Sie sind auf Seite 1von 166

INSTALLATION MANUAL

®
Trimble GCS900 Grade Control System for
Grading Applications

Version 11.20
Revision A
Part Number 59002-06-ENG
December 2009 F
Contact Information shall the installation Software be used to download the Software onto
Trimble Engineering and Construction Division more than one Device. A license for the Software may not be shared or
5475 Kellenburger Road used concurrently on different computers or Devices.
Dayton, Ohio 45424-1099 1.2 Other Rights and Limitations.
USA
(1) You may not copy, modify, make derivative works of, rent, lease,
800-538-7800 (toll free in USA) sell, distribute or transfer the Software, in whole or in part, except as
+1-937-245-5600 Phone otherwise expressly authorized under this Agreement, and you agree to
+1-937-233-9004 Fax use all commercially reasonable efforts to prevent its unauthorized use
www.trimble.com and disclosure.
Copyright and Trademarks (2) The Software contains valuable trade secrets proprietary to Trimble
© 2000–2009, Caterpillar Trimble Control Technologies LLC. All and its licensors. To the extent permitted by relevant law, you shall not,
rights reserved. nor allow any third party to copy, decompile, disassemble or otherwise
reverse engineer the Software, or attempt to do so, provided, however,
Trimble, the Globe & Triangle logo, and SiteVision are trademarks of that to the extent any applicable mandatory laws give you the right to
Trimble Navigation Limited, registered in the United States and other perform any of the aforementioned activities without Trimble's consent
countries. PROTECTED UNDER U.S. PATENTS: 5,107,932; in order to gain certain information about the Software for purposes
5,375,663; 6,691,437; 7,307,710; 7,246,456; 7,139,662; 5,987,379; specified in the respective statutes (e.g., interoperability), you hereby
6,324,455; 6,253,160; 4,888,890; 5,235,511; 4,924,374. agree that, before exercising any such rights, you shall first request such
SiteNet, CMR and CMR+ are trademarks of Trimble Navigation information from Trimble in writing detailing the purpose for which
Limited. you need the information. Only if and after Trimble, at its sole
For STL support, the software uses the STLPort adaptation of the discretion, partly or completely denies your request, may you exercise
Moscow Center for SPARC Technology Standard Template Library. such statutory rights.
Copyright © 1994 Hewlett-Packard Company, Copyright © 1996, 97 (3) The Software is licensed as a single product. You may not separate
Silicon Computer Systems, Inc., Copyright © 1997 Moscow Center for its component parts for use on more than one computer or Device
SPARC Technology, Copyright © 1999, 2000 Boris Fomitchev. except as specifically authorized in this Agreement.
Microsoft, Windows, and Windows NT are trademarks or registered (4) You may not rent, lease or lend the Software unless you are a
trademarks of Microsoft Corporation in the United States and/or other reseller of Trimble products under separate written agreement with
countries. Trimble and authorized by Trimble to do so.
Portions of the software are copyright © 2003 Open Design Alliance. (5) No service bureau work, multiple-user license or time-sharing
All rights reserved. arrangement is permitted. For purposes of this Agreement "service
All other trademarks are the property of their respective owners. bureau work" shall be deemed to include, without limitation, use of the
Release Notice 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
This is the December 2009 release (Revision A) of the GCS900 Grade other communications network.
Control System for Grading Applications Installation Manual, part (6) You may permanently transfer all of your rights under this
number 59002-06-ENG. It applies to version 11.20 of the GCS900 Agreement only as part of a permanent sale or transfer of the Device,
Grade Control System software. provided you retain no copies, you transfer all of the Software
The following limited warranties give you specific legal rights. You (including all component parts, the media and printed materials, any
may have others, which vary from state/jurisdiction to upgrades, and this Agreement) and the recipient agrees to the terms of
state/jurisdiction. this Agreement. If the Software portion is an upgrade, any transfer must
Trimble Navigation Limited include all prior versions of the Software.
END-USER LICENSE AGREEMENT (7) You may not use the Software for performance, benchmark or
IMPORTANT, READ CAREFULLY. THIS END USER LICENSE comparison testing or analysis, or disclose to any third party or release
AGREEMENT ("AGREEMENT") IS A LEGAL AGREEMENT any results thereof (all of which information shall be considered
BETWEEN YOU AND TRIMBLE NAVIGATION LIMITED and Trimble confidential information) without Trimble's prior written
applies to the computer software provided with the Trimble product consent.
purchased by you (whether built into hardware circuitry as firmware, (8) You may not directly or indirectly export or re-export, or knowingly
embedded in flash memory or a PCMCIA card, or stored on magnetic permit the export or re-export of the Software (or portions thereof) to
or other media), or provided as a stand-alone computer software any country, or to any person or entity subject to United States or
product, and includes any accompanying written materials such as a foreign export restrictions in contravention of such laws and without
user's guide or product manual, as well as any "online" or electronic first obtaining appropriate licenses; and
documentation ("Software"). This Agreement will also apply to any (9) You agree to cooperate with Trimble to track the number of Devices
Software error corrections, updates and upgrades subsequently or other devices using the Software at your site(s) to ensure compliance
furnished by Trimble, unless such are accompanied by different license with the license grant and installation restrictions in this Agreement. In
terms and conditions which will govern their use. You have acquired a the event the compliance check reveals that the number of installations
Trimble Product ("Device") that includes Software, some of which was exceeds the actual number of Devices obtained by you, you agree to
licensed by Trimble from Microsoft Licensing Inc. or its affiliates promptly reimburse Trimble three (3) times the then current applicable
(collectively "MS") and embedded in the Device. The Software list price for the extra licenses that are required to be compliant, but that
licensed from MS ("MS Software") is protected under this Agreement. were not obtained, as liquidated damages and as a reasonable penalty.
The Software is protected by copyright laws and international copyright (10) You acknowledge that the Software and underlying technology are
treaties, as well as other intellectual property laws and treaties. The subject to U.S. Export jurisdiction. You agree to comply with all
Software is licensed, not sold. All rights reserved. applicable international and national laws that apply to the Software
BY CLICKING "YES" OR "I ACCEPT" IN THE ACCEPTANCE and underlying technology, including U.S. Export Administration
BOX, OR BY INSTALLING, COPYING OR OTHERWISE USING Regulations, as well as end-user, end-use and destination restrictions
THE SOFTWARE, YOU AGREE TO BE BOUND BY THE TERMS issued by U.S. and other governments. For additional information see
OF THIS AGREEMENT. IF YOU DO NOT AGREE TO THE TERMS http://www.microsoft.com/exporting.
OF THIS AGREEMENT, DO NOT USE THE DEVICE OR COPY (11) Without prejudice as to any other rights, Trimble may terminate
THE SOFTWARE. INSTEAD, PROMPTLY RETURN THE UNUSED this Agreement without notice if you fail to comply with the terms and
SOFTWARE AND ACCOMPANYING TRIMBLE PRODUCT TO conditions of this Agreement. In such event, you must destroy all
THE PLACE FROM WHICH YOU OBTAINED THEM FOR A copies of the Software and all of its component parts.
REFUND. ANY USE OF THE SOFTWARE, INCLUDING, BUT NOT 1.3 Termination. You may terminate this Agreement by ceasing all use
LIMITED TO USE ON THE DEVICE, WILL CONSTITUTE YOUR of the Software. Without prejudice as to any other rights, Trimble may
AGREEMENT TO THIS AGREEMENT (OR RATIFICATION OF terminate this Agreement without notice if you fail to comply with the
ANY PREVIOUS CONSENT). terms and conditions of this Agreement. In either event, you must
1. SOFTWARE PRODUCT LICENSE destroy all copies of the Software and all of its component parts.
1.1 License Grant. Subject to the terms and conditions of this 1.4 Copyright. All title and copyrights in and to the Software
Agreement, Trimble grants you a non-exclusive right to use one copy of (including but not limited to any images, photographs, animations,
the Software in machine-readable form only on the Device. Such use is video, audio, music, and text incorporated into the Software), the
limited to use with the Device for which it was intended and into which accompanying printed materials, and any copies of the Software are
it was embedded. You may use the installation Software from a owned by Trimble and its licensors. You shall not remove, cover or
computer solely to download the Software to one Device. In no event alter any of Trimble's patent, copyright or trademark notices placed
upon, embedded in or displayed by the Software or on its packaging
and related materials.

2 GCS900 Grade Control System for Grading Applications Installation Manual


1.5 U.S. Government Restricted Rights. The Software is provided with 2.3 NO OTHER WARRANTIES. TO THE MAXIMUM EXTENT
"RESTRICTED RIGHTS". Use, duplication, or disclosure by the PERMITTED BY APPLICABLE LAW, TRIMBLE AND ITS
United States Government is subject to restrictions as set forth in this LICENSORS DISCLAIM ALL OTHER WARRANTIES, TERMS,
Agreement, and as provided in DFARS 227.7202-1(a) and 227.7202- AND CONDITIONS, EITHER EXPRESS OR IMPLIED, BY
3(a) (1995), DFARS 252.227-7013(c)(1)(ii) (OCT 1988), FAR STATUTE, COMMON LAW OR OTHERWISE, INCLUDING BUT
12.212(a) (1995), FAR 52.227-19, or FAR 52.227-14(ALT III), as NOT LIMITED TO, IMPLIED WARRANTIES, TERMS, AND
applicable. CONDITIONS OF MERCHANTABILITY AND FITNESS FOR A
1.6 Microsoft Corporation has contractually obligated Trimble to PARTICULAR PURPOSE, TITLE, AND NONINFRINGEMENT
include the following disclaimers in this Agreement: WITH REGARD TO THE SOFTWARE, ITS SATISFACTORY
QUALITY, AND THE PROVISION OF OR FAILURE TO PROVIDE
NOT FAULT TOLERANT. THE SOFTWARE IS NOT FAULT SUPPORT SERVICES. TO THE EXTENT ALLOWED BY
TOLERANT. TRIMBLE HAS INDEPENDENTLY DETERMINED APPLICABLE LAW, IMPLIED WARRANTIES, TERMS AND
HOW TO USE THE MS SOFTWARE IN THE DEVICE CONDITIONS ON THE SOFTWARE ARE LIMITED TO ONE (1)
PURCHASED BY YOU, AND MS HAS RELIED UPON TRIMBLE YEAR.
TO CONDUCT SUFFICIENT TESTING TO DETERMINE THAT
THE MS SOFTWARE IS SUITABLE FOR SUCH USE. YOU MAY HAVE OTHER LEGAL RIGHTS WHICH VARY FROM
STATE/JURISDICTION TO STATE/JURISDICTION.
NO WARRANTIES FOR THE MS SOFTWARE. THE MS
SOFTWARE is provided "AS IS" and with all faults. THE ENTIRE 2.4 LIMITATION OF LIABILITY. TO THE MAXIMUM EXTENT
RISK AS TO SATISFACTORY QUALITY, PERFORMANCE, PERMITTED BY APPLICABLE LAW, IN NO EVENT SHALL
ACCURACY AND EFFORT (INCLUDING LACK OF TRIMBLE OR ITS LICENSORS BE LIABLE FOR ANY SPECIAL,
NEGLIGENCE) IS WITH YOU. ALSO, THERE IS NO WARRANTY INCIDENTAL, INDIRECT OR CONSEQUENTIAL OR PUNITIVE
AGAINST INTERFERENCE WITH YOUR ENJOYMENT OF THE DAMAGES, HOWEVER CAUSED AND REGARDLESS OF THE
MS SOFTWARE OR AGAINST INFRINGEMENT. IF YOU HAVE THEORY OF LIABILITY (INCLUDING, WITHOUT LIMITATION,
RECEIVED ANY WARRANTIES REGARDING THE DEVICE OR DAMAGES FOR LOSS OF BUSINESS PROFITS, BUSINESS
THE SOFTWARE, THOSE WARRANTIES DO NOT ORIGINATE INTERRUPTION, LOSS OF BUSINESS INFORMATION, OR ANY
FROM AND ARE NOT BINDING ON MS. OTHER PECUNIARY LOSS), ARISING OUT OF THE USE OR
Note on Java Support. The MS Software may contain support for INABILITY TO USE THE SOFTWARE, OR THE PROVISION OF
programs written in Java. Java technology is not fault tolerant and is not OR FAILURE TO PROVIDE SUPPORT SERVICES, EVEN IF
designed, manufactured, or intended for use or resale as online control TRIMBLE HAS BEEN ADVISED OF THE POSSIBILITY OF SUCH
equipment in hazardous environments requiring fail-safe performance, DAMAGES, AND NOTWITHSTANDING ANY FAILURE OF
such as in the operation of nuclear facilities, aircraft navigation or ESSENTIAL PURPOSE OF ANY EXCLUSIVE REMEDY
communication systems, air traffic control, direct life support PROVIDED IN THIS AGREEMENT.
machines, or weapons systems, in which the failure of Java technology 2.5 IN NO EVENT SHALL TRIMBLE'S TOTAL LIABILITY IN
could lead directly to death, personal injury, or severe physical or CONNECTION WITH THIS AGREEMENT OR THE SOFTWARE,
environmental damage. Sun Microsystems, Inc. has contractually WHETHER BASED ON CONTRACT, WARRANTY, TORT
obligated Microsoft to make this disclaimer. (INCLUDING NEGLIGENCE), STRICT LIABILITY OR
No Liability for Certain Damages. EXCEPT AS PROHIBITED BY OTHERWISE, EXCEED THE ACTUAL AMOUNT PAID TO
LAW, MS SHALL HAVE NO LIABILITY FOR ANY INDIRECT, TRIMBLE FOR USE OF THE SOFTWARE GIVING RISE TO THE
SPECIAL, CONSEQUENTIAL OR INCIDENTAL DAMAGES CLAIM. BECAUSE SOME STATES AND JURISDICTIONS DO
ARISING FROM OR IN CONNECTION WITH THE USE OR NOT ALLOW THE EXCLUSION OR LIMITATION OF LIABILITY
PERFORMANCE OF THE MS SOFTWARE. THIS LIMITATION FOR CONSEQUENTIAL OR INCIDENTAL DAMAGES, THE
SHALL APPLY EVEN IF ANY REMEDY FAILS ITS ESSENTIAL ABOVE LIMITATION MAY NOT APPLY TO YOU.
PURPOSE. IN NO EVENT SHALL MS BE LIABLE FOR ANY 2.6 PLEASE NOTE: THE ABOVE TRIMBLE LIMITED WARRANTY
AMOUNT IN EXCESS OF U.S. TWO HUNDRED FIFTY PROVISIONS MAY NOT APPLY TO SOFTWARE PRODUCTS
DOLLARS. (U.S. $250.00). PURCHASED IN THOSE JURISDICTIONS (SUCH AS COUNTRIES
2. LIMITED WARRANTY OF THE EUROPEAN ECONOMIC COMMUNITY) IN WHICH
2.1 Limited Warranty. Trimble warrants that the Software will perform PRODUCT WARRANTIES ARE OBTAINED FROM THE LOCAL
substantially in accordance with the accompanying written materials DISTRIBUTOR. IN SUCH CASE, PLEASE CONTACT YOUR
(i.e., applicable user guide or product manual) for a period of one (1) TRIMBLE DEALER FOR APPLICABLE WARRANTY INFORMATION.
year from date of purchase. This limited warranty gives you specific 3. GENERAL
legal rights, you may have others, which vary from state/jurisdiction to
state/jurisdiction. The above limited warranty does not apply to error 3.1 This Agreement shall be governed by the laws of the State of
corrections, updates or upgrades of the Software after expiration of the California and applicable United States Federal law without reference
limited warranty period, which are provided "AS IS" and without to "conflict of laws" principles or provisions. The United Nations
warranty unless otherwise specified in writing by Trimble. Because the Convention on Contracts for the International Sale of Goods will not
Software is inherently complex and may not be completely free of apply to this Agreement. Jurisdiction and venue of any dispute or court
nonconformities, defects or errors, you are advised to verify your work. action arising from or related to this Agreement or the Software shall lie
Trimble does not warrant that the Software will operate error free or exclusively in or be transferred to the courts of the County of Santa
uninterrupted, will meet your needs or expectations, or that all Clara, California, and/or the United States District Court for the
nonconformities can or will be corrected. Northern District of California. You hereby consent and agree not to
contest, such jurisdiction, venue and governing law.
2.2 Customer Remedies. Trimble's and its licensors' entire liability,
and your sole remedy, with respect to the Software shall be either, at 3.2 Section 3.1 notwithstanding, if you acquired this product in
Trimble's option, (a) repair or replacement of the Software, or (b) return Canada, this Agreement is governed by the laws of the Province of
of the license fee paid for any Software that does not meet Trimble's Ontario, Canada. In such case each of the parties to this Agreement
limited warranty. The foregoing limited warranty is void if failure of irrevocably attorns to the jurisdiction of the courts of the Province of
the Software has resulted from (1) accident, misuse, abuse, or Ontario and further agrees to commence any litigation that may arise
misapplication; (2) alteration or modification of the Software without under this Agreement in the courts located in the Judicial District of
Trimble's authorization; (3) interaction with software or hardware not York, Province of Ontario. If you acquired this product in the European
supplied or supported by Trimble; (4) your improper, inadequate or Union, this Agreement is governed by the laws of The Netherlands,
unauthorized installation, maintenance or storage; or (5) if you violate excluding its rules governing conflicts of laws and excluding the United
the terms of this Agreement. Any replacement Software will be Nations Convention on the International Sale of Goods. In such case
warranted for the remainder of the original warranty period or thirty each of the parties to this Agreement irrevocably attorns to the
(30) days, whichever is longer. jurisdiction of the courts of The Netherlands and further agrees to
commence any litigation that may arise under this Agreement in the
courts of The Hague, The Netherlands.
3.3 Trimble reserves all rights not expressly granted by this
Agreement.
3.4 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.

GCS900 Grade Control System for Grading Applications Installation Manual 3


Product Warranty Information Europe
For applicable product warranty information, please refer to the This product has been tested and found to comply with the
Warranty Card included with this Trimble product, or consult your requirements for a Class B device pursuant to European
Trimble dealer. Council Directive 89/336/EEC on EMC, thereby satisfying the
requirements for CE Marking and sale within the European Economic
Notices Area (EEA). Contains Infineon radio module ROK 104001. These
Class B Statement – Notice to Users. This equipment has been tested requirements are designed to provide reasonable protection against
and found to comply with the limits for a Class B digital device, harmful interference when the equipment is operated in a residential or
pursuant to Part 15 of the FCC rules. These limits are designed to commercial environment.
provide reasonable protection against harmful interference in a
residential installation. This equipment generates, uses, and can radiate Australia and New Zealand
radio frequency energy and, if not installed and used in accordance with This product conforms with the regulatory requirements of the
the instructions, may cause harmful interference to radio Australian Communications Authority (ACA) EMC
communication. However, there is no guarantee that interference will framework, thus satisfying the requirements for C-Tick
not occur in a particular installation. If this equipment does cause Marking and sale within Australia and New Zealand.
harmful interference to radio or television reception, which can be
determined by turning the equipment off and on, the user is encouraged Taiwan – Battery Recycling Requirements
to try to correct the interference by one or more of the following The product contains a removable Lithium-ion battery.
measures: Taiwanese regulations require that waste batteries are recycled.
– Reorient or relocate the receiving antenna. Notice to Our European Union Customers
– Increase the separation between the equipment and the receiver.
– Connect the equipment into an outlet on a circuit different from that For product recycling instructions and more information, please go to
to which the receiver is connected. www.trimble.com/environment/summary.html.
– Consult the dealer or an experienced radio/TV technician for help. Recycling in Europe: To recycle Trimble WEEE (Waste
Changes and modifications not expressly approved by the manufacturer Electrical and Electronic Equipment, products that run on
or registrant of this equipment can void your authority to operate this electrical power.), Call +31 497 53 24 30, and ask for the
equipment under Federal Communications Commission rules. "WEEE Associate". Or, mail a request for recycling
instructions to:
Canada Trimble Europe BV
This digital apparatus does not exceed the Class B limits for radio noise c/o Menlo Worldwide Logistics
emissions from digital apparatus as set out in the radio interference Meerheide 45
regulations of the Canadian Department of Communications. 5521 DZ Eersel, NL
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.

4 GCS900 Grade Control System for Grading Applications Installation 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.

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

GCS900 Grade Control System for Grading Applications Installation Manual 5


Safety Information

Warnings

C WARNING – Do not operate this system unless you are fully trained on this equipment and
end-use equipment.

Maintenance of hydraulic hoses, fittings, and valves must be done by qualified service
personnel only. If inspection and service of hydraulic hoses, fittings, and valves is required, the
inspection and service should be performed at machine lubrication and service intervals.

Staring into a laser beam when a laser transmitter is operating may damage your eyes. To
avoid injury, do not look into the laser beam when it is in operation. For more information, refer
to the documentation that came with your laser.

The cutting edge of the machine may move without warning when automatic controls are on.
These sudden movements could cause injury to anyone near the cutting edge, or damage to
the machine. Always put the system in manual and engage the machine's park brake before
you leave the machine, or when somebody is working near the cutting edge.

When the cutting edge is not in operation, leaving it in the air could cause injury to you or
others, or damage to the machine. Always place the cutting edge on the ground when it is not
in use.

As the system equipment may extend beyond the extents of the cutting edge, operating the
machine close to people and objects could cause injury to them or damage to the machine or
system equipment. Maintain adequate clearance from people and objects when operating the
machine.

The cutting edge may move abruptly during hydraulic valve calibration. To avoid injury, make
sure the machine's park brake is engaged, and the calibrations are supervised by an operator
in the machine cab. Maintain adequate clearance from people and objects during the hydraulic
valve calibration.

C WARNING – Disconnect the negative battery terminal before commencing any welding.
Ensure that power is removed from the system by disconnecting the power input cable(s).
Failure to follow this warning may result in electric shock.

C WARNING – Ensure that all valve module connectors are correctly connected. Failure to do so
can result in personal injury from crushing, and permanent damage to the hydraulic system.

6 GCS900 Grade Control System for Grading Applications Installation Manual


Contents
Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1 Installation Workflow. . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.1 The installation process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.2 Restoring machine settings files . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.3 Upgrading from previous versions . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.4 Related Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.5 Training classes and technical assistance . . . . . . . . . . . . . . . . . . . . . . . 16
1.6 To learn more about Trimble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.7 Your comments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

2 Preparing for an Installation . . . . . . . . . . . . . . . . . . . . . . . . 17


2.1 Visiting the site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.2 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.3 Operational considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.4 Environmental considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.4.1 Shock and vibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.4.2 Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.4.3 Dust, dirt, and grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.4.4 Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.5 Bench test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2.5.1 Check the components . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2.5.2 Connect the components and power up . . . . . . . . . . . . . . . . . . . . 22
2.5.3 Configure the machine settings . . . . . . . . . . . . . . . . . . . . . . . . 22
2.5.4 Check the motor grader remote switch cable . . . . . . . . . . . . . . . . . 22

3 Machine Components . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.1 Machine configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.1.1 Optional components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.1.2 Additional components for conventional guidance . . . . . . . . . . . . . . 26
3.1.3 Additional components for 3D guidance . . . . . . . . . . . . . . . . . . . 27
3.1.4 Data radios . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
3.2 Machine-specific installation kits . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3.3 Device settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

4 Installing the Main Harness Assembly . . . . . . . . . . . . . . . . . . 29


4.1 Cable routing guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
4.2 Bulldozer / scraper harnesses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4.2.1 Front harness cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
4.2.2 Rear harness cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
4.2.3 Cab harness cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
4.2.4 Bulldozer system diagram . . . . . . . . . . . . . . . . . . . . . . . . . . 35
4.3 Motor grader harnesses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
4.3.1 Front harness cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

GCS900 Grade Control System for Grading Applications Installation Manual 7


Conte nts

4.3.2 Rear harness cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39


4.3.3 Cab harness cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
4.3.4 Motor grader system diagram . . . . . . . . . . . . . . . . . . . . . . . . . 41
4.4 The power cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
4.4.1 The power harness cable . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
4.4.2 Connect to the run relay. . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
4.4.3 Install a voltage protection cable . . . . . . . . . . . . . . . . . . . . . . . 44
4.4.4 The power module cable . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

5 Welding and Fitting Tasks . . . . . . . . . . . . . . . . . . . . . . . . . 47


5.1 System components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
5.2 Installation guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
5.2.1 Positioning the brackets . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
5.2.2 Attaching the brackets . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
5.3 The control box pole bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
5.4 Mounting plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
5.4.1 Select a location for the mounting plates . . . . . . . . . . . . . . . . . . . 51
5.4.2 Install the mounting plates . . . . . . . . . . . . . . . . . . . . . . . . . . 52
5.5 Rotating mast bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
5.5.1 Install the mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
5.5.2 Install the bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
5.5.3 Blade pitch sensor bracket . . . . . . . . . . . . . . . . . . . . . . . . . . 55
5.6 Scraper mast mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
5.7 Quick disconnect brackets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
5.7.1 Select a location for the quick disconnect brackets . . . . . . . . . . . . . . 56
5.7.2 Install the quick disconnect bracket. . . . . . . . . . . . . . . . . . . . . . 56
5.8 Blade slope sensor bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
5.8.1 Select a location for the blade slope sensor bracket . . . . . . . . . . . . . 58
5.8.2 Install the blade slope sensor bracket . . . . . . . . . . . . . . . . . . . . . 58
5.9 Mainfall sensor bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
5.10 Valve / power module bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
5.11 Sonic tracer mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
5.12 Sideshift stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
5.13 Lightbar brackets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
5.14 Radio brackets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
5.14.1 The SNRx10 radio modem assembly . . . . . . . . . . . . . . . . . . . . . 64
5.14.2 The SNM930 cellular modem. . . . . . . . . . . . . . . . . . . . . . . . . 65

6 Installing the Cab Components . . . . . . . . . . . . . . . . . . . . . . 67


6.1 The control box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
6.1.1 Select a location for the control box . . . . . . . . . . . . . . . . . . . . . 68
6.1.2 Install the control box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
6.2 Remote switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
6.2.1 The bulldozer remote switch . . . . . . . . . . . . . . . . . . . . . . . . . 70
6.2.2 Motor grader remote switches . . . . . . . . . . . . . . . . . . . . . . . . 70
6.2.3 Complete the remote switch installation . . . . . . . . . . . . . . . . . . . 73

8 GCS900 Grade Control System for Grading Applications Installation Manual


Contents

6.3 Towed scraper raise / lower switch . . . . . . . . . . . . . . . . . . . . . . . . . . 74


6.4 Valve module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
6.5 Power module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
6.6 Lightbars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
6.7 Radios . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
6.7.1 Install a SNRx10 radio modem / SNM930 cellular modem . . . . . . . . . 76
6.7.2 Install a third-party radio . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
6.8 Reversing buzzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

7 Installing the Fixed Components . . . . . . . . . . . . . . . . . . . . . 81


7.1 Bulldozer cross slope sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
7.1.1 Install the blade slope sensor . . . . . . . . . . . . . . . . . . . . . . . . . 82
7.1.2 Install the rotation sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
7.1.3 Install the mainfall sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
7.2 Motor grader cross slope sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
7.2.1 Install the blade slope sensor . . . . . . . . . . . . . . . . . . . . . . . . . 84
7.2.2 Install the rotation sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
7.2.3 Install the AS400 mainfall sensor. . . . . . . . . . . . . . . . . . . . . . . 87
7.3 The blade pitch sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
7.4 Fixed mast with an angled riser . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

8 Installing the Removable Sensor Components . . . . . . . . . . . . . 89


8.1 The electric mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
8.2 The SR300 laser receiver. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
8.3 LR400 and LR410 laser receivers . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
8.4 GPS receivers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
8.5 The MT900 machine target . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

9 Measure Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
9.1 Measure-up worksheet: bulldozer / scraper . . . . . . . . . . . . . . . . . . . . . 98
9.2 Measure-up worksheet: motor grader . . . . . . . . . . . . . . . . . . . . . . . 100
9.3 Preparing for measure-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
9.4 General guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
9.4.1 Optional mast measurements for conventional guidance systems . . . . . . 103
9.4.2 Electric mast measurements . . . . . . . . . . . . . . . . . . . . . . . . . 103
9.4.3 A-frame measurement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
9.5 Preparing the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
9.5.1 Bulldozers and scrapers . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
9.5.2 Motor graders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
9.6 Mast measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
9.6.1 Taking the measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
9.6.2 Standard mast measurements . . . . . . . . . . . . . . . . . . . . . . . . . 107
9.6.3 Additional measurements for an electric mast . . . . . . . . . . . . . . . . 108
9.7 Blade / cutting edge dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
9.7.1 Bulldozer / scraper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

GCS900 Grade Control System for Grading Applications Installation Manual 9


Conte nts

9.7.2 Motor grader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111


9.8 Ripper / machine body dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . 113
9.8.1 Bulldozer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
9.8.2 Motor grader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
9.9 Receiver positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
9.9.1 Height (to top of lower housing) . . . . . . . . . . . . . . . . . . . . . . . 114
9.9.2 Back from cutting edge . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
9.9.3 In from left blade tip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
9.10 The measure-up tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
9.10.1 Assembling the measure-up tool . . . . . . . . . . . . . . . . . . . . . . . 117
9.10.2 Using the measure-up tool . . . . . . . . . . . . . . . . . . . . . . . . . . 117

10 Setup Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121


10.1 Using the Setup menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
10.1.1 Setup Menu – Configuration . . . . . . . . . . . . . . . . . . . . . . . . . 122
10.1.2 Setup Menu – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
10.2 Machine Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
10.3 Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
10.4 Machine Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
10.4.1 Mast measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
10.4.2 Machine dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
10.5 Select Radio Band . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
10.6 Lightbar Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
10.7 Machine Radio Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
10.8 Calibrate Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
10.8.1 Blade slope sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
10.8.2 Mainfall, blade slope, and rotation sensors . . . . . . . . . . . . . . . . . . 131
10.8.3 Blade rotation sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
10.8.4 Mainfall sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
10.9 Control Box’s Radio Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
10.10 GPS Receiver Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134

11 Validation and Troubleshooting . . . . . . . . . . . . . . . . . . . . . . 135


11.1 Validating the cabling installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
11.2 Checking device connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
11.3 Checking the lightbars and control box . . . . . . . . . . . . . . . . . . . . . . . . 136
11.4 Verifying the blade tip position . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
11.5 Final validation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
11.6 No CAN bus connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
11.7 No automatic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
11.8 No power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
11.9 Related information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139

A Radio Declarations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141


A.1 SNR2400 data radio declaration . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142

10 GCS900 Grade Control System for Grading Applications Installation Manual


Contents

A.1.1 Notices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143


A.1.2 Japanese approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
A.2 SNRx10 data radio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
A.3 450 MHz data radio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
A.4 900 MHz data radio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145

B Towed Scraper Installations . . . . . . . . . . . . . . . . . . . . . . . . 147


B.1 Direct connect installations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
B.1.1 John Deere 8000 and 9000 series tractors . . . . . . . . . . . . . . . . . . 148
B.1.2 John Deere 30 series tractors . . . . . . . . . . . . . . . . . . . . . . . . . 150
B.1.3 Clearing John Deere faults . . . . . . . . . . . . . . . . . . . . . . . . . . 151
B.1.4 Case MX series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
B.1.5 Case STX series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
B.1.6 Case fault / error codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
B.1.7 Challenger MT B-series. . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
B.1.8 Calibrate the valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
B.2 Non-direct connect installations . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
B.2.1 Danfoss valve hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
B.2.2 Valve cable connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
B.2.3 Proportional time valves . . . . . . . . . . . . . . . . . . . . . . . . . . . 159

Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163

GCS900 Grade Control System for Grading Applications Installation Manual 11


Conte nts

12 GCS900 Grade Control System for Grading Applications Installation Manual


CHAPTER

1
Installation Workflow 1

In this chapter: Welcome to the GCS900 Grade Control System


for Grading Applications Installation Manual.
Q The installation process
The Trimble® GCS900 Grade Control System is
Q Restoring machine settings files designed specifically for earthmoving
Q Upgrading from previous versions equipment in the construction industry.
Q Related Information Even if you have used other machine guidance
Q Training classes and technical systems before, Trimble recommends that you
assistance spend some time reading this manual to learn
about the special features of this product.
Q To learn more about Trimble
Q Your comments

GCS900 Grade Control System for Grading Applications 13


1 Installation Workflow

1.1 The installation process


To streamline the installation process, Trimble recommends that you follow the steps
in the order that they appear below:

Procedure For more information see ...


Prepare for the installation Chapter 2, Preparing for an Installation, page 17
Bench test the system 2.5 Bench test, page 22
10.2 Machine Settings, page 123
Install the cables Chapter 4, Installing the Main Harness Assembly, page 29
Validate the cable installation 11.1 Validating the cabling installation, page 136
Mount the brackets and clamps Chapter 5, Welding and Fitting Tasks, page 47
Install the cab components Chapter 6, Installing the Cab Components, page 67
SNRx10 radios - set the radio band 10.5 Select Radio Band, page 128
Third party radios: 10.9 Control Box’s Radio Port, page 133
• set the parity and baud rate
• for Trimble SNM930 cellular modems,
enable VRS corrections
Note – To receive VRS corrections, the
MS990 GPS receivers require version
3.9x or later firmware.
Configure the lightbars 10.6 Lightbar Connections, page 128
Install the fixed sensors Chapter 7, Installing the Fixed Components, page 81
Install the removable sensors Chapter 8, Installing the Removable Sensor Components, page 89
Take the machine measurements Chapter 9, Measure Up, page 97
Set the units 10.3 Units, page 124
Enter the machine measurements 10.4 Machine Dimensions, page 125
Calibrate the sensors 10.8 Calibrate Sensors, page 130
Validate the install Chapter 11, Validation and Troubleshooting, page 135

During the installation you may also want to:


• save the system settings. For more information, refer to the GCS900 Grade
Control System Site Supervisor’s Manual.
• send an up-to-date .cfg site configuration file to the GPS receiver.
See 10.10, GPS Receiver Configuration.
For systems that use Auto controls, before the operator can use the machine you must:
• Install the hydraulic components, if applicable. Refer to the instructions
supplied with the kit.
• Install the Auto options key; calibrate and validate the valves. Refer to the
GCS900 Grade Control System Site Supervisor’s Manual.

14 GCS900 Grade Control System for Grading Applications


Installation Workflow 1

1.2 Restoring machine settings files


If you use a machine settings file that was created for another machine, note the
following:
• If the file was created in a previous version of the system, the Machine Name
Error dialog appears:

Use the Machine Settings wizard to set the machine name.


Note – If you do not set a machine name, the error appears every time you
restart the system.
• If the file includes items for which you do not have the option keys:
– A warning message appears in the guidance view.
– The Machine Settings summary page marks the option key items with an
asterisk (*).
– The Machine Settings wizard may not display some pages, and/or all of
the options on each page.
• If an option key restricts your system to conventional guidance only, and you
restore a file that specifies 3D sensors, or features that use 3D sensors, then the
Software Support Option dialog displays this message:
Note: Conventional Guidance Only.
• With this release of the system, you must use the Machine Settings wizard to
set up the wireless communications. Previously, you could access the Wireless
Communications Type dialog from the Setup Menu - Installation dialog.

GCS900 Grade Control System for Grading Applications 15


1 Installation Workflow

1.3 Upgrading from previous versions


If you upgrade from a previous version of the system, and then use the Mode softkey
to swap from 3D to 2D guidance mode, the following message may appear:

If this message appears, then you must enter the A-frame machine measurement
before you can continue to use 2D guidance.
For more information, see 9.7, Blade / cutting edge dimensions.

1.4 Related Information


Trimble manuals that are related to this product are available in PDF format on the
GCS900 Grade Control System Software CD. Use Adobe Reader (provided on the
CD) to view or print the manuals.

1.5 Training classes and technical assistance


Contact your local Trimble dealer for:
• Technical support.
• Information notes and other technical notes.
• Information about:
– the support agreement contracts for software and firmware
– extended warranty programs for hardware
– training classes

1.6 To learn more about Trimble


For an interactive look at Trimble, visit www.trimble.com.

1.7 Your comments


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

16 GCS900 Grade Control System for Grading Applications


CHAPTER

2
Preparing for an Installation 2

In this chapter: This chapter enables the installer to prepare the


site and aims to reduce the chance of
Q Visiting the site encountering problems during an installation.
Q Tools
Q Operational considerations
Q Environmental considerations
Q Bench test

GCS900 Grade Control System for Grading Applications Installation Manual 17


2 Preparing for an Installation

2.1 Visiting the site


Trimble recommends that you visit the site for a pre-installation check, so that you
save valuable time later. During your visit, discuss the installation with people
on-site, such as the site manager, foreman, and machine operators.
When on-site, do the following:
• Identify:
– which machine to install the system on.
Note – The system provides accurate guidance to a machine, however it
cannot turn an old machine with worn linkages into an accurate machine.
Trimble recommends that you install the the system on the best machine
available.
– where the installation will take place. If possible, install the equipment in
a fully equipped workshop and steam clean the machine before you start.
Installation is easier and faster on a clean machine.
– the service mechanic. In the future, this mechanic should service the
system. Decide on the method of mounting the equipment and cables.
– the tradespeople you will work with.
– for automatic systems, the type of hydraulics kit and valve module(s)
required and who will install them. Make sure that the kit is available.
• Organize any pre-work you want done:
– Identify where to weld parts to the machine, and which body panels to
remove.
– Determine if you need any custom-made brackets. Take the necessary
measurements and get the brackets made ahead of time.
• Ensure that a welder is available, and that the welder knows the size of plate to
weld. Check if you need to disconnect any electrical cables before the welding
begins.
• Plan the installation of the cables on the machine:
– Calculate the length of the planned cable route.
For more information, see 4.1, Cable routing guidelines.
– Determine the ease of feeding cables and connectors through the machine.
• For systems that use GPS, you must make sure that:
– there is a GPS base station on-site that you can use or access to a Trimble®
VRS™ system
– you know who is providing the site (GPS) calibration
– you have a list of known site survey control points and their coordinates

18 GCS900 Grade Control System for Grading Applications Installation Manual


Preparing for an Installation 2

Allow a full day for two experienced people to do the installation or more time for
inexperienced installers. The actual time taken will depend on the site, when you can
get access to the machine, and how long you have to wait for other tradespeople.

2.2 Tools
Make sure that you have the following tools available:

This tool... Is for...


Multimeter Checking:
• power
• impedance across the CAN bus
Deustch crimper (P/N 5401-1568) and Connecting the system to machine power
electrical terminals
Diagonal cutters
Wire strippers and pliers
A piece of pipe or wire Feeding cables through the machine
Cable ties and wrap Securing cables and preventing abrasion
Insulation tape
Industrial strength hook and loop tape
Wrenches:
• SAE
• Metric open
• Metric and imperial allen keys
• Box end
• Socket
• Torque drivers For fitting to specification
Red Loctite (P/N 33803)/ Preventing screws and bolts from loosening
Blue Loctite (P/N 3207-1340)
Anti seize compound
Contact cleaner
Rust prevention touch-up paint
RTV silicone sealer Sealing cable entry holes
A steel tape or ruler
Straight edge
Framing square
A spirit or digital level
A plumb line and string
Drill sets
Hole saws
A grinder
Clamps
A step ladder Reaching the higher parts of the machine

GCS900 Grade Control System for Grading Applications Installation Manual 19


2 Preparing for an Installation

2.3 Operational considerations


When you install the equipment, pay attention to the following:
• Safety. Do not remove or obstruct:
– Mirrors
– Hand rails
– Lights
– Alarms
– Horns
– Do not mount equipment where it obstructs the operator’s view, or could
come into contact with the operator during normal operation
• Ergonomics. Mount equipment so that:
– the operator can see the control box screen in their normal field of vision,
and easily reach the control box from their normal, seated position
– it does not block access for maintenance, or interfere with normal
operation of the machine.

2.4 Environmental considerations


While the system is designed to operate in an environment which is hard on electronic
equipment, when you install the system consider the effects of:
• Shock and vibration
• Temperature
• Dust, dirt, and grease
• Water

2.4.1 Shock and vibration


To reduce shock and vibration:
• Securely fastened the equipment to a solid part of the machine. Do not leave
room for movement or rattling.
• Attach the mounting brackets directly to a structural part of the machine.
• Use the shortest possible length for all mounting brackets. Long brackets
introduce more vibration than short ones.

20 GCS900 Grade Control System for Grading Applications Installation Manual


Preparing for an Installation 2

2.4.2 Temperature
The sensors give accurate guidance within their specified operating temperature
range. For optimum performance, do not mount the sensors near:
• Hydraulic lines
• Turbo chargers
• Exhaust systems
• Oil reservoirs
Some machines pressurize the instrument cluster area to distribute conditioned air. If
you drill the mounting brackets to these panels, make sure that you reseal these areas.

2.4.3 Dust, dirt, and grease


The system components are sealed to exclude dust, but you should also take the
following measures:
• When you attach the cables, keep the connectors clean. Place dust caps on
unused connectors. Dust in connectors is the main cause of connector failure.
• Keep the control box screen clean.

B Tip – Use a moist cloth or wet-wipe to clean the control box screen. Do not use your fingers –
you could scratch the screen.

2.4.4 Water
Certain system components, such as the control box, are sealed against water splash.
Other components are sealed against total water immersion. However you must take
care when selecting mounting locations.
Potential sources of water include:
• Condensation
• Rain
• Snow
• Ground water thrown up by passing vehicles or wheels
• Vehicle-washing systems (for example, waterblasters)

GCS900 Grade Control System for Grading Applications Installation Manual 21


2 Preparing for an Installation

2.5 Bench test


Bench testing helps to familiarize you with the system components. To carry out a
bench test, you need to:
• check that all components are present
• connect the components together (control box, sensors, cables and harnesses)
• connect to a power supply and power up the system
• enter your machine settings

2.5.1 Check the components


Use the shipping documents, which show the number of containers, and the
component list from each container, to check that all components are present.
If any containers or components are missing or damaged, notify the shipping carrier
or Trimble immediately.

2.5.2 Connect the components and power up


Lay the components out on a bench or table. Use the supplied cables to connect the
components to a power source. Start the system, and enter your machine settings.
For more information, see Chapter 4, Installing the Main Harness Assembly.
Note – Some components, such as the GPS receivers, may need to be outdoors to
function correctly.

2.5.3 Configure the machine settings


Use the Machine Settings wizard to configure your machine type and settings.
You must configure your machine before you enter any machine dimensions into the
system. See 10.2, Machine Settings.

2.5.4 Check the motor grader remote switch cable


The remote switch cable part numbers use this structure: P/N 1234-567X-xxx.
The X indicates the type of thread on the motor grader’s control lever; the remote
switch cable accomodates this. Use the following table to determine if you have the
correct cable:

For this motor grader type... X is... Thread type


Volvo and John Deere –C –1 3/8 – 16
Caterpillar –G, –H –2 3/8 – 24
John Deere older 570 –3 7/16 – 14
Fiat and Leeboy –4 1/2 – 13

22 GCS900 Grade Control System for Grading Applications Installation Manual


Preparing for an Installation 2

For this motor grader type... X is... Thread type


Komatsu –5 M8 x 1.25
Various –6 M10 x 1.5
Various –7 M12 x 1.75
John Deere –D (requires adapter 0794-2860) –8 0.473
Various –9 0.437

GCS900 Grade Control System for Grading Applications Installation Manual 23


2 Preparing for an Installation

24 GCS900 Grade Control System for Grading Applications Installation Manual


CHAPTER

3
Machine Components 3

In this chapter: This chapter describes the machine


configurations for the system, and the required
Q Machine configurations components for each assembly.
Q Machine-specific installation kits
Q Device settings

GCS900 Grade Control System for Grading Applications Installation Manual 25


3 Machine Components

3.1 Machine configurations


All machines require the following system components:
• Main harness
• Control box
Any additional components that you use will depend on the level of guidance that you
require. To determine what components to use for your system, see the following
sections.

3.1.1 Optional components

This machine type ... Can use this component ...


All machines lightbars
auto controls
reversing indicator
Note – If you have a single 3D system, Trimble recommends that you use a
reversing buzzer.
• Bulldozer An SR300 laser receiver with PM400 power module
• Motor grader

3.1.2 Additional components for conventional guidance

These machine types ... Support this guidance type ... Which requires these components ...
• Bulldozer Blade slope AS400 blade slope sensor
• Motor grader
• Bulldozer Lift/lift Two LR410 laser receivers
• Motor grader
• Bulldozer Cross slope Cross slope sensor group:
• Motor grader • AS400 blade slope sensor
• AS400 mainfall sensor
• RS400 blade rotation
Bulldozer Lift plus blade slope • AS400 blade slope sensor
• LR410 or SR300 laser receiver with PM400
power module
Motor grader Lift plus cross slope • Cross slope sensor group (see above)
• LR410 or SR300 laser receiver with PM400
power module or ST300 or ST400 sonic tracer

26 GCS900 Grade Control System for Grading Applications Installation Manual


Machine Components 3

3.1.3 Additional components for 3D guidance

These machine types ... Support this guidance type ... Which requires these components ...
• Bulldozer/Scraper 1 x GPS, cab mounted • 1 x GPS receiver
• Motor grader • A data radio
1 x GPS, mast mounted • 1 x GPS receiver
• A data radio
• Fixed or electric mast and PM400 power module
2 x GPS • 2 x GPS receivers
• A data radio
• Fixed or electric masts and PM400 power module
• Bulldozer 1 x UTS • UTS target
• Motor grader • A data radio
• Fixed mast or electric mast and PM400 power
module
Bulldozer 3D plus blade slope • 1 x GPS receiver or UTS target
• A data radio
• Fixed or electric mast and PM400 power module
• AS400 blade slope sensor
3D plus cross slope • 1 x GPS receiver or UTS target
• A data radio
• Fixed or electric mast and PM400 power module
• AS400 blade slope sensor
• AS400 mainfall sensor
• RS400 blade rotation
Motor grader 3D plus cross slope • 1 x GPS receiver or UTS target
• A data radio
• Fixed or electric mast and PM400 power module
• AS400 blade slope sensor
• AS400 mainfall sensor
• AS400 blade pitch sensor
• RS400 blade rotation

3.1.4 Data radios

Use this radio ... With a...


SNR2400 UTS or ATS system
SNR2410 UTS, ATS or GPS system
SNR900 An ATS600 with Trimble SNB900 radio, or GPS system
SNR900, SNR910, SNR410 GPS system

GCS900 Grade Control System for Grading Applications Installation Manual 27


3 Machine Components

3.2 Machine-specific installation kits


Some machine-specific installation kits have supplemental instructions for individual
machines. When installing a machine kit, ensure that you refer to the accompanying
documentation along with the information contained in this manual.
Available installation kits are listed in the Trimble Construction H&H Pricebook, on
the Trimble Construction Partners website: http://constructionpartners.trimble.com.

3.3 Device settings


Use this information if you move or swap a device:

For this device... This data ... Is stored in the ... Notes
VM4xx valve modules Valve calibration Machine file
RS400 rotation sensor Angle calibration Sensor Recalibrate the sensor of you move or
swap it.
EM400 electric mast Height offset Machine file
AS400 sensor Angle calibration Sensor
ST300/ST400 Bench N/A Sonic tracers bench when they are
sonic tracers powered up, but the system also
restores the last bench point
LB400 Lightbar Position Lightbar After removal, return each lightbar to the
Invert Machine file same position. Otherwise, you must set
Scale or tolerance display file the lightbar connections again.
See 10.6, Lightbar Connections
CB430 control box Settings Machine and display files
MS9xx GPS receivers The .cfg site Control box design folder When you load a design, the control box
configuration file or data card root directory sends the .cfg file to the GPS receiver .
To send a .cfg file from the data card, see
10.10, GPS Receiver Configuration
Machine radio Network and Machine file The control box automatically sets the
frequency settings network number in the machine radio.
So, if you swap radios, the control box
will set the network number that was
configured for the previous radio, onto
the current radio.
See 10.1, Using the Setup menus

28 GCS900 Grade Control System for Grading Applications Installation Manual


CHAPTER

4
Installing the Main Harness Assembly 4

In this chapter: The system cabling provides power to, and


connects, the system hardware.
Q Cable routing guidelines
This chapter describes:
Q Bulldozer / scraper harnesses
• the harness cables and connectors
Q Motor grader harnesses
• how to install the system harnesses
Q The power harness cable
Q Connect to the run relay
Note – The cabling diagrams in this chapter are
not to scale.
Q The power module cable

GCS900 Grade Control System for Grading Applications Installation Manual 29


4 Installing the Main Harness Assembly

4.1 Cable routing guidelines


Before you route the harness cables, you must confirm that the cable connectors can
reach the connectors on the system components. To do this:
1. Identify where you are going to mount the components.
2. Either:
– Use string to route along the anticipated installation paths, and then
measure the string against the cables.
– Drape the harness cables over the machine and cable tie them in place.

ATTENTION – Do not use a tool, such as pliers, to tighten a harness or component connector
C as this could damage the connector. Always hand-tighten the connectors.

When you route the harness cables:


• Make sure that:
– the cables do not interfere with, or catch on, any mechanical linkages
– you maintain access to any service panels, fuse holders and the fuses
– the cables are long enough to reach all of the system components
• Protect the cables where they pass over or through any sharp metal edges
• To prevent the cables from moving and chafing, secure them with cable ties
and silicone.
• To reduce stress on the connectors, secure the cables to something solid near
the connector.
• Do not tie the cables to machine parts that get hot.

ATTENTION – Do not cut off any left over cabling, as this could affect system performance.
C Bundle, tie wrap and store any extra cabling in a convenient place on the machine.

Once you have installed the cables, you must check the installation. For more
information, see 11.1, Validating the cabling installation.

30 GCS900 Grade Control System for Grading Applications Installation Manual


Installing the Main Harness Assembly 4

4.2 Bulldozer / scraper harnesses


This cable... Provides connections to the ... See Figure ...
Front harness • rear harness cable 4.1
(P/N 0395-9020) • MS980 and MS99x GPS receivers
• AS400 blade slope sensor
• RS400 rotation sensor
• AS400 pitch sensor
• EM400 electric masts
• RMT600 or MT900 ATS / UTS targets
• LR400, LR410 and SR300 laser receivers
Rear harness • front harness cable 4.2
(P/N 0395-9010) • data radio
• CB430 control box
• remote switches
• lightbars
• power module and power cable
• VM410, VM415, or VM420 valve modules
Cab harness • rear harness cable 4.3
(P/N 54020) • CB430 control box
• reversing buzzer cable

Figure 4.4 shows the cabling for a bulldozer automatic system with dual GPS
receivers.

GCS900 Grade Control System for Grading Applications Installation Manual 31


4 Installing the Main Harness Assembly

4.2.1 Front harness cable


Route the cable from the left and right nose connectors at = and >, through the
engine bay, and out to the rear harness cable connector at @.
The length from = to @ is 5.5 m (18 ft); from > to @ is 3.6 m (11.8 ft).

< =

A1

> ?
@

< CAN bus terminator


= Right nose GPS receiver or RS400 rotation sensor connector
> Left nose GPS receiver or RS400 rotation sensor connector
? Laser receiver and/or AS400 sensor connector
@ Rear harness cable connector

Figure 4.1 Bulldozer/scraper front harness cable

32 GCS900 Grade Control System for Grading Applications Installation Manual


Installing the Main Harness Assembly 4

4.2.2 Rear harness cable


Route the rear harness cable from the front of the cab at <, under and around the back
of the cab, and then into the cab to connect to the control box adapter cable under the
seat at C.
The length from < to C is 2.1 m (7 ft).

<
>
? @

D
A C
B

< Front harness connector


= Lightbar harness connector
> Switched/unswitched power connector
? Remote switches connector
@ Roof mounted GPS connector (Rooftop A) and CAN bus terminator
A Valve module connector
B Power harness connector
C Cab harness cable connector
D Data radio connector (Rooftop B) and CAN bus terminator

Figure 4.2 Bulldozer/scraper rear harness cable

GCS900 Grade Control System for Grading Applications Installation Manual 33


4 Installing the Main Harness Assembly

4.2.3 Cab harness cable


Route the control box adapter cable from under the seat at < to the control box at >.
The length from < to > is 2 m (6.56 ft).

=
>
<

< Rear harness connector


= Reversing buzzer connector
> Control box connector

Figure 4.3 Bulldozer/scraper cab harness cable

34 GCS900 Grade Control System for Grading Applications Installation Manual


Installing the Main Harness Assembly 4

4.2.4 Bulldozer system diagram

GPS receiver

Fixed C
mast

Quick disconnect
bracket
Laser receiver and/or
B AS400 sensor connector

GPS receiver
A To rear harness

CAN bus terminator

A Front harness cable (P/N 0395-9020)


B Quick disconnect cable (P/N 0395-9150-xxx)
C GPS receiver cable (P/N 0395-9450)

Figure 4.4 Bulldozer automatic system with dual GPS receivers (continued over page)

GCS900 Grade Control System for Grading Applications Installation Manual 35


4 Installing the Main Harness Assembly

CB430 control box

LB400 lightbars

H
Radio modem
F
MAN K
I J
D N CAN bus terminator
G
PM400

L
M
To front harness

VM420 valve module

CAN bus terminator

D Lightbar harness cable (P/N 54438) I Ignition switched & battery unswitched
E Valve cable: power cable (P/N 54486-xx)
without load sense (P/N 0395-9610) J Remote switch cable (P/N 0395-9254-xxx)
with load sense (P/N 0395-2610) K Cab harness cable (P/N 54020)
F Switched power cable w/o PM400 (P/N 57726-xx) L Radio cable (P/N 0395-9470-xxx)
G PM400 power module (P/N 0395-5020) M Rear harness cable (P/N 0395-9010)
H PM400 power cable (P/N 0395-9130-xxx) N Reversing buzzer connector

36 GCS900 Grade Control System for Grading Applications Installation Manual


Installing the Main Harness Assembly 4

4.3 Motor grader harnesses


This cable ... Provides connections to the ... See Figure ...
Front harness • rear harness cable 4.5
(P/N 0395-9800) • MS980 and MS99x GPS receivers
• AS400 mainfall and blade sensors
• RS400 rotation sensor
• RMT600 and MT900 ATS/UTS targets
• ST300 and ST400 sonic tracers
• EM400 electric masts
• LR400, LR410, and SR300 laser receivers
Rear harness • front harness cable 4.6
(P/N 0395-9810) • cab harness cable
• data radio
• PM400 power module or switched power without module
• VM410, VM415, or VM420 valve modules
Cab harness • rear harness cable 4.7
(P/N 57335) • CB430 control box
• switched ignition power and unswitched battery power
• remote switches including remote switch with sideshift
• lightbar harness cable
• reversing buzzer

Figure 4.8 shows the cabling for an motor grader automatic system with UTS and
sideshift.

GCS900 Grade Control System for Grading Applications Installation Manual 37


4 Installing the Main Harness Assembly

4.3.1 Front harness cable


Route the front harness cable from the cab at @, under the gooseneck cover plates,
down to the A-frame and back to the circle at <.
The length from < to @ is 4.8 meters (15.75 ft)

< >

?
@

< Blade slope and rotation sensor connector


= CAN bus terminators
> Mainfall sensor connector
? Left and right elevation sensor connector
@ Rear harness cable connector

Figure 4.5 Motor grader front harness cable

38 GCS900 Grade Control System for Grading Applications Installation Manual


Installing the Main Harness Assembly 4

4.3.2 Rear harness cable


Run the rear harness cable from the start of the gooseneck at <, under the cab and
then into the cab.
The length from < to ? is 1.3 meters (4.26 ft).

=
?
=

<

>
@

< Front harness connector


= Valve module connectors
> Power module connector
? Cab harness cable connector
@ Unused connector
A CAN bus terminators
B Data radio connector

Figure 4.6 Motor grader rear harness cable

GCS900 Grade Control System for Grading Applications Installation Manual 39


4 Installing the Main Harness Assembly

4.3.3 Cab harness cable


Route the cab harness cable from the rear harness cable connector at <, through the
cab to the control box connector at =.
The length from < to = is 2 meters (6.56 ft)

<
=

A
>
@

< Rear harness connector


= Control box connector
> Switched/unswitched power connector
? Reversing buzzer connector
@ Lightbar harness connector
A Remote switch harness cable connector

Figure 4.7 Motor grader cab harness cable

40 GCS900 Grade Control System for Grading Applications Installation Manual


Installing the Main Harness Assembly 4

4.3.4 Motor grader system diagram

AS400 blade slope sensor RS400 rotation sensor

UTS target

CAN bus terminator

G
To rear harness

C
CAN bus
terminator

EM400 electric mast

E
AS400 mainfall sensor

Unused connector
D Quick disconnect bracket

A Blade slope sensor cable (P/N 0793-0210-xxx) E Elevation sensors Y-cable (P/N 0395-9090-xx)
B Cross slope sensor Y-cable (P/N 0395-1590-xx) F Mainfall sensor cable (P/N 0395-1870-xx)
C UTS cable (P/N 0312-0990) G Front harness cable (P/N 0395-9800)
D Electric mast cable (P/N 0793-3350)

Figure 4.8 Motor grader automatic system with UTS and sideshift (continued over page)

GCS900 Grade Control System for Grading Applications Installation Manual 41


4 Installing the Main Harness Assembly

Lightbars
G H

CB430 control box


J

P
I

Q
To front harness U
L

N N

O
T
Radio modem
M
S R

G Power cable without PM400 (P/N 57726-xx) N CAN bus terminator (P/N 2114-2116)
H Power module cables (P/N 0395-9130-xxx) O Unused connector
I PM400 power module (P/N 0395-5020) P Lightbar harness cable (P/N 54438)
J Valve modules cables (P/N 0395-9610-xxx) or Q Cab harness cable (P/N 57335)
valve cable with load sense (P/N 0395-9620-xxx) R Sideshift remote switch cable (P/N 57636-xx)
K VM420 valve modules S Remote switch cable (P/N 57545-xx)
L Rear harness cable (P/N 0395-9810) T Ignition switched & battery unswitched
M Data radio cable (P/N 0395-9470-xxx) power (P/N 54486-xx)
U Reversing buzzer connector

42 GCS900 Grade Control System for Grading Applications Installation Manual


Installing the Main Harness Assembly 4

4.4 The power cable

C CAUTION – If you connect the system’s ground (negative) connection to the negative terminal
of the battery, and attempt to start the machine with the master disconnect switch open (or if
the machine has a defective master disconnect switch or battery ground cable), then the starter
current will flow through the system from a component ground on the chassis to the battery
terminal. This will damage the system.
To avoid damaging the system, you must connect the system’s ground (negative) connection
to the frame of the machine, not the negative terminal of the battery.

B Tip – While you are connecting the power, place a “Machine under service, do not turn on”
tag on the battery isolation switch.

4.4.1 The power harness cable


To connect the power harness cable (P/N 57726-xx):
1. Turn off the ignition and remove the battery isolation master key.
2. Connect the two positive (red and green) wires of the power cable to the
positive terminal of the battery.
3. Connect the three negative (black) wires of the power cable to a suitable
grounding lug on the machine chassis.
4. Connect the power cable to the rear harness cable and verify that all wire
connections are correct and tight.
5. Replace the battery isolation master key.

4.4.2 Connect to the run relay


To ensure that the system does not drain the machine battery, Trimble recommends
that you connect the ignition-switched power cable (P/N 54486-xx) to an ignition-
switched power source such as the run relay. See Figure 4.9.
If your machine has a ground master disconnect switch, you must also install a
voltage protection diode cable. See 4.4.3, Install a voltage protection cable.
1. Locate the run relay and identify these terminals:
– the main feed from the batteries
– the switched terminal (turned on and off by the ignition key)
2. Turn off the ignition and remove the battery isolation master key.
3. Route the power cable to the run relay, and secure the power harness cable in
place.
4. Connect the positive (blue) wire of the power cable to an ignition switched
source (not the key ignition switch) on the run relay.
5. Connect the positive (green) wire of the power cable to an unswitched source.

GCS900 Grade Control System for Grading Applications Installation Manual 43


4 Installing the Main Harness Assembly

6. Connect the black and white wires of the power cable to a suitable grounding
lug on the machine chassis.

=
<

>
?
@ A
B
>
24 V+

C
D

E F
< Switched power to machine B Two ground wires (black and white)
= Blue wire C Master disconnect switch
> Fuses D Machine batteries
? Cab harness E Voltage protection diode
@ Green wire F Ground lug on machine chassis
A Run relay

Figure 4.9 Connecting to the run relay

4.4.3 Install a voltage protection cable


1. Select a grounding point for the voltage protection diode cable (P/N 121022).
Make sure that:
– there is a guaranteed current path to the ground point of the battery. The
best locations are the machine frame or a plate welded directly to the
machine frame.
– the cable reaches the grounded negative terminal of the battery. The
grounded terminal is the terminal that connects to the master disconnect
switch.

44 GCS900 Grade Control System for Grading Applications Installation Manual


Installing the Main Harness Assembly 4

2. Connect the cable to the grounding point. Use the provided washer and nut to
secure the diode to either:
– A hole in the machine frame. For thin metal, drill a 9.525 mm (0.375 in)
hole; for thick metal, drill an 8.43 mm (0.332 in) hole and then tap the
hole with a 3/8 – 24 tap.
– The supplied square block (welded directly to the machine frame).
Note – To ensure that the diode comes in complete contact with the metal
surface, remove any existing paint. To keep the mounting surface from
rusting and the diode from loosening, make sure that you apply rust
prevention paint after you have secured the diode.
3. Torque the nut to:
– 14 N⋅m (125 lb-in) without lubricant
– 12.5 N⋅m (110 lb-in) lubricated
4. Use the provided nut to connect the lug end of the voltage protection diode
cable to the grounded negative (–) terminal of the battery.
5. Verify that all wire connections are correct and tight.
6. Replace the battery isolation master key. Turn the key to the on position.

GCS900 Grade Control System for Grading Applications Installation Manual 45


4 Installing the Main Harness Assembly

4.4.4 The power module cable


1. Turn off the ignition and remove the battery isolation master key.
2. Connect the three positive (red, white, and green) wires of the power cable to
the positive terminal of the battery.
3. Connect the three negative (black) wires of the power cable to a suitable
grounding lug on the chassis of the machine.
4. Connect the power cable to the power module and verify that all wire
connections are correct and tight.
5. Replace the battery isolation master key and turn on the ignition.

Power module cable


(P/N 0395-9130-xxx)

Red, white and green wires

Fuses
24 V+ Master disconnect switch

Black wires
Ground lug on chassis

46 GCS900 Grade Control System for Grading Applications Installation Manual


CHAPTER

5
Welding and Fitting Tasks 5

In this chapter: This chapter outlines how to install the mounts


and brackets for the system components.
Q System components
Typically, a tradesperson, maintenance
Q Installation guidelines technician, or someone other than the installer
Q The control box pole bracket performs these tasks.
Q Mounting plates
Q Rotating mast bracket
Q Scraper mast mount
Q Valve / power module bracket
Q Sonic tracer mount
Q Quick disconnect brackets
Q Blade slope sensor bracket
Q Mainfall sensor bracket
Q Sideshift stop
Q Lightbar brackets
Q Radio brackets

GCS900 Grade Control System for Grading Applications Installation Manual 47


5 Welding and Fitting Tasks

5.1 System components


The following images show where to mount the system components.

< Mast A Blade slope sensor

= Lightbars B Pitch sensor

> Control box C Rotation sensor

? Data radio D Mainfall sensor

@ Valve/power modules E GPS receiver

Note – For the optimum performance of dual GPS systems, Trimble recommends that
you mount the masts on the left and right sides of the machine.
Motor grader

>
< = ?

D CB A @

Push-arm bulldozer

?
>=

<
@
B
D

48 GCS900 Grade Control System for Grading Applications Installation Manual


Welding and Fitting Tasks 5

6-way blade bulldozer


? > =

<

@ A
D B
C

Scraper

> A
=
?
E

5.2 Installation guidelines


To prepare the machine:
1. Park the machine on level ground.
2. For a motor grader:
– Put the frame in a straight position (the gooseneck is not articulated).
– Ensure that the front wheels are vertical.
– Ensure the link bar is centered, with the locking pin in the middle hole.
3. Rest the cutting edge on the ground.
4. Use a spirit level to level the blade.

GCS900 Grade Control System for Grading Applications Installation Manual 49


5 Welding and Fitting Tasks

5.2.1 Positioning the brackets


Minimize the risk of damage to the sensor and cables:
• Keep the sensor away from hydraulic lines that may become hot during
operation.
• Ensure that the sensor, harness cable, and bracket are free from obstruction
throughout the full movement of the machine and cutting edge.
Confirm that the cables can reach the sensors:
• Tack the brackets and sensors into place.
• Drape the harness cables over the machine and tack them in place with cable
ties.
Make sure that the position of the bracket enables you to install the sensor with the
connector in the desired direction.
Once you have confirmed the location of the bracket:
• Mark an outline around the bracket.
• Remove the sensor.

5.2.2 Attaching the brackets

C WARNING – Disconnect the negative battery terminal before commencing any welding.
Ensure that power is removed from the system by disconnecting the power input cable(s).
Failure to follow this warning may result in electric shock.

When you weld a bracket onto the machine:


• Always weld lengthwise along the edge of the bracket.
• Never weld within 75 mm (3 in) of an existing weld.
• After welding, make sure that you apply rust-prevention paint to:
– the weld
– any bare-metal surface

5.3 The control box pole bracket


If the pole bracket supplied with the control box assembly is not suitable, you can
modify it or make your own.
If you do make a custom pole bracket, make sure that the diameter of the pole fits the
RAM mount properly. For example, use solid rod with an outer diameter of 8.5 mm
(1/3 in) narrowing to 6.25 mm (1/4 in).
Otherwise you can install the control box when you install the other cab components.
See 6.1, The control box.

50 GCS900 Grade Control System for Grading Applications Installation Manual


Welding and Fitting Tasks 5

5.4 Mounting plates


The following guidelines are for dual masts; similar principles apply to single mast
systems.

5.4.1 Select a location for the mounting plates


• For a bulldozer, position the mounting plates (P/N 0794-2320) as close as
possible to the ends of the cutting edge. Ensure that both plates are the same
distance:
– in from the ends of the cutting edge
– above the cutting edge bolts
• The mounting plates do not need to be flush with the top of the cutting edge.
• The mounting plates have five pre-drilled holes. Position the:
– 125 mm (4.92 in) spaced holes parallel to the machine centerline.
– 100 mm (3.94 in) spaced holes parallel to the blade. See Figure 5.1.

Cutting edge

Machine centerline

Figure 5.1 Positioning the mounting plate

GCS900 Grade Control System for Grading Applications Installation Manual 51


5 Welding and Fitting Tasks

5.4.2 Install the mounting plates


Use custom-made gussets to attach the mounting plate to the cutting edge. To
fabricate the gussets, use 12.7 mm (1/2 in) minimum to 19 mm (3/4 in) steel plate.
To attach the mounting plate:
1. Tack weld the mounting plate to the cutting edge.
2. With the cutting edge is in its normal operating position, check that the
mounting plates are level in all directions (forward and back, left and right).
Adjust if necessary.
3. When everything is correct, weld the mount securely.
The mounting plate welded clear of the blade end plate on a bulldozer:

5.5 Rotating mast bracket


When you select a location for the rotating bracket, consider the following:
• For two masts, mount the brackets symmetrically on the cutting edge. For one
mast, mount it on the left (when viewed from the cab).
• Position the mounts approximately the same distance in from the ends of the
cutting edge, and the same distance above the cutting edge bolts.
• Make sure that the mount is square with the cutting edge when it is in a normal
operating position.
• If you intend to use sonic tracer poles, take their mounting position into
consideration.
• Fix one edge of the mount to the top of the cutting edge, and the other to the
back of the cutting edge.

52 GCS900 Grade Control System for Grading Applications Installation Manual


Welding and Fitting Tasks 5

5.5.1 Install the mount


1. Tack weld the mount to the cutting edge:

2. Assemble the angle mast mount and check that the rotating bracket is in the
correct position.
3. When you are satisified that is everything is correct, weld the mount securely:

GCS900 Grade Control System for Grading Applications Installation Manual 53


5 Welding and Fitting Tasks

5.5.2 Install the bracket

Upper section

Lower section

Mount

1. Attach the lower section of the bracket to the mount.


2. Torque the bolts to 370 ± 50 N·m (273 ± 37 lbf ft).
3. Attach the upper section to the lower. Pay attention to the following:
– For accurate guidance, you must position the upper section so that the top
of the section is level (parallel to the cutting edge).
– You can use any of the seven bolt holes on the upper section with either of
the bolt holes on the lower section.
– You must use the supplied insert screw to fill the unused hole on the lower
section:

4. Take a note of the bolt hole number you use on the upper section: 1 is nearest
the front of the machine; 7 is nearest to the operator’s cab.
You will enter this number into the system at a later time.

54 GCS900 Grade Control System for Grading Applications Installation Manual


Welding and Fitting Tasks 5

5.5.3 Blade pitch sensor bracket


The following image shows the blade pitch sensor assembly:

Bolt the blade pitch sensor bracket to the underside of the rotating bracket: use the
bolts that secure the mast to the rotating bracket.

5.6 Scraper mast mount


If your scraper does not have a pre-installed mast mount, when you install the mount
make sure it will position the mast over the center of the blade.
The following image shows a typical scraper mast mount:

GCS900 Grade Control System for Grading Applications Installation Manual 55


5 Welding and Fitting Tasks

5.7 Quick disconnect brackets


The following image shows the quick disconnect bracket assembly:

5.7.1 Select a location for the quick disconnect brackets


Position the quick disconnect brackets:
• at the front or side of the bulldozer, behind the blade. For the:
– left mast, mount the bracket on the left side of the machine
– right mast, mount the bracket on the right side of the machine
– AS400 blade slope sensor, mount the bracket on the left side or center of
the machine
• on the gooseneck of the motor grader

5.7.2 Install the quick disconnect bracket


To attach the quick disconnect brackets to the machine, either:
• weld the bracket directly to the machine.
• use the supplied L-section angle iron and flat strip to clamp the bracket to a
solid surface such as the mainframe.

56 GCS900 Grade Control System for Grading Applications Installation Manual


Welding and Fitting Tasks 5

The following image shows a quick disconnect bracket mounted on a bulldozer:

The following image shows a quick disconnect bracket mounted on a motor grader:

GCS900 Grade Control System for Grading Applications Installation Manual 57


5 Welding and Fitting Tasks

5.8 Blade slope sensor bracket


ATTENTION – The position of the blade slope sensor is critical to system accuracy. You must
C make sure that the bracket is square to the cutting edge.

5.8.1 Select a location for the blade slope sensor bracket


Bulldozers
Position the bracket as near as possible to the center of the blade.
This minimizes the risk of damage to the sensor when back dragging, or if material
spills over the top of the blade.
Motor graders
Place the bracket in the pocket at the rear of the circle.
The slope of the pocket differs according to machine model. To allow for this, the kit
includes an extended sensor bracket.

5.8.2 Install the blade slope sensor bracket


Bulldozers
Weld or bolt the mounting bracket to the cutting edge.
If you use bolts, torque to 20 ± 2 N·m (15 ± 1.5 lbf ft) and secure with Blue Loctite.
Motor graders
1. Place the bracket into the sensor pocket.
2. Align the bracket parallel to the cutting edge, within 6 mm ( 1 ⁄4 in) when
measured across a 1.22 m (4 ft) span. See Figure 5.2.
3. Tack weld the bracket to the cutting edge.

58 GCS900 Grade Control System for Grading Applications Installation Manual


Welding and Fitting Tasks 5

4. Check that the bracket is square to the blade. Adjust as required to make
lengths A and B equal:

Blade

A B

Straight edge Sensor

1.22 m (4 ft) 1.22 m (4 ft)

Figure 5.2 Checking the blade slope sensor bracket

5. Once you confirm the measurements, secure the bracket to the blade.
If using bolts, torque the mounting bolts to 20 ± 2 N·m (15 ± 1.5 lbf ft). Secure
with Blue Loctite.

5.9 Mainfall sensor bracket


When you mount the mainfall sensor bracket, position the top of the bracket so that
when installed, the mainfall sensor is parallel to the machine centerline, with a
tolerance of 6 mm ( 1⁄4 in) per 1 m.
On a:
• bulldozer, attach the bracket to the machine body.
• motor grader, attach the bracket to the side of the gooseneck.
Note – Whichever side of the gooseneck you install the sensor on, you must
configure the system to reflect this. See 10.2, Machine Settings.

GCS900 Grade Control System for Grading Applications Installation Manual 59


5 Welding and Fitting Tasks

The following image shows a mainfall sensor mounted on a motor grader:

5.10 Valve / power module bracket


Mount the valve/power module bracket (P/N 0395-9170) in the under-cab area, close
to the valves. When you select a location, make sure that:
• air can circulate freely around the modules
• it allows for easy access
• there is sufficient cabling. See the following table:

This cable ... Is available in lengths up to ... Must reach ...


Power module 6 m (20 ft) From the power module to the battery
(P/N 0395-9130-xxx)
Valve module 9.1 m (30 ft) From the valve module to the valves
(P/N 0395-9610-xxx)
Rear harness Both the valve module and the power
module

60 GCS900 Grade Control System for Grading Applications Installation Manual


Welding and Fitting Tasks 5

The following image shows a bracket attached to existing weld bosses:

Valve/power module bracket

Existing weld bosses

Use one of the following methods to install the valve/power module bracket:
Option 1
1. Attach new weld bosses to the cab. Make sure that the weld bosses match the
hole patterns in the bracket.
2. Fix the bracket to the bosses.
Option 2
Fix the bracket to existing weld bosses.
If you use weld bosses with existing fixtures, you may have to use longer bolts
than those in the kit.
Option 3
Weld the bracket directly to the machine.

5.11 Sonic tracer mount


Use the sonic tracer mount to attach the sonic tracer clamp to the blade.
When you select a location for the mount, consider the following:
• The mounting tube of the sonic tracer must:
– extend past the end of the cutting edge. This is to ensure that the sonic
tracer sits vertically above the reference surface or stringline.
– clear the circle when you sideshift the moldboard.

GCS900 Grade Control System for Grading Applications Installation Manual 61


5 Welding and Fitting Tasks

• The mounting tube clamp and the adjustable mast mount of the mast connect to
the same mount, as shown below:

To install the mount, see 5.5, Rotating mast bracket.

5.12 Sideshift stop


The sideshift stop (P/N 0794-1080) prevents the rotating bracket mount from coming
into contact with another part of the machine when you sideshift the moldboard.

ATTENTION – If you do not install the sideshift stop, you must inform the operator of the
C potential for the rotating bracket mount to come into contact with another part of the machine.

Position the sideshift stop so that the rotating bracket mount is at least 50 mm (2 in)
from the part of the machine that the mount would otherwise contact.
To install the sideshift stop:
1. Tack weld the sideshift stop to the cutting edge.
2. Check that the position of the sideshift stop is suitable. Adjust if necessary.
3. Securely weld the sideshift stop.

5.13 Lightbar brackets


Mount the lightbars inside the machine cab. Suitable locations vary according to the
machine type; when you select a location, consider the following:
• The operator’s line of sight during normal machine operation. Mount the
lightbars near this line of sight so that they are easily visible but do not obstruct
the operator’s view.
• The LEDs on the lightbars are only visible from certain angles. Mount each
lightbar so that the operator gets the best view of the LEDs.
• Each lightbar housing is 174 mm (6.85 in) long, 53 mm (2.1 in) wide, and has a
height of 32 mm (1.3 in).

62 GCS900 Grade Control System for Grading Applications Installation Manual


Welding and Fitting Tasks 5

• The lightbar weighs approximately 200 g (1/2 lb).


Lightbars mounted on a bulldozer console:

Lightbars mounted on a motor grader windscreen:

To install the lightbar brackets, do one of the following:


• To attach the bracket to a surface that is at a 90°angle to the bracket, use the
supplied nuts, washers, and bolts.
• To attach the bracket elsewhere in the cab, use one of the following:
– the supplied nuts, washers, and bolts
– double-sided tape
– hook and loop tape
For more information, see Chapter 6, Installing the Cab Components.

GCS900 Grade Control System for Grading Applications Installation Manual 63


5 Welding and Fitting Tasks

5.14 Radio brackets


When you select a location for the radio, consider the following:
• To reduce damage from shock and vibration, position the radio on a solid part
of the cab.
• For optimum performance, choose a position above the roofline that has an
uninterrupted view.
• To prevent signal interference, keep the radio away from:
– other antennas, particularly if one of the other antennas is for a two-way
radio
– rotating beacons
– air conditioning fans
– strobe lights
• The radio cable must reach from the rear harness cable to the data radio.
Consider the:
– length of the radio cable (P/N 0395-9470-xxx). The -xxx in the part
number indicates the cable length.
– location of the rear harness cable data radio connector and the route for the
data radio cable.
For more information, see Chapter 6, Installing the Cab Components.

5.14.1 The SNRx10 radio modem assembly


1. Securely attach the adapter plate (P/N 71105) to the cab of the machine. Use
one of the following methods:
Option 1
a. Attach new weld bosses to the cab. Make sure that the bosses match the
hole patterns in the plate.
b. Fix the plate to the bosses.
Option 2
Fix the plate to existing weld bosses.
If you use weld bosses with existing fixtures, you may have to use longer bolts
than those in the kit.
Option 3
Weld the plate directly into position.
Option 4
Attach the plate to a custom fixture.

64 GCS900 Grade Control System for Grading Applications Installation Manual


Welding and Fitting Tasks 5

2. Bolt the data radio onto the data radio bracket. Ensure the mounting screws are
all fitted with washers and lock washers.
3. Use the rubber shock mount kit to bolt the data radio bracket to the adapter
plate. The bolts are included with the adapter plate.
4. Secure with Loctite.
The following image shows the SNRx10 mounted on the machine cab:

For more information, see Chapter 6, Installing the Cab Components.

5.14.2 The SNM930 cellular modem


Mount the SNM930 cellular modem inside the cab of your machine. For more
information, refer to the documentation suppied with the cellular modem.

GCS900 Grade Control System for Grading Applications Installation Manual 65


5 Welding and Fitting Tasks

66 GCS900 Grade Control System for Grading Applications Installation Manual


CHAPTER

6
Installing the Cab Components 6

In this chapter: Note – To mount the valve module onto the same
bracket as the power module, use the dual
Q The control box module mounting bracket (P/N 0395-9170).
Q Remote switches
Q Towed scraper raise / lower switch
Q Valve module
Q Power module
Q Lightbars
Q Radios
Q Reversing buzzer

GCS900 Grade Control System for Grading Applications Installation Manual 67


6 Installing the Cab Components

6.1 The control box


Trimble recommends that you install the control box in one of the front corners of the
cab. However, suitable locations will vary with the type of machine and the operator’s
requirements.
For information about custom pole brackets, see 5.3, The control box pole bracket.

6.1.1 Select a location for the control box


Make sure that:
• the control box:
– is within the operator’s reach; the data card is easy to remove and replace
– is easy to see but does not block the operator’s view
– will not interfere with the operator’s activities
– will not obstruct the operator when getting in or out of the cab
– is easy to connect and disconnect
• the cab cable reaches the control box

6.1.2 Install the control box

RAM mount

Control box

Pole bracket

1. Use the M5 screws and flat washers to attach the ball mount to the control box.
2. Use the M10x40 screws, washers, split lock washers and nut plate or hex nuts
to attach the pole bracket to the cab.
3. Fasten the RAM mount to the pole bracket.
4. Insert the ball mount into the RAM mount socket and fasten.
5. Connect the control box cable from the harness cable to the control box.

68 GCS900 Grade Control System for Grading Applications Installation Manual


Installing the Cab Components 6

B Tip – The control box is easy to remove from the RAM mount. To prevent vandalism or theft,
remove the control box at night.

The following image shows a control box installed in a motor grader:

For more information, refer to the instructions supplied with the control box
assembly.

GCS900 Grade Control System for Grading Applications Installation Manual 69


6 Installing the Cab Components

6.2 Remote switches


This section describes how to install a remote switch on motor graders and
bulldozers. For towed scrapers, see 6.3, Towed scraper raise / lower switch.

6.2.1 The bulldozer remote switch


To install the remote switch:
1. Use the integrated clamp to mount the remote switch onto the blade control
lever:

Note – If it is not practical to mount the remote switch on the blade control
lever, you can make a custom mount.
2. Route and secure the remote switch cable.
3. Connect the cable to the remote switch connector on the rear harness cable.
4. Finish the install. See 6.2.3, Complete the remote switch installation.

6.2.2 Motor grader remote switches


The motor grader system can use remote switches for:
• activating the automatic controls and controlling the elevation offset (standard)
• automatic control of the sideshift

70 GCS900 Grade Control System for Grading Applications Installation Manual


Installing the Cab Components 6

Select a location for the remote switches

Mount this switch ... On the ...


Left auto/manual Left-most blade control lever
Left elevation offset Fourth blade control lever in from the left
(increment/decrement)
Right auto/manual Right-most blade control lever
Right elevation offset Fourth blade control lever in from the right
(increment/decrement)
Sideshift Second blade control lever in from the left

So the operator can activate the switches with the thumb and index finger, orient the
switches in towards the console:

Note – Before you mount a remote switch, make sure that the position is suitable for
the operator.

Install the standard remote switch


1. Loosen the jam nut and carefully unscrew the knob from the lever. Take note of
the function of the lever.
2. Screw the remote switch assembly onto the lever.
3. If necessary, cut the remote switch assembly cable to length.
4. Use a Deutsch crimper to crimp the Deutsch pins.
Note – A bag of pins (P/N 0794-3360) is supplied.

GCS900 Grade Control System for Grading Applications Installation Manual 71


6 Installing the Cab Components

5. Insert the pins into the back of the blank Deutsch connector. See Figure 6.1.

Left Auto/Manual Right Auto/Manual


1 = White 12 = Red
2 = Red 11 = White 1 12

3 = Black 10 = Black 2 11

Left Offset Right Offset 3 10

4 = Black 9 = Black 4 9
5 = White 8 = Red
6 = Red 7 = White
5 8

6 7
Note – If you orient the switch outwards from the
console, you must reverse the red and white wires.

Figure 6.1 Connecting the standard motor grader remote switches

6. Connect the newly formed Deutsch connector, to either the:


– remote switch cable (P/N 57545-xx): no sideshift remote switch
– offset auto/manual connector on the sideshift Y-cable (P/N 57636-xx):
if you are also installing a sideshift remote switch
7. Connect the remote switch cable or Y-cable to the remote switch connector on
the cab harness.
8. Finish the install. See 6.2.3, Complete the remote switch installation.

Install the sideshift remote switch


To install a sideshift remote switch, you need:
• a Motor Grader Sideshift Kit P/N 57655-42.
• An additional VM4xx valve module. See 6.4, Valve module.
To install the sideshift remote switch:
1. Complete steps 1 to 4 of Install the standard remote switch, page 71.
2. Insert the three crimped wires into the back of the blank Deutsch connector.
See Figure 6.2.

72 GCS900 Grade Control System for Grading Applications Installation Manual


Installing the Cab Components 6

Use either the Left or Right pinouts, according to


which side of the cab that you mount the remote
switch on.
1 12
Left Auto/Manual Right Auto/Manual
1 = White 1 = Red 2 11
2 = Red 2 = White 3 10
3 = Black 3 = Black
4 9
Note – If you orient the switch outwards from the
console, you must reverse the red and white wires. 5 8

6 7

Figure 6.2 Connecting the motor grader sideshift remote switch

3. Connect the newly formed Deutsch connector to sideshift connector on the


sideshift Y-cable (P/N 57636-xx).
4. Connect the Y-cable to the remote switch connector on the cab harness.
5. Finish the install. See 6.2.3, Complete the remote switch installation.

6.2.3 Complete the remote switch installation


1. Verify the installation:
a. Connect the remote switch cable (P/N 57545-xx) or sideshift Y-cable
(P/N 57636-xx) to the control box cable (P/N 57335).
b. Observe the control box screen:

Check that this switch ... Affects this side of the By ...
blade...
Left auto/manual Left Going into Auto or Inactive
Right auto/manual Right Auto mode

Left elevation offset Left Offsetting the height in the


(increment/decrement) correct direction
Right elevation offset Right
(increment/decrement)

2. Cable tie the remote switch assembly cables to each lever. Ensure that the
cables do not adversely affect lever operation.
3. The remote switch assembly kit contains a set of stickers; each sticker indicates
a different control lever operation. Place an appropriate sticker onto each
remote switch assembly.

GCS900 Grade Control System for Grading Applications Installation Manual 73


6 Installing the Cab Components

6.3 Towed scraper raise / lower switch


The towed scraper raise/lower switch (P/N 60045), shown below, enables the
machine operator to raise or lower the towed scraper bowl.

Use hook and loop tape to install the switch in the machine cab, adjacent to the
machine controls.
To connect the switch to the system harness:
1. Cut the 6-pin connector off the end of the raise/lower switch cable.
2. Insert the six crimped wires into the back of the 8-pin remote switch connector
cap (P/N 0395-9230) supplied with the rear harness. See Figure 6.3.

1 = Empty 8 = Black
2 = Red 7 = Empty
1 8
3 = Green 6 = Brown
4 = Blue 5 = White 2 7

3 6

4 5

8-pin connector after re-wiring


Figure 6.3 Raise/lower switch wiring connections

3. Connect the newly formed 8-pin connector to the system rear harness.

74 GCS900 Grade Control System for Grading Applications Installation Manual


Installing the Cab Components 6

6.4 Valve module


C WARNING – Ensure that all valve module connectors are correctly connected. Failure to do so
can result in personal injury from crushing, and permanent damage to the hydraulic system.

1. Ensure the valve module bracket has been installed correctly.


See 5.10, Valve / power module bracket.
2. Bolt the valve module onto the bracket.
3. Use Red Loctite to secure the bolts.
4. Connect to the ‘Valve module 1’ main harness cable connector.
5. For the additional sideshift valve module, connect to the ‘Valve module 2’
main harness cable connector.

6.5 Power module


The following image shows the PM400 power module assembly:

To install the power module:


1. Ensure the power module bracket has been installed correctly.
See 5.10, Valve / power module bracket.
2. Bolt the power module onto the bracket.
3. Use Red Loctite to secure the bolts.
4. Connect the cables. For more information see 4.4.4, The power module cable.

6.6 Lightbars
To attach the lightbar directly to a suitable surface in the cab, use one of the
following:
• the supplied nuts, washers, and bolts
• double-sided tape
• hook and loop tape
To determine where to mount the lightbars, see 5.13, Lightbar brackets.

GCS900 Grade Control System for Grading Applications Installation Manual 75


6 Installing the Cab Components

To attach the lightbar to a:


• standard bracket, use hook and loop tape, or the nuts, washers, and bolts
provided
• custom-made bracket, use hook and loop tape

6.7 Radios
Before you connect any of the radios, make sure that the radio brackets are installed
correctly. See 5.14, Radio brackets.
Once you have connected the radio, use a cable tie to bundle any extra cable.

6.7.1 Install a SNRx10 radio modem / SNM930 cellular modem


Optionally, you can install both the SNRx10 radio modem and the SNM930 cellular
modem. This section describes the installation options for both radios.

SNRx10 only
1. Plug the 8-socket connector on the radio cable (P/N 0395-9470-xx) into the
SNRx10 radio modem.
2. Connect the 12-pin connector on the radio cable to the black rooftop radio
connector.
The SNRx10 radio modem installed on the machine cab:

For more information, refer to the SNRx10 Radio Modem User Guide.

76 GCS900 Grade Control System for Grading Applications Installation Manual


Installing the Cab Components 6

SNM930 only
1. Plug the 24-socket connector on the SNM930 interface cable (P/N 71330-xx)
into the SNM930 cellular modem.
2. Connect the interface cable to the black rooftop radio connector.

SNRx10 and SNM930


1. Plug the 24-socket connector on the SNM930 interface cable (P/N 71330-xx)
into the SNM930 cellular modem.
2. Connect the 12-pin connector on the SNM930 interface cable to the adapter
cable (P/N 71332-xx).
3. Connect the adapter cable to the black rooftop radio connector.
4. Plug the 8-socket connector on the radio cable (P/N 0395-9470-xx) into the
SNRx10 radio modem.
5. Connect the radio cable to the green rooftop radio connector.

6.7.2 Install a third-party radio


1. Connect the RS232 serial port on the third-party radio to the third-party radio
cable (P/N 0395-9570-xx). See the following pinout table:

Pin1 Color Function


1 Red PWR+
2 Black PWR–
3 Green RS232 Radio RXD, GCS TXD
6 White RS232 Radio TXD, GCS RXD
11 Brown RS232 GND

1. All other pins are unused.

GCS900 Grade Control System for Grading Applications Installation Manual 77


6 Installing the Cab Components

2. Plug the 12-pin Deutsch connector on the third-party radio cable into the
standard 12-socket radio connector on the main harness:.

Third-party radio

Third-party radio cable

6.8 Reversing buzzer


The reversing buzzer cable (P/N 65332):
Active terminator
Flying lead

J2

Note that the physical connection of the flying lead black and red wires are machine
dependent. As there is no polarity, both wires perform the same function.
See Figure 6.4.

Flying lead
Red
Black
1 1
2 2
J2 Black Active terminator (J1)
3 3
4 4
Red

Figure 6.4 Reversing buzzer cable pinouts

78 GCS900 Grade Control System for Grading Applications Installation Manual


Installing the Cab Components 6

To install the reversing buzzer cable:


1. Connect the J2 to the “Direction Indicator” connector on the control box cable.
2. Connect the flying lead in parallel (not in series) to the reverse switch:
3.

Reversing buzzer
Machine power flying lead Machine power
O
Machine reverse switch
Buzzer
O
O
Buzzer
Machine reverse switch
O

Reversing buzzer
Machine ground Machine ground flying lead
Parallel – Correct Parallel – Correct

Machine power

Machine reverse switch

Buzzer

O
O

Machine ground Reversing buzzer flying lead

Series – Incorrect

GCS900 Grade Control System for Grading Applications Installation Manual 79


6 Installing the Cab Components

80 GCS900 Grade Control System for Grading Applications Installation Manual


CHAPTER

7
Installing the Fixed Components 7

In this chapter:

Q Bulldozer cross slope sensors


Q Motor grader cross slope sensors
Q The blade pitch sensor
Q Fixed mast with an angled riser

GCS900 Grade Control System for Grading Applications Installation Manual 81


7 Installing the Fixed Components

7.1 Bulldozer cross slope sensors


• AS400 blade slope sensor.
• RS400 rotation sensor. Requires the:
– RS400 rotation sensor kit (P/N 59704-27)
– RS400 bracket and hardware kit (P/N 59704-28)
• AS400 mainfall sensor. Requires the mainfall sensor kit (P/N 59704-26).

7.1.1 Install the blade slope sensor


The following image shows the cables and connectors for the blade slope sensor:

=
< >

< AS400 blade slope sensor


= Coil cable P/N 0793-0950-xxx
> AS400 adapter cable P/N 0395-9440-xx

To install the sensor:


1. Ensure that the sensor bracket is installed correctly.
See 5.8, Blade slope sensor bracket.
2. Bolt the blade slope sensor to the bracket.
3. Torque the bolts to 20 ± 2 N·m (15 ± 1.5 lbf ft). Secure with Loctite.
4. Connect the coil cable to the blade slope sensor.
5. Tie the cable every 300 mm (12 in) to keep it free from damage.

7.1.2 Install the rotation sensor


To install the rotation sensor, refer to the Trimble Installation Manual for Dozer
Rotation Sensor (P/N 0367-3290).
When you install the rotation sensor, ensure that you:
• mount it on a ram pivot point that provides blade rotation
• keep the sensor cables away from the movement of the cutting edge

82 GCS900 Grade Control System for Grading Applications Installation Manual


Installing the Fixed Components 7

The following image shows the rotation sensor mounted on a pivot point at the back
of the blade:

7.1.3 Install the mainfall sensor


1. Ensure the sensor bracket is installed correctly.
See 5.9, Mainfall sensor bracket.
2. Bolt the mainfall sensor to the bracket.
3. Torque the bolts to 20 ± 2 N·m (15 ± 1.5 lbf ft). Secure with Loctite.
4. Connect the mainfall sensor harness to the system, between the front harness
(P/N 0395-9020) and one of the following:
– the rear harness (P/N 0395-9010)
– either of the quick disconnect cables (P/N 0395-9150-xxx)
– the 12-pin CAN bus terminator (P/N 0395-9210)
5. Connect the sensor to the 6-pin connector on the mainfall sensor harness
(P/N 67008).

GCS900 Grade Control System for Grading Applications Installation Manual 83


7 Installing the Fixed Components

7.2 Motor grader cross slope sensors


• AS400 blade slope sensor
• RS400 rotation sensor
• AS400 mainfall sensor

< = >
?

< AS400 blade slope sensor

= Blade slope sensor cable P/N 0793-0210-xxx

> Rotation and slope sensor Y-cable P/N 0395-1590-xx

? RS400 rotation sensor

@ Front harness cable P/N 0395-9800

A Mainfall sensor cable P/N 0395-1870-xx

B AS400 mainfall sensor

Figure 7.1 Motor grader cross slope sensor connections

7.2.1 Install the blade slope sensor


1. Ensure that the mounting bracket is installed correctly.
See 5.8, Blade slope sensor bracket.
2. Bolt the blade slope sensor to the bracket.
3. Torque the bolts to 20 ± 2 N·m (15 ± 1.5 lbf ft). Secure with Loctite.

84 GCS900 Grade Control System for Grading Applications Installation Manual


Installing the Fixed Components 7

4. Connect the cable to the AS400 blade slope sensor. See Figure 7.1.
5. Tie the cable every 300 mm (12 in) to keep it free from damage.
The following image shows the blade slope sensor in the rear circle pocket:

7.2.2 Install the rotation sensor


1. Position the cutting edge square to the machine.
2. Remove the existing hydraswivel lid, and fit the modified hydraswivel lid.
Face the recessed slot in the lid towards the right rear tires:
Rear of machine

3. Place the rotation sensor on the modified lid. Make sure that the:
– sensor arm fits into the recessed groove
– connector faces towards the rear of the machine
4. Use the provided screws and nylon bushings to secure the rotation sensor to the
modified lid.

GCS900 Grade Control System for Grading Applications Installation Manual 85


7 Installing the Fixed Components

Fit the nylon bushings into the groove on the rotation sensor:

5. Bolt the drive arm bracket to the inside frame of the circle so that the drive arm
fits securely over the rotation sensor.
6. Use the supplied shoulder bolt to attach the drive arm to the mounting bracket.
7. Position the drive arm near to the center of the drive arm mounting slot. To
install it, use one bolt; secure it firmly but not tight.
8. Connect the rotation sensor cable to the sensor.
9. Open the Diagnostics dialog and view the output from the sensor.
If the value is:
– within ± 32° of zero go to Step 17.
– outside the 32° go to Step 10.
10. Taking care not to move the drive arm relative to the sensor body, disconnect
the sensor cable and remove the rotation sensor from the lid.
11. Loosen the allen screw on the drive arm:

12. Place material, such as a folded business card, under the drive arm to space the
arm from the sensor. This gives the sensor drive arm some clearance when you
tighten the allen screw again.
13. Reconnect the rotation sensor cable.

86 GCS900 Grade Control System for Grading Applications Installation Manual


Installing the Fixed Components 7

14. Use a screwdriver to rotate the shaft until the the Diagnostics dialog shows
that the sensor output is within ± 32° of zero:

15. Tighten the allen screw on the drive arm and recheck the reading.
16. Repeat Step 3 to Step 7 to reattach the rotation sensor to the hydraswivel lid.
17. Slowly rotate the sensor and observe the the Diagnostics dialog for the sensor
output.
18. When the reading is within ± 32° of zero, install the second mounting arm bolt
and tighten both bolts:

19. Recheck the sensor rotation angle value on the control box.

7.2.3 Install the AS400 mainfall sensor


1. Ensure the sensor bracket is installed correctly.
See 5.9, Mainfall sensor bracket.
2. Bolt the mainfall sensor to the bracket.
3. Torque the mainfall sensor mounting bolts to 20 ± 2 N·m (15 ± 1.5 lbf ft).
Secure with Loctite.

GCS900 Grade Control System for Grading Applications Installation Manual 87


7 Installing the Fixed Components

4. Connect the mainfall sensor cable to the AS400 mainfall sensor.

7.3 The blade pitch sensor


1. Ensure the sensor bracket is installed correctly.
See 5.5.3 Blade pitch sensor bracket.
2. Bolt the sensor to the bracket: use the bolts supplied in the assembly. Make
sure that the sensor connector faces the left blade tip.
3. Torque the bolts to 20 ± 2 N·m (15 ± 1.5 lbf ft). Secure with Loctite.

7.4 Fixed mast with an angled riser


Note – For optimum stability, use the supplied bolts and washers to attach the riser.
1. Position the angled riser onto the flat plate or rotating bracket.
2. Secure in place with the supplied high tensile bolts and washers.
3. Torque the bolts to 305 N·m (225 lbf ft).
4. Install the fixed mast on to the angled riser.
The angle riser, rotating bracket and mount installed on a motor grader:

Angle riser

Rotating bracket

Mount

88 GCS900 Grade Control System for Grading Applications Installation Manual


CHAPTER

8
Installing the Removable Sensor
Components 8

In this chapter:

Q The electric mast


Q The SR300 laser receiver
Q LR400 and LR410 laser receivers
Q GPS receivers
Q The MT900 machine target

GCS900 Grade Control System for Grading Applications Installation Manual 89


8 Installing the Removable Sensor Components

8.1 The electric mast

ATTENTION – To avoid damage to the electric mast and/or shock mounts, make sure that you
C tighten all bolts to the specifications outlined below.

1. For a:
– bulldozer, position the shock mount on the mounting plate and use the
supplied grade 8 bolts and washers to attach it.
– motor grader, position the shock mount or vertical riser on the rotating
bracket and use the supplied grade 8 bolts and washers to attach it.
2. Torque the bolts to 305 N·m (225 lbf ft).
3. Remove the two bolts that attach the clamp to the upper cross bracket of the
shock mount.
4. Position the electric mast on the lower U-bracket of the shock mount and use
the supplied bolt and washer to bolt the mast onto the U-bracket.
Re-install the clamp onto the cross bracket.
5. Check that the mast is properly installed onto the shock mount.
6. Torque the mast bolt to 205 N·m (151 lbf ft).
7. Torque the clamp bolts to 8 N·m (6 lbf ft).
8. Remove the two 13 mm (1⁄2 in) bolts that secure the U-bracket to the lower part
of the shock mount and apply Loctite to them.
9. Reinstall the two bolts to the U-bracket and tighten to 54 N·m (40 lbf ft).

90 GCS900 Grade Control System for Grading Applications Installation Manual


Installing the Removable Sensor Components 8

8.2 The SR300 laser receiver


Install the SR300 laser receiver on the mast mount:

Note – Before you replace a mast with a laser receiver, disconnect the GPS receiver.
Reconnect the receiver once you complete the replacement.
1. Ensure that the base of the laser receiver and the top of the mast mount are free
from dirt.
2. Position the laser receiver on the mast mount so that it is square to the blade,
and the connector faces backwards.
3. Use the supplied bolt and lock washer to secure the laser receiver.

B Tip – When securing the bolt, apply some anti-seize compound to the bolt thread.

4. Torque the bolt to 370 ± 50 N·m (273 ± 37 lbf ft).

GCS900 Grade Control System for Grading Applications Installation Manual 91


8 Installing the Removable Sensor Components

8.3 LR400 and LR410 laser receivers


1. Mount the laser receiver onto the electric mast.
2. Connect the laser receiver coil cable to the electric mast and the laser receiver.
3. Connect the electric mast coil cable to the mast base and the quick disconnect
bracket. See Figure 8.1.

<

>

@
< Laser receiver
= Laser receiver coil cable P/N 0793-0860
> Electric mast
? Electric mast coil cable P/N 0793-3350
@ Quick disconnect bracket P/N 0791-0940

Figure 8.1 Connecting the LR410 laser receiver

92 GCS900 Grade Control System for Grading Applications Installation Manual


Installing the Removable Sensor Components 8

8.4 GPS receivers


You can install the GPS receiver onto:
• a fixed or electric mast. See 8.1, The electric mast.
• an SR300 laser receiver. See 8.2, The SR300 laser receiver.
Before you install the GPS receiver, check that:
• the top of the mast and mounting bracket are free of dirt.
• for an electric mast, the adapter sleeve (P/N 0367-2890) is done up tightly and
that strain relief is present.
A mast with an adapter sleeve and strain relief fitted:

To install the GPS receiver:


1. Slide the GPS receiver and mounting bracket (P/N 55353) onto the top of the
mast or laser receiver:

GCS900 Grade Control System for Grading Applications Installation Manual 93


8 Installing the Removable Sensor Components

ATTENTION – To ensure system accuracy, you must fully insert the mast or laser receiver into
C the GPS mounting bracket.

2. Firmly tighten the quick disconnect bracket lever.


3. Use the strain relief bracket to secure the GPS receiver coil cable.
4. Plug the coil cable into the quick disconnect bracket. See Figure 8.2.

> >
<
@
?
?

< Fixed mast


= GPS receiver
> GPS receiver coil cable P/N 0395-9450
? Quick disconnect bracket P/N 0791-0940
@ SR300 laser receiver

Figure 8.2 Connecting GPS receivers

94 GCS900 Grade Control System for Grading Applications Installation Manual


Installing the Removable Sensor Components 8

8.5 The MT900 machine target


You must use an adapter sleeve (P/N 0367-2890) when you mount the MT900
machine target on an electric mast, as the diameter of the bracket is greater than the
electric mast’s. See Figure 8.3.
Before you install the MT900 machine target, check that the adapter sleeve is done up
tightly and that strain relief is present.
To install the MT900 machine target:
1. Check the installation of the mast and mast mounting bracket.
2. Ensure that the top of each mast and mast mounting bracket are free of dirt.
3. Slide the MT900 machine target onto the top of the mast.
4. Connect the cable and firmly tighten the connector.

MT900 machine target

Adapter sleeve

Figure 8.3 MT900 machine target mounted on an electric mast

GCS900 Grade Control System for Grading Applications Installation Manual 95


8 Installing the Removable Sensor Components

96 GCS900 Grade Control System for Grading Applications Installation Manual


CHAPTER

9
Measure Up 9

In this chapter: For optimum system guidance, you must take


accurate machine measurements.
Q Measure-up worksheet: bulldozer /
scraper This chapter provides:
Q Measure-up worksheet: motor • measure-up worksheets
grader
• instructions on how to measure your
Q Preparing for measure-up machine correctly
Q General guidelines
Q Preparing the machine
Q Mast measurements
Q Blade / cutting edge dimensions
Q Ripper / machine body dimensions
Q Receiver positions
Q The measure-up tool

GCS900 Grade Control System for Grading Applications Installation Manual 97


9 Measure Up

9.1 Measure-up worksheet: bulldozer / scraper

Date:
Measurement units:
Machine name:

Edge: H. / V. Edge: Angle


Blade height: Blade height:
Blade width between tips: Blade width between tips:
Cutting edge horizontal distance: Cutting edge height:
Cutting edge vertical distance: Cutting edge angle:
.

Ripper back from cutting edge: Forward of cutting edge:


Back to cutting edge:

Center mast Mast: Left Right


Back from cutting edge bolts: Back from cutting edge bolts:
Above cutting edge bolts: Above cutting edge bolts:
In from left blade tip: In from blade tip:
Additional for electric masts
Mast lean in from blade tip:
Mast lean back:

98 GCS900 Grade Control System for Grading Applications Installation Manual


Measure Up 9

Single GPS cab or body mounted receiver

Height (to top of lower housing): Blade width between tips:


Back from cutting edge:
In from left blade tip:
.

Ripper back from cutting edge: Front to cutting edge:


Back to cutting edge:

GCS900 Grade Control System for Grading Applications Installation Manual 99


9 Measure Up

9.2 Measure-up worksheet: motor grader

Date:
Measurement units:
Machine name:

Edge: H. / V. Edge: Angle


Measurement bolt hole: Measurement bolt hole:
Cutting edge horizontal distance: Cutting edge height:
Cutting edge vertical distance: Cutting edge angle:
.

Ripper back from cutting edge: Front to cutting edge:


Back to cutting edge:

Blade height Mast: Left Right


Blade width between tips: Bolt hole:
Distance between lift rams: Back from cutting edge bolts:
A-frame distance: Above cutting edge bolts:
In from blade tip:
Additional for electric masts
Mast lean in from blade tip:
Mast lean back:

10 0 GCS900 Grade Control System for Grading Applications Installation Manual


Measure Up 9

Mast: Left Right Mast: Left Right


Bolt hole: Bolt hole:
Back from cutting edge bolts: Back from cutting edge bolts:
Above cutting edge bolts: Above cutting edge bolts:
In from blade tip: In from blade tip:
Additional for electric masts Additional for electric masts
Mast lean in from blade tip: Mast lean in from blade tip:
Mast lean back: Mast lean back:

Single GPS cab or body mounted receiver

Height (to top of lower housing): Blade width between tips:


Back from cutting edge:
In from left blade tip:
.

Ripper back from cutting edge: Front to cutting edge:


Back to cutting edge:

GCS900 Grade Control System for Grading Applications Installation Manual 1 01


9 Measure Up

9.3 Preparing for measure-up


1. Use a blank worksheet to record your machine measurements. Make sure that
you also record the:
– date
– measurement units (metric or imperial)
– machine type and, if applicable, its name
2. Make sure that you have all tools available. See 2.2, Tools.

9.4 General guidelines


Consider the following when you take these measurements:
• Bolt hole:
Take mast measurements for each bolt hole that you intend to use during
system operation.
• Measurement bolt hole:
Take a cutting edge measurement for the bolt hole that is currently in use.
There are seven bolt holes on the rotating bracket. Bolt hole 1 is nearest to the
front of the machine; 7 is nearest to the operator’s cab. See Figure 9.1.

Figure 9.1 Rotating bracket with bolt hole 5 in use

ATTENTION – The bottom section of the rotating bracket has two bolt holes; you can use either
C of these to attach the top section to the bottom. However, you must choose one or the other
and use only that one - you cannot take measurements for both and then swap between them.

10 2 GCS900 Grade Control System for Grading Applications Installation Manual


Measure Up 9

9.4.1 Optional mast measurements for conventional guidance systems


For conventional guidance systems, you must bench the mast before use. This makes
the following mast measurements optional:
• Above cutting edge bolts
• Back from cutting edge bolts
If you expect that the mast will carry a 3D sensor in the future, make sure that you
take these measurements.

9.4.2 Electric mast measurements


The position of the GPS receiver or UTS target relative to the blade tip can change as
the electric mast moves up and down. To allow for this, you must take the mast lean
measurements. See 9.6.3, Additional measurements for an electric mast.

9.4.3 A-frame measurement


For motor graders, you must take an A-frame measurement.
See 9.4.3, A-frame measurement.

9.5 Preparing the machine


Before you take any machine measurement, make sure that you position the machine
correctly.

9.5.1 Bulldozers and scrapers


1. Park the machine on level ground.
2. Rest the cutting edge on the ground.
3. Position the cutting edge so that:
– it is straight (that is, not angled)
– the top of the cutting edge is level

9.5.2 Motor graders


To prepare the motor grader for measure-up:
1. Position the motor grader.
2. Mark the circle.

GCS900 Grade Control System for Grading Applications Installation Manual 1 03


9 Measure Up

Position the motor grader


1. Park the machine on level ground.
Note – If the ground is uneven, place a board under each blade tip. Level the
boards at the same height. Ensure that the boards are large enough so that
when you lower a plumb line from the measure-up tool, it touches the board.
2. Put the frame in the straight position (so the gooseneck is not articulated).
3. Ensure that the front wheels are vertical.
4. Center the link bar with the locking pin in the middle hole.
5. Center the circle. To confirm that the circle is properly centered, secure a
plumb line from the center of the gooseneck so that the plumb line hangs just
above the center of the hydraswivel.
6. Use a spirit level to level the blade.

Mark the circle


1. Center the blade on the circle. To check the position of the moldboard, measure
from the circle frame to each side of the moldboard:

2. Rotate the blade so that it is more or less perpendicular to the mainframe.


3. Measure from the draft ball at the head of the A-frame to each end of the
moldboard:

10 4 GCS900 Grade Control System for Grading Applications Installation Manual


Measure Up 9

Note – You do not have to measure to the very tip of the moldboard, however,
you must measure to the same point at each end of the moldboard.
4. Compare the two measurements. If they are not equal, rotate the blade slightly.
5. Repeat Step 3 and Step 4 until the two measurements are equal.
6. Mark the rotating part of the circle where it lines up with the fixed part of the
circle. Make the mark prominent enough to see from the cab:.

Now, whenever you need to rotate the blade to zero, align the chisel mark with
the fixed part of the circle.

9.6 Mast measurements


To position the machine:
1. Rotate the blade to zero.
2. Rest the cutting edge on the ground and use a spirit level to ensure that the
cutting edge bolts are level.
3. Use a spirit level to check that the left mast is vertical in the forward/back
direction.
4. If you have an electric mast, set it to the lowest position.

9.6.1 Taking the measurements


When you take the mast measurements, pay attention to the following:
• Position the machine correctly, and measure both masts with the machine in
this position.
• Do not move the blade until the measurements are complete.
• Measure the left mast first, and then the right mast.
• For best results, use a measure-up tool.See 9.10, The measure-up tool.

GCS900 Grade Control System for Grading Applications Installation Manual 1 05


9 Measure Up

• If you do not use a measure-up tool, make the height measurements to either:
– the top of the mast (remove the mounting brackets and/or collars).
– the joint between the radome and the lower housing of the GPS receiver:

– the center of the tracking LEDs of an MT900 target:

– The center of the prism of any other ATS target.

ATTENTION – The Measure height to option in the Mast Measurements dialog defaults to
C Measure-up tool.
If you do not use a measure-up tool, make sure that you select the correct Measure height to
option. If you select the wrong option, this can introduce a substantial vertical error into the
positioning information that the system provides. See 10.4.1, Mast measurements.

10 6 GCS900 Grade Control System for Grading Applications Installation Manual


Measure Up 9

9.6.2 Standard mast measurements


• Back from cutting edge bolts: A
Note – If the mast is in front of the cutting edge bolts, A is negative.

Bulldozer Scraper Motor grader

• Above cutting edge bolts: B


• In from blade tip: C
Note – If the mast is out from the blade tip, C is negative.

Bulldozer Scraper

measure-up tool top of lower housing

B B
B

C C C

GCS900 Grade Control System for Grading Applications Installation Manual 1 07


9 Measure Up

Motor grader

measure-up tool top of lower housing

B B

C C

9.6.3 Additional measurements for an electric mast


• Use a digital level to take both of these measurements.
• For accurate guidance, the lean for both measurements must be less than 5°.

Mast lean in from blade tip


Measure the lean of the mast away from vertical in the side-to-side direction.
Make sure that the operating plane of the level is parallel to the cutting edge:

If the mast leans towards the blade tip, the measurement is negative.

10 8 GCS900 Grade Control System for Grading Applications Installation Manual


Measure Up 9

Mast lean back


Measure the lean of the mast away from vertical in the forward-to-back direction.
Make sure that the operating plane of the digital level is perpendicular to the blade:

If the mast leans forward, the measurement is negative.

9.7 Blade / cutting edge dimensions


You can measure the cutting edge horizontal and vertical distances (Edge H/V) or,
directly from the center of the cutting edge bolts to the cutting edge (Edge Angle).
Whichever measurements you take, make sure that you activate the appropriate fields
in Cutting Edge Dimensions (motor grader) Blade Dimensions (bulldozer/scraper)
dialog. See 10.4.2, Machine dimensions.
To measure the cutting edge horizontal distance:
1. Stand the spirit level against the front of the cutting edge.
2. Make sure that the level is vertical.
3. Measure from the center of the cutting edge bolts to the edge of the level:

GCS900 Grade Control System for Grading Applications Installation Manual 1 09


9 Measure Up

To measure the cutting edge vertical distance:


1. Rest the spirit level on the center of the cutting edge bolts.
2. Make sure that the level is horizontal.
3. Measure the from the bottom edge of the level to the tip of the cutting edge:

9.7.1 Bulldozer / scraper


• Blade height: F
Note – Measure from the center of the cutting edge bolts to the top of the blade.
This enables the system to display the relative height of the blade in the
cross-section view. The exact measurement is not critical.
• Blade width between tips: G

11 0 GCS900 Grade Control System for Grading Applications Installation Manual


Measure Up 9

Note – Take either the Edge H/V or Edge Angle measurements - you do not need both.
Edge H/V:
• Cutting edge horizontal distance: I
• Cutting edge vertical distance: K
Edge Angle:
• Cutting edge height: J
• Cutting edge angle: L

L
K

9.7.2 Motor grader


Edge H/V:
• Cutting edge horizontal distance: I
• Cutting edge vertical distance: K
Edge Angle:
• Cutting edge height: J
• Cutting edge angle: L

J
K
L

GCS900 Grade Control System for Grading Applications Installation Manual 111
9 Measure Up

• Blade height: F
• Blade width between tips: G
• Distance between lift rams: H

F H

• A-frame distance. Measure from:


a. the center of the draft ball, at the head of the A-frame:

b. to the center of the rotation sensor, on top of the hydraswivel:

11 2 GCS900 Grade Control System for Grading Applications Installation Manual


Measure Up 9

9.8 Ripper / machine body dimensions


Before you take the ripper measurement, lower the rippers to the ground.
• Ripper back from cutting edge: M
The system uses the following measurements for avoidance zone calculations:
• Any machine part forward of the cutting edge/Front to cutting edge: N
• Back to cutting edge: O
On a bulldozer, ‘N’ allows for any part of the machine that extends beyond the
cutting edge, such as a forward swept corner. See Figure 9.2.

9.8.1 Bulldozer

9.8.2 Motor grader

O N

GCS900 Grade Control System for Grading Applications Installation Manual 113
9 Measure Up

9.9 Receiver positions


This section outlines the measurement techniques for a cab or body mounted
single-antenna system. Generally, only bulldozers use this configuration.
When you take these measurements, for a:
• scraper, if the cutting edge is fitted with:
– a stinger, measure to the stinger
– teeth, measure to the cutting edge, not the teeth
• bulldozer, measure to the front of the blade not to the forward-swept corners:
Forward-swept corner

Guidance point

N
Front of blade
H x

A = Horizontal distance from cutting edge bolts back to left GPS receiver
H = Horizontal distance from cutting edge bolts to front of blade
C = Distance in from left blade tip

Figure 9.2 Plan view of a bulldozer blade and GPS receiver

9.9.1 Height (to top of lower housing)


1. Place a straight edge across the roof of the cab, perpendicular to the centerline
of the machine.
2. To hold the straight edge steady, clamp it in position.
3. Measure the height from the top of the lower housing on the GPS receiver to
the top of the straight edge = A.
4. Measure the height from the top of the straight edge to the ground = B.

11 4 GCS900 Grade Control System for Grading Applications Installation Manual


Measure Up 9

5. To calculate the height: A + B.

A
Straight edge

9.9.2 Back from cutting edge


Note – Because the receiver mount is behind the cutting edge, the measurement is
positive.
1. Place a straight edge across the roof of the cab. Ensure that it is perpendicular
to the centerline of the machine.
2. Secure a plumb line to the front of the straight edge so that it hangs down to the
ground and is in line with the left blade tip.
3. Measure the distance from the blade cutting edge to the plumb line, parallel to
the centerline = C.
4. Measure the distance from the center of the GPS receiver to the front of the
straight edge, parallel to the centerline = D.
5. To calculate the distance: C + D.
Straight edge

GCS900 Grade Control System for Grading Applications Installation Manual 115
9 Measure Up

9.9.3 In from left blade tip


1. Place a straight edge across the roof of the cab, perpendicular to the centerline
of the machine.
2. Measure the blade width.
3. Divide the blade width by 2 = G.
4. Measure the offset of the GPS receiver from the centerline = H.
5. Calculate the distance. If the center of the GPS receiver is to the:
– left of the centerline: G - H
– right of the centerline: G + H

Straight edge

Centerline

9.10 The measure-up tool


For the best results, use a measure-up tool (P/N 53326-00) to take the mast
measurements. The tool consists of:
• A length of angle alloy, with slots and mounting holes in both sides. The slots
mark the distance from the center of the mast. One side of the angle alloy
shows metric units, the other side shows feet and inches.
• A mounting bracket.
• Two bolts and four nuts.

11 6 GCS900 Grade Control System for Grading Applications Installation Manual


Measure Up 9

9.10.1 Assembling the measure-up tool


1. Use the supplied bolts and nuts to attach the length of angle alloy to the
mounting bracket. For accuracy, you must use the center nuts:

2. Mark the bottom edge of the mounting bracket at each 90° interval:

9.10.2 Using the measure-up tool

B Tip – When you mount the measure-up tool, make sure that the measurement units you prefer
to work in are on the horizontal surface.

To use the measure-up tool efficiently, take the measurements in this order:
a. Back from cutting edge bolts
b. Above cutting edge bolts
c. In from left/right blade tip
For dual antenna systems, where the tops of the masts are the same distance back
from the cutting edge bolts, this is a safe and quick way to align the measure-up tool:
1. Slide the measure-up tool onto the top of the mast you want to measure.
2. Point the measure-up tool at the other mast.
3. Mark the mast you are measuring, in line with the 90° marks on the bracket.
4. For measurements a and b, to rotate the bracket until it points straight forward,
align the marks on the bottom of the bracket with each mark on the mast.

GCS900 Grade Control System for Grading Applications Installation Manual 117
9 Measure Up

5. For c, to rotate the bracket another 90°, align the marks on the bottom of the
bracket with the next mark on the mast.

Back from cutting edge bolts


1. Remove the GPS receiver or UTS target from the mounting bracket.
2. Slide the measure-up tool onto the top of the mast.
3. Rotate the measure-up tool until it is perpendicular to the cutting edge and
points straight forward.
If you have a dual-antenna system, simply point a square at the other mast:

4. Secure a plumb line from one of the notches in the measure-up tool so that the
plumb line hangs just in front of the cutting edge bolts.
5. Record the measurement beside the notch you secure the plumb line to.
6. Measure the distance from the plumb line to the center of the cutting edge
bolts:

7. Subtract the value taken in Step 6 from the value taken in Step 5.

11 8 GCS900 Grade Control System for Grading Applications Installation Manual


Measure Up 9

Above cutting edge bolts


1. Leave the measure-up tool in the same position as for measuring the distance
back from the cutting edge bolts.
2. Anchor a measuring tape onto the measure-up tool:

3. Measure to the center of the cutting edge bolts:

4. Use a spirit level to ensure that the measure-up tool is level.


Note – Place the end of the spirit level directly over the center of the mast.
If the measure-up tool is not level, measure the distance from the top of the
measure-up tool to the bottom of the spirit level, at the point where you made
the measurement in Step 2, and add it to the height measured.

GCS900 Grade Control System for Grading Applications Installation Manual 119
9 Measure Up

In from left/right blade tip


1. Rotate the measure-up tool so that it is parallel to the cutting edge of the blade
and extends beyond the end of the blade.

B Tip – To align the measure-up tool, sight along the tool to the other mast:

2. Secure a plumb line from one of the notches on the measure-up tool, so that the
plumb line hangs just out from the end of the blade.
3. Record the measurement beside the notch you secure the plumb line to.
4. Measure the distance from the tip of the blade to the intersection of the steel
framing square and the plumb line:

5. Subtract the value measured in Step 4 from the measurement taken in Step 3.
Note – If the center of the mast is outside the blade tip, the measurement is
negative.

12 0 GCS900 Grade Control System for Grading Applications Installation Manual


CHAPTER

10
Setup Menus 10

In this chapter: This chapter describes how to use the Setup


menus to configure your system.
Q Using the Setup menus
Q GPS Receiver Configuration
Q Machine Settings
Q Units
Q Machine Dimensions
Q Select Radio Band
Q Lightbar Connections
Q Machine Radio Configuration
Q Calibrate Sensors
Q Control Box’s Radio Port

GCS900 Grade Control System for Grading Applications Installation Manual 1 21


10 Setup Menus

10.1 Using the Setup menus


At various stages during the install you must use the Setup menus. To ensure that you
have access to all menu items, you must start the control box in the Manager mode.
To access Manager mode:
1. Press and hold \ as you press P.
2. Hold down \until the control box displays the opening screen.

C CAUTION – If you lack experience with the GCS900 Grade Control System, when you are in
Manager mode be careful not to accidentally change any system settings.

The system has two modes: Operator and Manager.


Items that are active in Manager mode but disabled in Operator mode, appear as
follows:
• menu items with a red dot:
• softkeys that have red text

10.1.1 Setup Menu – Configuration


To access the Setup Menu – Configuration dialog, press M.

10.1.2 Setup Menu – Installation


To access the Setup Menu – Installation dialog:
1. Press M. The Setup Menu – Configuration dialog appears.
2. Press Installation.

12 2 GCS900 Grade Control System for Grading Applications Installation Manual


Setup Menus 10

10.2 Machine Settings


1. From Setup Menu – Installation, select Machine Settings:

The dialog that appears shows a summary of the current settings.


2. To enter the wizard, press Edit Machine.
3. To advance through the pages in the wizard, press 7.
The wizard guides you through the task of configuring your machine. The
pages that appear, and the items that appear on each page may differ according
to the selections that you make. If a page or list item appears that you are
unsure of, you can either:
– Press 8 to go back and check the previous page(s).
– Press=to discard all of the changes and start again.
Some of the pages in the wizard contain settings that are critical to system accuracy.
In particular, make sure that you select the correct option on the following pages:

For a bulldozer with RS400 as fixed sensor

GCS900 Grade Control System for Grading Applications Installation Manual 1 23


10 Setup Menus

To validate the rotation sensor mounting position, check that the rotation sensor
values:
• do not change when you tilt the blade
• increase when you move the right hand blade tip forward.
If the value decreases, invert the mounting direction.
Once you have configured all of the settings, the Finished page appears:

4. To save the system settings, press Finish. The summary page appears.
5. Check the summary page to ensure that the settings match your system type.

10.3 Units
1. From Setup Menu – Installation, select Units:

2. Set the Distance units.


3. Press each softkey in turn and enter the required unit type.
4. Press\.

12 4 GCS900 Grade Control System for Grading Applications Installation Manual


Setup Menus 10

10.4 Machine Dimensions


Use the Machine Dimensions wizards to enter your machine measurements into the
system.
To access the dialog, from Setup Menu – Installation, select Machine Dimensions:
• For systems with masts, the following dialog appears:

• For systems that do not use a mast, the blade dimensions page of the Machine
Dimensions wizard appears:

ATTENTION – Valid machine measurements are critical to system operation. Make sure that
C you enter all of the required measurements for your system type.

GCS900 Grade Control System for Grading Applications Installation Manual 1 25


10 Setup Menus

10.4.1 Mast measurements


The pages that appear for this wizard differ according to the machine type. The
following process shows the pages that appear for a motor grader.
1. Select Mast Measurements. The Welcome page appears:

2. Press 7. If the mast uses a rotating bracket, the Bolt Holes page appears:

If required, select the bolt holes that you are using and press 7.
3. The Mast Measurements page appears:

To ... Press ...


Enter values into the current field ] or [
Scroll through values in the Measure height to field
(or )
Scroll through the measurement items The up and down arrow softkeys
Move to the next page in the wizard 7

12 6 GCS900 Grade Control System for Grading Applications Installation Manual


Setup Menus 10

To ... Press ...


Cancel any changes =
Save the measurements 7 then Finish

ATTENTION – Make sure that you select the correct Measure height to option.
C If you select the wrong option, this can introduce a substantial error into the guidance
information that the system provides. For more information, see 9.6, Mast measurements.

10.4.2 Machine dimensions


The pages and softkeys that appear in this wizard differ according to the machine
type. The following process shows the pages and softkeys that appear for a bulldozer.
1. Select Machine Dimensions. By default, the Blade Dimensions page appears:

2. Enter the blade dimensions measurements.


Note that the above dialog shows the cutting edge horizontal and vertical
distances. If you measured the cutting edge height and angle, press Edge H. / V.
to activate those fields.
3. Press each of the remaining softkeys in turn and enter your machine
measurements.
4. Press \.

GCS900 Grade Control System for Grading Applications Installation Manual 1 27


10 Setup Menus

10.5 Select Radio Band


The SNRx10 data radio can support 900/2400 and 450/2400 MHz frequencies. You
must set the required frequency prior to operating the system.
1. From Setup Menu – Configuration, select Select Radio Band:

2. To change the radio band, press Set <x00 > MHz.


3. Press \.

10.6 Lightbar Connections


1. From Setup Menu – Installation, select Lightbar Connections.
For a cab or body mount machine, the following dialog appears:

For all other systems, a dialog similar to the following appears:

12 8 GCS900 Grade Control System for Grading Applications Installation Manual


Setup Menus 10

2. Check the LED pattern on the lightbars to see if they correspond to the dialog.
If they do not, for each lightbar that is wrong, do the following:

Connect this lightbar to the harness Then press this If the LEDs light up at the wrong end, then
(disconnect others) ... softkey ... press this softkey ...
Left/Vertical Set A Invert A
Center/Horizontal Set B Invert B
Right Set C Invert C

3. Press \.

10.7 Machine Radio Configuration


1. From Setup Menu – Installation, select Machine Radio Configuration:

2. Use the arrow keys to change the network number.


3. To save the changes, press \.
The network number uploads to the machine radio, and the machine radio is
programmed as a rover radio.
The following table outlines how to configure your machine radio:

To configure this Enter this number into the Enter the same number into the ...
radio ... Machine Radio Configuration dialog ...
SNR900 A network between 1-40 GPS base radio (via the base station radio
SNR910 display)
SNR2400/ A channel between: Internal UTS radio (via the face plate)
SNR2410 • 1-12 for the ATS600
• 31-60 for the SPSx30
SNR410 Refer to the documentation supplied with your radio

Notes – 1. If your site uses both GPS and UTS positioning systems with 900 MHz
radios, then the GPS radios and each UTS radio must use different
networks.
2. If you have a dual band SNRx10 radio, assign a network ID to both radio
modules so that you can switch between radio bands if necessary.

GCS900 Grade Control System for Grading Applications Installation Manual 1 29


10 Setup Menus

10.8 Calibrate Sensors


Before you use the system, you must calibrate the sensors.
From Setup Menu – Configuration, select Calibrate Sensors:

The list that appears on the first page of the wizard varies according to the sensors
that are connected to the harness. The following table describes the calibration
options for each machine:

For this machine ... These list items may appear ...
• Bulldozer Mainfall, blade slope and rotation sensors
• Motor Grader Note – You can calibrate the above sensors collectively, or individually;
you only need to calibrate them once.
Blade slope sensor
Blade pitch sensor
Blade rotation sensor
Mainfall sensor
Electric masts
Linked EM400 calibration
Mill/Cold planer Drum slope sensor
Other Blade slope sensor
Linked EM400 calibration

To ensure that the system provides accurate guidance, you must:


• calibrate all of the sensors listed on the first page of the wizard.
• complete all of the on-screen instructions for each sensor calibration.
For example, to calibrate the mainfall, blade slope and rotation sensors on a
motor grader, you must position the machine as described below:

13 0 GCS900 Grade Control System for Grading Applications Installation Manual


Setup Menus 10

10.8.1 Blade slope sensor


1. Select Blade slope sensor:.

2. Complete the on-screen instructions and press Calibrate. A ‘Calibrating’


message appears, then the Calibrate Sensors dialog.

10.8.2 Mainfall, blade slope, and rotation sensors


The pages and machine icon that appear in this wizard differ according to the system
and machine type.
The following process shows the pages that appear for a motor grader with a cross
slope sensor group.
1. Select Mainfall, blade slope and rotation sensors. The Welcome page appears:

2. Complete the on-screen instructions. A ‘Measuring’ message appears, then the


Align Blade page:

GCS900 Grade Control System for Grading Applications Installation Manual 1 31


10 Setup Menus

3. Complete the on-screen instructions. ‘Measuring’ appears then the Align


Wheels page:

4. Complete the on-screen instructions. ‘Measuring’ appears, then the Finished


page.
5. Press Finish.

10.8.3 Blade rotation sensor


1. Select Blade rotation sensor:

2. Complete the on-screen instructions. A ‘Calibrating’ message appears, then the


Calibrate Sensors dialog.

13 2 GCS900 Grade Control System for Grading Applications Installation Manual


Setup Menus 10

10.8.4 Mainfall sensor


1. Select Mainfall sensor:.

2. Complete the on-screen instructions. A ‘Calibrating’ message appears, then the


Calibrate Sensors dialog.

10.9 Control Box’s Radio Port


The Control Box’s Radio Port menu item is only available when you select a third
party radio in the Machine Settings wizard.
1. From Setup Menu – Installation, select Control Box’s Radio Port:

To ... Press ...


Enter values into the current field ][ (or )
Swap between the fields N
Cancel any changes =
Save the changes \
For a third-party radio
The settings in the Control Box’s Radio Port group must match the
communication port settings in the data radio.
To get these values, refer to the documentation for your radio. The system
supports baud rates up to 38400.

GCS900 Grade Control System for Grading Applications Installation Manual 1 33


10 Setup Menus

As a guideline, the default values for the SNR900 or SiteNet 450 are:
– Baud rate: 38400
– Parity: None
For the SNM930 cellular modem

If you connected to the ... Use this port number ...


black rooftop connector COM1
green rooftop connector COM3

To receive VRS corrections, set Yes in the GGA field of the External VRS
Device group.

Note – To receive VRS corrections, the MS99x GPS receivers require version
3.9x or later firmware.

10.10 GPS Receiver Configuration


1. From Setup Menu – Configuration, select GPS Receiver Configuration: .

The dialog lists all of GPS receiver configuration files in the root directory of
the data card.
The CMRs softkey displays which CAN bus the system is currently using to
relay information between the GPS receivers.
2. Select the correct .cfg file and press \. A message appears:
Loading. Please wait ...
3. Once the file loads, Setup Menu – Configuration appears. Check that the GPS
configuration file was correctly sent:
a. Measure and enter all the machine measurements.
b. Calibrate all the sensors.
c. Position the cutting edge on a known point and compare the coordinates
that appear on the control box with the known coordinates of the point.

13 4 GCS900 Grade Control System for Grading Applications Installation Manual


CHAPTER

11
Validation and Troubleshooting 11

In this chapter: This chapter describes how to:

Q Validating the cabling installation • validate the system installation


Q Checking device connections • investigate and troubleshoot the system
Q Checking the lightbars and control
box
Q Verifying the blade tip position
Q Final validation
Q No CAN bus connection
Q No automatic system
Q No power
Q Related information

GCS900 Grade Control System for Grading Applications Installation Manual 1 35


11 Validation and Troubleshooting

11.1 Validating the cabling installation


Use a multimeter to validate the harness and cabling installation, as follows:

On ... Check that ...


The 39-pin control box connector Battery voltage is present at pins D (+) and F (–)
The rear harness cable connector Battery voltage is present at pins 1 (+) and 2 (–)
Each CAN bus Both harness cable terminators are terminated correctly on
the 39-pin control box connector. This should measure as 60
ohms on CAN0 across pin J (CAN0 Low) and pin K (CAN0
High).

11.2 Checking device connections


Use the Diagnostics dialogs to check that each device is visible and working
correctly. If a device is not found:

Check the continuity between this pin on the And this pin on the missing component ...
control box ...
K (CAN0 Hi) C
J (CAN0 Lo) D

For more information about the Diagnostics dialogs, refer to the:


• GCS900 Grade Control System for Grading Applications Operator’s Manual
• GCS900 Grade Control System Site Supervisor’s Manual
Any problems may also be due to CAN bus communication. See 11.6, No CAN bus
connection.

11.3 Checking the lightbars and control box


When you power up the system, observe the start-up sequence of the lightbars and
control box to make sure that they function correctly.
For more information, refer to the GCS900 Grade Control System Operator’s
Manual, Section 3.2 Power up checks.

11.4 Verifying the blade tip position


Verify the northing and easting of the blade tip on a known point. Reverse out and
come back to the known point again from a direction that is 90° to 180° perpendicular
to your original approach. Re-check the position.
Note – The system pitch buffer on a motor grader may affect this reading. Ensure that
you do not approach the point too quickly or turn abruptly.

13 6 GCS900 Grade Control System for Grading Applications Installation Manual


Validation and Troubleshooting 11

11.5 Final validation


Validate the installation by cutting some dirt, turning 180°, and cutting back along the
cut you first made. Check to see if the two cuts match.

11.6 No CAN bus connection


If there appears to be no CAN bus communication present on the system:
Check the terminators:
1. Connect all the system components to the harness and turn the system off.
2. Check that all CAN terminators are correctly installed on the machine harness.
3. Disconnect the system harness from the device. Use a multimeter to check that
the impedance of each CAN bus is approximately 60 Ω

At this harness connector ... Check CAN0 Hi at pin ... Check CAN0 Lo at pin ...
Data radio 4 5
ATS / UTS target C D
Valve module C D
Electric mast C D
Laser receiver C D
AS400 angle sensor C D
RS400 rotation sensor C D

For a GPS system, check CAN1 Hi at pin P; CAN1 Lo at pin L.


4. If the bus impedance reads:
– 120 Ω, then one terminator is faulty
– 0 Ω, then both terminators are faulty
To identify a faulty terminator, swap out each terminator with a known good
terminator.
Confirm voltages:
1. Power up the system.
2. Use a multimeter to check that there is ~2 to 3 volts between the ground pin F
and pins C or D.
If the voltage is 0, the CAN bus line is grounded, probably due to a machine
voltage short.
Confirm continuity:
Use a multimeter to check continuity through the harnesses.

GCS900 Grade Control System for Grading Applications Installation Manual 1 37


11 Validation and Troubleshooting

11.7 No automatic system


When there appears to be no automatic mode on the system, complete the following
checks:
• Confirm that the auto option is installed.
• Use a multimeter to check that there is voltage at the valve.
• To see if there is a hydraulic fault, check that you can operate the hydraulics
manually.

11.8 No power
Where there appears to be no power present on the system, check that:
• power is connected correctly; use a multimeter to trace the voltage from the
source through all the components of the system
• all fuses are working
• all the pinouts are connected correctly
If you suspect that a component is faulty, swap in a known good component
and then re-check the machine power.
If the control box does not power up:
1. Remove the main harness connector from the control box.
2. On the power circuit between the battery and the control box, check the:
– connections to battery positive and chassis ground: tighten any loose
connections, and re-check the control box.
– fuses on the switched and/or unswitched positive power flying leads:
replace any blown fuses, and re-check the control box.
– power cables and connectors between the battery and the control box.
3. Ensure that battery voltage is present at pins D and F on the control box
connector. See Figure 11.1.
If the control box is receiving power, suspect a faulty control box. Swap in a
known good control box and then re-check the machine power and control box.

13 8 GCS900 Grade Control System for Grading Applications Installation Manual


Validation and Troubleshooting 11

W A
V B
C
U X
j Y
T i D
k Z
S h r m a E
R g F
q n b
P p G
f
Pin Function Pin Function
N e d c H
A SPARE N/C X IGNITION / WAKE UP INPUT
M J
B SWITCH INPUT 0 L K Y SWITCH INPUT 1
C SWITCH INPUT 3 Z SWITCH INPUT 6
D BATT + a RCA LINE OUT Hi
E SWITCH COMMON GROUND b RCA LINE OUT Lo
F BATT – c CDL Lo
G SPARE N/C (Not Connected) d CDL Hi
H SWITCH INPUT 4 e CAN1 BUS SHIELD
J CAN0 Lo f RS232-0 RTS
K CAN0 Hi g RS232-0 CTS
L CAN1 Hi h RS232-0 RXD
M CAN1 Lo i RS232-0 TXD
N RS232-2 TXD j RADIO SWITCH
P RS232-2 RXD k SWITCH INPUT 2
R RS232-2 GND m BATT–
S RS232-1 GND n AWAKE GROUND
T RS232-1 RXD p AWAKE
U RS232-1 TXD q RS232-0 GROUND
V SWITCH INPUT 5 r SPARE N/C (Not Connected)
W BATT +

Figure 11.1 Control box power connector pinouts

11.9 Related information


For more troubleshooting information, refer to the:
• GCS900 Grade Control System for Grading Applications Operator’s Manual
• GCS900 Grade Control System Reference Manual
To identify connector pinouts, refer to the GCS Series Cable Diagrams Manual.

GCS900 Grade Control System for Grading Applications Installation Manual 1 39


11 Validation and Troubleshooting

14 0 GCS900 Grade Control System for Grading Applications Installation Manual


APPENDIX

A
Radio Declarations A

In this chapter:

Q SNR2400 data radio declaration


Q SNRx10 data radio
Q 450 MHz data radio
Q 900 MHz data radio

GCS900 Grade Control System for Grading Applications Installation Manual 1 41


A Radio Declarations

A.1 SNR2400 data radio declaration


The Trimble SNR2400 data radio is a 2.4 GHz spread-spectrum radio transceiver.

C CAUTION – The use of this radio equipment requires individual authorization for outdoor
operation in Latvia.

Language Declaration
English Hereby, Trimble Navigation, declares that this 2.4 GHz Spread Spectrum Radio Transceiver,
SNR2400, is in compliance with the essential requirements and other relevant provisions of
Directive 1999/5/EC.
Finnish Trimble Navigation vakuuttaa täten että 2.4 GHz Spread Spectrum Radio Transceiver, SNR2400,
Suomi tyyppinen laite on direktiivin 1999/5/EY oleellisten vaatimusten ja sitä koskevien direktiivin muiden
ehtojen mukainen.
Dutch Hierbij verklaart Trimble Navigation dat het toestel 2.4 GHz Spread Spectrum Radio Transceiver,
Nederlands SNR2400, in overeenstemming is met de essentiële eisen en de andere relevante bepalingen van
richtlijn 1999/5/EG
Bij deze verklaart Trimble Navigation dat deze 2.4 GHz Spread Spectrum Radio Transceiver,
SNR2400, voldoet aan de essentiële eisen en aan de overige relevante bepalingen van Richtlijn
1999/5/EC.
French Par la présente Trimble Navigation déclare que l'appareil 2.4 GHz Spread Spectrum Radio
Francais Transceiver, SNR2400, est conforme aux exigences essentielles et aux autres dispositions
pertinentes de la directive 1999/5/CE
Par la présente, Trimble Navigation déclare que ce 2.4 GHz Spread Spectrum Radio Transceiver,
SNR2400, est conforme aux exigences essentielles et aux autres dispositions de la directive
1999/5/CE qui lui sont applicables
Swedish Härmed intygar Trimble Navigation att denna 2.4 GHz Spread Spectrum Radio Transceiver,
Svensk SNR2400, står I överensstämmelse med de väsentliga egenskapskrav och övriga relevanta
bestämmelser som framgår av direktiv 1999/5/EG.
Danish Undertegnede Trimble Navigation erklærer herved, at følgende udstyr 2.4 GHz Spread Spectrum
Dansk Radio Transceiver, SNR2400, overholder de væsentlige krav og øvrige relevante krav i direktiv
1999/5/EF
German Hiermit erklärt Trimble Navigation, dass sich 2.4 GHz Spread Spectrum Radio Transceiver,
Deutsch SNR2400, in Übereinstimmung mit den grundlegenden Anforderungen und den anderen
relevanten Vorschriften der Richtlinie 1999/5/EG befindet". (BMWi)
Hiermit erklärt Trimble Navigation die Übereinstimmung des Gerätes 2.4 GHz Spread Spectrum
Radio Transceiver, SNR2400, mit den grundlegenden Anforderungen und den anderen relevanten
Festlegungen der Richtlinie 1999/5/EG. (Wien)
Greek ΜΕ ΤΗΝ ΠΑΡΟΥΣΑ Trimble Navigation ΔΗΛΩΝΕΙ 2.4 GHz Spread Spectrum Radio Transceiver,
Ellhnikdz SNR2400, ΕΥΜΜΟΡΦΩΝΕΤΑΙ ΠΡΟΣ ΤΙΣ ΟΥΣΙΩΔΕΙΣ ΑΠΑΙΤΗΣΕΙΣ ΚΑΙ ΤΙΣ ΔΟΙΠΕΣ ΣΧΕΤΙΚΕΣ
ΔΙΑΤΑΞΕΙΣ ΤΗΣ ΟΔΗΓΙΑΣ 1999/5/ΕΚ
Italian Con la presente Trimble Navigation dichiara che questo 2.4 GHz Spread Spectrum Radio
Italiano Transceiver, SNR2400, è conforme ai requisiti essenziali ed alle altre disposizioni pertinenti
stabilite dalla direttiva 1999/5/CE.
Spanish Por medio de la presente Trimble Navigation declara que el 2.4 GHz Spread Spectrum Radio
Español Transceiver, SNR2400, cumple con los requisitos esenciales y cualesquiera otras disposiciones
aplicables o exigibles de la Directiva 1999/5/CE
Portuguese Trimble Navigation declara que este 2.4 GHz Spread Spectrum Radio Transceiver, SNR2400, está
Portuguese conforme com os requisitos essenciais e outras disposições da Directiva 1999/5/CE.

14 2 GCS900 Grade Control System for Grading Applications Installation Manual


Radio Declarations A

A.1.1 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.
Changes and modifications not expressly approved by the manufacturer or registrant
of this equipment can void your authority to operate this equipment under Federal
Communications Commission rules.
This Class B digital apparatus complies with Canadian ICES-003.
Cet appareil numérique de la classe B est conforme à la norme NMB-003 du Canada.
The SNR2400 operates in the 2400 to 2483.5 MHz frequency band (2400 to 2454
MHz in France). It contains a transmitter module that is certified for unlicensed use in
this band as a transmitter pursuant to 47 C.F.R. §§ 15.247 Subpart C of Part 15 of
FCC Rules regarding Spread Spectrum Systems for the United States.
License-free operation in Canada is covered by RSS-210 of Industry Canada; in the
European Union is covered by harmonized standard EN 300 328; in Australia and
New Zealand by gazetted standard AS/NZS 4771:2000.

GCS900 Grade Control System for Grading Applications Installation Manual 1 43


A Radio Declarations

A.1.2 Japanese approval


The Trimble SNR2400 is based on the Cirronet WIT2410 2.4 GHz Spread Spectrum
radio module, which is approved by TÜV Rheinland Japan to operate in Japan under
certification number 005NYCA0241.
TÜV Rheinland Japan is a Certification Body accredited by the MPHPT (Ministry of
Public Management, Home Affairs, Posts and Telecommunications) to carry out
mandatory approvals of specified radio equipment.

14 4 GCS900 Grade Control System for Grading Applications Installation Manual


Radio Declarations A

A.2 SNRx10 data radio


To use the SNRx10 data radio outside of the United States, you must gain approval
from the local radio authority. Contact your local radio authority for operating
regulations and restrictions that may apply in your country or area.

A.3 450 MHz data radio


Licence free operation in some European countries

A.4 900 MHz data radio


The 900 MHz data radio operates in the 902 MHz to 928 MHz frequency band:
• Certified for unlimited use in this band as a transmitter, pursuant to 47 C.F.R.§§
15.247, 15.249 (1993) (unlicensed, low power devices) Subpart C of Part 15 of
FCC Rules regarding Spread Spectrum Systems for the United States.
• Licence-free operation in Canada is covered by RSS–210 of Industrie Canada.
The data radio can be purchased with a reduced frequency range for use in Australia
and New Zealand, and is available in single frequency mode for other countries.
The 902–928 MHz frequency band is a shared-use band, and as such it is subject to
interfering signals. Regulations regarding its use vary greatly from country to country.

GCS900 Grade Control System for Grading Applications Installation Manual 1 45


A Radio Declarations

14 6 GCS900 Grade Control System for Grading Applications Installation Manual


APPENDIX

B
Towed Scraper Installations B

In this chapter: This appendix provides information on how to


install a towed scraper, and other agricultural
Q Direct connect installations machines.
Q Non-direct connect installations For more information, refer to the
GCS Series Grade Control Systems Cable
Diagrams Manual.

GCS900 Grade Control System for Grading Applications Installation Manual 1 47


B Towed Scraper Installations

B.1 Direct connect installations


This section describes describe how to install and configure machines that do not
require additional hydraulics to control the implement valves:
• John Deere 8000 and 9000 series tractors
• John Deere 30 series tractors
• Case MX series
• Case STX series
• Challenger MT B-series
Once you have configured your machine, you must calibrate the valves via the
GCS900 Grade Control System. For more information, refer to the GCS900 Grade
Control System Site Supervisor’s Manual.

B.1.1 John Deere 8000 and 9000 series tractors


The instructions in this section apply to the following tractors:
• 8010 and 8020
• 9000 and 9020
Note – John Deere 8000 and 9000 series tractors manufactured in 1996 and earlier
may not have the correct software and/or hardware to support the direct drive of the
implement electronic control module.
For more information, contact the local John Deere dealership for information, or
download the Trimble John Deere document (P/N TCSG-051) from the Trimble
Partners web site.

Connect the valve


Two cables connect the VM415 valve module to the machine electronic control
module:
1. To access the electronic control module, remove the cover panel on the back of
the cab.
2. Locate the left control unit and remove the plug from the machine harness
connector:

14 8 GCS900 Grade Control System for Grading Applications Installation Manual


Towed Scraper Installations B

3. Connect the 10-pin connector of the John Deere valve cable assembly
(P/N 0793-1030) to the machine harness connector.
4. Connect the 9-pin connector of the John Deere valve cable assembly to the 9-
socket connector of the John Deere direct connect valve cable (P/N 57765).
5. Connect the 6-pin connector of the John Deere direct connect valve cable to the
6-socket connector of the VM415 valve module.

Calibrate the tractor valve


Note – For dual GPS systems, calibrate the SCV1 quick disconnect valve, then the
SCV3 valve.
1. Turn off the tractor ignition switch.
2. Remove the fuse from the ‘Spare’ slot in the fuse panel and place it in the
‘Diag’ slot:
Spare slot

Diag slot

3. Start the tractor.


Note – For 8000 series tractors, the transmission will not operate in diagnostic
mode.
4. Operate the right-turn signal lever until SCU appears on the display screen:
SCU appears here

5. Pull the turn signal lever toward the steering wheel.

GCS900 Grade Control System for Grading Applications Installation Manual 1 49


B Towed Scraper Installations

6. To select a laser system, operate the right-turn signal lever until LAS appears
on the display screen.
7. Briefly turn on the HAZARD switch. CAL appears, signifying calibration.
Note – If it does not receive a signal change within 30 seconds, the control
system enters SUS (suspend) mode. To return the tractor to calibrate mode,
briefly turn on the hazard switch and then turn it off again.
8. Make sure the system is in Active Control (AC) mode. To put the hydraulic
system into AC, move the hydraulic paddle switch into its downward detent
position and then release it:

If the tractor moves out of AC, it goes into External Command (EC) mode. If
this happens, repeat Step 8.
9. Once the calibration is complete, turn off the tractor ignition switch and then
return the diagnostic fuse to the spare fuse slot.

B.1.2 John Deere 30 series tractors


Complete the following steps:
1. Connect the valve. See Connect the valve, page 148.
2. Configure the tractor. See the instructions below.
3. Calibrate the tractor valves. See Calibrate the tractor valve, page 149.
To configure the tractor:
1. Turn off the tractor ignition switch.
2. Start the tractor while simultaneously holding the "Tractor" and "Hitch"
switches. Hold the switches until the Diagnostic screen appears.
3. Rotate the Selector knob to select SCU.001-T.
4. Press the Left Arrow switch to accept SCU.001-T.
5. Rotate the Selector knob to select CAL:051.
If you see 051 with hash marks below it, this indicates faults that you must
clear. See Clearing John Deere faults, page 151.
6. Press the Left Arrow switch to accept CAL:051.

15 0 GCS900 Grade Control System for Grading Applications Installation Manual


Towed Scraper Installations B

7. Rotate the Selector knob to highlight the center icon (right pointing arrow) on
the right side of the screen.
8. Press the Left Arrow switch. The 30-second timer starts.
9. To put the tractor hydraulic system into Active Control (AC), move the
hydraulic paddle switch into its downward detent position and then release it.
If the tractor moves out of AC mode, it goes into External Command (EC)
mode. To put the system back into AC mode, repeat Step 9.
Note – If the system does not receive a signal change within 30 seconds, it
enters SUS (suspend) mode. To restart the 30 seconds, press the Left Arrow
switch.

B.1.3 Clearing John Deere faults


1. Turn off the tractor ignition.
2. Disconnect the valve cable from the valve module.
3. Start the tractor while simultaneously holding the Tractor and Hitch switches.
Hold the two switches until the Diagnostic screen appears.
4. Rotate the Selector knob to 001. If fault codes have been tripped, CODE
appears on the display.
5. Press the Left Arrow switch to accept.
6. Rotate the Selector knob. The display shows the fault code numbers and CLR?
Highlight CLR?
7. Press the Left Arrow switch to clear the faults.
8. Turn off the tractor ignition.
9. Reconnect the valve cable to the valve module.
10. Start the tractor while simultaneously holding the Tractor and Hitch switches.
Hold the switches until the Diagnostic screen appears.
11. For each fault, repeat Step 6 to Step 7 .

B.1.4 Case MX series


The following instructions apply to Case MX and STX series tractors.

Connect the valve


To connect the VM415 valve module to the machine electronic control module:
1. Locate the electronic control module connector near the back of the remote
control valves.
2. Connect the 6-pin Deutsch connector of the Case direct connect valve cable
(P/N 54376) to the electronic control module connector.

GCS900 Grade Control System for Grading Applications Installation Manual 1 51


B Towed Scraper Installations

3. Connect the other 6-pin connector of the Case direct connect valve cable to the
6-socket connector of the VM415 valve module.

Calibrate the valve


Note – There are two versions of the machine console. Text that applies to the earlier
version appears in brackets.
1. Turn on the tractor ignition.
2. Within 10 seconds, press and hold the PROG button on the instrument panel.
The CONFIG MENU (INST SET) appears.
To view an item in the menu, press INCR or DECR; to select the item, press
PROG.
3. View and then select AUX/HITCH/PTO (AUX SET MENU). For AUX SET
MENU, go to Step 5.
4. View then select EHR MENU.
5. View then select AUX SETUP.
6. Press INCR or DECR to select the number of scrapers attached to the tractor;
None, 1 or 2. [This option is not available on Accusteer tractors.]
7. Press PROG to accept the number of scrapers.
8. View then select AUX EXIT (go to Step 10).
9. View then select CONFIG TMF EXIT.
10. View then select EXIT (EXIT SET MENU).
11. Turn off the tractor ignition.

B.1.5 Case STX series


1. Connect the power:
a. Connect the battery terminal connectors of the supplied power cable
(P/N 0395-9130) to the battery, or to a power terminal under the back of
the cab.
b. Connect the 8-socket connector on the power cable to the PM400 power
module.
c. Connect the 8-pin Power Module connector on the GCS900 Grade
Control System harness (P/N 0395-9030) to the PM400 power module.
2. Connect and calibrate the valve. See:
– Connect the valve, page 151.
– Calibrate the valve, page 152

15 2 GCS900 Grade Control System for Grading Applications Installation Manual


Towed Scraper Installations B

B.1.6 Case fault / error codes


If AUX FAULT appears on the instrument cluster, the system is not correctly
connected to the tractor harness. Press and hold the RESET button to temporarily
clear AUX FAULT from the display. The number of the defective section flashes.
To access the error codes:
1. Press and hold the DIAG button to view or select INSTR DIAG MENU.
2. Press INCR or DECR to view or select AUX DIAG MENU.
3. Press PROG to view or select AUX error codes.
4. Press INCR or DECR to see the last ten unique error codes. (1 is the most
recent).
5. Press PROG to exit.
6. View and then select EXIT DIAG MENU.

B.1.7 Challenger MT B-series


The following sections describe how to install and configure AGCO/CAT Challenger
MT series tractors. The Challenger instrument panel is shown below:

Menu selection knob

Enter button
Drive knob
Right arrow button

Left arrow button

Check the valve calibration


For the GCS900 Grade Control System to operate, you may need a qualified AGCO
technical representative to calibrate the control valve.
To check if a valve calibration is required:
1. Turn the Drive knob on the instrument panel to zero.
2. Turn the Menu selection knob to the Implement 1 and 3 icon.
3. When the Implement Control Valve screen appears, turn the Drive knob
counterclockwise to decrease the valve drive to zero.
4. Attempt to manually raise the implement on the control valve that is set to zero.
If there is movement, an AGCO technical representative must calibrate the
valve.

GCS900 Grade Control System for Grading Applications Installation Manual 1 53


B Towed Scraper Installations

Validate the machine


To install a direct valve connection, the machine must have an ISO harness and
connector (a Class 3 tractor option).
To check for the Class 3 tractor option:
1. Locate the Deutsch ISO connector at the rear of the tractor:

2. Turn on the tractor ignition switch.


3. Turn the Menu selection knob to the Diagonal icon:

4. The Translator ECM screen shows if the Class 3 option is present and enabled:

Note – If the option is not enabled, the screen displays “ISO 11783 Class 3 is
Disabled”.
If the Translator ECM is present, but not enabled:
1. Turn the Menu selection knob to the Diagonal icon.

15 4 GCS900 Grade Control System for Grading Applications Installation Manual


Towed Scraper Installations B

2. Turn the Drive knob to highlight and enter P3:

3. Use the Left arrow button to highlight Class 3 Enable.


4. Rotate the Drive knob to highlight ENABLE.

Install the direct connect cable


The Challenger MT series tractor uses a custom cable (P/N 58559) to provide:
• power to the system
• a direct connection to the tractor electronic control module to drive the valve

8-socket connector
9-socket connector

3-pin Deutsch connector

This connector ... Connects to the ... See Figure ...


9-socket 9-pin ISO connector at the rear of the tractor B.1
8-socket 8-pin connector of the power cable B.2
(P/N 0395-9130)
3-pin Deutsch 3-socket Deutsch connector of the system B.2
harness (P/N 0395-9030)
Note – Before you make this connection, you must remove the 3-pin Deutsch terminator
on the system harness that is next to the green capped 12-pin Deutsch connector (the
cab mounted GPS connector).

To validate the install, check that the CLASS 3 option is enabled. See Validate the
machine, page 154.

GCS900 Grade Control System for Grading Applications Installation Manual 1 55


B Towed Scraper Installations

Figure B.1 9-pin ISO connector

0395-9130

Challenger direct
connect cable

58559

0395-9030

Figure B.2 System diagram for a Challenger MT series tractor

15 6 GCS900 Grade Control System for Grading Applications Installation Manual


Towed Scraper Installations B

B.1.8 Calibrate the valve


To calibrate the valve, enable the stationery override feature:
1. Put the machine in park mode.
2. Rotate the Menu selection knob to select M/E.
3. Rotate the Drive knob to highlight and display P3.
4. Press the Enter and Right arrow push button switches simultaneously to display
P5:

5. Press the Right arrow button to highlight the Stationary Override window, and
then rotate the Adjustment knob to highlight ENABLE.
Note – Every time you turn off the tractor and then turn it back on again, you
must repeat this step.
6. Press the rocker switch for the required remote valve.

B.2 Non-direct connect installations


This section provides electrical diagrams for non-direct connect agricultural
machines, including:
• Tractors that do not support direct-connect valve drives
• Trenchers
• Plows
• Drag box applications

B.2.1 Danfoss valve hydraulics


When you add the hydraulics for automatic controls, Trimble recommends that you
use a Danfoss control valve. These valves provide a smooth response with less wear
on the machine hydraulics.
Contact Trimble support for assistance in selecting the Danfoss valve that is correctly
rated for your machine.

GCS900 Grade Control System for Grading Applications Installation Manual 1 57


B Towed Scraper Installations

B.2.2 Valve cable connections


The main Danfoss valve cable (P/N 58742):

A > Red A
B > Blue B
C > Green C
D > White D
E > Brown E
F > Black F
G > Gray G
H > Orange H
N/U I
N/U J

A single Danfoss valve cable (P/N 58729):

Top view
Red A of valve wiring
White B 1
Black C White
Red
Green D
N/U E
F 3 Black
Solid 2
buss N/U G
bar
H Green

A dual Danfoss valve cable (P/N 58739):

Front

Rear

Front

A Top view
Red
B of valve wiring
White
Black C 1

Green D White
Red
Red E
White F
Black Black
G 3
2
Green H
Green
Rear

15 8 GCS900 Grade Control System for Grading Applications Installation Manual


Towed Scraper Installations B

B.2.3 Proportional time valves


Automatic control systems installed on drainage machines and other applications may
require connections to a voltage reference or a proportional time (PT) valve.
The diagrams that follow show the valve cable connections for PT valves.
The main PT valve cable (P/N 58932):

A > Black A
B > Brown B
C > Red C
D > N/U D
E > N/U E
F > Orange F
G > Yellow G
H > Green H
Red I
Black J
1 >
2 >

A single PT valve cable (P/N 58947):

N/U A
N/U B
N/U C
N/U D
N/U E
Orange F
Yellow G
Black H

A dual PT valve cable (P/N 58953):


Front

Rear

Front

Orange A
Yellow B
Black C
N/U D
N/U E
Orange F
Yellow G
Black H

Rear

GCS900 Grade Control System for Grading Applications Installation Manual 1 59


B Towed Scraper Installations

16 0 GCS900 Grade Control System for Grading Applications Installation Manual


Glossary
base station A base station must be set up with the system which includes a GPS receiver and
data radio. This station transmits CMR messages to the machine to improve
position accuracy.

bench The process of aligning the machine blade position (Northing, Easting, and/or
Elevation) to a benchmark. The bench calibration offsets your machine position to
that of the benchmark, improving accuracy and providing a point that you can
return to later for accuracy checks.

CAN Controller Area Network. A system used for communications between electronic
devices.

CMR Compact Measurement Record. A satellite measurement message that is broadcast


by the base receiver. The RTK GPS receivers use it to calculate an accurate vector
from the base station to the rover.

cross slope The average grade or slope of a parcel or area expressed as a percentage of vertical
difference in elevation to the horizontal distance. A level surface has a cross slope
of zero.

data card The plug-in, removable storage card which holds all the design and system files.

detent A mechanism that temporarily keeps one part in a certain position relative to that
of another, and can be easily released by applying force to one of the parts.

dialog A screen where you enter text or numbers, or select options.

firmware Software stored in flash memory. Firmware runs the GCS900 system.

GLONASS Global Orbiting Navigation Satellite System. GLONASS is a Soviet space-based


navigation system comparable to the American GPS system. The operational
system contains 21 satellites in 3 orbital planes, with 3 on orbit spares.

GNSS Global Navigation Satellite System. The standard generic term for satellite
navigation systems that provide autonomous geo-spatial positioning with global
coverage.

GPS Global Positioning System. A technique that uses satellite technology to calculate
an accurate three-dimensional position.
A GPS system consists of a space segment (up to 24 NAVSTAR satellites in six
different orbits), the control segment (five monitor stations, one master control
station and three upload stations), and the user segment (GPS receivers).

LED Light Emitting Diode. A small, bright (usually colored) light used in electronic
componentry.

lightbar A bar or unit of LEDs that guide you when using the system. Lightbars give
cut/fill or left/right guidance depending on how they are set up.

GCS900 Grade Control System for Grading Applications Installation Manual 161
Glossary

orientation The direction the blade is facing.

pitch The forward and aft grade (or mainfall) of the machine.

radome A dome like shell transparent to radio-frequency radiation, used to house a radar
antenna.

softkeys on the screen keys associated with physical front panel keys. The operation
performed by a softkey varies depending on the current screen. A softkey on the
screen is controlled by a hard key that is adjacent to it on the front panel. Press the
hard key to activate the softkey.

VRS Virtual Reference Station. Trimble's VRS™ networks use RTK solutions from the
Trimble RTKNet software to provide high-accuracy, real-time kinematic (RTK)
GNSS positioning for wider areas.

162 GCS900 Grade Control System for Grading Applications Installation Manual
Index

A motor grader 37
scraper 31
above cutting edge bolts 107, 119 calibration and configuration settings 28
calibration, sensors 130
CB430 control box
B install custom post 50
back from cutting edge 115 installation 68
back from cutting edge bolts 107, 118 pinout information 138
bench test 22 connector failure, dust 21
blade dimensions 109 control box, CB430 pinout information 138
blade pitch sensor bracket 55 Control Box’s Radio Port 133
blade pitch sensor, installation 88 cutting edge dimensions 109
blade slope sensor
installation, bulldozer 82
installation, motor grader 84 D
blade slope sensor bracket 58
dialogs
bracket installation
Calibrate Mainfall Sensor 133
blade pitch sensor bracket 55
Calibrate Rotation Sensor 132
blade slope sensor 58
Calibrate Sensors 130
lightbars 62
Calibrate Slope Sensor 131
mainfall sensor 59
Control Box’s Radio Port 133
quick disconnect assembly 56
GPS Receiver Configuration 134
rotating bracket 52
Lightbar Connections 128
scraper mast mount 55
Machine Dimensions 125
sonic tracer mount 61
Machine Name Error 15
vale module/power module 60
Machine Radio Configuration 129
bulldozer
Machine Settings 123
install harness cable 31
Select Radio Band 128
system components 48
Setup Menus
system diagram 35
Configuration 122
Installation 122
Units 124
C diode, over-voltage protection 44
cab or body mounted systems, receiver position 114 direction indicator, installation 78
cable installation distance between lift rams 112
bulldozer 31
ignition switched power 43
machine power 43, 46 E
motor grader 37
electric mast measurements 103, 108
planning 18
electric mast, installation 90
power module 46
environmental factors 20
routing harnesses 30
ergonomics 20
scraper 31
external VRS device 133
validation 136
cables
bulldozer 31

GCS900 Grade Control System for Grading Applications Installation Manual 1 63


Ind ex

F rotation sensor, motor grader 85


sideshift remote switch, motor grader 72
fixed mast sideshift stop 62
install angled riser or rotating angle bracket 88 SNRx10 radio modem 64
third-party radio 77
tools 19
G UTS target 95
GPS Receiver Configuration 134 valve module 75
GPS receiver installation 93 verify motor grader remote switches 73

H L
harness cable routing 30 laser receiver installation
height (to top of lower housing) 114 LR400/LR410 92
SR300 91
Lightbar Connections 128
I lightbars
install brackets 62
ignition switched power cabling 43 install lightbars 75
in from left blade tip 116
in from left/right blade tip 107, 120
installation M
angled riser on fixed mast 88
blade pitch sensor 88 machine body dimensions 113
blade slope sensor machine configurations 26
bulldozer 82 Machine Dimensions 125
motor grader 84 Machine Name Error 15
CB430 control box 68 machine power, cabling 43, 46
direction indicator 78 Machine Settings 123
electric mast 90 mainfall sensor
environmental factors 20 installation, motor grader 87
GPS receiver 93 mainfall sensor bracket 59
harness cable mainfall sensor installation, bulldozer 83
bulldozer 31 manager mode 122
motor grader 37 mast lean back 109
scraper 31 mast lean in from blade tip 108
laser receiver measure-up
LR400/LR410 92 above cutting edge bolts 107, 119
SR300 91 back from cutting edge 115
lightbars 75 back from cutting edge bolts 107, 118
mainfall sensor, bulldozer 83 blade dimensions 109
mainfall sensor, motor grader 87 cab or body mounted systems 114
mounting plates 51 cutting edge dimensions 109
operational considerations 20 distance between lift rams 112
power module 75 height (to top of lower housing) 114
radio modem 64 in from left blade tip 116
radio, SNRx10 76 in from left/right blade tip 107, 120
remote switches 70 machine body dimensions 113
reversing buzzer 78 marking the motor grader circle 104
rotating angle bracket on fixed mast 88 mast lean back 109
rotation sensor, bulldozer 82 mast lean in from blade tip 108

16 4 GCS900 Grade Control System for Grading Applications Installation Manual


Index

positioning the machine 103 rotation sensor installation, motor grader 85


ripper dimensions 113
rotating bracket bolt hole 102
measure-up tool, about 116 S
measure-up worksheets
structure 101 safety 20
modes safety information 5
manager 122 scraper
operator 122 install harness cable 31
motor grader system components 49
install harness cable 37 scraper mast mount 55
marking the circle 104 Select Radio Band 128
system components 48 Setup Menus
system diagram 41 Configuration 122
mounting plates 51 Installation 122
shock, reducing 20
sideshift stop 62
sideshift, motor grader
O remote switch installation 72
operational considerations 20 SNRx10 radio modem, installing 64
operator mode 122 sonic tracer mount 61
over-voltage protection diode 44 system components 48
system diagram
bulldozer 35
P motor grader 41
pinout information, CB430 control box 138
power module
bracket 60
T
cabling 46 temperature, effects of 21
install power module 75 tools 19
towed scraper installations 147
direct connect 148
Q non-direct connect 157
troubleshooting
quick disconnect brackets 56
no automatic system 138
no CAN bus 137
no power 138
R related information 139
radio
third-party installation 77
radio declarations 142 U
radio modem
Units 124
install brackets 64
UTS target, installation 95
radio, SNRx10
install radio modem 76
recieving VRS corrections 133
remote switches, installation 70
V
reversing buzzer, installation 78 validation
ripper dimensions 113 cable installation 136
rotating bracket 52 check diagnostics 136
rotation sensor installation, bulldozer 82 check the lightbars 136

GCS900 Grade Control System for Grading Applications Installation Manual 1 65


Ind ex

confirm correct power up 136


final validation 137
verify blade tip position 136
valve module
bracket 60
install valve module 75
sideshift, motor grader 75
valve/power module bracket 60
vibration, reducing 20
visiting the site 18

W
water, preventing seepage 21

16 6 GCS900 Grade Control System for Grading Applications Installation Manual