Terms and Conditions ............vii Manual Conventions ............ix Chapter 1 Introduction ............1-1 mmGPS 3D Paver Components ........1-1 Jobsite Components ............1-3 Hand-held Controller with Pocket-3D ...... 1-5 Machine Components ............1-6 Daily Care and Preventative Maintenance ...... 1-18 Chapter 2 Setting up the Jobsite and Pocket-3D ....
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Alignment Display Options ........3-40 Linework Display Options ......... 3-41 Point Display Options ..........3-42 Changing the Background Color ....... 3-43 Point Files ..............3-44 Exit 3DMC ..............3-45 Control Menu ..............3-45 Machine Setup ............3-45 mmGPS 3D Paver Reference Manual...
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Table of Contents Selecting a Machine Configuration ....3-46 Creating a Machine Configuration ..... 3-47 Steer Indication ............3-51 Steer to Polyline ............3-51 PZS-MC Receiver ............. 3-53 PZL-1 Transmitters ........... 3-54 Copying PZL-1 Transmitter Information ... 3-55 Calibrate Sensors (Averaging) ........3-56 Averaging Value Range: 1-100 ......
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3DMC Setup .............. 5-13 Setting up the PZL-1Transmitter in 3DMC ....5-14 Machine Sensor Calibrations ........... 5-15 Calibrating the Sensors Using the Slope Control Key 5-15 Setting the Valve Offsets ........... 5-16 GPS Localization .............. 5-18 mmGPS 3D Paver Reference Manual...
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Table of Contents Principles of GPS Localization ......... 5-18 Entering Localized GPS Coordinates ......5-20 Control Methods .............. 5-23 mmGPS Control ............5-23 Placing Transmitters at the Jobsite ..... 5-24 Using Multiple Transmitters ....... 5-26 Slope Control ............5-26 Sonic Control ............5-29 Laser Control .............
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UHF Radio Usage ............C-1 FCC Compliance .............. C-2 Community of Europe Compliance ........C-3 Canadian Emission Labeling Requirements ....C-3 WEEE Directive ............... C-4 Appendix D Warranty Terms ........... D-1 Appendix E Glossary ............... E-1 Index mmGPS 3D Paver Reference Manual...
Preface This manual has been developed to provide the operator with information necessary to operate and maintain TOPCON products. Proper service and use is important to the reliable operation of the equipment. The procedures described herein are effective methods for performing service and operation of this system.
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Preface Bluetooth® word mark and logos are owned by Bluetooth SIG, Inc. and any use of such marks by Topcon Positioning Systems, Inc. is used under license. Product and company names mentioned herein may be trademarks of their respective owners.
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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.
CAUTION performance, data integrity, or personal health. Notification that an action will result in system damage, loss of data, loss of warranty, or personal WARNING injury. Under no circumstances should this action be DANGER performed. mmGPS 3D Paver Reference Manual...
The mmGPS 3D Paver system provides multiple 3D and 2D options for control applications (Figure 1-1). Regardless of the option(s) selected, the control box analyzes design data and cross references it with current sensor data to provide real-time information for immediate operator and/or hydraulic response.
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Figure 1-2 displays the setup of components on a screed. 1. MC-2.5 GPS+ Receiver Box 2. 9168 Control Box 3. Laser Tracker & Trackerjack 4. mmGPS PZS-MC 5. Slope Sensor 6. Junction Box 7. Sonic Sensor II Figure 1-2. mmGPS 3D Paver Component Placements mmGPS 3D Paver Reference Manual...
The Base Station Kit (Figure 1-3) sends position Base Station Kit corrections to an unlimited number of machines or survey Rovers. The kit includes Topcon’s Legacy-E+ receiver (with PG-A1 antenna and external radio modem) or a HiPer brand receiver, tribrach, cables, and a hard carrying case.
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33ft in height. Up to four laser transmitters can be linked for use on large sites. Each PZL-1 laser transmitter also supports multiple rovers, even at different elevations for continuous production. Figure 1-5. PZL-1 Laser Transmitter mmGPS 3D Paver Reference Manual...
• Set up machine files for mmGPS equipment • Set up the PZS-1 sensor • Check the height of the transmitter • View a history of surface activity To enable Pocket-3D for mmGPS, contact your local Topcon representative to obtain the upgrade. P/N 7010-0781...
GPS vibration pole on the machine blade, and cables connect the receiver to the MC-2.5 Receiver Box for sending corrections to the 9168 control box. Dummy connectors are Sold Separately. They do not come in the Kit. NOTE mmGPS 3D Paver Reference Manual...
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Machine Components Figure 1-7. PZS-MC Machine Control mmGPS Sensor The GPS vibration pole (Figure 1-8) installs on GPS Vibration Pole the machine, sliding onto the pivot post attached to the tow arm. The GPS vibration pole provides a lightweight, fixed mount for the PZS- MC, and utilizes shock isolation and vibration dampening.
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SLOPE Figure 1-9. Slope Sensor The junction box (Figure 1-10 on mmGPS 3D Paver Junction Box page 1-9) allows the various components and hydraulics to be linked together for accurate paving. The junction box and associated cables are installed when first installing the system onto a Paver. No adjustments are necessary, but ensure that caps are in place on unused connectors.
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9168 Control Box is the operator’s interface, as well as the primary control for the mmGPS 3D Paver components. The 9168 control box combines the System Five platform with a computer graphic display into a single, rugged unit that provides dual hydraulic control for stakeless 3D GPS+, mmGPS, and 2D control.
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Introduction Figure 1-11. mmGPS 3D Paver 9168 Control Box The MC-2.5 Receiver Box MC-2.5 Receiver Box (Figure 1-12 on page 1-11) attaches to the machine with shock isolated magnetic mounts. No manual adjustments are required and it can be removed at the end of the day for storage.
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Machine Components 3DMC processes these real time measurements to compute paving and graphical mapping information. Figure 1-12. MC-2.5 Rover GPS Receiver Box Three LED indicators on the MC- MC-2.5 Receiver Box Functions 2.5 Receiver Box provides status on power, satellites, and radio signal (Figure 1-13 on page 1-12).
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Blink 3. GLONASS S/N ratios are good. Blink 4. Oscillator’s frequency offset is less than three ppm. Blink 5. Oscillator’s Allan Variance is better than 2.7e-10. Blink 6. Continuous tracking time is more than 15 minutes. mmGPS 3D Paver Reference Manual 1-12...
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Machine Components The color of the blink indicates that information for test is unavailable (orange), the receiver passed the test (green), or the receiver failed the test (red). 1. To switch to EIM, press and quickly release (within one second) the Main FN button.
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When the system has not been used for several days or months, the antenna might have been removed for storage or transportation. To reinstall the radio antenna, set it up as described above and ensure the magnet mount attaches to an even and smooth surface. mmGPS 3D Paver Reference Manual 1-14...
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Machine Components Rover Radio Antenna Figure 1-15. Machine Radio Antenna Setup The Simple Auto/Manual Knob Simple Auto/Manual Knob (Figure 1-16) mounts on the control lever for easy access and allows the operator to switch between Automatic and Manual control. • Automatic Control – Flip the switch forward to activate this control mode.
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A transducer, located in the bottom of the Tracker, generates sound pulses like a speaker and listens for returned echoes like a microphone. Figure 1-17. Sonic Tracker II mmGPS 3D Paver Reference Manual 1-16...
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(Figure 1-18) provides a sturdy, lightweight, fixed mount for the Laser Tracker and Trackerjack for use in rough applications. Figure 1-18. Trackerjack Vibration Pole Figure 1-19 shows the system configuration System Configuration for the mmGPS 3D Paver. Figure 1-19. mmGPS 3D Paver System Configuration P/N 7010-0781 1-17...
• Check the Sonic Tracker II™ Transducer daily to make sure the Filter Foam and Transducer are clean and free of debris. If the Filter Foam is clogged with dirt, replace it. If the Transducer appears to be covered with debris and performance is being mmGPS 3D Paver Reference Manual 1-18...
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Daily Care and Preventative Maintenance affected, clean or replace it using the steps listed in “Care and Maintenance of the Sonic Tracker” on page 6-9. P/N 7010-0781 1-19...
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Introduction Notes: mmGPS 3D Paver Reference Manual 1-20...
Chapter 2 Setting up the Jobsite and Pocket-3D Pocket-3D field software, which is required for some mmGPS operations, runs on a portable hand-held controller and uses files common with other equipment on the jobsite. Using Pocket-3D allows multiple users to work at the same time. Hand-held Controller and Pocket-3D Pocket-3D is grade and staking control software for hand-held...
Connect all Base Station components and cables. Select the correct radio settings. Refer to your Base Station’s documentation for specific radio configuration procedures. The Base and Machine must use the same radio settings. Initialize the Base station. mmGPS 3D Paver Reference Manual...
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Setting Up the Base Station Once you have set up the Base Station, simple checks at the machine ensure the machine receives corrections from the Base station: if the elevation control key is green, the Base Station is ready. Figure 2-2 on page 2-4 shows a completed Base Station setup. Use a plumb bob for quick and easy setup of the tripod, especially if the ground is uneven.
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Turn leveling screws A and B to move the bubble in the circular level. The bubble is now located on a line perpendicular to a line running through the center of leveling screws A and B. mmGPS 3D Paver Reference Manual...
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Setting Up the Base Station Leveling screw C Leveling screw A Leveling screw B Turn leveling screw C to center the bubble in the circular level. 5. Center Using the Plate Level. Rotate the instrument horizontally using the horizontal motion/ clamp screw and place the plate level parallel with the line connecting leveling screws A and B.
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Base Station. • For the PG-A1 Base Station, attach the radio modem, radio antenna, MC-2.5 Receiver Box, and power source (optional). • For the HiPer Lite+ Base Station, attach a power source (optional). mmGPS 3D Paver Reference Manual...
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Setting Up the Base Station PG-A1 Base Station with HiPer Lite+ Base Station Legacy-E+ GPS receiver Figure 2-3. Base Station Setup (Legacy-E+ or Step 3: connect component cables to the receiver HiPer Lite+), then connect the cables to other components (Figure 2-4 on page 2-8).
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LEDs are off. from the control point to the Step 5: measure the antenna height rim (slant) or ARP (vertical) of the antenna (Figure 2-5 on page 2-9). This measurement is used when initializing the Base Station. mmGPS 3D Paver Reference Manual...
Setting Up the Base Station HiPer Lite+ PG-A1 Slant Height Vertical Height to Edge of to ARP Antenna Vertical Height Slant Height to SHMM to ARP Station Marker Station Marker Figure 2-5. Measure Base Station Antenna Height Base Station Initialization Before initializing the Base Station, check the Units used in the current jobsite (Setup Units) and that the correct Control Point file is selected (Data Control).
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Base Station converts the Base to a Rover. CAUTION 7. Check that the TX LED on the Base radio flashes once a second. This indicates data transmission. Figure 2-6. Enter Base Station Information and Start Base – PG-A1 and Legacy-E+ Example mmGPS 3D Paver Reference Manual 2-10...
Base Station once using Pocket-3D. The Topcon receiver remembers the initial settings. However, if any setting stored in the receiver has been changed or initialized (like a reset function), you need to re-initialize the Base Station.
(Figure 2-7 on page 2-13). To assign a channel to the transmitter, press the channel button until the corresponding LED lights up. 4. Connect the transmitter and Pocket-3D controller (Figure 2-7 on page 2-13). mmGPS 3D Paver Reference Manual 2-12...
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Setting up PZL-1 FC-100 Press button to select channel for transmitter. Connect Pocket-3D controller and transmitter. Figure 2-7. Setup PZL-1 Laser Transmitter, Select Channel, and Connect Controller 5. In Pocket-3D, check that a mmGPS-enabled machine configuration is loaded. Then tap Setup mmGPS Transmitters to set up from one to four transmitters.
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• Transmitter – select the ID of the transmitter • Control Point – select the control point over which the transmitter is set up • TX height – enter the height of the transmitter mmGPS 3D Paver Reference Manual 2-14...
Equipment Setup: GPS • Measured to – select where on the transmitter (Base or Mark/ Slant) the height was measured 8. If needed, repeat steps 6 and 7 for up to three other transmitters. 9. Press OK when done. Figure 2-9. Enter Transmitter Channel and Control Point Data Equipment Setup: GPS Equipment setup consists of jobsite files to ensure correct data is used for positioning activities and a machine file to ensure the correct...
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2. Tap Add to enter the local coordinates for the control point. 3. Enter a name and description for the control point and its local coordinates. Press Ok. 4. Repeat steps 2 and 3 for each control point. 5. Press Ok to save the data. mmGPS 3D Paver Reference Manual 2-16...
Equipment Setup: GPS Figure 2-11. Enter Control Points Step 2: Setup and Initialize a Base Station/Transmitter For a GPS Base Station, enter antenna and radio information (Figure 2-12 on page 2-18): 1. Connect the controller and receiver. Tap Setup Base station. 2.
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3. Tap the Channel tab and press Edit Channel to select the channel, the transmitter description, the transmitter ID, and the control point over which the transmitter is installed. Enter the height of the tripod. mmGPS 3D Paver Reference Manual 2-18...
Equipment Setup: GPS 4. Press Ok. Transmitter information is stored in the control point file; copy this file to the machine for mmGPS grading applications. Figure 2-13. Enter Base Transmitter Information Step 3: Create a Range Pole Equipment Configuration Pocket-3D creates an equipment configuration for a range-pole Rover (Figure 2-14 and Figure 2-15 on page 2-20).
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5. For a mmGPS Rover (PZS-1 and receiver), enter mmGPS parameters. Refer to the Pocket-3D User’s Manual for important information about these settings. Press Next. 6. Select the configuration and press Ok. Press Yes (Figure 2-16 on page 2-21). mmGPS 3D Paver Reference Manual 2-20...
Equipment Setup: GPS Figure 2-16. Enter Radio (and mmGPS Information); Set As Equipment Step 4: Setup the Rover Radio Configuring the range pole Rover radio (Figure 2-17) ensures proper communication with the Base. 1. Tap Setup Radios. 2. Select the radio type and enter its communication settings. If needed, press Configure to select the channel.
For mmGPS, setup the mmGPS receiver (Figure 2-19). 1. Tap Setup mmGPS receiver. 2. Enter mmGPS parameters. See Pocket-3D or 3DMC manuals for important information about these settings. Press Ok. Figure 2-19. Enter mmGPS Information for mmGPS Rover mmGPS 3D Paver Reference Manual 2-22...
Equipment Setup: GPS Step 7: Connect to the Rover After setting up the rover, connect to the GPS receiver to begin using Pocket-3D at the jobsite (Figure 2-20). 1. On the main screen, tap the GPS setup button. 2. Once the connection has been established, press Ok. Notice that the GPS setup button changes color from red to green, indicating successful communication between the Base and Rover.
3. Check the local coordinates and press the GPS tab. Figure 2-21. Select Control Point to Localize 4. Enable “Use horizontal” and “Use Vertical” and press Measure. Press Ok to save the measurement (Figure 2-22). Figure 2-22. Measure Control Point mmGPS 3D Paver Reference Manual 2-24...
Creating Files in Pocket-3D 5. Repeat steps 2, 3, and 4 for each control point. 6. View the results and press Ok to save the control point file (Figure 2-23). Figure 2-23. Localized Control Points Creating Files in Pocket-3D In preparation for collecting point and polyline data, create a points file and a linework file for the jobsite.
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Press Ok (Figure 2-25). 5. Repeat step 4 for any other layers. 6. Press Ok to save the file. Press Yes to apply the file to the current jobsite. Figure 2-25. Add Layers to Points File mmGPS 3D Paver Reference Manual 2-26...
Creating Files in Pocket-3D Creating a Linework File 1. Tap Data Linework [<none> or file name]. Press New (Figure 2-26). 2. Enter a name for the linework file and press Ok. 3. Press Layers. Figure 2-26. Create Linework File 4. Press New. Enter a name for the layer and the layer’s parameters. Press Ok (Figure 2-27).
2. Set up the PZS-1 sensor. Power on the sensor and receiver. Connect the sensor and Pocket-3D controller. Use a bi-pole to ensure the sensor remains steady throughout the calibration process. mmGPS 3D Paver Reference Manual 2-28...
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mmGPS Operations with Pocket-3D 3. Walk several feet away from the transmitter and face the sensor towards the transmitter (Figure 2-28). 10 ft Figure 2-28. Setup Transmitter and Sensor 4. In Pocket-3D, tap Setup mmGPS transmitters. 5. On the Channel tab, press Edit Channel. 6.
2. Set up the PZS-1 sensor over a known point. Power on the sensor and receiver. Connect the sensor and Pocket-3D controller. Use a bi-pole to ensure the sensor remains steady throughout the calibration process. 3. In Pocket-3D, tap Setup mmGPS transmitters. mmGPS 3D Paver Reference Manual 2-30...
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mmGPS Operations with Pocket-3D 4. On the Channel tab, press Edit Channel. 5. Press Benchmark check (Figure 2-30). 6. On the transmitter height dialog box, select one of the following and press Start to measure (Figure 2-30). During the measurement, the Measuring dialog box displays. •...
Use a bi-pole to ensure the sensor remains steady throughout the calibration process. Hold Plumb Beam Key, then turn on power ~50 m (100 ft) ~50 m (100 ft) Figure 2-32. Setup Transmitter and Sensor mmGPS 3D Paver Reference Manual 2-32...
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mmGPS Operations with Pocket-3D 5. In Pocket-3D, tap Setup mmGPS transmitters and press TX Calibration (Figure 2-33). If indicated, check the setup listed on-screen (Figure 2-33). Figure 2-33. Begin Field Calibration Adjustment 6. If needed, adjust the height of the sensor so the angle is less than 1°.
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• If either or both Axis measurements are more than 10'', disconnect from the sensor and connect to the transmitter. Press Finish to upload the adjustments to the transmitter. When finished uploading, the transmitter applies the adjustments and turn off. mmGPS 3D Paver Reference Manual 2-34...
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mmGPS Operations with Pocket-3D Figure 2-36. Adjustment Results After loading the new self-leveling offset data into the transmitter, re-calibrate to check the system. The transmitter may need to be calibrated a couple of times depending on site conditions. Note that this process only applies an offset to the self-leveling mechanism to ensure correct grade, the control point file is not affected.
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Setting up the Jobsite and Pocket-3D Notes: mmGPS 3D Paver Reference Manual 2-36...
Chapter 3 Setting up the Machine and 3DMC The components of the mmGPS 3D Paver provide real-time elevation and slope information to the 9168 control box. The control box then takes this information and applies various algorithms to calculate and display accurate, current surface information.
Setting up the Machine and 3DMC 9168 Control Box Buttons and Features The control box is the operator’s interface to mmGPS 3D Paver, receiving signals from the sensors, and using these signals to determine if grade or slope corrections are necessary. If the machine...
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9168 Control Box Buttons and Features automatic grade control. The AUTO LEDs are independent of each other. The grade indicators visually translate, in real Grade Indicators time, the distance of the screed to on-grade. Table 3-1 describes the visual patterns to on-grade. Table 3-1.
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They also illuminate to indicate that you can use the grade adjustment knobs to change values while in adjustment and calibration modes. Rotate Knob Rotate Knob Counterclockwise Clockwise To To Reach Grade Reach Grade Figure 3-2. Grade Adjustment Arrows mmGPS 3D Paver Reference Manual...
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9168 Control Box Buttons and Features This window allows an internal optical Brightness Sensor Window sensor to measure ambient light, providing automatic adjustment of the display’s backlight. Blocking the brightness sensor may cause incorrect adjustments of the display’s brightness level. NOTE The touch screen display provides textual Touch Screen Display...
When copying files to or deleting files from a compact flash card, the control box screen displays an hourglass, indicating the system is busy. Once the hourglass goes away, you can remove the compact flash card. mmGPS 3D Paver Reference Manual...
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9168 Control Box Buttons and Features Occasionally, the control box may not properly detect the compact flash card during a hot-swap NOTICE procedure. If this occurs, simply turn off and restart the control box. The card can be damaged if you remove it before completing the copying/deleting process.
Connectors The connectors (Figure 3-5) supply power to the mmGPS 3D Paver machine and link system sensors and components installed on the machine with the 9168 control box.
The main screen (Figure 3-6) displays a graphical view of the current design surface, the machine, and status information of connected components. Topcon Logo Key Zoom In Zoom Out Slope Control Key Elevation Control Key Figure 3-6.
Setting up the Machine and 3DMC • Topcon Logo Key – provides access to menus that control a variety of functions. See “Topcon Logo Key” on page 3-12 for more information on the key and its menus. • Zoom In Key – increases the magnification of the design view each time you tap this key.
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3DMC • Delete – Removes an existing file or element from the internal memory. To delete a file or select it and press the Delete key. Once you delete a file, it no longer exists. The file NOTICE must be created from the beginning. •...
Figure 3-8. Keyboards Topcon Logo Key The Topcon Logo key at the top right corner of the Main Screen displays a pop-up bar of four menus: File, Control, Tools, and View. To access the Topcon Logo menus, tap the Topcon Logo in the far right corner.
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3DMC Table 3-3 describes the functions available under each menu. Table 3-3. 3DMC Menus Description Menu Available Functions File menu • creating, editing, and deleting control point files • creating, editing, and selecting working and reference (design) surface files • selecting alignment files •...
Control Point Files The first task, when setting up the mmGPS 3D Paver on a new jobsite, is to create a new Control Point file. You can use either the machine to create a control point file, or copy a control point file from a Pocket-3D controller.
File Menu Selecting a Control Point File 1. When the 3DMC main screen displays, press Topcon Logo File Control. 2. Select the control point file for the jobsite and press Ok (Figure 3-10). Figure 3-10. Applying a Control Point File...
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5. Enter the following information for the control point (Figure 3-13 on page 3-17): • Name – enter a unique name • Site coords – enter the coordinates for northing (N), easting (E) and elevation (Z) mmGPS 3D Paver Reference Manual 3-16...
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File Menu • WGS84 – if you have precise GPS coordinates, enter the coordinates for latitude (Lat), longitude (Lon) and height (Hgt) • Localization check boxes – only enable these if currently performing a GPS localization 6. Press Ok to save this control point. Figure 3-13.
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Data entry errors have a direct affect on paving NOTICE accuracy. You must press Ok to save the file. Failure to do so results in losing all information and require you to NOTICE repeat the process. mmGPS 3D Paver Reference Manual 3-18...
GPS Localization GPS Localization After you have setup all the hardware components and initialized the Base Station, you need to localize the GPS coordinates to the jobsite’s coordinates. This section gives information on the principles of GPS localization and entering GPS localization, into the Control Box. Principles of GPS Localization The GPS+ system is capable of precise positioning, but the positions it computes are relative to a global reference system defined in terms...
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NEZ coordinates. A control point file can be localized using one of the following methods: • Measuring each control point with a Topcon GPS+ or GPS RTK Survey Rover System and Pocket-3D. Then entering this information into 3DMC.
GPS coordinates directly into the 9168 control box. One of the following sources can measure points and provide coordinates: • Each control point is measured with a Topcon GPS+ or GPS RTK Survey Rover System and Pocket-3D. • A third party source provides GPS coordinates.
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6. Tap the two GPS localization check boxes to enable (check) them for performing the GPS localization mathematical conversion (Figure 3-16). Figure 3-16. Control Point Coordinates and GPS Localization 7. Press Ok to return to the Control point files dialog box. mmGPS 3D Paver Reference Manual 3-22...
GPS Localization 8. Repeat step 4 and step 7 on page 3-22 for all listed control points. When finished, check the horizontal (H.Error) and vertical (V.Error) values listed on the Control points dialog box. They should be within acceptable tolerances (Figure 3-17). Figure 3-17.
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• Subgrade of existing road – Creates a surface with a cross slope different from the design road surface. For most road surfaces, the cross slopes for the finish design surface is different from the subgrade design slopes. mmGPS 3D Paver Reference Manual 3-24...
GPS Localization Working Surface Display Options When using a TIN surface model file, press Topcon Logo View Display options Working surface to display the Working surface dialog box (Figure 3-18). Figure 3-18. Working Surface Display Options This dialog box has the following selections for displaying information on the main screen (Figure 3-19 on page 3-26): •...
When setting up 3DMC design files, first select the working surface then select the reference surface. 1. On the 3DMC main screen, press Topcon Logo File Surfaces Working. 2. Select the working surface file for the jobsite and press Ok (Figure 3-20 on page 3-27).
Occasionally, a flat or sloping plane surface may need to be adjusted to fit current conditions at the jobsite. 1. On the 3DMC main screen, press Topcon Logo File Surfaces Working or Reference. 2. Select the plane surface file and press Edit (Figure 3-22 on page 3-28).
The flat plane surface model is composed of a reference elevation point through which the plane intersects. The operator should be prepared with the elevation reference point to fulfill the requirements for creating the surface. mmGPS 3D Paver Reference Manual 3-28...
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1. Press Topcon Logo File Surfaces Working or Reference and press New. Enter and select the following information for the new surface file. Press Next (Figure 3-24).
• a crossfall grade and • a reference elevation point on the plane. Just like aligning the rotating laser plane and adjusting the laser receiver height, the operator needs to be prepared with a set of mmGPS 3D Paver Reference Manual 3-30...
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1. Press Topcon Logo File Surfaces Working or Reference and press New. Enter and select the following information for the new surface file. Press Next (Figure 3-27 on page 3-32).
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B point coordinates separately. Also, it allows the operator to manually type in a grade by pressing the entry box. A positive sign (+) designates an upgrade from A to B, and the negative (-) sign designates a downgrade from A to B. mmGPS 3D Paver Reference Manual 3-32...
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GPS Localization View Measured Mainfall Direction and Grade Figure 3-28. Measure Points A and B to Determine Mainfall 6. Press the Crossfall Grade entry box and enter a crossfall (Figure 3-29). The crossfall grade is the grade that falls across at a 90° angle to the line of Mainfall (see Figure 3-26 on page 3-31), and together with the Mainfall, determines the plane with the compound slope.
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10. Review the created surface plane (Figure 3-31 on page 3-35). If needed, press Back to change parameters or measurements for the surface. Press Next. 11. Press Finish to save the new surface file and end the process. mmGPS 3D Paver Reference Manual 3-34...
3DMC so that the cut/fill reference is from 0 (zero) rather than from -6” (negative six). 1. Press Topcon Logo File Surfaces Working or Reference and press New. Enter and select the following information for the new surface file. Press Next (Figure 3-32 on page 3-36).
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This value is applied to the centerline of the working/reference surface. • A negative number lowers the subgrade in comparison to the working/reference surface. This value is applied to the centerline of the working/reference surface. mmGPS 3D Paver Reference Manual 3-36...
This function is only available if the reference surface is a road surface. 1. Press Topcon Logo File Surfaces Working or Reference and press New. Enter and select the following information for the new surface file. Press Next (Figure 3-34 on page 3-38).
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(lateral offset from centerline). The left/right grade is copied from the existing road. 4. Select the slope extension for both the left and right side (Figure 3-35 on page 3-39). mmGPS 3D Paver Reference Manual 3-38...
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GPS Localization • If selecting Vertical, the cross section of the subgrade stops at the same horizontal offset as the cross section of the reference surface. • If selecting Continue, the last element of both surfaces selected in the “Maximum extension” entry box is continued. Select this option if there are more intersection points expected beyond the end of the cross section.
Figure 3-36. New Road Subgrade Alignment Display Options When using either a road surface model or an alignment file, press Topcon Logo View Display options Alignment to display the Alignment dialog box (Figure 3-37). Figure 3-37. Alignment Display Options This dialog box has the following selections for displaying information on the main screen: •...
• Show station labels – displays station labels for each station on the Main Screen. Linework Display Options When using a Linework file, press Topcon Logo View Display options Linework to display the Linework layers dialog box (Figure 3-38). Figure 3-38. Linework Layers Linework files contains layers composed of a group of lines, each identified with a color.
2. Press Ok to return to the Main Screen (Figure 3-39). Figure 3-39. Linework Display – Main Screen Point Display Options When using a Point file, press Topcon Logo View Display options Points to display the Points dialog box (Figure 3-40). Figure 3-40. Points Display Options Point files contain information about surveyed points and may represent topographic information, control coordinates, “as-build”...
Select a color that contrasts with on-screen information. 1. To change the background color of the Main Screen, press Topcon Logo View Display options Background color. 2. Select a color and press Ok (Figure 3-42 on page 3-44). P/N 7010-0781...
Setting up the Machine and 3DMC Figure 3-42. Color Selections Point Files Points can represent topographic information, backup control coordinates, “as-build” information, and so forth. See “Creating a Points File” on page 2-25 for more information. mmGPS 3D Paver Reference Manual 3-44...
Control Menu Exit 3DMC To exit mmGPS 3D Paver, tap Topcon Logo File Exit 3DMC (Figure 3-43). Figure 3-43. Exit 3DMC Control Menu In the Control menu, you can create, edit, copy, and delete machine setup files. If a road file is selected as the reference surface, you can set road subgrade properties.
Use the Edit button on the Machine files dialog box to view the selected configuration’s setup screens and parameters. 1. On the 3DMC main screen, press Topcon Logo Control Machine setup. 2. Select the machine file and press Ok (Figure 3-44).
Control Menu Creating a Machine Configuration 1. When the main screen displays, press Topcon Logo Control Machine setup. 2. Press New and enter or select the following information (Figure 3-45). Then press Next. • Configuration name – enter a name for the machine Include the application and/or sensor type in the machine name to easily identify the configuration.
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Incorrect measurements or data entry errors have a direct affect on paving accuracy. Take each NOTICE measurement twice to ensure accuracy. 4. Select the GPS precisions for measuring moving and static points. Press Next to continue (Figure 3-47 on page 3-49). mmGPS 3D Paver Reference Manual 3-48...
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Control Menu Figure 3-47. Enter GPS Precisions 5. Select the following radio information and press Next (Figure 3-48). • Radio type – use the same radio type used in the Base setup. • Connected to – the serial port the radio is connected to, usually Serial Port B.
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This option works well at large (300m) distances and steep angles. Figure 3-49. Enter Lazer Zone Information for mmGPS Configurations 7. Press Finish to save the machine configuration file. mmGPS 3D Paver Reference Manual 3-50...
Steer to Polyline 1. Press Topcon Logo File Linework, select the Linework file for the job, and press Ok. 2. Press Topcon Logo View Display options Linework and select the polylines to display.
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Stationing Grade at edge Figure 3-50. Steer to Polyline 5. Press Topcon Logo Control Steer indication to change the following (Figure 3-51). Press Ok when done. • Point of interest – the edge of the screed side of the machine to steer from •...
PZS-MC sensor. The original settings (from the machine configuration file) are restored after turning off the 9168 control box. 1. At the control box, press Topcon Logo Control PZS-MC receiver and select the following receiver parameters (Figure 3-53 on page 3-54): •...
PZL-1 Transmitter information is saved in the control point file. Ensure the correct control point file is selected for the jobsite. 1. Press Topcon Logo Control PZL-1 transmitters. 2. Tap the channel tab that corresponds to the channel at the transmitter (Figure 3-54 on page 3-55).
To copy transmitter information from an existing control point first make sure the control point file has been copied to the file, control box from Pocket-3D. 1. Press Topcon Logo Control PZL-1 transmitters. 2. Tap the Transmitters tab and press Copy (Figure 3-55 on page 3-56). P/N 7010-0781...
A larger value averages more elevation measurements, making the system less reactive to fluctuations in grade, such as with laser “beam-bounce” on windy days. Averaging does not affect slope control. NOTICE mmGPS 3D Paver Reference Manual 3-56...
1. Raise the screed so that both sides rest a few inches above the ground. 2. At the control box, tap Topcon Logo Control Valve offsets. Since the screed is about to move, automatically, DANGER HANDS and FEET should be clear of the screed! 3.
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Figure 3-57. Setting Valve Offset Values 5. Press the Set key for each of the remaining selections, repeating step 3 on page 3-57 and step 4 above until all four valve offsets are complete. mmGPS 3D Paver Reference Manual 3-58...
1. Tap Topcon Logo File Point files to display the Point files dialog box. Create a new point file or select an existing point file. Press Ok to return to the Main Screen.
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Figure 3-58. Enter Parameters for a Topo Survey 3. Press Ok to start the topo survey function. 4. Begin paving. When the machine begins to move, 3DMC begins measuring and logging the data. mmGPS 3D Paver Reference Manual 3-60...
Position Check The position check option provides a daily benchmarking tool to verify that the calculated elevation and position are repeatable. 1. To check the position of the screed, press Topcon Logo Position check. The Position Check dialog box displays Tools (Figure 3-60 on page 3-62).
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3. When finished, the Position Check dialog box displays the point on the job at the selected edge of the blade (Figure 3-61). Press Cancel to return to the Main Screen. Figure 3-61. Position of Point of Interest mmGPS 3D Paver Reference Manual 3-62...
Base Station. 1. Press Topcon Logo Tools Configure radio and press Configure (if available) to run the radio setting program. 3DMC may take a few seconds to a few minutes to connect to the radio module and check the current setting.
• display the Profile, Section, Light bar, or Cut/fill history (for mmGPS applications) from the Lower window • select Display options for various data, depending on the files selected for display • view 3DMC information, authorization codes, and options. mmGPS 3D Paver Reference Manual 3-64...
Display options for the main window include a Plan view, a Section view, and a Profile view. To access the selected main window view, press Topcon Logo View Main window (Figure 3-64), then tap the appropriate view; a check mark indicates the active view.
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(Figure 3-67) displays a side view of the machine The Profile view where the right side of the screen is always the forward direction of machine travel. Figure 3-67. Profile View on Main Window mmGPS 3D Paver Reference Manual 3-66...
Display options for the left window include a Profile view, a Section view, and a Grade indicator. To access the lower window view, press Topcon Logo View Left window (Figure 3-68), then tap the view you want; a check mark indicates the active view.
Only the grade indicator is available as a view in the right window. To access the right window view, have the Plan view visible and press Topcon Logo View Right window (Figure 3-70), then tap the view you want; a check mark indicates the active view. None indicates no right window is active.
Section view, a Cut/fill history view for mmGPS applications, and a Light bar. To access the lower window view, press Topcon Logo View Lower window (Figure 3-72 on page 3-70), then tap the view you want; a check mark indicates the active view. None indicates no lower window is active.
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GPS readings. The red line indicates mmGPS detection; the blue line indicates GPS only detection. In the example below, the background color of the main screen was changed to better display the cut/fill history. mmGPS 3D Paver Reference Manual 3-70...
“Changing the Light Bar Scale” on page 3-75. Figure 3-73. Lower Window Views Display Options To set the type of units used in the job, press Topcon Logo View Display options Display units to display the Display Units dialog box (Figure 3-74 on page 3-72).
• Coordinates – select either North-East-Elev, East-North-Elev, or X-Y-Z. Figure 3-74. Display Units About 3DMC To view About 3DMC information, press Topcon Logo View About 3DMC. The About 3DMC dialog box displays the version number, copyright date and publisher, and registered user (Figure 3-75).
The Grade Indicator acts as an infinitely scrolling grade tape, and displays the amount of cut or fill in regards to the design surface. To view the grade indicator, press Topcon Logo View Left or Right window Grade indicator. This process applies to both the left and right Grade Indicators.
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1.25Ft, even if elevation reference (red arrow) is on the right edge of the screed. Figure 3-77. Example: Grade Indicator and In From Left Edge Cut/fill mmGPS 3D Paver Reference Manual 3-74...
• Single number – in 2D control, displays the current elevation setting, and can be changed at any time. • Elevation Control Key color – the background color of the elevation control key indicates sensor status. – Green: indicates sensor status suitable for paving. mmGPS 3D Paver Reference Manual 3-76...
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Elevation Control Key – Red: indicates an error status and automatic control will be disabled. – Orange: in mmGPS applications, indicates low GPS precisions. • Icon color – for mmGPS applications, the icon color will be BLUE when the system is receiving a mmGPS signal, and GRAY when a mmGPS signal is unavailable.
• Zero – sets the elevation set point value to zero. • GPS info – displays the GPS information dialog box; see “Viewing GPS Information” on page 3-82 for details. Figure 3-82. Adjust Elevation Dialog Box – mmGPS Control mmGPS 3D Paver Reference Manual 3-78...
Elevation Control Key Adjust Elevation in 2D Control To display the following elevation settings for 2D applications (Figure 3-83), press the Elevation Control Key: • Elevation (left edge) – disabled for 2D control. • Elevation (right edge) – disabled for 2D control. •...
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Ok (Figure 3-85). A negative value is a Cut; a positive value is a Fill. Figure 3-85. Use Numeric Keyboard to Change Offset 4. Press Ok to set the new offset value and return to the 3DMC Main Screen. mmGPS 3D Paver Reference Manual 3-80...
Elevation Control Key Adjusting Valve Gain A Valve Gain adjustment allows the operator to speed up or slow down the response of the hydraulic valves, and can be adjusted on the fly while in Automatic Control. • If the screed seems to be moving too slow and the Grade Indicators take too long to reach on-grade, increase the gain value to cause the hydraulics to respond faster.
To view the GPS information dialog box and tabs, press the Elevation control key, then press the GPS info button (Figure 3-88). Figure 3-88. View GPS Information The following sections describe the GPS information tabs. mmGPS 3D Paver Reference Manual 3-82...
Elevation Control Key GPS Status and Quality The Fix tab displays satellite status and positioning quality based on GPS satellites currently being tracked (Figure 3-89). Once a GPS solution is initialized, 3DMC reports the Fix status. The positioning quality is an estimation computed from valid satellite status (RMS: Root Mean Square).
(type, latency, and quality) for the GPS receiver in the MC-2.5 Receiver Box. • Reset RTK – press to reset RTK ambiguities. • Reset receiver – press to clear all data and reset all settings stored for the MC-2.5 Receiver Box. mmGPS 3D Paver Reference Manual 3-84...
Elevation Control Key Figure 3-92. GPS Info – Info Tab Satellite Planning Information The Planning tab displays the estimated grading precisions on an hourly scale (Figure 3-93). • Press the Next key to display the chart for the next day. •...
1. To view information about 3DMC, press Topcon Logo View About 3DMC. The about 3DMC dialog box displays version number, copyright date and publisher, and registered user (Figure 3-94).
Viewing and Updating 3DMC Options 6. Press Ok to apply the new codes and options. Press Ok on each screen to return to the Main Screen. 7. Turn off the control box, wait a couple seconds, and then turn on the control box to activate the new passwords.
• Color of Slope Key – the background color of the Slope Control Key indicates sensor status. – Green: indicates sensor status suitable for paving. – Red: indicates an error status and Automatic Control is disabled. mmGPS 3D Paver Reference Manual 3-88...
Slope Control Key Type of Control Application Angle of Blade Design Cross Slope Figure 3-97. Slope Control Key Adjust Slope in mmGPS Control To display the following slope settings for mmGPS applications (Figure 3-98 on page 3-90), press the Slope Control Key: •...
• Survey – used to quickly lock the screed on-grade. • Change to Elevation – used to switch to 2D elevation control. mmGPS 3D Paver Reference Manual 3-90...
Slope Control Key Figure 3-99. Adjust Slope Dialog Box – 2D Control Setting the Slope Offset and Locking On-grade 1. Press the Slope Control key, then press the Blade slope Set key. Enter the slope offset using the pop-up keyboard or the up/down arrows (Figure 3-100).
To change the elevation side of the machine to slope, (Figure 3-86 on page 3-81) 1. Press the Elevation Control key. 2. Press Change to Slope to use the slope method for control. mmGPS 3D Paver Reference Manual 3-92...
Chapter 4 Paving Principles This chapter describes the components of pavers and the basics in paving principles. Paver Components Modern pavers (Figure 4-1) consist of two major units: the tractor and the screed. The primary function of the tractor is to propel the truck or paver feeding device, to convey and distribute the paving material, and to tow the screed.
• If the screed angle of attack is increased, the screed rises, increasing the mat thickness (Figure 4-3). • If the screed angle of attack is decreased, the screed settles, providing a thinner mat surface (Figure 4-3). Figure 4-3. Screed Determines Mat Thickness mmGPS 3D Paver Reference Manual...
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Paver Components Because the screed floats, it does 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 4-4). • If the tow point is changed by a unit of one, the paver must move one tow arm length before the screed corrects 63% of the elevation.
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Check several spots to get an average (Figure 4-6). If an elevation change is made, wait 3 tow arm lengths for full correction. Too much cranking and stabbing causes raising and lowering changes that produces an uneven mat surface. Figure 4-6. Checking Mat Thickness mmGPS 3D Paver Reference Manual...
Paver Components The screed has four main forces acting on it at all times, whether paving in manual or with automatics (Figure 4-7). A change in any one of the forces causes the screed to rise or fall, changing the mat depth.
Avoid trucks pulling away prior to completely dumping all material. Use a dump person to monitor and regulate truck movements in front of the paver. mmGPS 3D Paver Reference Manual...
Paver Components Head of Material (“M”) One of the primary functions of the paver tractor is to convey and distribute paving material onto the ground in front of the entire width of the screed. This material, once deposited in front of the screed is the head of material over which the screed passes.
“R”). The key element to bear in mind is that the screed passing over the paving material compacts the material to a certain degree. Variables in the resistance of the material to compactive forces causes changes in the screed’s angle of attack, mmGPS 3D Paver Reference Manual...
Paver Components which in turn affects mat thickness and therefore, mat smoothness (Figure 4-12). Reaction of Material Under Screed (Force "R") Figure 4-12. Reaction of Material Under Screed Gradation Mix Characteristics This aspect of the paving material varies according to the intended use of the material as a base course, binder course, or the final wearing surface.
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“Center Streak” segregation is also caused by feeder gates being set too low. Adjust as necessary to provide sufficient uniform material at the center of the paver. “Center Streak” segregation can be limited and NOTICE even eliminated by slowing paving speed. mmGPS 3D Paver Reference Manual 4-10...
Paver Components Mix Temperature Characteristics A common paving problem is inconsistent temperatures in the asphalt mix. As the material cools it loses its viscosity making it more difficult to compact. If the resistance to compaction increases, the screed naturally increases its angle of attack and begin to float up. This changes the mat depth, resulting in bumps in the surface.
An extended screed has fewer psi, which means less compaction, causing the screed to raise. Figure 4-14. Width of Screed Affects Weight of Screed mmGPS 3D Paver Reference Manual 4-12...
Paver Components Quality of Base Being Paved There are factors other than the four main forces that can have an effect on the quality of the mat. An important one is the quality of the base to be paved. It makes more sense to build smoothness from the base up, than to try to smooth a road in the last lift of paving.
Controlling Mat Quality The primary purpose of the asphalt paver is to place a smooth mat of material. The primary function of mmGPS 3D Paver is to control the vertical position of the screed in relation to the surface being paved.
This chapter is designed to get the paving crew started using the mmGPS 3D Paver system. The job application and the actual results determines what type of controls should be used; that is, mmGPS, sonic, slope, or laser.
Base Station is ready. See “Setting up the Jobsite and Pocket-3D” on page 2-1 for more information on using Pocket-3D to set up the jobsite using for mmGPS-3D Paver. mmGPS 3D Paver Reference Manual...
Equipment Setup and Calibration: PZL-1Transmitter Equipment Setup and Calibration: PZL-1Transmitter For machine control applications, the PZL-1 transmitter attaches to either a standard tripod or a fixed 2m tripod over a surveyed point. To locate the transmitter over an unknown point, see “Performing a Resection”...
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Figure 5-1. Setup PZL-1 Laser Transmitter, Select Channel, and Connect Controller 5. In Pocket-3D, check that a mmGPS-enabled machine configuration is loaded. Then tap Setup mmGPS Transmitters to set up from one to four transmitters. mmGPS 3D Paver Reference Manual...
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Equipment Setup and Calibration: PZL-1Transmitter 6. On the Transmitters tab, select the connection method used between the controller and transmitter. Then perform one of the following functions (Figure 5-2): • To load transmitter data for the first time – tap Download to retrieve calibration data from the connected transmitter.
Connect the Control Box to the machine and connect the cables. Accurately measure the PZS-MC Sensor on the machine. Set up 3DMC for the machine and jobsite. Select the PZL-1 Transmitter for the jobsite. mmGPS 3D Paver Reference Manual...
Equipment Setup: Machine Components PZS-MC Setup After mounting the PZS-MC receiver to the vibration pole, use 3DMC to configure the receiver for the machine. Figure 5-7 on page 5-11 shows the mounting and cable connections for the PZS-MC receiver. The PZS-MC receiver has the following setup requirements: NOTICE •...
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Getting Started LED's FORWARD Level GPS Vibration Pole Figure 5-4. Level the GPS Vibration Pole and Attach the PZS-MC Sensor mmGPS 3D Paver Reference Manual...
Equipment Setup: Machine Components Screed and Antenna Measurements Take the following measurements for the antenna and machine; record these measurements for entering into 3DMC (Figure 5-5): • Above (1) – enter the vertical distance from the metal rim of the antenna to the bottom edge of the screed (when elevated to the proper mat thickness).
To reinstall the radio antenna, set it up as described above and ensure the magnet mount attaches to an even and smooth surface. Rover Radio Antenna Figure 5-6. Machine Radio Antenna Setup mmGPS 3D Paver Reference Manual 5-10...
Equipment Setup: Machine Components MC-2.5 Receiver Box Setup for mmGPS Applications The MC-2.5 Receiver Box is designed for quick attachment at the beginning of the day and quick removal at the end of the day. When connecting cables to the receiver box (Figure 5-7), ensure that the cables do not impede machine operation.
(Figure 5-8). 2. Connect the various electrical cables (Figure 5-8). Power Cable to Junction Box Communication Cable to Junction Box Cable to MC-2.5 Receiver Figure 5-8. Attach 9168 Control Box to Machine and Component Cables mmGPS 3D Paver Reference Manual 5-12...
3DMC machine and job files. Chapter 2 describes in more detail the items in the following checklist. Select the correct Machine Configuration file. Topcon Logo Control Machine setup Select the Control Point file. Topcon Logo File Control Select the Working and/or Reference Surface files.
PZL-1 Transmitter information is saved in the control point file. Ensure the correct control point file is selected for the jobsite. 1. Press Topcon Logo Control PZL-1 transmitters. 2. Tap the channel tab that corresponds to the channel at the transmitter (Figure 5-9).
Machine Sensor Calibrations Machine Sensor Calibrations Calibrating machine components ensures accurate, consistent, and efficient paving. Operators or technicians perform calibrations in the following instances: • Upon initial installation of machine components. • After servicing the system, performing maintenance, or replacing a component.
If valve offsets are set too low, the screed will not reach on-grade. Likewise, if the valve offsets are set too high, the screed moves too far and overshoot on-grade. mmGPS 3D Paver Reference Manual 5-16...
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1. Raise the screed so that both sides rest a few inches above the ground. 2. At the control box, tap Topcon Logo Control Valve offsets. 3. Press the Raise left Set button to enable the entry box and calibrate the left valve offset value (Figure 5-11).
To be useful for local site work, global GPS coordinates need to be converted into local site coordinates, defined in terms of a distance north and east of some origin point and some distance above an elevation datum. These north, east, and elevation coordinates (often mmGPS 3D Paver Reference Manual 5-18...
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MC-2.5 Receiver Box to local NEZ coordinates for a particular project. The following steps help to ensure a high-quality localization suitable for centimeter-level machine paving with mmGPS 3D Paver. • First, the surveyor’s local Control Points must be precisely measured. The quality of measurements directly affects paving accuracy.
GPS coordinates directly into the 9168 control box. One of the following sources can measure points and provide coordinates: • Each control point is measured with a Topcon GPS+ or GPS RTK Survey Rover System and Pocket-3D. • A third party source provides GPS coordinates.
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GPS Localization 2. Press Topcon Logo File Control. The Control point files dialog box displays (Figure 5-13). 3. Select the correct control points file, and press Edit. The Control points dialog box displays, listing all control points for the file and jobsite (Figure 5-13).
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9. Press Ok until you return to the 3DMC main screen, saving the control point localization information and the control points file. At this time, make a backup copy of the control point file on a CF card. mmGPS 3D Paver Reference Manual 5-22...
Control Methods Control Methods The following sections describe the four types of control possible with the mmGPS 3D Paver: mmGPS, slope, sonic, and laser. mmGPS Control mmGPS uses Topcon’s unique LazerZone™ technology to produce millimeter accuracy. LazerZone technology combines the simplicity...
On small projects, place the laser transmitter off the working area (Figure 5-17 on page 5-25). The working distance from your laser will indicate the type of project (small or large). mmGPS 3D Paver Reference Manual 5-24...
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Control Methods 2000' Figure 5-17. Laser Transmitter Placement – Small Project On larger projects, place the laser transmitter in the center of the project to maximize the area you can pave and minimize the distance from the laser (Figure 5-18). 2000' 2000' Figure 5-18.
Figure 5-19. Multiple Laser Transmitter Placement Slope Control mmGPS 3D Paver uses a slope sensor mounted to the transducer beam on the paver to measure and control the slope of the mat being laid (Figure 5-20 on page 5-27). The sensor contains an electronic level vial, that acts as a “precision carpenter’s level”.
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Control Methods Figure 5-20. Position of Slope Control on Paving System If the slope changes, or to make required slope changes, do the following: • If the required slope changes, (while in automatic mode) the two point cylinder on the slope side will raise or lower until the slope sensor measures the new slope (Figure 5-21 on page 5-28).
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Getting Started Figure 5-21. 9168 Control Box Directing Where the Slope Sensor Paves mmGPS 3D Paver Reference Manual 5-28...
Control Methods Sonic Control The Sonic Tracker II™ measures and controls the elevation of the machine, controlling grade from a physical grade reference, such as a curb, stringline, or existing road surface. The Sonic Tracker II sends out sound pulses 39 times per second. As soon as the Tracker sends out a sound wave, it starts a stop watch.
(Figure 5-23). Figure 5-23. 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 5-24 on page 5-31). mmGPS 3D Paver Reference Manual 5-30...
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Control Methods Figure 5-24. Laser Control – Above Grade As the screed is lowered the beam of light hits the laser receiver above the center, a raise signal is indicated (Figure 5-25). Figure 5-25. Laser Control – Below Grade P/N 7010-0781 5-31...
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Getting Started Notes: mmGPS 3D Paver Reference Manual 5-32...
Chapter 6 2D Paving Applications The type of controls you should use for paving depends on the end result or the finished product you want. Some projects require smoothness and improved rideability. Others are concerned with mat thickness, and some require new asphalt to match curb and gutter or existing grades.
1. Position the machine next to the reference. 2. Bend the L-bars to align in the same direction and fold inward towards the screed (Figure 6-1). Loosen the clamp handles if needed. Figure 6-1. Align L-bars mmGPS 3D Paver Reference Manual...
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Using Sonic Control at the Jobsite 3. Connect the coil cord to the Sonic Tracker (Figure 6-2). Figure 6-2. Attach Coil Cord to Tracker 4. Bolt the Tracker to the bracket, and visually check to get the L-Bar and Tracker plumb (Figure 6-3 on page 6-4). 5.
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Although the Tracker can be set as close as 14 inches and as far as 55 inches from the grade reference, consider the job application for the best set up. For example, when tracking multiple references—using elevated string on one pass, then matching mmGPS 3D Paver Reference Manual...
Using Sonic Control at the Jobsite ground on the next pass—consider the Tracker position so it works for both applications without having to move the Tracker. CURB Figure 6-4. Position L-Bar and Tracker Over Grade Reference Step 2: Set up 9168 Control Box After attaching the control box to the machine and connecting cable, configure 3DMC for paving with the Sonic Tracker.
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Communication Cable to Junction Box Cable to MC-2.5 Receiver Figure 6-5. Attach 9168 Control Box to Machine and Attach Component Cables 3. Turn on the control box. When 3DMC starts up, press Topcon Logo Control 2D Control to activate 2D control mode (Figure 6-6).
Figure 6-7. Select Machine Configuration File 3DMC Operations for Sonic Tracker Applications When using the mmGPS 3D Paver system for 2D control applications, only the Control menu, the View menu, the Elevation Control key, and the Slope Control key are relevant to 2D control applications.
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Ok to set this as the machine for the job. You must press Finish to save the file. Failure to do so results in losing all information and require you NOTICE to repeat the process. mmGPS 3D Paver Reference Manual...
Care and Maintenance of the Sonic Tracker Care and Maintenance of the Sonic Tracker The following guidelines provide for trouble-free operation: • Clean and dry all components prior to placing them into the carrying case. • Ensure that protective connector caps, provided on some components, are in place when not using the cables.
2. Remove the four screws and the black retaining ring. Remove and discard the “O”-Ring (Figure 6-10 on page 6-11). Always remove and discard used “O”-Rings. Used “O”-Rings are distorted and can loose elasticity due NOTICE to weather or exposure to diesel fumes. mmGPS 3D Paver Reference Manual 6-10...
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Care and Maintenance of the Sonic Tracker The Transducer Replacement Kit includes an “O”-Ring and four replacement screws; however, use the original screws and keep the four supplied in the kit for replacements in the event one or more are lost. Figure 6-10.
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Place the Ty-Wrap in the slot next to the elevated (gray wire) tab, tighten and trim. DO NOT pinch the wires (Figure 6-12 on page 6-13). mmGPS 3D Paver Reference Manual 6-12...
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Care and Maintenance of the Sonic Tracker CAR EFULL Y PLACE WIRE CONNEC TOR S ON T A BS TRIM EXCESS TY- WRAP PLACE NE W T Y-W RAP AROUND WIRES AND TIGHTEN Figure 6-12. Replace Transducer, Connectors, and Ty-Wrap 5.
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Loctite® attacks and degrades the plastic retaining NOTICE ring. Over tightening the screws can distort the transducer metallic material and may crack the NOTICE retaining ring. The “O”-ring provides tightness while preventing vibration from loosening the mounting screws. mmGPS 3D Paver Reference Manual 6-14...
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Care and Maintenance of the Sonic Tracker Figure 6-14. Replace and Tighten Mounting Screws 8. Ensure the metallic surface inside the transducer has no visible wrinkles. If distortion is evident, repeat step 5 on page 6-13 to step 8. Place a new filter foam over the transducer. The Sonic Tracker II is now ready for operation.
3. Press the Elevation Control key (Figure 6-17 on page 6-17). 4. Enter an offset value into the Elevation set point Set entry box. 5. Press Survey to quickly lock on-grade. 6. Press Ok to return to the Main Screen. mmGPS 3D Paver Reference Manual 6-16...
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Paving City Streets with Sonics Figure 6-17. Set the Depth of Asphalt to be Laid 7. Switch the A/M Knob into automatic and begin paving. Check the depth of mat at centerline and verify joint matches at lip of gutter. After compaction, make the necessary adjustments. If the road width varies, it is easier to keep the tracker over the gutter if the tracker is mounted to the extension on the paver.
Figure 6-19. Paving with Cross Slope If the curbs are at different elevations, a .36 foot rise at centerline produces incorrect slopes (Figure 6-20). .36'RISE 2.3% 1.7% 36.0' Figure 6-20. Curbs with Different Elevations mmGPS 3D Paver Reference Manual 6-18...
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Paving City Streets with Cross Slope When the system is used to pave a true 2.0% slope, the crown of the street is not at the centerline (Figure 6-21). Centerline at 2.0% Grade Cut 2.0% Original Centerline Figure 6-21. 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.
Figure 6-24. Checking Curb Elevations 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. mmGPS 3D Paver Reference Manual 6-20...
Paving Streets Through Intersections Method 1 for Paving Intersections For this method, the base of the intersecting road is used as the reference. 1. With both sides in elevation control, pave to the intersection (Figure 6-25). Figure 6-25. Paving Through Intersections 2.
1. Take a section of 1/8” diameter string and nail or secure it to the curb. 2. Pull the string tight through the intersection and nail or secure it to the other curb (Figure 6-28 on page 6-23). mmGPS 3D Paver Reference Manual 6-22...
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Paving Streets Through Intersections If the intersecting road has a crown, hike the stringline up in the middle of the road to place the string at the proper height. A hub or a stake with a piece of wire to hold the stringline works fine. Figure 6-28.
2. Press the Slope Control Key to switch from slope to elevation control on the control box. 3. Press Survey on the Adjust Elevation dialog box to survey the tracker on-grade (Figure 6-30 on page 6-25). mmGPS 3D Paver Reference Manual 6-24...
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Paving Intersections with Cross Slope Figure 6-30. Switching to Elevation Control and Surveying On-grade 4. Pave through the intersection with the sonic tracker in automatic (Figure 6-31). Figure 6-31. Paving Through Intersection 5. Upon reaching the end of the intersection (Figure 6-31), switch the A/M Knob into manual.
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To get back to the correct slope, continue paving in automatic and slowly dial the display to the slope you want. Failing to survey when changing back to slope control could result in a bump in the mat. mmGPS 3D Paver Reference Manual 6-26...
In general, as long as you follow the maintenance and safety instructions provided in this manual, you should have few problems with your mmGPS 3D Paver system. This chapter helps you diagnose and solve some common problems you may encounter with the various components.
Check that the power cable is correctly incorrectly connected connected to the battery—RED to positive or damaged. and BLACK to negative—and that the battery is charged. If the power cable is damaged, contact your dealer to purchase a new cable. mmGPS 3D Paver Reference Manual...
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Base Station The radio receives Some radios do not require a separate power through the power supply, but are supplied power Legacy-E+ receiver. through the port on the Legacy-E+. For these radios, check that the Legacy-E+ is also switched on. Problem Pocket-3D does not connect to Legacy-E+ or Hiper Lite+.
Check that connected. the cable is properly connected The control box does The MC-2.5 Receiver Box turns on only not have power. while the control box is powered on. mmGPS 3D Paver Reference Manual...
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MC-2.5 Receiver Box The MC-2.5 Receiver If power is supplied through another cable Box receives power connected to the power port, check that the from another source, origin of the power cable, and other which is not on. connectors, are secure. The power cable may be connected to an ignition switch or a master circuit on the machine, if so, turn on the power source.
The Control Point may Move to an alternative Control Point or be located too close to have the surveyor place a new Control obstructions. Point away from the obstructions. mmGPS 3D Paver Reference Manual...
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GPS Localization The Rover GPS+ has The status indicates “waiting for better not yet initialized; the precision”. The Rover GPS+ may take system may be several minutes to initialize. tracking many satellites. The range-pole was Make sure that the pole is held steady while unsteady.
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Points are measured and used for the GPS check boxes may not localization. This troubleshooting is useful have been selected. when the Pocket-3D is being used to perform GPS localization as well as the control box. mmGPS 3D Paver Reference Manual...
9168 Control Box 9168 Control Box This section lists possible 9168 control box problems you may encounter. If you still have problems after trying the solutions listed here, contact TPS customer support. Problem Control box does not power on. Causes Solutions The cable is the wrong Check that the power cable supplies 12 to...
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2. Look for the folder named “Disk C”, and double-tap on it. 3. Look for the “Control Box” icon and double-tap on it. The application program opens and returns to the Main Screen. mmGPS 3D Paver Reference Manual 7-10...
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9168 Control Box Problem “Control file has no GPS localization” message. Causes Solutions Not enough Control Press the Ok pad to exit the message Points used for screen. Check that the Control Points file localization. used has a minimum of three localized points.
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See “Equipment Setup and Initialization: Base Station” on page 5-2 and “Equipment Setup: Machine Components” on page page 5-6 for information. mmGPS 3D Paver Reference Manual 7-12...
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9168 Control Box Problem Elevation Control key displays: “Waiting for Initialization” Causes Solutions The MC-2.5 Receiver Check that the rover GPS antenna has a Box has not been clear view of the sky. successful tracking Check for obstructions, such as trees, enough valid satellites.
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Junction Box to connect the coil cord. Wrong control mode Deactivate 2D Control Mode: tap Topcon selected. Logo Control 2D Control. mmGPS 3D Paver Reference Manual...
3. DO NOT attach system brackets or hose connections while the machine is running. 4. DO NOT allow any mmGPS 3D Paver system component to limit the visibility of the operator. 5. Use Ty-wraps, supplied with the mmGPS 3D Paver system, to keep hoses and wires secured and away from possible wear or pinch points.
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10. To prevent vandalism or theft, do not leave removable Topcon components on the machine at night. Remove the components each evening and store appropriately in the carrying case.
$82,500, confiscation of surveying equipment and legal action, if the rules are ignored. Topcon cannot obtain the license for the user. There are companies to assist with licensing. Two are listed here: • Professional Licensing Consultants Inc.
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Safety Information Notes: mmGPS 3D Paver Reference Manual...
Appendix B Specifications The sections in this appendix give the features and specifications for the physical components of the mmGPS 3D Paver system. Control Box The 9168 control box is backward compatible with System Four+ and System Five sensors and remote switches. Table B-1 lists specification details for the 9168 control box.
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For the tones, beeps, and chimes of audible alerts Computer Board 300 MHz processor 28 MB SDRAM Operating System Microsoft Windows® CE.NET™ Figure B-1 shows the dimensions of the 9168 control box. 10.68 7.20 7.40 Figure B-1. Control Box Dimensions mmGPS 3D Paver Reference Manual...
Table B-3 lists specification details for the Simple Auto/Manual Knob. Table B-3. Simple Auto/Manual Knob Specifications Details Profile Epoxy Switches One for switching between Auto and Manual control Mounting Threads .375-16 x.60 inch deep course threads mmGPS 3D Paver Reference Manual...
MC-2.5 Receiver Box Figure B-3 shows the dimensions of the Simple A/M Knob: Ø0.5 Figure B-3. Simple Auto/Manual Knob Dimensions MC-2.5 Receiver Box The MC-2.5 Receiver provides the industry’s most advanced GLONASS and GPS dual-frequency satellite tracking system in a heavy-duty construction design with a shock absorbing mounting bracket.
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Up to 38400 bps RTK Update Rate 10 Hz GPS+ Tracking 20 channels GPS L1+L2+GLONASS Channels Figure B-4 shows the dimensions of the MC-2.5 Receiver Box: 6.75 14.75 11.5 Figure B-4. MC-2.5 Receiver Box Dimensions mmGPS 3D Paver Reference Manual...
PZS-MC Sensor PZS-MC Sensor The PZS-MC sensor combines the MC-A1 GPS antenna with laser sensor technology. The sensor attaches to a GPS vibration pole on the machine blade, and cables connect the receiver to the control box. Table B-5 lists specification details for the PZS-MC Sensor. Table B-5.
Weight 29.0 lbs (13.0 kg) Figure B-6 shows the dimensions of the GPS Vibration Pole: Ø2.0" Ø1.75" ± .015 30" 92" CABLE MOUNT MOUNTING POST 2.00 12.5" Ø4.5" 11.5" Figure B-6. GPS Vibration Pole Dimensions mmGPS 3D Paver Reference Manual...
Trackerjack Vibration Pole Trackerjack Vibration Pole The Trackerjack Vibration Pole has a lightweight, shock isolation, and vibration dampening design and is reinforced for rough applications. Table B-7 lists specification details for the Trackerjack Vibration Pole. Table B-7. Trackerjack Vibration Pole Specifications Housing Base: Cast aluminum;...
Supply Voltage 10 to 30 VDC Operating Current Typical: 200 mA Operating 0 to +60 deg C (32 to 140 deg F) Temperature On-grade Zone +/- 0.013ft (variable with beam spot) Beam Acceptance 360° mmGPS 3D Paver Reference Manual B-10...
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Laser Tracker Figure B-8 shows the dimensions of the Laser Tracker: Figure B-8. Laser Tracker Dimensions P/N 7010-0781 B-11...
24 VDC for 9220 Operating Current Typical: 0.5A Maximum: 10.5A Operating 0 to +60 deg C (32 to 140 deg F) Temperature Figure B-9 shows the dimensions of the Trackerjack: Figure B-9. Trackerjack Dimensions mmGPS 3D Paver Reference Manual B-12...
Sonic Tracker II Sonic Tracker II The Sonic Tracker II™ has ruggedly sealed electronics, a field replaceable sonic transducer, and temperature compensation for atmospheric disturbances that contribute to industry standard accuracies. With bright grade indication lights and a patented working window, it’s easy to use and see for controlling grade. Table B-10 lists specification details for the Sonic Tracker II™.
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Specifications Figure B-10 shows the dimensions of the Sonic Tracker II: Figure B-10. Sonic Tracker II Dimensions mmGPS 3D Paver Reference Manual B-14...
Appendix C Regulatory Information The following sections provide information on this product’s compliance with government regulations for use. UHF Radio Usage Using a UHF radio requires a license. Operating a UHF radio without a license may result in fines or NOTICE other penalties.
• Consult the dealer or an experienced radio/television technician for additional suggestions. Any changes or modifications to the equipment not expressly approved by the party responsible for CAUTION compliance could void your authority to operate such equipment. mmGPS 3D Paver Reference Manual...
Community of Europe Compliance Community of Europe Compliance The product described in this manual is in compliance with the R&TTE and EMC directives from the European Community. Canadian Emission Labeling Requirements 1. Operation is subject to the following two conditions: (1) this device may not cause interference, and (2) this device must accept any interference, including interference that may cause an unwanted operation of the device.
For more detailed information about the take-back and recycling of this product, please contact your supplier where you purchased the product or consult. mmGPS 3D Paver Reference Manual...
1. The warranty against defects in Topcon battery, charger, or cable is 90 days. P/N 7010-0781...
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Warranty Terms Service assistance can be provided by Service Information contacting your local TOPCON dealer or by calling the Corporate Service Center. Phone: (800) 443-4567 8 a.m. to 5 p.m. Pacific Time Monday through Friday FAX: (925) 460-1329 Travel charges are applied for any on-site service whether warranty or non-warranty in nature.
Automatic Grade and Slope Controls Sensing equipment used on paving machines to set and maintain proper elevations and percent slope. The mmGPS 3D Paver system provides paver operators with automatic grade and slope control. Bail A wire frame added to the Tracker that acts as a fixed target to compensate for rapid air temperature changes.
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The transition line between two different slopes (that is, between lanes or between lanes and shoulders). Density Compactness of paving material. Elevation The vertical height or depth of the surface being laid. Elevation is measured in centimeters, inches, or feet. mmGPS 3D Paver Reference Manual...
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Liquid Crystal Display. LCD is used in the display window on the 9168 Control Box and Sonic Tracker II™ to show numbers and symbols for mmGPS 3D Paver functions. Light Emitting Diodes. These are the red lights seen on the faces of the PZS-MC Sensor, the PZL-1 Laser Transmitter, the 9168 Control Box, the Sonic Tracker II™, and the Laser Tracker.
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A means for controlling the transverse elevation of the fresh laid mat in relation to the grade. Slope Sensor An electrical device which detects positive and negative change in lateral elevation using the grade controlled side of the machine as a reference. mmGPS 3D Paver Reference Manual...
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Glossary Thickness Control Screws The adjusting crank located at the rear of each side arm, used to control the angle of attack of the screed. Tow Points (Pull Points) The points where the side arms of the screed are attached to the Tractor unit.
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Glossary Notes: mmGPS 3D Paver Reference Manual...
Index Index Numerics 2D Components A and B point measurements 3-32 Sonic Tracker II About 3DMC 1-16 3-86 Trackerjack Vibration Pole Adjust slope 1-17 5-15 See also removable components Alignment files and grading 1-18 3-51 2D control display options 3-40 machine configuration files Angle of attack 3-45,...
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Index Creating a Machine Configuration 3-47 Configuration name 3-47 Change Location 3-47 color 3-25 Machine type 3-47 radio channel 3-63 Radio information 3-49 units 3-71 Type of antenna 3-47 Change the light bar scale 3-75 Units of measure 3-47 Changing Offsets Creating a sloping plane surface 3-30 using the Elevation Control key...
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Index change on-grade 3-75 cut/fill 3-73 Edit files 3-10 display 3-68 Editing a Plane Surface File 3-27 purpose 3-73 1-12 Grade indicators LED blink indications 1-13 Elevation adjust for 3D 3-78 adjust in 2D 3-79, 3-89, 3-90 Head of material, force M 3-76 Elevation reference 3-74...
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1-13 Main screen components display elevation control key 3-10 Offset 3-76, 3-78 slope control key 3-10 change 3-80, 3-81 Topcon logo key 3-10 On-grade zoom in 3-10 zoom out 3-10 Manual control Simple A/M Knob control 1-15 Paver Components Manual mode...
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Index Points performing 2-28 display Reset receiver 3-43 3-84 Polylines Right window 3-68 steer to See also Views 3-51 Position check 3-61 purpose 3-61 power switch Satellites 3-85 PZL-1 Transmitter Satellites, GPS 3-84 setup in 3DMC 3-54, 5-14 Screed PZL-1 transmitter information and angle of attack copying 3-55...
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3-66 right window 3-68 Teledesign radio 1-10 section view 3-66 Test 1-12 1-12 Tools menu 3-13 Topcon logo 3-12 Warranty Terms Topo survey Warranty terms display points 3-43 Weight of screed, force W 4-5, 4-12 Topographic survey 3-59–3-61 Working distance...
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