Trimble GCS900 Operator's Manual

Operator's Manual

Trimble®GCS900 Grade Control System for

Excavators

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

11

Contact Information

Trimble Engineering and Construction Division
5475 Kellenburger Road
Dayton, Ohio 45424-1099
USA
800-538-7800 (toll free in USA)
[phone] Phone
[phone] Fax
www.trimble.com

Copyright and Trademark s

© 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.

3.4 CTCT reserves all rights not expressly granted by this Agreement.
2011©, Caterpillar Trimble Control Technologies LLC. All Rights
Reserved.

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

1

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 [e-mail].

14 GCS900GradeControlSystem for Excavators Operator's Manual

C H A P T E R

2

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.

GCS900GradeControlSystem for Excavators Operator's Manual 15

2 Usingthe ControlBox andLightbars

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

1

Next key

4

Zoom-out key

7

OK key

a

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

3

Beeper

6

Arrow keys

9

Menu key

c

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

+

-

N

M

( )

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

\

=

P

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

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.

GCS900GradeControlSystem for Excavators Operator's Manual 17

2 Usingthe ControlBox andLightbars

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

1

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

2

(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

P

P

P

P

P

P

P

P

GCS900GradeControlSystem for Excavators Operator's Manual 19

2 Usingthe ControlBox andLightbars

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.

2.

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.

2.

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.

20 GCS900GradeControlSystem for Excavators Operator's Manual

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.

2.

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.

GCS900GradeControlSystem for Excavators Operator's Manual 21

2 Usingthe ControlBox andLightbars

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

Direction

- Press to open the

- Press to open the

dialog.

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

- Press to open 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.

GCS900GradeControlSystem for Excavators Operator's Manual 23

2 Usingthe ControlBox andLightbars

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:

24 GCS900GradeControlSystem for Excavators Operator's Manual

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

1

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 =.

GCS900GradeControlSystem for Excavators Operator's Manual 25

2 Usingthe ControlBox andLightbars

Highlighted menu item

1

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:

l

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 +.

26 GCS900GradeControlSystem for Excavators Operator's Manual

UsingtheControl Box andLightbars 2

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

l

) steps to the next character to the right.

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

l

( 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

GCS900GradeControlSystem for Excavators Operator's Manual 27

2 Usingthe ControlBox andLightbars

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

1

Guidance settings status

3

bar

Figure 2.5 Guidance screen components

Optional text i nformation

2

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.

28 GCS900GradeControlSystem for Excavators Operator's Manual

UsingtheControl Box andLightbars 2

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

GCS900GradeControlSystem for Excavators Operator's Manual 29

2 Usingthe ControlBox andLightbars

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

1

icon

Vertical offset

4

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

Horizontal offset

2

Mapping/Recording icon -

5

set to Auto

Elevation guidance icons

3

30 GCS900GradeControlSystem for Excavators Operator's Manual