct orientation for benching. In this case, you need to transfer the bench elevation with you as you move.

The system provides two methods for transferring a benchmark reference elevation around the site:

l Using a laser plane.

l Using Touch Point.

The choice of method will depend on:

l the type of surface model you are working

l how you are working with the surface model

l the sensors and site infrastructure you have available

Using a laser plane

If you have a depth model selected, check with your site supervisor to make sure the laser plane is level.

If you have a depth and slope or profile model selected, check with your site supervisor to make sure the laser plane has been set up so that the:

l slope of the laser plane is parallel to the mainfall of the surface

l slope is the same as the slope used on the machine (for example, if the

machine slope is 15% the laser grade must also be 15%)

Using a laser plane is the most flexible method for transferring the benchmark elevation. You can use a laser elevation reference for all surface model types. However you do need a laser catcher installed and enabled on your machine, and a laser transmitter set up correctly to provide the laser plane.

WARNING — Do not stare into the laser beam when the laser transmitter is operating. For

more information, refer to the documentation that came with your laser.

To use a laser plane to transfer a benchmark elevation:

1. Before you move the machine from the location in which it was benched, and with the cab in the “as benched” orientation, raise the boom and curl the stick

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Using2D DepthAnd SlopeGuidancein the Field 4

so that the laser catcher is vertical and receiving laser strikes. The laser light bar indicates that strikes are being received. The laser catcher must be reasonably steady in the laser plane. Once the system has detected valid strikes, the Laser softkey appears.

Note – The Laser softkey is only displayed while the laser catcher is receiving laser strikes. The system stores the position of the arm at the time valid strikes were detected, and if strikes are lost, the arm position is retained for three seconds (3s.). During this period the Laser softkey continues to be displayed and can be pressed to accept the valid strike elevation.

2. Press Laser. The laser strike elevation is accepted as a reference.

3. Move the machine to the new working location, and rotate the cab into the correct orientation for benching.

4. Again, raise the boom and accept the laser strike elevation, as described in step 1 and step 2. The system is now benched against the original benchmark elevation.

5. Repeat step 4 every time you move the machine.

Using Touch Point

The Touch Point feature allows you to transfer the bench elevation simply by touching the bucket on a point easily accessible from both your original position and your new position. Using the Touch Point feature to transfer a bench elevation requires no additional site infrastructure, and is an easy way to transfer the bench elevation when working with depth models.

ATTENTION — The Touch Point feature can be used with depth and slope models, however the common point must be chosen so that the machine will be in its “as benched” orientation when the Touch Point feature is used.

To use the Touch Point feature to transfer a benchmark elevation:

ATTENTION — Initiating Touch Point with the tilt bucket warning indicator displayed may give poor results.

1. Before you move the machine from the location in which it was benched, touch the bucket focus to any easily identifiable point that can be reached from both your current, and your new, working positions. Press Touch Point. The Touch Point dialog appears:

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4 Using2D Depth And Slope Guidance in theField

2. Move the machine to the new working position, touch the focus of the bucket to the point you touched previously (the common point), and press \. The

system is now benched against the original benchmark elevation. The guidance screen re-appears.

3. Repeat step 1 and step 2 every time you move the machine.

4.5.2 Using the bucket position to measure site features

The system lets you determine differences in reach and elevation, and calculate slope distances and slopes between points, by moving the arm and bucket. The calculated slope between two points can be saved into the slope memories.

Note – The measurement is taken to the tip of the bucket that has focus.

To measure between two points:

From any guidance screen, press M.

2. Select Measure Mode.

3. Check that the correct position for the bucket focus point has been selected. If required, press Bucket Tip: <Focus> to cycle through the focus point positions.

Note – If you change the bucket focus during the measurement procedure you will clear the stored origin position.

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4. Move the focused bucket tip to the starting point of the measurement, and press

Origin.

5. Without rotating or moving the machine, move the bucket focus to the end point of the measurement.

As shown below, once the bucket has moved enough to give a measurable change in position, the display changes to show the start point as a green mark and the current position of the bucket focus as a red mark on the bucket icon. In addition, a straight red line is drawn between the start and end points, and the

Save Slope softkey appears.

6. With the focused bucket tip at the end point, record the measured values displayed. If required, press Save Slope to save the measured value of the slope into a slope memory. The slope is automatically assigned the next available name.

To exit, press \ or =.

Note – If you saved the slope value to a slope memory, and exit from the Measure Mode dialog by pressing =, the slope value will still be held in

memory.

8. If you had a slope selected for your model, and you saved the measured slope to memory, the new slope will be automatically selected for use in the model.

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C H A P T E R

5Using 3D Guidance in the Field

In this chapter:

n Preparing 3D sensors

n Checking 3D cutting edge

guidance

n Loading or creating a design

n Working with 3D guidance

This chapter describes how to set up 3D guidance systems and use them in the field.

For more information about 3D guidance systems and their sensors, refer to the GCS900 Grade Control System Reference Manual.

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5.1 Introduction

Some systems store a three dimensional (3D) digital map of the design surface in the control box. Using 3D sensors, the system fixes the location and elevation of the machine and its bucket focus on this surface. The system then calculates the difference between the bucket focus elevation and the design elevation.

Systems that have this capability are called 3D guidance systems and use GPS and GLONASS receivers and/or a UTS (Universal Total Station) instrument, a type of robotic total station.

The system now supports the MS972 and MS992 GPS/GLONASS receivers. These receivers provide GPS and RTK or GPS+GLONASS and RTK functionality.

5.2 Preparing 3D sensors

Common tasks that you must perform before you can use a UTS system are:

Task When To learn how, see ...

Set up the UTS instrument Every time the instrument is moved or

when a new job is started

Start UTS positioning When you need to use UTS position

information for guidance

Bench a UTS machine Every time you set up a UTS

instrument and do not know the instrument elevation, or if you want to use a benched elevation in preference to a measured elevation

Set UTS accuracy requirements

Initialize machine orientation

When you are having problems establishing a UTS system’s orientation

Every time you change the location of the machine

5.2.1 Starting the UTS system

5.2.2 Benching a UTS target

5.2.3 Setting the UTS accuracy level

5.2.4 Initializing single-3D excavator orientation

Note – In this manual the generic term GPS is used to refer to both the GPS and GLONASS positioning systems.

Common tasks that you may need to perform before you can use a GPS receiver system are:

Task When To learn how, see ...

Set GPS accuracy requirements

Every time you begin a new job

5.2.5 Setting GPS accuracy mode

Load a GPS Geoid grid When the GPS position is out of the

range of the loaded geoid grid

Initialize machine orientation

86 GCS900GradeControlSystem for Excavators Operator's Manual

Every time you change the location of the machine

5.2.6 GPS geoid grid support

5.2.4 Initializing single-3D excavator orientation

5.2.1 Starting the UTS system

To learn how to set up your UTS instrument for machine control, talk to your site supervisor or refer to the Trimble SCS900 Getting Started Guide.

To start the UTS instrument, and connect the UTS instrument to the system:

1. From any guidance screen, press UTS.

Using3D Guidancein theField 5

2. To set the target ID:

a. Press Target ID.

Note – The Target ID softkey is only available when the UTS is stopped.

b. Enter the selected target ID into the Target ID field. By convention, target

IDs of 9 through 16 are used for machine control applications, with IDs of 1 through 8 reserved for surveying applications. Ask your site supervisor which target ID you should use. To set the default value of 9, press the

Default softkey.

To confirm the settings, press \; to exit without saving changes, press

=. The UTS start-up dialog appears.

3. Set the Auto search status as required.

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5 Using3D Guidancein the Field

If Auto search is turned on (Yes) and the UTS loses lock on the target, it will automatically attempt to locate and lock onto the target again by searching the area bounded by the search window defined during UTS set-up.

If Auto search is turned off and the UTS loses lock, follow the steps in 5.5.6

Reacquiring UTS lock, to reacquire lock.

4. Press Start. The UTS system starts and the UTS instrument automatically searches for the target in the area bounded by the search window defined during UTS set-up.

When the target is acquired, the UTS dialog changes to its “Tracking” layout, shown below:

UTS instrument status

Machine target ID

Figure 5.1 SPSx30 instrument start up dialog

Tip – If the UTS takes too long to find the target, press = to stop the search and the

UTS start-up.

To confirm the settings, press \; to exit without saving changes, press=. A

Battery charge

Elevation exists on UTS instrument

guidance screen appears.

Tip – The UTS instrument’s power supply is automatically measured and displayed in the

UTS Battery: field. If an external battery is used to power the UTS instrument, the UTS battery status is not available.

Some common UTS set up problems are as follows:

Problem Action

Start

dialog.

softkey in

UTS

The machine data radio has not synchronized with the UTS instrument data radio. Follow the procedure described in 7.3

Running system diagnostics, to check that the UTS components

are connected and running.

Check that the UTS instrument data radio is turned on.

88 GCS900GradeControlSystem for Excavators Operator's Manual

Problem Action

UTS fails to start Ask your site manager to check that the radio channel, and network if

See Table 7.1 on page 122 for a description of the UTS dialog field values.

5.2.2 Benching a UTS target

You must bench the target if the UTS instrument was set up with northing and easting values, but no elevation was specified.

You may bench the target even if the UTS instrument’s location was specified with an elevation value, in which case the benched elevation is used to calculate the target location, not the entered elevation of the UTS.

The Height from field in the UTS dialog displays the origin of the UTS height. The contents of the Height from field are shown below. If the Height from field displays “No heights”, you must bench the UTS target before you can use the UTS system.

Using3D Guidancein theField 5

Check the instrument battery.

applicable, are compatible with the instrument radio. Follow the procedure described in that the UTS components are connected and running.

7.3 Running system diagnostics

, to check

Height from

Benching The machine has been benched. Heights are in terms of the benchmark

UTS The machine has not been benched. Heights are in terms of UTS height.

No heights The machine has not been benched. No height information entered during

field Description

the machine was benched over.

UTS setup has station elevation and instrument height entered.

UTS set up.

To bench the target:

From any guidance screen, press and hold down \.

Note – Alternatively, to begin benching, select Bench from the Setup Menu – Configuration menu.

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5 Using3D Guidancein the Field

2. Enter the elevation of the benchmark into the Bucket elevation field.

3. Position the bucket on or beside the benchmark.

4. Depending on the part of the bucket you are using to reference the bench mark, press either Bench Center, Bench Left, or Bench Right to begin benching.

When benching finishes, the Setup Menu – Configuration menu appears.

5.2.3 Setting the UTS accuracy level

The system provides an interface that enables you to change the accuracy of the UTS data it uses to estimate the machine’s orientation. Occasionally it may be difficult to get an orientation estimate, if, for example, the UTS instrument is operating at the limit of its range, or if the machine is rocking a lot. In these cases, if the system does not require high accuracy guidance information, you can relax the accuracy of the UTS data used to estimate orientation.

To adjust the accuracy of the UTS data required for an orientation estimate:

From any guidance screen, press M.

2. Select UTS Accuracy.

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Note – The UTS data generated when the machine’s body swings is used to determine the machine’s center of rotation. This information is used to estimate the machine’s orientation.

3. Highlight the appropriate accuracy level for your job.

To confirm the settings, press \; to exit without saving the changes, press

5.2.4 Initializing single-3D excavator orientation

You must initialize the orientation of a single-3D machine when a single-3D system is first started, or when a single-3D machine is moved more than a very short distance. Until the machine orientation is initialized, guidance is not available and the following flashing warning message will be displayed:

Using3D Guidancein theField 5

To initialize the machine’s orientation, without moving the tracks swing the machine’s upper body in one direction. As the body begins to swing, a progress bar displays, as shown in Figure 5.2.

Progress bar

Figure 5.2 Initializing single-3D machine orientation

As the initialization progresses, the bar’s fill extends, and the fill color shades to green. The amount of rotation required to initialize the machine’s orientation depends on the GPS or UTS accuracy settings. The more GPS or UTS accuracy required, the further you have to swing the cab.

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Note – The estimated orientation of the machine is continually re-calculated, and as you swing the body while working, the orientation estimate improves.

If the progress bar disappears and the Rotate Machine message flashes, then the initialization has failed. If the initialization fails, repeat the initialization procedure.

5.2.5 Setting GPS accuracy mode

If you are using one or more GPS receivers as position sensors, make sure that the selected GPS accuracy mode is appropriate for the work you are about to do.

To check and/or set the GPS accuracy mode:

1. From any guidance screen, press GPS. A dialog similar to Figure 5.3 appears.

Note – GPS accuracy mode can also be set from the GPS Accuracy dialog in the Setup Menu – Configuration menu.

Current accuracy setting

Figure 5.3 GPS accuracy mode dialog

To swap between fine, medium, and coarse accuracy modes, press B.

Note – When coarse mode is selected, your site supervisor can enable the use of low accuracy corrections broadcast from satellites (SBAS). If you use SBAS GPS, check with your site supervisor that you have a suitable GPS configuration file loaded into the GPS receiver(s).

To confirm the settings, press \; to exit without saving changes, press =.

5.2.6 GPS geoid grid support

A small embedded geoid grid can be placed in a GPS receiver configuration file. The geoid grid is used to determine the GPS receiver elevation.

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This gives the user more accurate elevations, especially in highly mountainous areas where the geoid cannot be easily approximated with an inclined plane adjustment.

To load a geoid grid into the GPS receiver configuration file, see your site supervisor.

When the GPS position is out of the range of the loaded geoid grid, the following flashing message appears on the guidance screen.

Out of Geoid Range

When this flashing message appears:

l The positions that the GPS receiver generates are flagged as:

not having a valid GPS coordinate system

out of range from the geoid

l The design and the current machine position are still drawn on the plan view.

l All height information and values generated from that height information (such

as cut/fill values) are marked invalid, and appear as N/A if they are text items.

l The machine does not appear on the profile or cross section view or any other

view that would show the relative height of the machine to the design.

Move the machine until the flashing message disappears, or contact your site supervisor.

5.3 Checking 3D cutting edge guidance

Before you start work, always check the accuracy of the system. Compare the coordinates of the cutting edge focus shown on the control box with the known 3D coordinates of a survey control point.

To check accuracy:

1. Check that the current coordinates (easting, northing, and elevation) of the cutting edge focus point are displayed on one of the guidance screens, typically in one of the text view guidance screens. If the focus point coordinates are not available in one of the guidance screens, ask your site supervisor to configure a screen for you.

2. If you are using GPS for guidance, select Fine accuracy mode. See 5.2.5

Setting GPS accuracy mode.

3. Use one of these possible techniques to get a focus position:

With the arm within its normal working range of movement, place the bucket focus on the ground and then mark its position with paint. Remove

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4. Compare the position on the display with the known position of the cutting edge focus point.

Tip – Trimble recommends that you regularly check the accuracy of the system. This helps determine the wear on the cutting edge. Always check the system accuracy after you restore a display or machine configuration.

A possible problem that can occur with excavator guidance is:

Problem Action

Poor guidance Possible causes are:

the bucket. Use a total station or GPS rover to measure the marked position of the bucket focus.

Position the body of the excavator so that when the bucket focus is placed on the control point, the arm is within its normal working range of movement. Position the bucket focus on the control point.

The orientation of one or more arm position sensors is not configured correctly. Ask your site supervisor to check the AS300/AS45x orientations.

The wrong bucket model has been selected for the bucket you are using.

incorrect machine dimensions

incorrect calibrations

incorrect coordinate system loaded in the GPS receiver(s)

5.4 Loading or creating a design

Before you can receive guidance, you must have a design loaded into the system. You can load a design supplied by an engineer in the office, or you can create a design while you are working in the field.

5.4.1 Loading a design

Most design types are loaded using a few simple key presses. However, if you are loading a 3D lines design file, once the file is loaded, you must select the 3D line you want to work with.

Loading the design file

To select and load a design:

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1. From the Setup Menu – Configuration menu, select Select Design.

2. Highlight the design you want to load.

3. If the design you highlighted is a road design with sideslopes defined, make sure that the Side Slope: <value> displays either Cut or Fill:

Cut, if you are cutting down to the design surface.

Fill, if you are filling up to the design surface.

To confirm the settings, press \; to exit without saving changes, press =. If the loaded design specifies only a single design surface, the plan view guidance screen appears.

Selecting a 3D line

If the loaded design is a 3D lines design, which may specify multiple design surfaces, the Select 3D Guidance Line dialog appears:

To select a 3D line for guidance:

1. From the Select 3D Guidance Line dialog, move the cross-hairs to the 3D line that you require. Use any of the following tools to move the cross-hairs:

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All linework for the design, including the site map and any avoidance zones, is shown in this dialog. You can only select a line that is a 3D line.

Tip – If several lines are grouped closely, press Zoom Target to zoom in for easier selection. Alternatively, move the cross-hairs to an area where the lines are more easily seen. To move the cross-hairs large distances across the screen, zoom out and then hold down an arrow key. This lets you move rapidly across the design.

2. To select the 3D line for horizontal and vertical guidance, press Select. The line closest to the center of the crosshairs is selected. The selected 3D line appears as a thick red line. See Figure 5.4.

To move the cross-hairs around the screen, use the arrow keys.

To zoom the current view in and out, press + or -.

To resize the current view to the immediate area around the cross-hairs, press Zoom Target.

To view all of the linework, press Zoom All.

To view the extents of the selected 3D line, press Zoom Selection

A (start)

Figure 5.4 Selected 3D line

3. Press Set Width.

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4. If required, use one or more of the following tools to specify the width of the design:

Edit the Design Width field directly.

To add or subtract 10mm (0.4inches) to or from the current width, press

+0.010 or -0.010.

To set the width to 2.0m (6.5ft), press Default 2.000.

To confirm the settings, press \; to exit without saving changes, press =.

5. Press Extend Length.

6. If required, to extend the line at one or both of the A and B ends, use one of the following tools:

Edit the Extend A and/or Extend B fields directly.

To add or subtract 500mm (20inches) to or from the current extension, press +0.500 or -0.500.

To reset the extension to zero, press Set 0.000.

To confirm the Extend 3D Line settings, press \; to exit without saving changes, press =. The Select 3D Guidance Line dialog appears.

To confirm the Guidance Line settings, press \; to exit without saving changes, press = .

5.4.2 Creating a design

There are two simple design surfaces you can create in the field:

l Level designs

l Sloping designs

Creating a level design surface

To create a level surface design file:

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1. From the Select Design File dialog, press New Level, New Slope, or New Map.

2. Select one of the following options:

1: To use the same coordinate system as the last loaded design, select Use last (<name>). This option maintains your Northing, Easting and Elevation reference.

2: To automatically create a new coordinate system based on your current position, select Auto create on load. (MS9x2-based systems only, with firmware version 4.40 or later).

3: To use an existing coordinate system stored in the root directory of the control box file system, select the coordinate system name.

Press \. The New Map dialog, the New Design: Level Surface dialog, or the New Design: Sloping Surface dialog appears.

2. Use any of the following tools to specify the design elevation:

Edit the Design Elevation field directly.

To use the current elevation of the focus point, press Here.

To change the focus point, press either Bucket Tip: Left, Bucket Tip: Center, or Bucket Tip: Right.

To confirm the settings, press \.

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The system gives the design a default name.

If required, edit the default name and press \. The Select Design File dialog appears. The design just created is highlighted.

To load the new level surface design, press \. The Setup Menu – Configuration menu appears.

Creating a sloping design surface

WARNING — If you create a ramp or other work platform that is too steep, machines and

Note – To learn more about the elements that make up a sloping surface, refer to the GCS900 Grade Control System Reference Manual.

To create a sloping surface design file:

1. From the Select Design File dialog, press New Level, New Slope, or New Map.

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2. Select one of the following options:

Press \. The New Map dialog, the New Design: Level Surface dialog, or the New Design: Sloping Surface dialog appears.

1: To use the same coordinate system as the last loaded design, select Use last (<name>). This option maintains your Northing, Easting and Elevation reference.

2: To automatically create a new coordinate system based on your current position, select Auto create on load. (MS9x2-based systems only, with firmware version 4.40 or later).

3: To use an existing coordinate system stored in the root directory of the control box file system, select the coordinate system name.

By default, the dialog shows the softkeys and fields needed to define a sloping surface using the 2-Points method.

If you want to define the surface by using the Point-and-Direction method, go to step 3 below.

1. Use any of the following tools to specify Point 1:

Edit the Northing, Easting, and Elevation fields directly.

To use the current northing, easting, and elevation of the focus point, press

Here.

To change the focus point, press either Bucket Tip: Left, Bucket Tip: Right, or Bucket Tip: Center.

2. Press Point 2. Use the procedure outlined in step to specify Point 2.

Tip – When both points are entered, the system calculates the direction and grade values. To view the calculated values, press Method: 2 Points. The 2Points and Pt/Dir dialogs update each other with information. The Point1 and CrossSlope values are always the same in both dialogs. Enter Point2 values and then change to the Pt/Dir dialog to see the calculated direction and grade. Check that the calculated direction and grade are within design limits. If you change the Direction setting or change the Grade setting in the Pt/Dir dialog, the change clears the value of

100 GCS900GradeControlSystem forExcavators Operator'sManual

Trimble GCS900 Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Safety Information

1About This Manual

1.1 Scope and audience

1.2 Trimble training classes and technical assistance

1.3 To learn more about Trimble

1.4 Your comments

2Using the Control Box and Lightbars

2.1 Introduction

2.2 Control box basics

2.2.2 System memory and the USB flash drive

2.2.1 Power key

2.2.3 Transferring data to and from the control box

2.3 Working with control box information

2.3.1 Working with menus and dialogs

2.3.2 Working with guidance screens

2.3.3 Guidance views

2.4 Understanding lightbar information

2.4.1 External lightbars

2.4.2 Internal lightbars

2.4.3 3D excavator lightbar behaviour

2.4.4 2D excavator lightbar behavior

2.5 3D remote switch

2.6 System beeper

3Preparing to Work

3.1 Introduction

3.2 Power up checks

3.2.1 Lightbar power up

3.2.2 Control box power up

3.3 Software option keys

3.3.1 Option key structure

3.3.2 Software support

3.3.3 Troubleshooting option keys

3.4 Work preparation checks

3.4.1 Machine settings

3.4.2 Switching guidance modes

3.4.3 Main screen views

3.4.4 Display brightness

3.4.5 Keypad backlight brightness

3.4.6 Lightbar brightness

3.4.7 Display settings

3.4.8 Lightbar tolerances

3.4.9 Set depth and slope increment values

3.4.10 Checking bucket wear

3.5 Configuring the machine radio

3.6 Wi-Fi networking

3.6.1 About cellular modems

3.6.2 About Wi-Fi networking

3.6.3 SNRx20 radio modem status indicators

3.6.4 Managing Wi-Fi networks

3.6.5 Connecting to a Wi-Fi network

3.7 Exchanging files with a Connected Community filespace

3.7.1 Initiating Connected Community file exchange from the machine

3.7.2 Connected Community file synchronization

3.7.3 Troubleshooting Connected Community file exchange

3.8 Selecting an excavator bucket

3.9 Selecting a 3D vertical guidance method

3.10 Selecting a Depth and Slope vertical guidance method

4.1 Introduction

4.2 Setting the focus point

4.3 Selecting or creating a guidance model

4.3.2 Depth and Slope system softkeys

4.3.3 Depth and slope models

4.3.4 Depth dual slope models

4.3.5 Profile models

4.4 Establishing an elevation reference

4.4.1 Using the bucket focus as the reference elevation

4.4.2 Using a laser plane as the reference elevation

4.5 Working with Depth and Slope guidance

4.5.1 Transferring a benchmark reference elevation

4.5.2 Using the bucket position to measure site features

5Using 3D Guidance in the Field

5.1 Introduction

5.2 Preparing 3D sensors

5.2.1 Starting the UTS system

5.2.2 Benching a UTS target

5.2.3 Setting the UTS accuracy level