Topcon Paver System 5 Operator's Manual

Topcon Paver System 5 Operator's Manual

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Summary of Contents for Topcon Paver System 5

  • Page 1 For more information contact Synergy Positioning Systems or visit the Synergy Positioning Systems website at www.synergypositioning.co.nz All branches: Phone 0800 867 266 Email: info@synergypositioning.co.nz...
  • Page 3 Rev F ©Copyright Topcon Positioning Systems, Inc. April, 2004 All contents in this manual are copyrighted by Topcon. All rights reserved. The information contained herein may not be used, accessed, copied, stored, displayed, sold, modified, published, or distributed, or otherwise reproduced without...
  • Page 4 ECO#2223...
  • Page 5: Table Of Contents

    able of Contents Preface ..............vii Terms and Conditions ............vii Manual Conventions ............x What’s New............xi Chapter 1 System Overview ..........1-1 Getting Acquainted ............1-3 Control Box ............... 1-3 Sonic Tracker II ............1-4 Slope Sensor .............. 1-5 Smoothtrac Sonic Averaging System (SAS) .....
  • Page 6 Function Indicator LEDs ........... 4-6 Set/Menu Button ............4-7 Using the Set Mode ..........4-7 Using the Menu Mode ........4-8 Cross Communication Button ........4-8 Slope/Elevation Button ..........4-11 Slope Mode ............4-11 Elevation Mode ........... 4-11 Topcon Paver System Five Operator’s Manual...
  • Page 7 Table of Contents Survey/Indicate Button ..........4-12 Using the Survey Function ......... 4-12 Using the Indicate Function ........ 4-12 Auto/Manual Button ..........4-13 Using Automatic Mode ........4-13 Using Manual Mode ........... 4-13 Making Selections in the Performance Menu ..4-14 Jog Button ..............
  • Page 8 Sonic Tracker II Transducer Replacement ...... 8-3 Chapter 9 Troubleshooting ........... 9-1 Control Box Symptoms ............ 9-1 Tracker Symptoms ............9-11 Slope Sensor Symptoms ..........9-14 SAS Symptoms ..............9-17 Appendix A Safety Precautions ..........A-1 Topcon Paver System Five Operator’s Manual...
  • Page 9 Table of Contents Appendix B Limited Warranty ..........B-1 Electronic and Mechanical Components ......B-1 Return and Repair ............B-1 Warranty Disclaimer ............B-1 Service Information ............B-2 Glossary Index P/N 7010-0341 www.topconpositioning.com...
  • Page 10 Table of Contents Notes: Topcon Paver System Five Operator’s Manual...
  • Page 11: Preface

    Manual without Topcon’s express written consent and may only use such information for the care and operation of your product. The information and data in this Manual are a valuable asset of TPS and...
  • Page 12 Preface TRADEMARKS – System Five™, Topcon® and Topcon Positioning Systems™ are trademarks or registered trademarks of TPS. Windows® is a registered trademark of Microsoft Corporation. Product and company names mentioned herein may be trademarks of their respective owners. DISCLAIMER OF WARRANTY – EXCEPT FOR ANY...
  • Page 13 All information, illustrations, and applications contained herein are based on the latest available information at the time of publication. TOPCON reserves the right to make product changes at any time without notice. Comments, suggestions, and questions about TOPCON products are welcomed.
  • Page 14: Manual Conventions

    WARNING WARNING Notification that an action will result in system damage, loss of data, loss of warranty, or personal injury. ANGER DANGER NDER NO CIRCUMSTANCES SHOULD THIS ACTION BE PERFORMED Topcon Paver System Five Operator’s Manual...
  • Page 15: What's New

    hat’s New... This manual includes the changes for version 1.7 of the 9256 Control Box code. In this version: The range of the following settings has changed: • Gain (Elevation) range is now 1–200 • Gain (Slope) range is now 1–200 See “Performance Menu Settings”...
  • Page 16 What’s New... Notes: Topcon Paver System Five Operator’s Manual...
  • Page 17 Chapter 1 ystem Overview System Five™ is a complete, non-contacting control system which combines both elevation control and slope control into a simple, easy to use package (Figure 1-1). The primary function of System Five is to provide screed control so that the paving material is placed into position at the correct elevation and slope.
  • Page 18: Chapter 1 System Overview

    System Overview Figure 1-2 displays the setup of components on a screed. Figure 1-2. Paver System Five Top View Topcon Paver System Five Operator’s Manual...
  • Page 19: Getting Acquainted

    Getting Acquainted Getting Acquainted A standard System Five Paver system includes two Control Boxes, two Sonic Trackers and a single Slope Sensor. When setup and connected, the Control Boxes control either the left or right side of the machine for either elevation or slope. Control Box The Control Box (Figure 1-3) is the operator’s interface to System Five.
  • Page 20: Sonic Tracker Ii

    At the end of the day, Sonic Tracker II should be removed for proper storage in the carrying case. Figure 1-4. Sonic Tracker II Topcon Paver System Five Operator’s Manual...
  • Page 21: Slope Sensor

    Getting Acquainted Slope Sensor The slope sensor (Figure 1-5) is a precision electronic sensor which functions much like a precision carpenter's level. The slope sensor reads the inclination (tilt) of the screed and sends the signal to the Control Box. The slope sensor measures slopes from +20% to -20%.
  • Page 22: Smoothtrac Sonic Averaging System (Sas)

    The Smoothtrac replaces the mechanical ski that drags on the ground. The Smoothtrac connects to the Control Box through the tracker cable. Figure 1-6. Smoothtrac Sonic Averaging System (SAS) Topcon Paver System Five Operator’s Manual...
  • Page 23: Laser Tracker & Trackerjack

    Getting Acquainted Laser Tracker & Trackerjack The laser tracker (Figure 1-7) is an elevation control sensor that measures and controls the elevation of the screed. After receiving a signal from a rotating laser, the laser tracker sends a signal to the Control Box, which then sends a raise or lower signal to the tow point cylinder.
  • Page 24: Care And Preventive Maintenance

    A Carrying Case is provided with each System Five. The Carrying Case is lined and includes pre-cut sections for each Sonic Tracker II and the Control Boxes. A cut-out section is also provided for storing coil cords (Figure 1-8 on page 1-9). Topcon Paver System Five Operator’s Manual...
  • Page 25 Care and Preventive Maintenance Figure 1-8. Carrying Case NOTICE NOTICE Keep the carrying case dry and store in a dry location. Never let the interior of the carrying case become wet. If the case does become wet, remove the components and let it dry. P/N 7010-0341 www.topconpositioning.com...
  • Page 26 System Overview Notes: 1-10 Topcon Paver System Five Operator’s Manual...
  • Page 27 Chapter 2 aving Principles & Control Methods This chapter describes the components of pavers and the basics in paving principles, as well as control methods used for paving. Paver Components Modern pavers (Figure 2-1) consist of two major units: the Tractor and the Screed.
  • Page 28: Paving Principles & Control Methods

    • If the screed angle of attack is increased the screed rises, increasing the mat thickness (Figure 2-3). • If the angle of attack is decreased, the screed will settle, providing a thinner mat surface (Figure 2-3). Figure 2-3. Screed Determines Mat Thickness Topcon Paver System Five Operator’s Manual...
  • Page 29 How a Screed Works Because the screed floats, it will not immediately react to a change in the tow point. It needs a certain amount of time or distance to make a correction in the mat thickness (Figure 2-4). • If the tow point is changed by a unit of one, the paver must move one tow arm length before the screed will correct 63% of the elevation.
  • Page 30 3 tow arm lengths for full correction. Too much cranking and stabbing will cause raise and lower changes that will produce an uneven mat surface. Figure 2-6. Checking Mat Thickness Topcon Paver System Five Operator’s Manual...
  • Page 31: Tow Point Force ("P")

    How a Screed Works The screed has four main forces acting on it at all times, whether paving in manual or with automatics (Figure 2-7). A change in any one of the forces will cause the screed to rise or fall, changing the mat depth.
  • Page 32: Truck Exchange, Another Tow Point Force

    The truck driver should apply only light pressure on the brakes, sufficient to maintain contact with the paver. Topcon Paver System Five Operator’s Manual...
  • Page 33: Head Of Material ("M")

    How a Screed Works 4. Dumping of material in front of the paver as the truck pulls away after emptying its load into the hopper, can cause the paver to ride over the pile of material with subsequent adverse effects on mat quality. Avoid trucks pulling away prior to completely dumping all material.
  • Page 34 Maintained Correct Head of Material Screed Rises Due To Increased Head of Resistance Material Too High Screed Settles Due To Decreased Head of Resistance Material Too Low Figure 2-11. Head of Material Affects Mat Topcon Paver System Five Operator’s Manual...
  • Page 35: Reaction Of Material Under Screed ("R")

    How a Screed Works Reaction of Material Under Screed (“R”) Ideally, every truck load of material delivered to the paver would be exactly like every other load, with no variation. However, as a practical matter, changes in mix characteristics such as mix temperature, density, gradation, A.C. Content, segregation, etc., will affect the internal stresses developed within the mix, which in turn affects the resistance of the mix to flow under the screed (reaction of material under screed, “R”).
  • Page 36 If It Doesn't Look Right, It Isn't Right: Surface and texture 2-10 irregularities indicate that the homogeneous characteristics Topcon Paver System Five Operator’s Manual...
  • Page 37: Mix Temperature Characteristics

    How a Screed Works of the material in the mat have been interrupted, which usually results in bumpiness and premature failure of the pavement in those areas. Segregation can also be the result of excessively worn augers: “Center Streak” segregation can be caused by worn “Kicker Paddles”...
  • Page 38: Weight Of Screed ("W")

    The weight of the screed is measured in pounds per square inch. Weight of Screed (Force "W") Figure 2-13. Weight of Screed Members of the paving crew climbing on and off the screed 2-12 will also have some affect on the weight of screed force. Topcon Paver System Five Operator’s Manual...
  • Page 39: Quality Of Base Being Paved

    How a Screed Works The primary factor affecting this force is changing the width of the screed (Figure 2-14). Extendible screeds weigh the same whether they are fully retracted or fully extended. The difference is the wider the extension of the screed the greater the surface area of paving material to support.
  • Page 40: Rolling Techniques

    • Non-stop, continuous operation of paver • Constant speed of paver • Truck exchange 2-14 • Head of material Topcon Paver System Five Operator’s Manual...
  • Page 41: Control Methods

    Control Methods • Mix characteristics – Gradation – Segregation – Mix Temperature • Screed Compaction • Quality of Base Being Paved • Rolling Techniques NOTICE NOTICE Changes in any of these factors will cause a change in mat thickness, density, surface appearance and mat quality.
  • Page 42: Working Window And Sonic "Footprint

    Built into the Tracker is an operational zone, or Working Window, 2.4 inches above and below the grade reference (Figure 2-17 on page 2-17). The grade lights on the Sonic Tracker and Control Box continuously display this grade information to the operator. 2-16 Topcon Paver System Five Operator’s Manual...
  • Page 43 Control Methods onic racker NO CORRECTION MADE (OUT OF SLOW BLINKING UP ARROW WORKING WINDOW) SOLID UP ARROW BLINKING UP ARROW COARSE 2.4'' BLINKING UP ARROW/ON GRADE CORRECTION ON GRADE (AUTOMATIC) BLINKING DOWN ARROW/ON GRADE 2.4'' BLINKING DOWN ARROW SOLID DOWN ARROW FINE CORRECTION (AUTOMATIC)
  • Page 44: Sonic Tracker Operation And Its Position

    (Figure 2-19 on page 2-19). If the Tracker is on-grade, the mat being laid will be at the desired depth. 2-18 Topcon Paver System Five Operator’s Manual...
  • Page 45 Control Methods STOPWATCH Grade onic racker Figure 2-19. Sonic Tracker On-Grade If the screed and the Sonic Tracker II start to raise, the watch stops at a longer time (Figure 2-20). The Tracker and Control Box will indicate a down correction arrow, and lower hydraulic valve corrections are applied to bring the Tracker back to on-grade.
  • Page 46 If the Sonic Tracker II is side shifted off a stringline, the sound waves reflect off the ground and the Tracker's stopwatch indicate a longer time (Figure 2-22 on page 2-21). The Tracker is out of the Working Window, and no on-grade corrections are applied. 2-20 Topcon Paver System Five Operator’s Manual...
  • Page 47 Control Methods STOPWATCH onic racker Grade Figure 2-22. Sonic Tracker Scanning Outside of Stringline If the Tracker sees an obstruction closer than the reference signal, such as a grade pin, the watch stops at an even shorter time (Figure 2-23). The Tracker is out of the Working Window, and no on-grade correction signals are applied.
  • Page 48: Sonic Tracker And Temperature Changes

    Temperature Bail Heat Induced Heat Induced Target Reference Target Error Target Error onic racker onic racker Wind Blown Heat Off of Freshly Paved mat Figure 2-24. Working with Sonic Trackers and Temperature Changes 2-22 Topcon Paver System Five Operator’s Manual...
  • Page 49 Control Methods In the upper right hand corner of the Sonic Tracker II faceplate is a small symbol used to represent the use of the temperature bail. The LED symbol automatically illuminate when the bail is connected to the tracker. The tracker is cast with holes on each side for the bail to snap and lock into place (Figure 2-25).
  • Page 50: Laser Control

    Figure 2-26. Laser Control – On-Grade As the screed is raised, the beam of light hits the laser receiver below the center and a lower signal is indicated (Figure 2-27 on page 2-25). 2-24 Topcon Paver System Five Operator’s Manual...
  • Page 51 Control Methods Figure 2-27. Laser Control – Above Grade As screed is lowered the beam of light hits the Laser Receiver above the center a raise signal is indicated (Figure 2-28). 2-25 Figure 2-28. Laser Control – Below Grade P/N 7010-0341 www.topconpositioning.com...
  • Page 52: Slope Control

    (Figure 2-29). The sensor contains an electronic level vial, that acts as a “precision carpenter's level”. Slope control with this electric level vial is very accurate and repeatable. Figure 2-29. Position of Slope Control on Paving System 2-26 Topcon Paver System Five Operator’s Manual...
  • Page 53 Control Methods If the required slope changes, the screed operator dials the new slope into the System Five Control Box (Figure 2-30). The tow point cylinder on the slope side will raise or lower until the slope sensor measures the new slope. AUTO SURVEY System...
  • Page 54 Paving Principles & Control Methods Notes: 2-28 Topcon Paver System Five Operator’s Manual...
  • Page 55 The sonic stringline setup consists of readily available materials and up to 500 feet of nylon stringline. Topcon’s Sonic Tracker II works with many sizes and types of stringline, for best results use an 1/8 inch diameter nylon stringline.
  • Page 56: Chapter 3 Stringline Setup

    Sometimes, the surface to be milled contains pot holes or surfaces too broken to use as a joint match reference Setting elevated stringline would be too time consuming, especially for small, divided projects. In these applications, surface stringline provides a simple, easy alternative. Topcon Paver System Five Operator’s Manual...
  • Page 57 Setting Surface Stringline Position the tracker 14 to 18 inches above the stringline (Figure 3-2). onic racker 14" 18" Figure 3-2. Position of Tracker in Correlation to Stringline NOTICE NOTICE It is important to use a stringline with a diameter at least 1/8”...
  • Page 58 (Figure 3-4). Figure 3-4. Stringline Reference • When the sonic tracker sends out a sound wave, the first thing the tracker sees will be the reference stringline. Topcon Paver System Five Operator’s Manual...
  • Page 59: Setting Elevated Stringline

    Setting Elevated Stringline • Since the stringline is pulled tight, any small irregularities in the existing surface will be spanned (Figure 3-5). Figure 3-5. Stringline Spans Surface Irregularities As a verifiable grade reference, potential problems can be pointed out to the inspector before paving. Setting Elevated Stringline On some projects the asphalt must be laid to a specified elevation.
  • Page 60 Stringline Setup Your local Topcon dealer carries the following supplies for setting elevated stringline: • Sonic Stringline, 1000’ roll (p/n 7020-0101) • Sonic Grade Clips, box of 100 (p/n 7020-0121) • Cut/fill Offset Tap, feet/tenths (p/n 7000-1026) • Cut/fill Offset Tap, metric (p/n 7000-1027) Although Topcon’s Sonic Tracker will work with many sizes and...
  • Page 61: Making A Cut/Fill Lath

    Once you have the stringline setup, fine-tune the height of the stringline above the grade. To do this, make a cut/fill lath using a lath and a Topcon Cut/Fill Decal. 1. Assemble the required number of laths for the job.
  • Page 62 The stringline is now set to 2 feet above finished grade. 4. Repeat step 3 on page 3-8 at each station before starting to cut (Figure 3-11). 2.0' 2.0% 2.0' OFFSET Figure 3-11. Stringline Set at Desired Elevation Topcon Paver System Five Operator’s Manual...
  • Page 63: Attaching Stringline To The Grade Stake

    Setting Elevated Stringline Attaching Stringline to the Grade Stake Some jobs may require the stringline to be secured directly to the grade stake rather than attached to the clip. 1. Mark the lath with the desired “hike-up” above grade (Figure 3-12). Figure 3-12.
  • Page 64: Setting Projected Slope Stringline

    • If the road rises away from the stringline, the stringline will need to be lowered (Figure 3-14). 2.0% SLOPE X 2.00' OFFSET = .04' LOWER .04' 2.0' 2.0% 2.0' OFFSET Figure 3-14. Lower Stringline: 2% Cross Slope with 2 Foot Offset 3-10 Topcon Paver System Five Operator’s Manual...
  • Page 65 Setting Projected Slope Stringline • If the road slopes down from the stringline, the stringline will need to be raised (Figure 3-15). 3.0% SLOPE X 2.00' OFFSET = .06' RAISE .06' 2.0' 2.0' OFFSET Figure 3-15. Raise Stringline: 3% Cross Slope with 2 Foot Offset 3.
  • Page 66: Verifying Grade

    1. Construct a Grade Checking Lath using a lath, a level bubble, nails, and standard hand tools as shown in Figure 3-16. 1 . 5 1 . 5 I L S 2 . 0 Figure 3-16. Grade Checking Lath 3-12 Topcon Paver System Five Operator’s Manual...
  • Page 67 Verifying Grade 2. Set the Grade Checking Lath on the edge of the newly cut ground so the level bubble extends over the Sonic Stringline (Figure 3-17). 1 . 5 STRINGLINE STRINGLINE FINISHED G RADE FINISHED G RADE (CORRECT) APPROX. . 05' TOO HIGH Figure 3-17.
  • Page 68 Stringline Setup Notes: 3-14 Topcon Paver System Five Operator’s Manual...
  • Page 69: Operation & Menu Settings

    Chapter 4 peration & Menu Settings System Five™ uses a Control Box and Sonic Trackers to produce exceptional paving solutions. This chapter describes using the various components, including: • The buttons, knobs, and switches on the Control Box. • How to change settings, access information, and take readings using the various buttons, knobs, and switches.
  • Page 70: Control Box

    Figure 4-1. 9256 Control Box Cross Communication Button Light Sensor for LED Display Slope/Elevation Button Power Switch Survey Button Grade Adjustment Knob 10. Auto/Manual Button Grade Adjustment LED 11. Jog Button Set (Menu) Button Topcon Paver System Five Operator’s Manual...
  • Page 71: Lcd

    Control Box The LCD (Liquid Crystal Display) allows the operator to view text and graphic symbols that represent elevation or slope settings that System Five currently maintains for the paver (Figure 4-2). Figure 4-2. LCD Display Light Sensor for LED Display The light sensor monitors ambient light to adjust the brightness of the LED display for better visibility.
  • Page 72: Grade Adjustment Knob

    SURVEY System Five (MENU) Figure 4-4. Adjusting Grade Height • Knob adjusts the percentage of slope while in cross slope control (Figure 4-5). AUTO SURVEY System Five (MENU) Figure 4-5. Adjusting Cross Slope Control Topcon Paver System Five Operator’s Manual...
  • Page 73: Grade Adjustment Direction Arrows

    Control Box Grade Adjustment Direction Arrows The grade adjustment arrows are located at the upper left and upper right of the grade adjustment knob. These two arrows (Figure 4-6) light up in red to indicate the direction to turn the knob to reach on-grade. R otate K nob R otate K nob C ounterclockwise...
  • Page 74: Function Indicator Leds

    • CON – indicates the box is in Control Mode. • SUR – indicates the box is in Survey Mode. • ELEV – indicates the LCD displays the current elevation. • AVG – indicates the LCD displays the calculated average elevation. Topcon Paver System Five Operator’s Manual...
  • Page 75: Set/Menu Button

    Control Box F unction I ndicator ELEV LED s (MENU) Figure 4-8. Function Indicator LEDs Set/Menu Button The Set/Menu button (Figure 4-9) has two functions: • Set Mode – used to change the reference number viewed on the display to a desired value. •...
  • Page 76: Using The Menu Mode

    Control Box. AUTO SURVEY System Five (MENU) Figure 4-10. Cross Communication Button During cross communication, the Control Box that initiates the communication (primary) displays and controls the settings of the second Control Box. Topcon Paver System Five Operator’s Manual...
  • Page 77 Control Box 1. Press and hold the Cross Communication button (Figure 4-11). AUTO SURVEY System Five (MENU) Figure 4-11. Initiate Cross Communication • The left arrow illuminates, indicating cross communication has started (Figure 4-12). AUTO SURVEY System Five (MENU) Figure 4-12. Cross Communication Started •...
  • Page 78 (Figure 4-14). AUTO SURVEY System Five (MENU) Figure 4-14. Remotely Change Second Control Box Settings 3. When finished, or to apply new settings to the second box, release the cross communication button. 4-10 Topcon Paver System Five Operator’s Manual...
  • Page 79: Slope/Elevation Button

    Control Box Slope/Elevation Button The elevation/slope button (Figure 4-15) is used to set the System Five™ for slope or elevation control AUTO E levation S lope M ode M ode SURVEY System Five (MENU) Figure 4-15. Slope/Elevation Button Slope Mode If the Control Box is connected to a slope sensor, the desired cross slope can be dialed in for automatic control.
  • Page 80: Survey/Indicate Button

    Control Box emits a second beep. “IND” briefly displays on the LCD, then the grade or slope setting. The Grade Adjustment LEDs remain dark. To exit Indicate Mode, push either the Survey/Indicate button or the Auto button. 4-12 Topcon Paver System Five Operator’s Manual...
  • Page 81: Auto/Manual Button

    Control Box Auto/Manual Button The auto/manual button (Figure 4-17) has three functions: • In Automatic Mode, the tow point cylinders are automatically adjusted as needed. • In Manual Mode, displays grade corrections without adjusting the tow point cylinders. • Makes selections in the Performance Menu. AUTO AUTO SURVEY...
  • Page 82: Making Selections In The Performance Menu

    1. Mounting Knob – secures the Control Box to its mounting bracket. The bracket has a jaw that matches up with the jaw located on the side of the Box. 2. Serial Number Plate – contains Systems Five part and serial numbers. 4-14 Topcon Paver System Five Operator’s Manual...
  • Page 83 Control Box 3. Audible Beeper – When the power is turned on, or calibration selections are made, the beeper will sound. The beeper may be turned Off or On for certain functions by using the Beeper Alarm Mode (see the Accessing System Five Performance Settings section).
  • Page 84: Performance Menu Settings

    Gain (Elevation) 1 – 200 Gain (Slope) 1 – 200 Valve Offset 1 – 999 Averaging 1 – 100 Elevation 1 – 30 mm 3 mm Deadband Slope Deadband .025% – .75% 0.075% 4-16 Topcon Paver System Five Operator’s Manual...
  • Page 85 Performance Menu Settings Table 4-2. Performance Menu Settings (Continued) Menu LED Symbol Range Factory Setting Beeper on/off Unit in, ft, cm Test open, short, pass no setting Factory settings are preset values that will run most pavers. If your machine does not perform properly within those preset values, adjust the setting accordingly until you have satisfactory machine performance.
  • Page 86 System Five (MENU) Figure 4-21. Scrolling through the Performance Menu 3. Press the Auto button to select a menu item (Figure 4-22). AUTO SURVEY System Five (MENU) Figure 4-22. Selecting Performance Menu Items 4-18 Topcon Paver System Five Operator’s Manual...
  • Page 87 Performance Menu Settings 4. Turn the Grade Adjustment Knob to view the options available for the Menu selection (Figure 4-23). AUTO SURVEY System Five (MENU) Figure 4-23. View Menu Options 5. Press the Auto button again to store value (Figure 4-24). AUTO SURVEY System...
  • Page 88: Gain (Elevation)

    Gain (Elevation) (Figure 4-25). AUTO SURVEY System Five (MENU) Figure 4-25. Selecting Gain Elevation 2. Turn the Grade Adjustment Knob to select the desired value, typically 25 for most paving applications (Figure 4-26 on page 4-21). 4-20 Topcon Paver System Five Operator’s Manual...
  • Page 89: Gain (Slope Control)

    Performance Menu Settings AUTO SURVEY System Five (MENU) Figure 4-26. Selecting Gain Menu Option 3. Press the Auto button again to store value. 4. Rotate the Grade Adjustment Knob to access another item in the Performance Menu, or press the Set/Menu button to exit.
  • Page 90 Figure 4-28. Selecting the Gain Value 3. Press the Auto button again to store value. 4. Rotate the Grade Adjustment Knob to access another item in the Performance Menu, or press the Set/Menu button to exit. 4-22 Topcon Paver System Five Operator’s Manual...
  • Page 91: Valve Offset

    Performance Menu Settings NOTICE NOTICE Do not set slope gain at a higher value than the elevation gain on the other side of the paver. A higher value may cause the slope to be over reactive. Valve Offset The valve offset is the minimum amount of electrical signals sent to the valve which causes the hydraulic cylinder to move.
  • Page 92 (Figure 4-30). AUTO SURVEY System Five (MENU) Figure 4-30. Setting the Raise Valve Offset Value 3. Press the Auto button to store the Raise Offset Value 4-24 (Figure 4-31 on page 4-25). Topcon Paver System Five Operator’s Manual...
  • Page 93 Performance Menu Settings Pressing the Auto button also switches the box to Lower Offset. The Lower Grade Correction Display arrow will illuminate and the Control Box will begin sending a lower correction signal to the value (Figure 4-31). AUTO SURVEY System Five (MENU)
  • Page 94: Averaging

    • Averaging value range – 1 to 100 • Factory preset – 50 1. From the Performance Menu, press the Auto button to select Averaging (Figure 4-33). AUTO SURVEY System Five (MENU) Figure 4-33. Select Averaging 4-26 Topcon Paver System Five Operator’s Manual...
  • Page 95: Deadband Elevation

    Performance Menu Settings 2. Turn the Grade Adjustment Knob to select the desired value (Figure 4-34). AUTO SURVEY System Five (MENU) Figure 4-34. Select Value 3. Press the Auto button again to store the value. 4. Rotate the Grade Adjustment Knob to access another item in the Performance Menu, or press the Set/Menu button to exit.
  • Page 96 Figure 4-36. Select Value 3. Press the Auto button again to store the value. 4. Rotate the Grade Adjustment Knob to access another item 4-28 in the Performance Menu or press the Set/Menu button to exit. Topcon Paver System Five Operator’s Manual...
  • Page 97: Deadband Slope

    Performance Menu Settings Deadband Slope Deadband is the area of the Working Window that is on-grade. While the reference is within that area, the paver’s valves are idle (closed). Therefore the wider the Deadband (on-grade area), the more a reference can move up or down without a correction being initiated.
  • Page 98 Figure 4-38. Select Value 3. Press the Auto button again to store the value. 4. Rotate the Grade Adjustment Knob to access another item in the Performance Menu, or press the Set/Menu button to exit. 4-30 Topcon Paver System Five Operator’s Manual...
  • Page 99: Beeper Alarm

    Performance Menu Settings Beeper Alarm When in Automatic Mode and the Sonic Tracker receives a reference signal outside of the Working Window (more than 2.0" from grade), a single audible beep will be heard. 1. From the Performance Menu, press the Auto button to select Beeper (Figure 4-39).
  • Page 100: Unit

    Units (Figure 4-41). AUTO SURVEY System Five (MENU) Figure 4-41. Select Units 2. Rotate the Grade Adjustment Knob to select a unit for measuring (feet, inches, or centimeters) (Figure 4-42 on page 4-33). 4-32 Topcon Paver System Five Operator’s Manual...
  • Page 101 Performance Menu Settings AUTO SURVEY System Five (MENU) Figure 4-42. Select Measuring Unit Table 4-4 displays and describes the three options available for the Units menu. Table 4-4. Unit Measurement Descriptions Numerical Measurement Description Display Description Display Example Inches 2 1/2 inches Feet 25 hundredths of a foot...
  • Page 102: Test

    • The display shows “Pass” if the lower valves test OK. • If there is a problem, the display will read “Open” or “Short”. Table 4-5 on page 4-35 summarizes the Test solutions. 4-34 Topcon Paver System Five Operator’s Manual...
  • Page 103 Performance Menu Settings Table 4-5. Test Solutions Test Display Description Good Valve Valve NOT connected (OR Danfoss valve output being used) (OR connected to existing proportional control valves) Valve wires have shorted electronically 3. Press the Auto button once more to return to the Menu selections.
  • Page 104 Operation & Menu Settings Notes: 4-36 Topcon Paver System Five Operator’s Manual...
  • Page 105: Getting Ready To Pave

    Chapter 5 etting Ready to Pave This chapter is designed to get the paving crew started using System Five™. The job application and the desired results will determine what type of non-contacting controls should be used; i.e. sonic, slope, laser and SAS. •...
  • Page 106: Control Box Setup

    S onic M achine T racker C able C able S lope C able Figure 5-1. Attach Control Box and Connect Cables NOTICE NOTICE Due to different types of machine configuration, cable connections may vary. Topcon Paver System Five Operator’s Manual...
  • Page 107: Screed Setup

    Screed Setup Screed Setup To start paving with System Five, set up the paver just as you would under manual control. 1. Place the screed on blocks or lath set for the desired paving thickness (Figure 5-2); make sure to account for material compaction.
  • Page 108: Sonic Tracker Setup

    5. Place the Sonic Tracker over the reference: raise or lower the Tracker bracket to position it at a proper height above the grade reference. 6. Push the Survey button on the Control Box to lock trackers on- grade. Topcon Paver System Five Operator’s Manual...
  • Page 109 Sonic Tracker Setup 7. Push and hold the Set button while dialing in mat depth. 8. Put the Control Box in Auto and begin paving. Figure 5-5. Sonic Tracker Setup P/N 7010-0341 www.topconpositioning.com...
  • Page 110: Sas Setup

    The control box will reconfigure to the number of trackers. Changing the number of trackers may change the average distance. Re-survey the Control Box to lock SAS on- grade. Topcon Paver System Five Operator’s Manual...
  • Page 111: Control Box Setup For Elevation

    Control Box Setup for Elevation Once one of the Trackers has been eliminated from the averaging, the balance point of the beam will have changed. If the faulty Tracker is not replaced the beam will need to be repositioned to adjust for the new balance point.
  • Page 112 4. Press the Auto/manual button to put the Control Box into automatic mode (Figure 5-8). The Auto LED will light up. 5. Begin paving. AUTO SURVEY System Five (MENU) Figure 5-8. Selecting Automatic Mode Topcon Paver System Five Operator’s Manual...
  • Page 113 Control Box Setup for Elevation After you begin paving, check the mat depth to ensure the desired thickness is being laid (Figure 5-9). The blocks initially placed under the screed may cause the mat to be too thick or too thin. Check the mat several times to get an average before making any corrections.
  • Page 114 Highways require gradual changes, parking lots require quick changes. The display should now read the depth of the mat being laid. AUTO SURVEY System Five (MENU) 5-10 Figure 5-11. Slowly Adjusting Grade Topcon Paver System Five Operator’s Manual...
  • Page 115: Control Box Setup For Cross Slope

    Control Box Setup for Cross Slope Control Box Setup for Cross Slope The slope sensor should already be mounted on the transverse beam of the paver. The sensor can talk to both control boxes, but only one at a time. The sensor communicates to the Control Box through the cable.
  • Page 116 Smart Level then you can begin paving. Make sure to push the Auto/manual button to put the Control Box into automatic control. 5-12 Figure 5-14. Identifying Slope Topcon Paver System Five Operator’s Manual...
  • Page 117 Control Box Setup for Cross Slope • If the slope displayed in the box does not match the surface, then the sensor must be calibrated. Press and hold the Set button while turning the Grade Adjustment Knob to change the display to match the slope of surface (Figure 5-15).
  • Page 118 Figure 5-16. Producing a Smooth Slope Transition If a smooth transition is not required, then dial in the desired slope and begin paving. 5-14 Topcon Paver System Five Operator’s Manual...
  • Page 119: Tracker And Sas Placement

    Chapter 6 racker and SAS Placement Whether setting up a standard Sonic Tracker II system or a Smoothtrac SAS, consider the following for each Tracker: • The Tracker has a total working range of 14 inches to 55 inches—41 inches of adjustment—allowing the Tracker to be set over a stringline on one pass, then match grade on the next pass without moving the tracker.
  • Page 120: Sonic Tracker Positioning In Relation To Reference

    Placing the tracker too far from the reference may not allow for accurate temperature compensation. onic racker 14" (35.5cm) 14" Recommended Height for Paving Total 55" Tracker 24" (140cm) Range Figure 6-1. Recommended Tracker Placement Topcon Paver System Five Operator’s Manual...
  • Page 121: L-Bar Positioning

    Sonic Tracker Positioning in Relation to Reference L-bar Positioning Position the L-Bar horizontally so the tracker will be over the reference. For example, when tracking a curb and gutter, place the screed or extension flush with the edge of gutter and slide the L-Bar so the Tracker is over the lip of the gutter (Figure 6-2).
  • Page 122 Mounting to the extension will make it easier to keep the tracker over the reference. onic racker CURB Figure 6-3. Position of L-Bar with Tracker on Bracket Topcon Paver System Five Operator’s Manual...
  • Page 123: Cub And Gutter Tracking

    Sonic Tracker Positioning in Relation to Reference Cub and Gutter Tracking When tracking a curb and gutter, keep the tracker 14 to 24 inches above the lip of gutter (Figure 6-4). If the tracker is placed too high, the sonic cone may pick up an unwanted surface, such as the face of the curb.
  • Page 124: Placement When Using A Temperature Bail

    2' of effectivity of the ski. For example, if the sensor is moved foreword or backward 2 1/2' (12 1/2' from the end) you are using a 25' ski. Topcon Paver System Five Operator’s Manual...
  • Page 125: Placement When Using Elevated Stringline

    Sonic Tracker Positioning in Relation to Reference onic racker Min. String or Wire 4" Min. of 4" Above Ski Figure 6-7. Tracker & Mechanical Ski Placement Placement When Using Elevated Stringline Some jobs may require the mat be laid to a specified elevation. In an application like this, an elevated stringline or wire may be set up.
  • Page 126: Placement When Using Surface Stringline

    A rule of thumb is to place the tracker about 1/3 to 2/3 the length of the tow arm forward of the screed pivot point (Figure 6-10 on page 6-9). Topcon Paver System Five Operator’s Manual...
  • Page 127 Sonic Tracker Placement in Relation to Screed Grade onic racker Reference Desired Grade Screed Pivot Point Figure 6-10. Correct Tracker Placement in Relation to Screed If the tracker is not placed between these points, then incorrect screed responses could result. The following examples describe the possible, incorrect placements and the errors that would occur.
  • Page 128 (Figure 6-13 on page 6-11). Any tracker elevation changes will cause the tow point cylinder to move immediately. The problem with the tracker placed here is the lack of feedback from the screed. 6-10 Topcon Paver System Five Operator’s Manual...
  • Page 129 Sonic Tracker Placement in Relation to Screed Grade onic racker Reference Desired Grade Incorrect Placement Figure 6-13. Incorrect Placement of Tracker at Tow Point If any of the forces acting on the screed change, then the screed will rise or fall without the tracker sensing the movement. For example, if the amount of material in front of the screed was decreased, the head of material force (“M”) also decreases and the screed would begin to fall (Figure 6-14).
  • Page 130 18 feet (6 feet x 3 tow arm lengths). This would be a better tracker position for applications where 6-12 smoothness is desired such as mainline paving or when using a mechanical or non-contacting (SAS) ski. Topcon Paver System Five Operator’s Manual...
  • Page 131: Smoothtrac Sas Placement And Setup

    Smoothtrac SAS Placement and Setup Smoothtrac SAS Placement and Setup Topcon's Smoothtrac® Sonic Averaging System (SAS) is a non- contacting averaging system that uses multiple sonic trackers to smooth out the bumps and dips in a mat surface (Figure 6-16). The...
  • Page 132 Bend the L-bars so they are aligned in the same position and fold inwards so they are close to the paver. Make sure the clamp 6-14 handles are loose enough so bars can move. Topcon Paver System Five Operator’s Manual...
  • Page 133 Smoothtrac SAS Placement and Setup 5. Lower each of the Tracker hangers on the SAS and mount a Sonic Trackers using the L-handle bolt (Figure 6-19). An extra washer may need to be added so the L-handle does not block the cable connection.
  • Page 134: Positioning The Sas

    The best method is the one you are presently using or the one in which you are most comfortable (Figure 6-22 on page 6-17). 6-16 Topcon Paver System Five Operator’s Manual...
  • Page 135 Positioning the SAS Figure 6-22. Example Placement of SAS Trackers Over Reference 6-17 P/N 7010-0341 www.topconpositioning.com...
  • Page 136 (Figure 6-24 on page 6-19). The SAS coil cable will easily reach the tracker. 6-18 Topcon Paver System Five Operator’s Manual...
  • Page 137: Placement Of Sas On Paver

    Placement of SAS on Paver Figure 6-24. Repositioning the Sonic Tracker Placement of SAS on Paver The center connection point of the SAS is the balance point. The position of the balance point to the tow arm is very critical. By moving the balance point, the performance of the system is greatly affected.
  • Page 138 This will give you the placement of the balance point of the SAS on your machine (Figure 6-25). B alance P oint of B eam C enter of B eam Figure 6-25. Placement of SAS 6-20 Topcon Paver System Five Operator’s Manual...
  • Page 139: Paving Applications

    Others are concerned with mat thickness and some require the new asphalt to match curb and gutter or existing grades. Topcon's System Five™ is very versatile and can be used in all these applications. The following are a few examples of what controls might be used and how to set them up.
  • Page 140 After compaction, make the necessary adjustments at the Control Box. If the road width varies, it will be easier to keep the Tracker over the gutter if the Tracker is mounted to the extension on the paver. Topcon Paver System Five Operator’s Manual...
  • Page 141 Paving City Streets with Sonics 5. To pave the other side of the road, position the left tracker over the lip of the gutter and place the right tracker over the new mat (Figure 7-4). SUBGRADE CENTERLINE OF ROAD Figure 7-4. Paving Other Side of Road 6.
  • Page 142: Paving City Streets With Cross Slope

    Figure 7-5. Paving with Cross Slope If the curbs are at different elevations, a .36 feet rise at centerline will produce incorrect slopes (Figure 7-6). .36'RISE 2.3% 1.7% 36.0' Figure 7-6. Curbs with Different Elevations Topcon Paver System Five Operator’s Manual...
  • Page 143 Paving City Streets with Cross Slope When System Five is used to pave a true 2.0% slope, the crown of the street will not be at the centerline (Figure 7-7). CENTERLINE AT 2.0% GRADE CUT 2.0% ORIGINAL CENTERLINE Figure 7-7. Curb with Same Slope To pave from uneven curbs using slope control, choose the side of the road with the highest curb and position the tracker over the curb.
  • Page 144 RL-HB rotating laser. Set the laser at the lip of one curb, then use the detector and a folding rule to take a reading on the other curb (Figure 7-10). Spot check every 25-50 feet by just moving the laser. POWER Figure 7-10. Checking Curb Elevations Topcon Paver System Five Operator’s Manual...
  • Page 145: Paving Streets Through Intersections

    Paving Streets Through Intersections Paving Streets Through Intersections As you pave city streets, you will come upon intersections where the curb stops. There are a couple of methods for controlling grade through the intersection. Method 1 for Paving Intersections For this method, the base of the intersecting road will be used as the reference.
  • Page 146 Figure 7-14. Paving Through Intersection 5. Without stopping, continue paving until the tracker is back on the lip of the curb. Survey the tracker on-grade (Figure 7-15 on page 7-9) and put back into automatic control. Topcon Paver System Five Operator’s Manual...
  • Page 147: Method 2 For Paving Intersections

    Paving Streets Through Intersections AUTO SURVEY System Five (MENU) Figure 7-15. Survey to On-Grade and Return to Automatic Control You may find after surveying that for the tracker on the curb the number has changed slightly from the curb on the other side of the intersection.
  • Page 148: Paving Intersections With Cross Slope

    “mainline” cross slope does not change. If the slope does change, then a combination of slope and Tracker should be used (Figure 7-17). 7-10 Figure 7-17. Paving Intersections with Cross Slopes Topcon Paver System Five Operator’s Manual...
  • Page 149 Paving Intersections with Cross Slope 1. Put the slope side of Paver in manual mode just before the slope of the intersection begins to change (Figure 7-18). AUTO SURVEY System Five (MENU) Figure 7-18. Switching to Elevation Control and Surveying On-grade 2.
  • Page 150 Survey the slope to get an on-grade signal (Figure 7-21). Figure 7-20. Paving Through Intersection AUTO SURVEY System Five (MENU) AUTO SURVEY System Five (MENU) 7-12 Figure 7-21. Returning to Manual and Surveying On-Grade Topcon Paver System Five Operator’s Manual...
  • Page 151 Paving Intersections with Cross Slope NOTICE NOTICE You may find after surveying the slope that the number displayed is not the same as the desired cross slope. This will occur if the surface being paved is not also at the desired slope. To get back to the correct slope continue paving in automatic and slowly dial the display to the desired slope.
  • Page 152 Paving Applications Notes: 7-14 Topcon Paver System Five Operator’s Manual...
  • Page 153: Maintenance

    Chapter 8 aintenance This section contains information regarding preventative maintenance and daily care of System Five™. Also included are: • Cleaning procedures for the Sonic Tracker II™ Transducer. • Replacement procedures for the Sonic Tracker II Transducer. Preventative Maintenance & Daily Care A good preventative maintenance and daily care routine will prevent many problems before they occur.
  • Page 154: Sonic Tracker Ii Transducer Cleaning

    2. Mix a mild detergent with water and place the mixture in a spray bottle (use Simple Green® where available). 3. With the Sonic Tracker upright, thoroughly spray the Transducer with the detergent solution. Topcon Paver System Five Operator’s Manual...
  • Page 155: Sonic Tracker Ii Transducer Replacement

    Sonic Tracker II Transducer Replacement 4. After spraying the Transducer with the detergent, fill the spray bottle with clean water and rinse any residual detergent off of the Transducer. 5. Allow the Sonic Tracker to thoroughly dry. Sonic Tracker II Transducer Replacement If the ability of the Sonic Tracker II to “see”...
  • Page 156 Ty-Wrap, then remove the small wire connectors from their tabs (Figure 8-3 on page 8-5). NOTICE NOTICE When cutting the Ty-Wrap, be careful not to cut or damage the wires. Topcon Paver System Five Operator’s Manual...
  • Page 157 Sonic Tracker II Transducer Replacement TY-WRAP CAREFULLY REMOVE WIRE CONNECTORS Figure 8-3. Remove Transducer, Cut Ty-Wrap, and Remove Connectors 4. Place the wire connectors of the new transducer firmly on their tabs; the gray wire connector is placed on the elevated tab. Place the Ty-Wrap in the slot next to the elevated (gray wire) tab, tighten and trim.
  • Page 158 (the two wire tabs have to sit down into the extra deep area of the recess). Place the new “O”-ring around the transducer and seat firmly between the transducer and the Sonic Tracker II transducer recess (Figure 8-5 on page 8-7). Topcon Paver System Five Operator’s Manual...
  • Page 159 Sonic Tracker II Transducer Replacement TRANSDUCER WIRE CONNECTOR PINS Figure 8-5. Replace Wires, Transducer, and “O”-ring 6. Place the black retaining ring over the transducer assembly with the beveled edges out and the flat surface against the Sonic Tracker II base. Line up the holes for the mounting screws. The mounting screw holes are set to an irregular pattern, ensuring the retaining ring only lines up with the mounting holes one way (Figure 8-6 on page 8-8).
  • Page 160 8. Ensure the metallic surface inside the transducer has no visible wrinkles. If distortion is evident, repeat steps 5 on page 8-6 to step 8. 9. Place a new filter foam over the transducer. The Sonic Tracker II is now ready for operation. Topcon Paver System Five Operator’s Manual...
  • Page 161: Troubleshooting

    Chapter 9 roubleshooting Control Box Symptoms 1. Control Box LCD does not Display 2. Control Box LCD displays “Error” 3. Cannot adjust to On-Grade when Elevation Control is selected. 4. Tow point cylinder does not move Up or Down 5. Tow point cylinder moves in the wrong direction 6.
  • Page 162 Do not use electrical contact cleaner to clean the Tracker's transducer. 4. Swap Control Boxes from left to right side. 5. For System Four™ bypass Junction Box by plugging coil cord from paver to J-Box directly into Control Box. Topcon Paver System Five Operator’s Manual...
  • Page 163 Control Box Symptoms Control Box Symptom 2 “Control Box LCD shows Error” (Figure 9-1). AUTO SURVEY System Five (MENU) Figure 9-1. Error Display Probable Cause No communication with the sensor selected. 1. Check that all cables are properly connected to System Five™...
  • Page 164 Maintenance and Parts section of this manual. 6. Swap the Tracker with the unit on the opposite side. 7. Averaging may be set too low if tracking an uneven reference. Factory setting is 50. Topcon Paver System Five Operator’s Manual...
  • Page 165 Control Box Symptoms Control Box Symptom 4 “The tow point cylinder doesn't move up or down.” Probable Cause Machine electrical switches are not in the proper position, or hydraulics to the cylinder are not active. 1. Check that all locking pins have been removed and that all hydraulic blocking valves are in the open and correct position for automatic control.
  • Page 166 Typically between 12 to 15 seconds. 2. Adjust Gain Performance Settings. Factory setting is 25. 3. Adjust Valve Offsets. Refer to Valve Offset section in the Performance Section within this Manual. Topcon Paver System Five Operator’s Manual...
  • Page 167 Control Box Symptoms Control Box Symptom 7 “System intermittently drives the cylinder all the way up or down when tracking a mechanical ski.” Probable Cause Tracker is intermittently picking up signals from the ski. 1. Verify string is at least 4 inches above the surface of the ski.
  • Page 168 6. Verify Tracker is not picking up erroneous signals from undesired reference. Example: Head of material, end gate, shoulder grade or material spillage from hopper. 7. If using Stringline, verify line is not bouncing. Topcon Paver System Five Operator’s Manual...
  • Page 169 Control Box Symptoms 8. Check to see if Averaging in Performance Menu is set too low. Factory setting is 50. 9. Check Deadband in Performance Menu is not less than 3mm. Control Box Symptom 10 “The valve is driving the hydraulic cylinder too far, overshooting grade.”...
  • Page 170 Tracker to 14 to 16 inches from the reference. 2. Move Tracker away from gusty heat source, such as engine fan exhaust. 3. Temperature Cutout is set too low. Factory setting is 7. Refer to Technicians manual. 9-10 Topcon Paver System Five Operator’s Manual...
  • Page 171: Tracker Symptoms

    Tracker Symptoms Tracker Symptoms 1. Sonic Tracker will not power on. 2. Sonic Tracker is ticking, but will not adjust to Grade 3. Tracker grade lights flash high and low and will not stay On-Grade. 4. Sonic Tracker is not matching joint or curb. 5.
  • Page 172 Typically 12 to 15 seconds. 2. Check Valve Offsets are set correctly. Refer to setting valve offsets. 3. Make sure Gain Setting is not too high. Factory setting is 25. 9-12 Topcon Paver System Five Operator’s Manual...
  • Page 173 Tracker Symptoms If problem exists in manual mode, then Tracker is setup incorrectly or Performance Settings are incorrect. 1. Verify that temperature bails are clean and securely attached. 2. Verify temperature bail symbol “T” is displayed on face of Tracker. If not, clean or replace transducer. 3.
  • Page 174: Slope Sensor Symptoms

    Probable Cause Both Control Boxes are selected for slope or have a defective cable. 1. Cross slope operates one side at a time. Verify only one 9-14 Control Box has been selected for slope. Topcon Paver System Five Operator’s Manual...
  • Page 175 Slope Sensor Symptoms 2. Verify that the slope cable is connected securely and properly. 3. Swap slope cable from other side to check cable. Slope Sensor Symptom 2 “Cross Slope drives cylinder in the wrong direction.” Probable Cause Slope sensor installed incorrectly. 1.
  • Page 176 1. Calibrate the Slope Sensor as described in “Daily Cross Slope Calibration” in the Function and Operations section. 2. Check that the Transverse Beam is mounted according to the manufacturer’s instructions and that it is not loose or damaged. 9-16 Topcon Paver System Five Operator’s Manual...
  • Page 177: Sas Symptoms

    SAS Symptoms 3. Recheck slope using a good reference such as a laser or level. Wait at least 3 tow arm lengths before checking the slope after a change has been made. 4. If the paver's mat thickness controls have been used then the slope calibration may have to be changed.
  • Page 178 Figure 9-3. Temperature Bail Symbol Indicating Code Revision Example: Flash twice, pause flash twice means the code in the Tracker is 2.2. SAS requires trackers with code of 2.2 or 9-18 higher. Topcon Paver System Five Operator’s Manual...
  • Page 179 SAS Symptoms SAS Symptom 2 “A Tracker stops working.” Probable Cause Defective Tracker. 1. Check SAS cable connections at each tracker. 2. Turn off Control Box and swap tracker showing error with another tracker on the SAS. (Tracker number is on the cable at the tracker connector.) Turn the Control Box back on to reset SAS.
  • Page 180 Chapter 8 to replace the transducer if necessary. 3. Check that Trackers are between 14 and 24 inches from reference. 4. If there are gusty winds, lower SAS to get Trackers 9-20 closer to reference. Topcon Paver System Five Operator’s Manual...
  • Page 181 SAS Symptoms 5. Move the Tracker away from gusty heat source, such as engine fan exhaust. 6. Verify that the Trackers are not picking up erroneous signals from undesired reference. Example: Head of material, end gate shoulder grade or material spillage from hopper. 7.
  • Page 182 Troubleshooting Notes: 9-22 Topcon Paver System Five Operator’s Manual...
  • Page 183: Safety Precautions

    Remember, most accidents are caused by failure to observe basic safety precautions. 1. Read and become familiar with the machine manufacturer’s operation manual, including safety information before installing, using, or servicing the Topcon System Five. WARNING WARNING Improper operation, lubrication, maintenance, or repair of this product can be dangerous and could result in injury or death.
  • Page 184 9. Use appropriate welding precautions and practices when welding. After welding, paint all affected areas with a rust inhibitor. NOTICE NOTICE Disconnect all TOPCON system electrical cables prior to welding on the machine. WARNING WARNING Do not weld near hydraulic lines or on any equipment when in operation.
  • Page 185 The warnings contained herein, therefore, are not all inclusive. If you use a tool, procedure, work or operating method other than those Topcon recommends, ensure the safety of yourself and those around you before continuing. P/N 7010-0341...
  • Page 186 Safety Precautions Notes: Topcon Paver System Five Operator’s Manual...
  • Page 187: Limited Warranty

    Components TOPCON warrants that the electronic components manufactured by TOPCON shall be free of defects in materials and workmanship for a period of one year from the original date of shipment to the dealer. TOPCON warrants that all valves, hoses, cables and mechanical...
  • Page 188: Service Information

    Limited Warranty consequential damages arising from the purchase or use of TOPCON’s components or any performance hereunder or any claims of negligence, even if TOPCON has been advised of the possibility of such damages. Service Information Service assistance can be provided by contacting your local TOPCON dealer or by calling the Corporate Service Center.
  • Page 189: Glossary

    lossary Aggregate Various hard, inert materials such as sand, gravel, pebbles, etc. used as the bulk material in asphaltic mixes. Angle of Attack The angle that exists between the bottom of the screed and the grade over which the screed is traveling. Auger The broad, spiral flange on a screed which rotates and spreads paving material evenly in front of the screed.
  • Page 190 Tracker. Conveyor The assembly used to move paving material from the hopper to the auger. Cross Slope The angle of slope required to produce a desired surface slope. Cross slope is measured in percent. Topcon Paver System Five Operator’s Manual...
  • Page 191 Glossary Crown The transverse contour of a finished mat. The contour of the screed plate. The transition line between 2 different slopes (i.e. between lanes or between lanes and shoulders). Lead Crown The contour or profile from side to side of the leading edge of the screed.
  • Page 192 Head of Material The volume of paving material directly in front of and across the entire length of the screed. Hopper The area at the front of the paving machine which receives the paving material. Topcon Paver System Five Operator’s Manual...
  • Page 193 Glossary Hydraulic Liquid in motion under pressure, the flow of which causes work to be accomplished. Hydrostatic Transmission Power transmitted by a positive displacement pump through a liquid under pressure to a positive displacement motor. Inclinometer See Slope Sensor Joint Matcher See Automatic Level Control Liquid crystal display.
  • Page 194 Rollers mounted at the front of the paver to control the contact area between he paver and the asphalt truck tires. Quarter Points Points on the screed midway between the center and the ends. Topcon Paver System Five Operator’s Manual...
  • Page 195 Glossary Ripples Short frequent changes in the elevation of a mat surface. Screed The assembly behind the tractor. The screed strikes off, smooths and compacts the paving material into a semi-finished mat. Screed Extensions Attachments for increasing screed width. Screed Heaters (Burners) Devices which preheat the screed plate to a temperature approximately that of the material to be laid.
  • Page 196 Wave Long repeating changes in the elevation of the mat surface. Working Window Adjustable region of measurement used by the Sonic Tracker II™ to determine if elevation correction is required. Topcon Paver System Five Operator’s Manual...
  • Page 197: Index

    ndex 1-2, 1-3 Components control box Air temperature laser tracker 1-4, 2-22, 6-1, compensating for slope sensor Smoothtrac SAS Arrows Sonic Tracker II and Cross Communication trackerjack and Set Mode 1-3, 4-2 Control box 4-24, 4-25 and Valve Offset and moisture grade adjustment 4-13 auto mode...
  • Page 198 Head of material, force M 4-14 Lower cylinder w/ jog button 4-12 Indicate button 4-13 Manual mode 4-12 Indicate mode 4-14 and jog button See also Manual mode Index 7-7–7-8 and paving 4-13 auto/manual button Topcon Paver System Five Operator’s Manual...
  • Page 199 changing mat depth 4-14 control 4-14 Raise cylinder w/ jog button 2-4, 5-9, 7-2 Mat depth 2-5, 2-9 Reaction of material, force R Menu settings Reference 4-16 default See Elevation reference 4-14 select Mix characteristics gradation 2-10 segregation 2-11 temperature 6-19–6-20 paver placement 6-13...
  • Page 200 Survey mode 1-3–1-5 System See also Components 2-22, 2-23, 6-1, 6-6 Temperature bail 5-4, 6-15 attach 2-23 2-22 Temperature changes 4-34 Test valves Tow point force P truck exchange Tow point path Trackerjack Index Topcon Paver System Five Operator’s Manual...
  • Page 201 Notes Notes: Notes www.topconpositioning.com...
  • Page 202 Notes Notes: Notes Topcon...
  • Page 204 Topcon Positioning Systems, Inc. 5758 W. Las Positas Blvd. Pleasanton, California U.S.A. Phone: 925 • 460 • 1300 Fax: 925 • 460 • 1315 ©2004 Topcon Corporation All rights reserved No unauthorized duplication P/N: 7010-0341 Rev. F Printed in U.S.A 04/04 450...

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