7010-0354 Dual System Five Dozer Manual Rev D

Dual Dozer System Five
Performance & Installation Manual
NOTICE
This manual will cover the basic installation information com-
mon to all dual function Dozers. The dealer preforming the
install will need to have a copy of the technicians manual (7010-
0377) on hand to enabling them to configure the proper valve
current.
© 2003Topcon Laser Systems, Inc. 1 Rev D CO# 134 8/03

P/N: 7010-0354
Important Notes Read First
Topcons System Five control box has been designed to be backwards compatible on
System Four Dozers. The valve drive type will need to be changed to accommodate
for the older style machine. The System four control box is not forward compatible
due to the addition of a separate valve cable and single A/M switch.
The factory defaults for the valve drive on a System Five Dozer are Proportional
source, and the max current is set at 1.75 amp. If a System Five control box is
installed on an existing system four Dozer the valve drive will need to be changed to
Proportional Sink.
If the System Five dozer is installed with Danfoss valves the technician will need to
configure the valves to Danfoss. When using the System Five on an older style Dozer
where the Danfoss valve being driven through the 9062-1025 Danfoss interface box,
the valve type should be set to PWM Sink and the PWM Freq should be set at 1220hz.
Changing the type of valve drive can be found in the Dual Dozer Technician manual
and should only be done by a qualified service technician.

Contents
Important Notes Read First ..................................................................... 3
INTRODUCTION ........................................................................................ 6
Safety Precautions ..................................................................................... 6
SYSTEM SPECIFICATIONS ...................................................................... 8
Introduction to Automatic Dozer Systems ................................................... 8
Controllability .............................................................................................. 8
What is Optimum Performance? ................................................................ 9
System Overview ................................................................................... 10
General .................................................................................................... 10
Connectors ............................................................................................... 10
MECHANICAL SYSTEM .......................................................................... 11
Control Box Bracket ................................................................................. 11
Auto/Manual Knob and Bracket................................................................ 11
Dual Mast Mounting ................................................................................. 12
Single Mast Mounting ............................................................................... 12
ELECTRONIC SYSTEM........................................................................... 14
9164 Control Box / Dual Function ............................................................. 14
9408 Junction Box / Dual Function ........................................................... 16
4501 Slope Add-On, Dozer ...................................................................... 17
4400 Add-On Sonic Tracker System ........................................................ 17
5100 Laser Tracker System (Manual) ...................................................... 18
5000 TrackerJack System (24V Motorized) ............................................. 19
5005 TrackerJack System (12V Motorized) ............................................. 19
HYDRAULIC SYSTEM ............................................................................. 20
General Notes .......................................................................................... 20
Hydraulic Hose and Fitting sizes............................................................... 20
Hydraulic Hose Pressure Ratings and Minimum Bend Radius ................. 20
Use of Mobile Hose Trucks ...................................................................... 20
High Pressure Closed Center................................................................... 22
Adjusting Pressure Reducing Valve ......................................................... 23
Load Sense Booster Valve ....................................................................... 24
Open Center Conversion Valve ................................................................ 25
Open Center Conversion Valve ................................................................ 26
Counter Balance Setting Procedures ....................................................... 27
Dozer Control modes ............................................................................. 28
Standard Control ...................................................................................... 28
Soft Key menu items ................................................................................. 29
Machine Setup and Calibration ............................................................. 31
3D Control ................................................................................................ 34
GPS Control ............................................................................................. 37
Valve ........................................................................................................ 39
9305-0000 DO5 13GPM 24V ................................................................... 39
9305-0001 DO5 8GPM 24V ..................................................................... 40
9305-0002 20GPM 24V Pilot .................................................................... 41
9305-0003 20GPM 24V Pilot .................................................................... 42
9321-0000 DO5 13GPM 12V ................................................................... 43
9321-0001 DO5 8GPM 12V ..................................................................... 44
9304-0000 DO3 2GPM 24V ..................................................................... 45
9304-0006 DO3 2GPM 12V ..................................................................... 46
9304-0007 DO3 4GPM 12V ..................................................................... 47
9304-0008 DO3 4GPM 24V ..................................................................... 48

Dozer System Five Performance & Installation
INTRODUCTION
Safety Precautions
1. Read and become familiar with the dozer manufacturer’s operations manual, including safety
information before installing or using Topcon System Four.
2. Working around heavy construction equipment can be dangerous. Always use extreme caution on
the job site.
WARNING
Do not stand or sit on Dozer Blade or other parts of the dozer not meant for opera-
tion.
3. The dozer blade and rippers should be grounded before working on or around the dozer.
4. Do Not attach System Four components to the dozer while the engine is running.
5. DO NOT allow any System Four component to limit the visibility of the operator in an unsafe man-
ner.
6. Use Ty-Wraps supplied with System Four to keep hoses and wires secured and away from possible
wear or pinch joints.
7. Use eye protection when welding, cutting, or grinding is being done on the machine.
8. Hydraulic lines can be under extreme pressure even when the machine is turned off. When working
on or near hydraulic lines, protect yourself at all times and wear protective clothing.
WARNING
Relieve all pressure in the hydraulic lines before disconnecting or removing any
lines, fittings, or related components. If injury does occur, seek medical assistance
immediately. Consult the dozer’s OEM Operator’s Manual for details.
9. When using laser control, avoid direct exposure to your eyes.
CAUTION
Do Not stare into the laser beam or view the beam directly with optical equipment.
© 2003 Topcon Laser Systems, Inc. 6 Rev D 8/03

10. When welding, always use appropriate welding precautions and practices. Use shielding to prevent
onlookers from staring into the light.
11. After welding, all affected areas should be painted with a rust inhibitor.
NOTICE
Disconnect all TOPCON system electrical cables prior to welding on the machine.
WARNING
Do not weld near hydraulic lines or on any equipment when in operation.
NOTICE
All mounting bracket welds must be secure and strong to prevent the sensor equipment
from vibrating excessively or from becoming detached at the weld during operation.
NOTICE
Keep the Carrying Case dry at all times. DO NOT allow moisture to get inside the case.
Moisture trapped in the case can adversely affect components.
If moisture does enter the Carrying Case, leave it open and allow it to dry thoroughly before
storing any components.
12. To prevent vandalism or theft, do not leave the removable TOPCON components on the machine
during off hours. Remove the components after work and store in carry case.
13. Read all hydraulic information contained in this book carefully. Improper installation procedures
could cause a safety hazard or future mechanical problems for customers.
©2003 Topcon Laser Systems, Inc. 7 Rev D 8/03

SYSTEM SPECIFICATIONS
Introduction to Automatic Dozer Systems
Welcome to the System V Dozer Installation and Technical Manual. You will notice
that this manual is different from other installation manuals that Topcon publishes in
support of its products. This is because the System V Dozer system is kited and sold
differently from other Topcon Machine Control products.
The Topcon Dozer System is made up of several kits that are ordered separately and
can be mixed and matched to meet your customers specific automation and application
requirements. Specific information on base kits, add-on kits, and custom hydraulic
kits, can be found in your Machine Control Price List.
The most critical thing to remember about Bulldozer’s is that no two are exactly alike.
Hoses are not included in Topcon Dozer kits because you will waste more time trying
to make stock hoses work than if you just placed your valve where convenient and
measured the hoses yourself.
Installation of a Dozer system can be a daunting task, but if you plan the job well and
attack with the purpose and understanding of the Dozer’s Hydraulic system, you will
be successful.
Controllability
A Dozer is a unique piece of equipment compared to most automated construction
machinery. Motorgraders, pavers, mills, scrapers, and even ag scrapers all have one
thing in common, they are dragged, not pushed. A Motorgraders blade has the luxury
of being suspended between a long frame that averages out the bumps of a job and
provides a stable platform for producing smooth grade. A similar averaging action in
Pavers allows the screed to float independent from the tractor. A Dozer blade however
is pushed mere inches from the front of the tractor. The tractor and the blade are one,
constantly fighting each other. The bumps that the blade creates are the bumps that the
tractor will ride over causing a sharp wave effect.
Dozer automation can be tricky, but when done properly will leave the customer with a
precision tool that can greatly increase productivity, flexibility, and material control.

What is Optimum Performance?

When Topcon Engineers a System V Dozer kit, our goal is to let our electric over
hydraulic proportional valve run the blade as efficiently as the manual valves. When this
is accomplished, we know that when calibrated and operated correctly, it can move the
blade as quickly as the operator. This performance is achieved by selecting a propor-
tional valve matched for the performance of the machine. Then, care must be taken to
use hoses and fittings that are as large as the manual valve system. This will ensure that
the Topcon system is not impeding any oil flow.
Fast response is not the only factor to consider for Dozer automation. A proportional
valve will help reduce bumps and waves caused by over correction; however, there
may be a need to sacrifice some accuracy for smoothness. Fortunately, the system can
always be turned down using the gain adjustments built in to the 9164 and 9256 control
box.
Remember, every job and application is different. Optimum performance is the balance
between speed, accuracy, and smoothness that in the end helps the contractor to best
perform the job. When setting up a Dover for automatic control the performance of
the machine will very depending on the travel speed and material conditions. We at
Topcon feel that a Dozer cutting finish grade half throttle in second gear is an achiev-
able goal on most all Dozers.
Small Dozer Notes:

Due to the short track length on smaller Dozers, a wash board affect can occur if the
ground speed is too fast. Through testing we have found operators may need to slow
down on the final or last pass.

System Overview
General Soft Buttons (7)
AUTO light
and knob turn Mounting
Rotary Encoders (2)
Power Switch
Lower (Amber)
On Grade (Green)
Raise (Red)
Connectors Conn A
Power/
Comm Bus
Conn D
Valve
Conn C
RS-232 Serial Conn B
(For GPS/ PC Comm/Valve
Connections) (to Mast and
Valves)
Conn A (14-5 Pin Bay) Conn C (18-7 Soc Scr)
A Batt Uns wit A RX
B Buf Clk B TX
C Buf Data C RTS
D V Suply D CTS
E Gnd E Batt Uns wit
F V Swit
Conn B (18-11 Soc Bay) G Gnd
A Com m A
B Com m B Conn D (18-11 Soc Bay)
C V Swit A Valve Power
D Gnd B Valve Power
E Motor/Valve Power C Gnd
F Motor/ Valve Gnd D Gnd
G Rais e (Front / Left) E Gnd
H Rais e (Rear / Right) F Gnd
J Lower (Front / Left) G Rais e (Front / Left)
K Lower (Rear / Right) H Rais e (Rear / Right)
l None J Lower (Front/Left)
K Lower (Front/Right

MECHANICAL SYSTEM
Control Box Bracket
Due to operator preference and varying cab designs the Dual Dozer base kit comes
with a custom bracket (9164-1042) allowing the installer the ability modify the bracket
to best fit the operators needs.
9164-1042
Auto/Manual Knob and Bracket

The 9095-1035 Auto/Manual knob cable has three wires, one male connector (Com-
mon) and two female electrical connectors. This will allow the knob to be mounted on
either the right or left side of the machine with the forward position of the switch acti-
vating the Auto function.
9095-1035
9095-1036
(Includes Hardware)

Dual Mast Mounting
When using a dual laser system. One laser mast

should be positioned on top of the middle pivot
point of the blade and be connected to the
elevation cylinders. The other laser mast should be
positioned to one side and tied to the slope
cylinders.
View from Cab
Single Mast Mounting
When using a laser mast for single function

elevation or dual function elevation and slope
sensor, position the laser mast at the center pivot
point of the blade. This will keep the slope sensor or
the operator from changing elevation when pitching
the blade.


ELECTRONIC SYSTEM
9164 Control Box / Dual Function
6401V Dual Function Dozer Base Kit

1 9164-0004 Assy, Control Box 1
2 9060-5116 Cable CB to J-Box 1
3 9408-1000 Sensor Junction Box 1
4a 9063-1024-17 Valve Cable Vickers** 1
4b 9063-1025-17 Valve Cable Danfoss** 1
5 9063-1032-8 Power/Auto Manual Cable 1
6 9095-1035 Auto Manual Knob 1
**Valve cable supplied in hydraulic add-on kit

9164 Control Box / Dual Function

9408 Junction Box / Dual Function
Schematics and Pin Assignments

Pin A Comm A
Pin B Comm B
Pin C Vsupply LEFT SIDE
Pin D Ground
ONLY USE:
Pin H Config
Laser Receiver
TrackerJack
Sonic Tracker
CONTROL BOX
LEFT RIGHT
TOP VIEW
RIGHT SIDE
ONLY USE:
Laser Receiver
TrackerJack
Control Box Sonic Tracker
Slope Sensor

4501 / 4503 Slope Add-On, Dozer
4501 Slope Add-On Kit 7.5'

9152P-0000 Assy, Slope Sensor, Wide Range 1
9060-5075 Coil Cord 7.5' Slope Sensor 1
9062-1024 Kit, Slope Sensor Brkt 1
4503 Slope Add-On Kit 15'

9152P-0000 Assy, Slope Sensor, Wide Range 1
9060-5131 Coil Cord 15', Slope Sensor 1
9062-1024 Kit, Slope Sensor Brkt 1
4400 Add-On Sonic Tracker System
4400 Sonic Add-on Kit
9060-1143 Bar, 2" L Standard 1

9060-1167 Assy, 3 Bolt/3Pad L Bar Bkt 1
9060-1168 Asy, Sonic Tracker Bkt 1
9060-1253 Kit, Sonic Tracker Bolt- 3/4" 1
9060-5045 Coil Cord, 15 Ft 1
9142-0000 Assy, Sonic Tracker II 1

5100 Laser Tracker System (Manual)
5100 Add-On Laser Tracker System
9060-5045 Coil Cord, 15' Sys IV 1

9090-1000 Assy, Vib Pole Feet/Metric 1
9130-0000 Assy, Laser Tracker 1
9130-1018 Assy, Bracket Laser 9130 1

5000 TrackerJack System (24V Motorized)

5005 TrackerJack System (12V Motorized)
5000 Add-On Laser TrackerJack System
9060-1297 Assy, Tracker Jack Case W/Label 1

9060-5045 Coil Cord, 15' Sys IV 1
9220-0000 Assy, TrackerJack (24 V) 1
5005 Add-On Laser TrackerJack System
9060-1297 Assy, Tracker Jack Case W/Label 1

9060-5045 Coil Cord, 15' Sys IV 1
9221-0000 Assy, TrackerJack (12 V) 1

HYDRAULIC SYSTEM
General Notes
Hydraulic Hose and Fitting sizes
Selecting the right hose and fittings for hydraulic installations is important for many reasons. Using inad-
equate hose diameters can put extra heat on various equipment components as well as Topcon parts. This
can lead to a catastrophic failure of a dozer’s hydraulic system, or at least more frequent repair. Inadequate
hose sizing can also negatively affect the performance of System Four.
The rule of thumb for selecting hose size is to pick a diameter and strength of hose that is the same size as
the dozer’s. If a pressure line is using #16 size fittings and 1” hose, select the same if the Topcon part will be
handling the same oil flow and pressure.
Hydraulic Hose Pressure Ratings and Minimum Bend Radius
Ensure that all hoses are rated for the pressures of the application. If a pumps pressure is 3000 psi, you
should have a hose that is printed as being rated for an operating pressure of 3000 psi.
Also remember that the higher the rated pressure of hose, the less you can bend the hose without reducing
its performance and life. A sharply bent hose can reduce the hoses life by 90 %.
Use of Mobile Hose Trucks
If you have a mobile hose making service in your area, they can be a great help in installing a Dozer system
quickly and efficiently. These specialists can measure and produce the right hoses for your application.
Large dual steel braided rubber hoses are very difficult to bend and a 1 inch deviation too long or too short
can turn an install into a wrestling match.


High Pressure Closed Center

Adjusting Pressure Reducing Valve
Setting procedure
1. Adjust regulated pressure adjustment all the way out. (CCW)
2. Connect pressure gauge to regulated pressure out port (RP).
3. With engine idling, dead head ripper cylinder to fully stroke hydraulic pump.
4. Screw in regulated pressure adjustment until gauge on pressure out reads
2800 psi. Tighten locking nut on the pressure adjustment.

Load Sense Booster Valve
Setting procedure
1. With machine NOT running screw LS adjustment out. (CCW)
2. Attach pressure gauge to machine LS port #1.
3. Start machine and adjust the LS adjustment screw until the gauge reads
100 psi (at machine idle). Tighten locking nut.
*Note If using a low pressure gauge, it will be damaged if the
pump is fully stroked. Use a 0-3600 psi gauge.

Open Center Conversion Valve

Open Center Conversion Valve
IN
OUT
PRESSURE OUT ADJ
LS FLOW
RELIEF PRESSURE ADJ RETURN TO SYSTEM TANK

TO TOPCON MANIFOLD
TO TOPCON MANIFOLD TANK
PRESSURE OUT TO TOPCON MANIFOLD
SETTING THE REX ROTH VALVE

After all line connections to the Rex Roth are complete and no leaks are found, connect a pressure gauge to the
pressure out line leading to the Topcon manifold (a high pressure gauge must be used).
1. With the engine running and the LS Flow Control backed out, adjust the Pressure Out Adjustment until the
pressure gauge reads 200psi. Tighten the locking nut.
2. Set the relief pressure 200psi above the machine’s relief pressure. (The relief pressure can be found in the
Machine Service Manual, or by dead heading one of the implements and noticing the Max pressure on the
pressure gauge). To set the relief, back out the Relief Pressure Adjustment CCW, and screw in the LS Flow
Adjustment. This will cause the Rex Roth to full stroke dumping over the relief. Now adjust the Pressure
Relief Adjustment until the gauge reads 200psi above the systems relief, then open the LS flow control all
the way. NOTE* DO THIS PROCEDURE AS QUICKLY AS POSSIBLE TO PREVENT THE RELIEF
FROM BECOMING TOO HOT.
3. Slowly screw in the LS Flow Control Valve until the pressure on the Pressure Out just begins to increase.
Tighten the locking nut.

Counter Balance Setting Procedures

SETTING COUNTER BALANCES
The counter balance valves apply a back pressure to the desired implement, which our system must over-
come before the implement can move. If the counter balance is set to low the system will over shoot grade
causing the machine to oscillate. With the counter balances set to high it induces a false load which will
affect the performance of the automatic system.
SETTING THE ELEVATION COUNTER BALANCE VALVES

1. Manually lower the Dozer blade until the front of the machine is lifted in the air. The front of the machine
should remain in the air, if it drifts down the counter balance is set to low. To adjust the counter balances
loosen the counter balance until the machine begins to drop. At this point tighten the counter balance half to
one turn. ( Screwing the adjustment out will increases the counter balance pressure )
2. Now manually raise the blade in the air. The blade should remain in the air and not drift down. If the
blade drifts down the counter balance valve is set to low. To adjust the counter balances loosen the counter
balance until the blade begins to drop. At this point tighten the counter balance half to one turn. (Screwing
the adjustment out will increases the counter balance on valve)
SETTING THE SLOPE COUNTER BALANCE VALVES.

1. Place the blade on the ground, and force one corner into the dirt using the tilt function. The setting of the
slope counter balances is the same as the elevation.
2. Loosen one of the counter balances until the blade starts to move then tighten it half to one turn. Next
loosen the other counter balance valve until the blade begins to move and again tighten it half to one turn.
All Topcon single valves contain:

CBCA LAN counterbalance valves.
• With counterbalance screwed in CW 0 PSI
• Each full turn out CCW approximately increases
pressure 1400 PSI

Dozer Control modes
When the 9164 is first powered up, the control option screen is displayed. This screen
allows the operator to select either standard control, LPS control or GPS control. The
next few pages will discuss each of the control options.
Standard Control
Soft key menus
Elevation/slope display
Elevation display
Communication status box
The standard control screen will allow the operator to either control his machine using
dual elevation or a combination of elevation control along with slope control. The
control screen is spilt into two separate displays. The Left display will always control
an elevation device where as the Right screen can either control an elevation sensor or
a slope sensor, as shown in the display above.
In the center of the display, you will see a symbol of the dozer blade. This symbol
gives the operator a visual indication of the direction of blade slope. On either side of
the blade symbol you will see another symbol indicating which type of sensor is being
used (Tracker, Laser receiver or Slope sensor). In the center of the display an
indication of which set point is active (see the section regarding set points for more
details.
Active set point

Blade symbol indicating slope
falling to the right
Left side of blade
being controlled by Right side of blade
Sonic Tracker being control by Cross
Slope
Laser Receiver indication

Soft Key menu items
The menu items located at the top of the control box display can be accessed using the
soft keys located directly above the menu item. The next few pages will cover each of
the soft key menu functions.
Menu Key
Selecting the MENU key will change the display back to the main control selection
screen
Set key
The SET key located above the left display has two functions. The first function is
used to change the reference number viewed on the display to a desired value. Using
set will not change the grade or elevation, only the reference number viewed. By
turning the left grade knob the operator can set the display to the desired reading. The
second function is used to calibrate the slope sensor. The operator would start by
manual placing the blade on some known grade, then using the right grade knob, adjust
the slope display until the display indication is the same reading as the blade. After any
changes are made to either display the operator must select ENTER. If EXIT is
selected the changes will not be stored.
Auto key
There are two AUTO keys, one located on the left side of the display and the other
located on the right. When the auto key is selected the red Auto symbol above the
grade knob will begin to flash. This indicates the systems autos are armed and can be
activated by simply switching the single remote switch on, giving the operator a single
switch that will control both left and right.

+/- key
The +/- key will allow the operator to change the direction of slope with a single push
of a button.
Set point key

The set point key allows the operator to select between the three set points. (See the
setup section for information on how to access the set points)
Gain key
By selecting the GAIN key the operator can make adjustments to the left or right valve
while still under full automatic control. The right control knob will make adjustments to
the right elevation valve and the left grade knob will make adjustments to the left slope
valve. The number displayed below the elevation or slope display number, is the gain
setting. In the example below the elevation gain is 53 and the slope gain is 14.

Machine Setup and Calibration
Setup
The SETUP menu is where all the machine setup is preformed. Prior to making any
adjustments in the Setup menu, the Topcon service rep will need to set the Maximum
current setting for the largest valve being used. The max current setting is located in
the Technicians Menu. (Refer to the technicians manual 7010-0364 for detailed
information) Located in the back of this manual, a listing of all the valves Topcon
supplies in their dozer kits is available. Each valve has the max current rating listed.
The max current setting should be set to match the rating of the largest valve being
used. NOTE* All Released System Five Dozers Systems Should Be Configured
For Source Current, Unless a Danfoss Valve Is Used (See notes on Page 3).
This section will cover all the setup menu options as well as machine calibrations.
1 Confirm External switch selection (Topcon rep/operator)

2 Maximum valve current setting (Topcon service rep only)
3 Adjust valve offsets (Topcon rep/operator)
4 Blade slope calibration (Topcon rep/operator)
Setup Menu
Adjust Valve Offsets

This adjustment sets the minimum signal required to operate the hydraulic valve. Start
by raising the dozer blade off the ground. With the engine at full throttle select either
the raise or lower soft key for the elevation valve (Left). Using the left rotary knob dial
the number to 0. Slowly increase the number until the blade just begins to move. Set
the other three in the same manner then select ENTER. Selecting Exit will not save any
changes.

Set Points
The SET POINT selection will allow the operator to select the number of active set
points. The control box is sent from the factory without any set points active. Once
the operator has selected the desired number of set points they are able to step through
the set points by pressing the Key. The display in the center of the screen will
indicate which set point is active.
Measurement Units
The MEASUREMENT UNIT allows the operator to change the elevation display from
Feet to Meters.
Check Hourmeters
They system has two hourmeters built in. By selecting the Check Hourmeters under
the menu screen, the system will display both hours On and Hours On in Automatic.
Adjust Led Brightness

By following the on screen directions, the operator can adjust the Back Light as well as
the Brightness of the LED’s

System Test
The system test has been developed to give the operator an easy way of looking at the
attached components. At any time the operator sees a Comm Error which will appear
below one of the displays in normal Control Mode, they should enter the Test Mode.
If a sensor is not connected the message following the sensor description will indicate
ERROR.
Beeper On
By highlighting the BEEPER selection and pressing Enter the Beeper can be toggled on
or off. The system has a built-in audible feature that will sound when an elevation
reference is lost.
External Switches
The System Five control box can either work with Topcons Smart Knobs or a
standard contact closure switch. For dozer applications Topcon supplies an A/M
switch which would be considered a Simple switch. The External switches menu
allows the operator to select the type of switch being used. The factory default for
dozer applications will be simple switch.

3D Control
Selecting Topcon 3D or LPS control mode is as simple as the touch of a button.
When 3D or LPS is selected the system will automatically configure itself for 3D
control. While in 3D control all elevation and slope information will be sent to the
dozer through Topcons patented fan beam technology using the GRT-2000, and
received by Topcons LS-2000.
Soft key menu items
All the soft key menu items remain the same as described in the standard control mode
except for the addition of RESET LINE.
Reset Line
3D job data is either setup as a DTM or Pollyline, when controlling the dozer using
Pollyline data, the center steering indicator is active displaying the dozer blade offset
from the Pollyline. As the dozer moves left or right of the Pollyline the picture of the
dozer will move accordingly, and the numbers below the graphical display will indicate
the distance from the Pollyline. By selecting RESET LINE the graphic of the dozer
will center in the display. The number below the graphic display will always indicate
actual distance from the Pollyline. This number can not be reset or changed.

3D Control Screen
The 3D control screen is filed with valuable information on the status of the data being
sent from the GRT as well as system and control information. The next few screen
shots will identify and explain all the possible indications available.
Delta H indicator
Slope signal indication
Mast elevation
GRT status window Slope sensor indication
Elevation sensor communication status Slope sensor communication status

Distance from Pollyline indicator
Delta H Indicator
The Delta H indicator will either display NO SIGNAL when the no GRT signal is
present, or display the Delta H (height error from grade) when the machine is within the
design surface. It is important to remember if the mast elevation is set to anything
other than 0.00, the Delta H display will be (mast elevation + Delta H).
Mast Elevation
The Mast elevation allows the operator to adjust any cut or fills if required. When the
grade adjustment knob is turned the mast will either raise or lower depending on the
direction the knob is turned, the amount of adjustment made will be displayed on the
screen.
GRT Statue Window
The GRT status window will display one of three messages. NO GRT SIGNAL
indicates the dozer is not receiving any GRT information. GRT TRACKING indicates
the dozer is either out of the design area or out of the control tolerance. GRT
CONTROLLING indicates the dozer is within the control tolerance.
Elevation Sensor Communication Status
If this signal is displayed the system is not communicating to the machines elevation
sensor.

Distance From Pollyline Indicator

When MS-2000 is running the job as an alignment the distance from the blade to the
Pollyline will be displayed. When the job data is in the DTM form or the dozer is out
of the design area three dashes will be displayed.
Slope Sensor Communication Status
If this signal is displayed the system is not communicating to the machines slope
sensor.
Slope Sensor Indication
During normal control conditions the display will indicate the slope sensor reading on
the machine. The NO SIGNAL display along with three dash lines indicates a
communication error. This indication should also be accompanied by the comm error
directly below.
Slope Signal Indication
The slope signal indication will display the design slope data being sent by the GRT. If
no slope data is being sent the NO SIGNAL indication will be displayed.

GPS Control
Selecting Topcons GPS control mode is as simple as the touch of a button. When
GPS is selected the system will automatically configure itself for GPS control. While
in GPS control all elevation and slope information will be controlled by the on board
computer. The slope and elevation correction will be sent to the System Five control
box from the on board GPS computer which will in turn drive the hydraulic system.
Soft key menu items. All the soft key menu items remain the same as described in the
standard control mode except for the addition of RESET LINE.
Reset Line
GPS job data is either setup as a DTM or Pollyline, when controlling the dozer using
Pollyline data, the center steering indicator is active displaying the dozer blade offset
from the Pollyline. As the dozer moves left or right of the Pollyline the picture of the
dozer will move accordingly, and the numbers below the graphical display will indicate
the distance from the Pollyline. By selecting RESET LINE the graphic of the dozer
will center in the display. The number below the graphic display will always indicate
actual distance from the Pollyline. This number can not be reset or changed.

GPS Control Screen

The GPS control screen is filed with valuable information on the status of the data
being sent from the GPS computer as well as system and control information. The
information provided in the 3D Control screen section is exactly the same as for GPS
control. Refer to the 3D section for detailed screen information.

Valve
9305-0000 DO5 13GPM 24V
Max Current Setting 1.75

9305-0001 DO5 8GPM 24V


9305-0002 20GPM 24V Pilot


9305-0003 20GPM 24V Pilot


9321-0000 DO5 13GPM 12V


9321-0001 DO5 8GPM 12V


9304-0000 DO3 2GPM 24V


9304-0006 DO3 2GPM 12V


9304-0007 DO3 4GPM 12V


9304-0008 DO3 4GPM 24V


7010-0354 Dual System Five Dozer Manual Rev D

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Dual Dozer System Five

Performance & Installation Manual

© 2003Topcon Laser Systems, Inc. 1 Rev D CO# 134 8/03

© 2003Topcon Laser Systems, Inc. 3 Rev D CO# 134 8/03

© 2003Topcon Laser Systems, Inc. 5 Rev D CO# 134 8/03

9. When using laser control, avoid direct exposure to your eyes.

© 2003 Topcon Laser Systems, Inc. 6 Rev D 8/03

Do not weld near hydraulic lines or on any equipment when in operation.

©2003 Topcon Laser Systems, Inc. 7 Rev D 8/03

© 2003 Topcon Laser Systems, Inc. 8 Rev D 8/03

What is Optimum Performance?

Small Dozer Notes:

©2003 Topcon Laser Systems, Inc. 9 Rev D 8/03

Rotary Encoders (2)

© 2003 Topcon Laser Systems, Inc. 10 Rev D 8/03

Auto/Manual Knob and Bracket

©2003 Topcon Laser Systems, Inc. 11 Rev D 8/03

Dual Mast Mounting

When using a dual laser system. One laser mast

View from Cab

Single Mast Mounting

When using a laser mast for single function

© 2003 Topcon Laser Systems, Inc. 12 Rev D 8/03

©2003 Topcon Laser Systems, Inc. 13 Rev D 8/03

6401V Dual Function Dozer Base Kit

**Valve cable supplied in hydraulic add-on kit

© 2003 Topcon Laser Systems, Inc. 14 Rev D 8/03

9164 Control Box / Dual Function

©2003 Topcon Laser Systems, Inc. 15 Rev D 8/03

9408 Junction Box / Dual Function

Schematics and Pin Assignments

© 2003 Topcon Laser Systems, Inc. 16 Rev D 8/03

4501 / 4503 Slope Add-On, Dozer

4501 Slope Add-On Kit 7.5'

4503 Slope Add-On Kit 15'

4400 Add-On Sonic Tracker System

4400 Sonic Add-on Kit

9060-1143 Bar, 2" L Standard 1

©2003 Topcon Laser Systems, Inc. 17 Rev D 8/03

5100 Laser Tracker System (Manual)

5100 Add-On Laser Tracker System

9060-5045 Coil Cord, 15' Sys IV 1

© 2003 Topcon Laser Systems, Inc. 18 Rev D 8/03

5000 TrackerJack System (24V Motorized)

5000 Add-On Laser TrackerJack System

9060-1297 Assy, Tracker Jack Case W/Label 1

5005 Add-On Laser TrackerJack System

9060-1297 Assy, Tracker Jack Case W/Label 1

©2003 Topcon Laser Systems, Inc. 19 Rev D 8/03

Hydraulic Hose Pressure Ratings and Minimum Bend Radius

Use of Mobile Hose Trucks

© 2003 Topcon Laser Systems, Inc. 20 Rev D 8/03

©2003 Topcon Laser Systems, Inc. 21 Rev D 8/03

High Pressure Closed Center

© 2003 Topcon Laser Systems, Inc. 22 Rev D 8/03

Adjusting Pressure Reducing Valve

©2003 Topcon Laser Systems, Inc. 23 Rev D 8/03

Load Sense Booster Valve

© 2003 Topcon Laser Systems, Inc. 24 Rev D 8/03

Open Center Conversion Valve