Leica PowerGrade User Manual
Contents
1. PowerGrade k MCP1300 Control panel 764836 MMB1300 Cradle 764910 External Multi Switch 764850 Cross slope sensor 767439 Rotation sensor 767435 Laser receiver 760862 Power mast manual mast 760863 764847 Sonic tracker 764031 MJB1301 Junction box Grader 767438 Hydraulic valve Machine battery 39 Operation PowerGrade Dozer Setup 8 a b c d h aj f g h i j k 40 MCP1300 Control panel 764836 MMB1300 Cradle 764910 External Switch for Dozer 764849 Laser receiver 760862 Power mast manual mast 760863 764847 MJB1300 Junction box Dozer 767437 Machine battery Hydraulic valve Cross slope sensor 767439 Remote junction box 764856 Remote display 764841 3 1 General information Periodic checks 3 2 Transport in the field Transport in a road vehicle Shipping Care and Transport Care and Transport General Notices Servicing the system only requires a minimum of time All electronic components are enclosed in robust housings to safeguard them against mechanical damage If any PowerGrade components are subjected to severe impact be sure to check for proper operation prior to performing any work with the system Transport When transporting the equipm2. N Warning Safety Directions If the product is operated with connecting cables attached at only one of their two ends for example external supply cables interface cables the permitted level of electromagnetic radiation may be exceeded and the correct functioning of other products may be impaired Precautions While the product Is in use connecting cables for example product to external battery product to computer must be connected at both ends PowerGrade 33 Safety Directions 4 7 N Warning N Warning PowerGrade 54 FCC Statement Applicable in U S This equipment has been tested and found to comply with the limits for a Class B digital device pursuant to part 15 of the FCC rules These limits are designed to provide reasonable protection against harmful interference in a residential installation This equipment generates uses and can radiate frequency energy and if not installed and used in accordance with the instructions may cause harmful interference to radio commu nication However there is no guarantee that interference will not occur in a particular installation If this equipment does cause harmful interference to radio or television reception which can be determined by turning the equipment off and on the user is encouraged to try to correct the interference by one or more of the following measures e Reorient or relocate the receiving antenna e Increase the separation between the equ
3. KM a Side View b String PowerGrade a Side View b Edge 29 Operation Setting up the Tri Sonic PowerGrade 30 Setting up the Tri Sonic Sensor over a reference When setting the Tri Sonic sensor over a reference string curb or previous pass the best performance will be achieved when the sensor Is positioned square to the reference not turned or leaning Setup over a curb When setting the Tri Sonic sensor over a curb it is generally recommended to use the GROUND mode and use the flat surface of the gutter as the reference as shown here Setup over an EDGE Use of the curb edge as a reference requires extra care be taken to ensure a proper distance and control of PowerGrade system Unlike a string or a flat surface a curb edge can present some special problems It is best that this mode be used only by experienced operators Over any reference It is important to rotate and roll the blade of the motorgrader to its approximate working position before setting and adjusting the Tri Sonic sensor the blade edge and the refer ence 2 4 Set up and operation Level 1 Level 2 CE Operation Swap Function The swap function allows the operator to quickly and easily swap sensors turn the machine around and grade in the opposite direction by following the previously pass There are two levels to the swap function available e Level 1 Swap the cro
4. lt 500 mA Dimensions 28 x 12 x 7 2 cm without mounting bracket Weight 2 5 kg incl clamp Detection angle 360 Linear detection height 190 mm Operating range 300 m radius Accuracy dead bands 1 2mm 2 mm 3 11 mm 4 15 mm 5 25 mm Sensor pick up range 18 5 cm Parameter Specification Laser requirement All Rotating Lasers HeNe or Infrared Laser diodes visible and invisible Pulsed display 5 pulses per second CS The Laser sensor can be used for manual visual control by connecting directly to the battery r nsor Cross slope senso Dan ates Specification Voltage range 12 24 V DC nom Nominal voltage 24 V DC Range 10 V 30 V Power consumption lt 0 25 Dimensions 15 3 x 8 7 x 3 9 cm Weight 0 855 kg Accuracy cross slope 0 1 slope at 25 Working range 80 Interfaces CAN MIL FOAHONSENSO Parameter Specification Voltage range Power consumption Technical Data PowerGrade 12 24 V DC nom Nominal voltage 24 V DC Range 10 V 30 V lt 0 25 A 67 Technical Data Environmental specifi cations PowerGrade 68 Parameter Specification Dimensions 16 0 x 22 6 x 5 9 cm Weight 1 56 kg Working range 0 360 Temperature Type Operating temperature C Storage temperature C PowerGrade control panel 20 to 60 30 to 70 PowerGrade cradle 20 to 60 30 to 70 Juncti
5. Leica PowerGrade User Manual Version 1 2 English when it has to be right eca Geosystems Introduction Introduction AW Product identification PowerGrade 2 Congratulations on your purchase of a PowerGrade system The PowerGrade system is an ideal tool for increasing productivity in all aspects of the construction earthmoving industry This manual contains important safety directions as well as instructions for setting up the system and operating it Refer to 4 Safety Directions for further information Read carefully through the User Manual before you switch on the product To ensure safety when using the system please also observe the directions and instructions contained in the User Manual and Safety Handbook issued by the e Machine manufacturer The type and serial number of your products are indicated on the label on the base of the unit Enter the model and serial number in your manual and always refer to this information when you need to contact your agency or Leica Geosystems authorized service workshop Type PowerGrade control panel Serial No 0 PowerGrade Cradle Serial No 2 Symbols Validity of this manual Introduction The symbols used in this manual have the following meanings Type Z Danger N Warning N caution CE Description Indicates an imminently hazardous situation which if not avoided will result in death or serious injury Indicates a potentially hazard
6. Operation is subject to the following two conditions 1 This device may not cause harmful interference and 2 this device must accept any interferences received including interference that may cause undesired operation 58 Labelling PowerMast DBA mr WEmin lt nOmO Type MPM700 Art No 760863 Power 10 30V 0 2A max S No Leica Geosystems AG CH 9435 Heerbrugg 123456 Manufactured 2007 Made in Denmark This device complies with part 15 of the FCC Rules Operation is subject to the following two conditions 1 This device may not cause harmful interference and 2 this device must accept any interferences received including interference that may cause undesired operation Safety Directions PowerGrade 59 Safety Directions PowerGrade 60 Labelling Tri Sonic Art No Type MUS1300 766992 Power 11 30V 0 5A max S No Leica Geosystems AG 123456 CH 9435 Heerbrugg Manufactured 2008 Made in Switzerland KK C Patents U S 5 327 345 4 733 355 This device complies with part 15 of the FCC Rules Operation issubject to the following two conditions 1 This device may not cause harmful interference and 2 this device must accept any interf ences received including interference that may cause un sired operation Labelling rotation sensor Safety Directions PowerGrade TYPE MRS1300 Art No Power 12 24V DC 64 max 761010 Leica Geosystems AG S No CH 9
7. The product Is not to be operated until the user has been Instructed on how to work with it N Warning Safety Directions Unauthorized modification of building and constructions machines by mounting or installing the product may alter the function and safety of the machine Precautions Follow the instructions of the machine manufacturer If no appropriate instruction is avail able ask machine manufacturer for instructions before mounting or installing the product PowerGrade 45 Safety Directions PowerGrade 46 4 3 Limits of Use Environment Suitable for use in an atmosphere appropriate for permanent human habitation not suitable for use in aggressive or explosive environments Z Danger Local safety authorities and safety experts must be contacted before working in hazardous areas or in close proximity to electrical installations or similar situations by the person in charge of the product 4 4 Manufacturer of the product Manufacturers of non Leica Geosystems accessories Person in charge of the product N Warning N Warning N Warning Safety Directions Responsibilities Leica Geosystems AG CH 9435 Heerbrugg hereinafter referred to as Leica Geosystems is responsible for supplying the product including the user manual and original accessories in a completely safe condition The manufacturers of non Leica Geosystems accessories for the product are responsible for developing implementing and
8. avail able ask the machine manufacturer for instructions before mounting the product Special keys Up key Down key Enter key Auto Manual key Menu key Sensor select key Fuction keys Display a Left on grade indication b Right on grade indication d Above grade c Side shift alignment indication e Below grade Product Overview PowerGrade Product Overview PowerGrade 10 Cradle b c a Power and data transfer LED indicators b Holding magnets c On off switch d Release key for control panel Getting Started System start To get the system started complete the following steps 1 Snap control panel onto cradle To connect the control panel to the cradle 1 Put the control panel on the holding hooks in the bottom of the cradle 2 Then snap the control panel onto the cradle by pressing it towards the cradle Product Overview PowerGrade 11 Product Overview PowerGrade 12 2 Turn on the control panel To turn the system on and off use the power switch on the right side of the cradle This is the master switch for the entire system CS Removing the panel will also turn off the power CS To release the control panel simply press the release key at the bottom of the cradle and pull the control panel towards you and then lift it up 1 3 Sensor setup keys External Multi Switch for Grader Product Overview Sensor Setup Keys The sen
9. changing the elevation reference Operation PowerGrade 33 Operation 2 6 How to set 3D sensors PowerGrade 34 3D Sensors To select 3D Height press the left or right sensor key once and then press the Adjust function key to enter the adjust menu Note that it s only the current selected sensor in either left or right side that is adjusted If the 3D system is configured to indicate which sensor is currently in use select AUTO If not then select either TRACKER or GPS from the menu _ a 10 Height Once Auto GPS Tracker is selected it is required to EXIT from this menu for the change to take effect and then re enter the menu to adjust gains Gains need to be set for both GPS or Tracker depending on which sensor is used If AUTO is selected the PowerGrade will use the gains set in the Tracker and GPS settings Use the right arrow key to enter the gains settings Refer to chapter 2 7 Setting the Value for Gain and Deadband for configuring Gains To select 3D Slope Press the left or right sensor key once and then press the Adjust function key to enter the adjust menu Note that it s only the current selected sensor in either left or right side that is adjusted Set gains for 3D Slope as explained in chapter 2 7 Setting the Value for Gain and Dead band Operation PowerGrade 35 Operation 2 7 Adjust the gain and deadband DEADBAND PowerGrade 36 Setting the Value for G
10. point the laser beam is lost while the control panel is set in auto mode it will give a beep and a red cross will appear with a text message saying laser beam lost Laser Sensor and To use the Laser Sensor with a manual mast for controlling the elevation of the blade manual mast complete the following steps 1 Select the Laser Sensor on one of the sides 2 Place the cutting edge of the blade at the desired height 3 Move the mast up or down until the Laser Sensor detects the laser beam Continue to move the mast until the indication led s on the Laser Sensor is showing a green line 4 Press the left A key to set the machine in Auto Mode 5 When the control panel is in Auto Mode the machine will start to move the raise lower hydraulic cylinders so that the laser beam always is in the center of the Laser Sensor Laser Sensor and To use the Laser Sensor with a power mast for controlling the elevation of the blade power mast complete the following steps 1 Select the Laser Sensor in one of the sides 2 Place the cutting edge of the blade at the wanted height 3 Enter SEEK mode 4 Press the D or key to tell the mast in which direction it should start to seek The mast will now move in the given direction until the Laser Sensor detects the laser beam and has it in the center of the sensor 5 Press the left 12 key to set the machine in Auto Mode 6 The D and keys can now be used to move the mast up or down and thereby
11. product Precautions Deflect the mechanically moving machine components as far as possible and define a safe installation zone Beware of inadequate steering if machine is defective like after a crash or other damaging events or alterations to the machine Precautions Periodically perform control measurements and field adjustments on the machine as speci fied in the User Manual While working construction and grading should be checked by appropriate means for example spirit level tachymeter before and after important meas uring tasks While steering or navigating the machine accidents may occur due to a the operator not paying attention to the surroundings persons ditches traffic etc or b malfunctions of a system component interference etc Precautions The operator assures that the machine is operated guided and monitored by a qualified user e g driver The user has to be able to take emergency measures for example an emergency stop N Warning N caution Z Danger Safety Directions The absence of instruction or the Inadequate imparting of instruction can lead to Incorrect or adverse use and can give rise to accidents with far reaching human material financial and environmental consequences Precautions All users must follow the safety directions given by the manufacturer and the directions of the person responsible for the product Watch out for erroneous measurement results if the pro
12. 435 Heerbrugg samy XXXXXXXX Manufactured 2008 I Made in Denmark nce comolies with part 15 of the 61 Safety Directions Labelling cross slope sensor PowerGrade TYPE M551300 Power 12 247 DC 64 max Leica Geosystems AG CH 9435 Heerbrugg s Manufactured 2008 ef Made in Denmark A 62 Art No 764842 S No KAAARA AA 5 1 CE System accuracy PowerGrade control panel PowerGrade cradle Technical Data Technical Data PowerGrade Technical Data The PowerGrade system Is designed to operate from standard vehicle power systems at 12V DC or 24V DC check to ensure proper connection and polarity 3mm Standard Deviation Depending on sensors in use atmospheric condition machine condition machined material Parameter Voltage range Power consumption Graphic display Specification 12 24 V DC nom Nominal voltage 24 V DC Range 10 V 30 V lt 200 mA 4 LCD colour screen Keypad 18 keys with Dacklight Interfaces Infrared Dimensions 12 5 x 18 0 x 3 7 cm Weight 0 5 kg Parameter Specification Voltage range PowerGrade 12 24 V DC nom Nominal voltage 24 V DC Range 10 V 30 V 63 Technical Data Junction box PowerGrade 64 Parameter Power consumption Specification lt 2 5 Awith control panel connected and no load at 12 V Dimensions 12 4 x 15 2 x 4 4 cm Weight 0 320 kg Communication I
13. ain and Deadband To adjust the gain and deadband of each of the sensors complete the following steps l Press the left or right key once and then press the Adjust function key to enter the adjust menu Note that it s only the current selected sensor in either left or right side that is adjusted 2 Use the K or gt key to scroll through the settings 3 Use the 4 or key to change the value 4 To exit the adjust menu press the menu key The deadband controls the precise motion of machine hydraulics These values do not corre spond to accuracy but only to hydraulic speeds These values should not be confused with overall machine performance and or precision Adjust the deadband for each sensor This is done in the adjust menu for each sensor Sensor Dozer Grader GPS 1 0 cm 1 0 cm Laser 0 7 cm 0 7 cm Cross slope 0 6 0 3 Tracker 0 5 cm 0 5 cm Sideshift na 2 0 cm GAIN This is the scaling of hydraulic speeds for each of the sensors These values should be meas ured at the initial calibration but can be fine tuned as needed heavy or rough material wet dirt fine grading etc To enter Gains select the Lower Left or Lower Right buttons to open up the available sensors Select appropriate sensor and then the F1 or F4 key depending on left or right side to enter the Adjust Menu Adjust the gain of the hydraulic system for each sensor This is done by pressing the test butt
14. c radiation and electrostatic discharges are present and without causing electromagnetic distur bances to other equip ment Electromagnetic radiation can cause disturbances in other equipment Although the product meets the strict regulations and standards which are in force in this respect Leica Geosystems cannot completely exclude the possibility that other equipment may be disturbed There is a risk that disturbances may be caused in other equipment if the product is used in conjunction with accessories from other manufacturers for example field computers personal computers two way radios non standard cables or external batteries Precautions Use only the equipment and accessories recommended by Leica Geosystems When combined with the product they meet the strict requirements stipulated by the guide lines and standards When using computers and two way radios pay attention to the infor mation about electromagnetic compatibility provided by the manufacturer Disturbances caused by electromagnetic radiation can result in erroneous measurements Although the product meets the strict regulations and standards which are in force in this respect Leica Geosystems cannot completely exclude the possibility that the product may be disturbed by very intense electromagnetic radiation for example near radio transmitters two way radios or diesel generators Precautions Check the plausibility of results obtained under these conditions
15. communicating safety concepts for their products and are also responsible for the effectiveness of those safety concepts in combination with the Leica Geosystems product The person in charge of the product has the following duties e To understand the safety instructions on the product and the instructions in the user manual e To be familiar with local regulations relating to safety and accident prevention e To inform Leica Geosystems immediately if the product and the application becomes unsafe The person responsible for the product must ensure that it is used in accordance with the instructions This person is also accountable for the training and the deployment of personnel who use the product and for the safety of the equipment in use Unauthorized modification of machines by mounting the product may alter the function and safety of the machine Precautions Follow the instructions of the machine manufacturer If no appropriate instruction is avail able ask machine manufacturer for instructions before mounting the product This product may be installed on building machinery only by an appropriately trained and qualified specialist PowerGrade 47 Safety Directions 4 5 N Warning N caution N Warning N Warning PowerGrade 48 Hazards of Use Only Leica Geosystems authorised service workshops are entitled to repair these products Installing near mechanically moving machine components may damage the
16. ction of move ment of the Tri Sonic sensor Operation Installation and Set Up Tri Sonic The Tri Sonic can be installed quickly and easily with the simplest of tools Mount a support in a suitable location that is adjustable for height and lateral motion This will enable setting up of the Tri Sonic over any reference The support may differ according to the machine and reference In case of large differences in temperature between the storage and working environments allow 30 minutes for the sensor to adapt to the working environment prior to operation While ground and curb scanning the Tri Sonic should move longitudinally for the averaging of the scanned values For Stringline and Edge the Tri Sonic should be placed at an angle of 90 to the reference with the face plate orientated to back of the machine a Working direction b stringline PowerGrade 25 Operation PowerGrade 26 Stringline and Edge For stringline sensing the Tri Sonic must be positioned across the reference wire The Auto sensing matic Side Shift control of the Tri Sonic will keep the sensor always over the reference using the hydraulics of the third valve section to regulate the Blade in and out Mounting the Tri Sonic Normal operation on the support 1 Release the clamping screw on the support 2 Insert the round centering pivot on the top of the sensor housing vertically into the support 3 Rotate the sensor to the required sensing mo
17. de refer to previous page 4 Lock the centering pivot of the sensor with the clamping screw Edge operation For sensing Edges it is required to tilt the sensor toward the Edge as shown on the picture Slacken the knob on the bracket tilt the bracket and tighten the knob again N caution System Components can protrude from the machine which could lead to bodily injury and or product damage Precautions Exercise caution in operation to avoid striking any objects or persons near the working area Operation PowerGrade 27 Operation 2 3 2 PowerGrade system flexibility Mount the Tri Sonic Sensing range Reference ground PowerGrade 28 Operation with the Tri Sonic Sensor Multifunctional and multitask PowerGrade system can be operated in various combinations for the most demanding job requirements Mount the Tri Sonic to the appropriate height for its maximum performance according to the reference used The sensing range shows the mimimum and maximum values possible wherever It can be achieved to obtain the range of best perfomance Reference Sensing Range Best Performance String 15 36 inch 38 91 cm 24 inch 60 cm Edge 15 36 inch 38 91 cm 24 inch 60 cm Flat Ground 15 99 inch 38 250 cm 24 inch 60 cm noe ane a Side View b Ground Reference stringline Reference edge Operation JL LL 7 V MZ
18. duct has been dropped or has been misused modified stored for long periods or transported Precautions Periodically carry out test measurements and perform the field adjustments indicated in the user manual particularly after the product has been subjected to abnormal use and before and after important operations Because of the risk of electrocution it is very dangerous to use poles and extensions in the vicinity of electrical installations such as power cables or electrical railways Precautions Keep at a safe distance from electrical installations If it is essential to work in this environ ment first contact the safety authorities responsible for the electrical installations and follow their instructions PowerGrade 49 Safety Directions N Warning N Warning N caution N Warning PowerGrade 50 During dynamic applications there is a danger of accidents occurring if the user does not pay attention to the environmental conditions around for example obstacles excavations or traffic Precautions The person responsible for the product must make all users fully aware of the existing dangers Inadequate securing of the work site can lead to dangerous situations for example in traffic on building sites and at industrial installations Precautions Always ensure that the work site is adequately secured Adhere to the regulations governing Safety and accident prevention and road traffic If the accessor
19. ed Warranty Software License Agreement This product is Subject to the terms and conditions set out in the International Limited Warranty which vou can download from the Leica Geosystems home page at http www leica geosystems com internationalwarranty or collect from your Leica Geosys tems distributor The foregoing warranty is exclusive and is in lieu of all other warranties terms or conditions express or implied either in fact or by operation of law statutory or otherwise Including warranties terms or conditions of merchantability fitness for a particular purpose satisfac tory quality and non infringement all of which are expressly disclaimed This product contains software that is preinstalled on the product or that is supplied to you on a data carrier medium or that can be downloaded by you online pursuant to prior author ization from Leica Geosystems Such software is protected by copyright and other laws and Its use is defined and regulated by the Leica Geosystems Software License Agreement which covers aspects such as but not limited to Scope of the License Warranty Intellectual Property Rights Limitation of Liability Exclusion of other Assurances Governing Law and Place of Jurisdiction Please make sure that at any time you fully comply with the terms and conditions of the Leica Geosystems Software License Agreement Such agreement is provided together with all products and can also be referred to and downloaded at t
20. ent in the field always make sure that you carry the product in its Original transport container Never carry the product loose in a road vehicle as it can be affected by shock and vibration Always carry the product in its transport container and secure it When transporting the product by rail air or sea always use the complete original Leica Geosystems packaging transport container and cardboard box or its equivalent to protect against shock and vibration PowerGrade 41 Care and Transport 3 3 Product 3 4 Product Cables and Plugs Damp products PowerGrade 42 Storage Respect the temperature limits when storing the equipment particularly in summer if the equipment is inside a vehicle Refer to 5 Technical Data for information about temperature limits Cleaning and Drying e Blow off dust e Use a clean soft lint free cloth for cleaning If necessary moisten the cloth with water or pure alcohol Do not use other liquids these may attack the polymer components Keep plugs clean and dry Blow away any dirt lodged in the plugs of the connecting cables Dry the products at a temperature not greater than 40 C 108 F and clean them Do not repack until everything is completely dry 4 4 1 Description Safety Directions Safety Directions General The following directions should enable the person responsible for the product and the person who actually uses the equipment
21. g to be used and exit the sensor selection menu by pressing Z or f The control panel will automatically exit the sensor selection menu if no key is pressed for ten seconds 4 The chosen sensor is indicated by a small icon in the upper corner of the display and by an icon shown on the blade in relation to the actual placement of the sensor a b 0 0cm 1 0 i es Seek FZ Seek Swap a Laser indication b Cross Slope A cross slope is selected in the right side and in the left side a Laser Sensor is selected Operation PowerGrade 17 Operation 2 2 Inspection Manual mode PowerGrade 18 Setting a Reference Height When a sensor is selected the control panel automatically uses the last set reference height for that sensor There are two ways to change the reference e Manual mode e Seek mode Use the D keys to change the reference height up or down Seek mode Operation Press the and keys simultaneously to enter the seek mode In seek mode the screen shows the current sensor value of the selected sensor Pressing both keys simultaneously again exits the seek mode Or press F1 for seek mode While in Seek Mode the height values at the top of the screen will be green z 0 0cm 0 SAA Gl 7 E __ a seek Fa seek oWap CS If both keys are pressed and held for more than three seconds the control panel will take the current sensor value and store as the new refe
22. gg Switzerland CLCa when it has t Phone 41 71 727 31 31 j o be dE www leica geosystems com Geosystems
23. he Leica Geosystems home page at http www leica geosystems com swili cense or collected from your Leica Geosystems distributor You must not install or use the software unless you have read and accepted the terms and conditions of the Leica Geosystems Software License Agreement Installation or use of the software or any part thereof is deemed to be an acceptance of all the terms and conditions of such license agreement If you do not agree to all or some of the terms of such license agreement you may not download install or use the software and you must return the unused software together with its accompanying documentation and the purchase receipt to the dealer from whom you purchased the product within ten 10 days of purchase to obtain a full refund of the purchase price International Limited Warranty Software PowerGrade 73 License Agreement Total Quality Management Our commitment to total customer satisfaction 5 E i Leica Geosystems AG Heerbrugg Switzerland has been N E certified as being equipped with a quality system which meets rts i O IVI the International Standards of Quality Management and Quality N i Systems ISO standard 9001 and Environmental Management o Systems ISO standard 14001 a N Ask your local Leica Geosystems dealer for more information about our TQM program Printed in Switzerland 2008 Leica Geosystems AG Heerbrugg Switzerland Leica Geosystems AG Heinrich Wild Strasse CH 9435 Heerbru
24. ies used with the product are not properly secured and the product is subjected to mechanical shock for example blows or falling the product may be damaged or people may sustain injury Precautions When setting up the product make sure that the accessories for example tripod tribrach connecting cables are correctly adapted fitted secured and locked in position Avoid subjecting the product to mechanical stress If the product is improperly disposed of the following can happen e f polymer parts are burnt poisonous gas are produced which may impair health e f batteries are damaged or are heated strongly they can explode and cause poisoning burning corrosion or environmental contamination Safety Directions e By disposing of the product irresponsibly you may enable unauthorized persons to use it in contravention of the regulations exposing themselves and third parties to the risk of severe Injury and rendering the environment liable to contamination Precautions Dispose of the product appropriately in accordance with the regulations in force in your country Always prevent access to the product by unauthorized personnel PowerGrade 51 Safety Directions 4 6 Description N Warning N caution N caution PowerGrade 52 Electromagnetic Compatibility EMC The term Electromagnetic Compatability is taken to mean the capability of the product to function smoothly in an environment where electromagneti
25. ipment and the receiver e Connect the equipment into an outlet on a circuit different from that to which the ceiver IS connected e Consult the dealer or an experienced radio TV technician for help Changes or modifications not expressly approved by Leica Geosystems for compliance could void the user s authority to operate the equipment Labelling PowerGrade control panel Labelling PowerGrade cradle Safety Directions TYPE MCP1300 Power 12 247 DC GA max a Eis H 9 Heerbrugg ER Manufactured 2008 Made in Denmark Art No 764836 a Na XAXXXXXX PowerGrade TYPE MMB1300 Power 12 24V DC GA max Leica Ge CH 9435 oo AE if ug gs Manufactured 2008 ig in Denmark eh cart 15 of ihe FOG Art Mo 764910 S Na XAKXXXXX 55 Safety Directions PowerGrade 56 Labelling junction box Dozer imo H0OSNJ5 NH AH LHDN TA TYPE MJB1300 Art No Tue poy TE 40 Power 12 IC BA max 164838 S Na XAXKXXXXX Labelling junction box Grader Safety Directions HOSNAS IHH OSN35 HYDR OUT LEFT RIGHT TYPE MJB1301 Art M 164839 n M DCE CRE CC PowerGrade 57 Safety Directions PowerGrade Labelling laser receiver MLS700 Type MLS700 Art No 760862 Power 10 30V 0 2A max S No Leica Geosystems AG CH 9435 Heerbrugg 123456 Manufactured 2007 Made in Denmark This device complies with part 15 of the FCC Rules
26. nfrared 1 Mbit Output 2x RS232 RX TX 12V 2Amp GND 2 x MikroCAN and J1939 Parameter Specification Voltage range Power consumption Dimensions Weight 12 24 V DC nom Nominal voltage 24 V DC Range 10 V 30 V lt 0 5 Awith no sensors and valve connected Dozer 13 8 x 18 3 x 6 4cm Grader 14 5 x 18 3 x 6 4cm 2 kg Hydraulic Output Settings Proportional valves Interfaces Battery MIL Cradle M12 Valves 2x MIL CAN A MIL CAN B MIL CAN A M12 MUS1300 Tri Sonic MPM700 PowerMast Manual mast Technical Data Parameter Specification Dimensions 17 2 x 18 3 x 14 cm Weight 2 5 kg Accuracy within 0 125 cm 30 5 cm Input voltage Power Consumption 11 to 30 V DC 0 5 A max Parameter Specification Voltage range 12 24 V DC nom Nominal voltage 24 V DC Range 10 V 30 V Power consumption lt 2 5A Mast height extended 2 9 m Mast height retracted 1 7 m Mast travel 1 2 m Mast travel speed 85 mm per second Positions repeatability 1 mm Weight 30 kg Parameter Specification Height extended 3 257 m PowerGrade 65 Technical Data MLS700 Laser receiver PowerGrade 66 Parameter Specification Height retracted 1 857 m Travel 1 4m Scale Metric Inch Weight 14 kg Parameter Specification Voltage range Power consumption 12 24 V DC nom Nominal voltage 24 V DC Range 11 V 30 V
27. on box Grader 20 to 60 30 to 70 Junction box Dozer 20 to 60 30 to 70 MPM700 PowerMast 20 to 60 30 to 70 MLS700 Laser receiver 20 to 60 30 to 70 MUS1300 Tri Sonic 20 to 65 40 to 85 Cross slope sensor 20 to 60 40 to 80 Rotation sensor 20 to 60 40 to 80 Protection against water dust and sand Type Protection PowerGrade control panel IP67 PowerGrade cradle IP54 Junction box Grader IP67 Type Protection Junction box Dozer IP67 MPM700 PowerMast IP45 MLS700 Laser receiver IP68 MUS1300 Tri Sonic IP54 Cross slope sensor IP68 Rotation sensor IP67 Humidity Type Protection PowerGrade control panel Max 95 non condensing The effects of condensation are to De effectively counter acted by periodically drying out the instrument PowerGrade 69 Technical Data Technical Data PowerGrade 70 5 2 Conformity to National Regulations regulations compliance with the essential requirements and other relevant provisions of the applicable European Directives The declaration of conformity may be consulted Conformity to national Hereby Leica Geosystems AG declares that the PowerGrade control panel is in at http www leica geosystems com ce PowerGrade 71 International Limited Warranty Software License Agreement 6 International Limited Warranty Software License Agreement PowerGrade 72 International Limit
28. on in the adjust menu for each sensor The error and time settings are set by default to 1cm 4 and 2 seconds these settings should not be changed S Please follow the on screen instructions Elevation Press the Test button to adjust the value so that it corresponds to the below distances For example during 2 seconds of movement the blade should move 8 cm for GPS Sensor Dozer Grader Laser Sonics Tri Sonics GPS 8 cm 13 cm Tracker 4 cm 7 cm Operation PowerGrade 37 Operation PowerGrade 38 Second laser for cross slope This should be measured 1 5 meters from the centre of the blade Press the Test button to adjust the value so that it corresponds to the below distances For example during 2 seconds of movement the blade should move 8 cm for a laser sensor controlling tilt Laser 8cm 2D and 3D cross slope sensor This should be measured 1 5 meters from the centre of the blade Press the Test button to adjust the value so that it corresponds to the below distances For example during 2 seconds of movement the blade should move 6 5 cm for 3D cross slope Sensor Dozer Grader Sideshift Grader only Enter the Tri Sonic or 3D height adjust menu Press the Test button to adjust the value so that it corresponds to the below distances 2D and 3D sideshift 13 cm 2 8 Grader Setup Operation Machine Setups
29. ous situation or an unintended use which tf not avoided could result in death or serious injury Indicates a potentially hazardous situation or an unintended use which if not avoided may result in minor or moderate injury and or appreciable material financial and environmental damage Important paragraphs which must be adhered to In practice as they enable the product to be used in a technically correct and efficient manner This manual applies to the PowerGrade control panel PowerGrade 3 Table of Contents Table of Contents In this manual PowerGrade Topic Page 1 Product Overview 6 1 1 Product Description and Features 6 1 2 Getting Started 11 1 3 Sensor Setup Keys 13 2 Operation 15 Rid Select the Input Source 15 2 2 Setting a Reference Height 18 2 3 Using the Tri Sonic Tracker 21 2 3 1 Installation and Set Up Tri Sonic 25 2 3 2 Operation with the Tri Sonic Sensor 28 2 4 Swap Function 31 2 5 Using the Laser Sensor 32 2 6 3D Sensors 34 2 7 Setting the Value for Gain and Deadband 36 2 8 Machine Setups 39 3 Care and Transport 41 3 1 General Notices 41 3 2 Transport 4l 3 3 Storage 42 3 4 Cleaning and Drying 42 4 Safety Directions 43 4 1 General 43 4 2 Intended Use 44 4 3 Limits of Use 46 4 4 Responsibilities 47 4 5 Hazards of Use 48 4 6 Electromagnetic Compatibility EMC 52 4 7 FCC Statement Applicable in U S 54 5 Technical Data 63 5 1 PowerGrade Technical Data 63 5 2 Confo
30. rence height While holding these buttons the F1 key will change from Seek to 0 0 Once the new reference height has been set the height values at the top of the screen will change back to black PowerGrade 19 Operation Automatic detection of the laser beam PowerGrade 20 For systems with a PowerMast entering seek mode will start an automatic search for the laser beam If the laser sensor is out of beam the operator can select in which direction the mast should start moving to look for the laser beam using the D and keys The mast will then start moving in that direction until the laser sensor has the beam centered If the mast during a seek reaches its top or bottom limit it will automatically switch moving direction and continue to seek for the laser beam until it is found or it hits the next end point 2 3 Using Tri Sonic Operation Using the Tri Sonic Tracker PowerGrade The Tri Sonic can also measure the horizontal distance to a stringline and therefore it can be used to control the sideshift on a grader To do that complete the following steps 1 Place the machine so that the Tri Sonic is above ground the edge or stringline The sensor needs an edge or string to follow before it can control the sideshift 2 Move the blade to the working position 3 Move the Tri Sonic to a good working height This is 40 70 cm above the reference 4 Select the Tri Sonic on the same side as where I
31. rmity to National Regulations 70 6 International Limited Warranty Software License Agreement 72 Table of Contents PowerGrade Product Overview 1 1 1 General Power supply commu nication PowerGrade 6 Product Overview Product Description and Features The control panel has keys surrounding the screen for user input The 4 colour display incorporates a state of the art LCD colour screen making it easy to use even in bright sunny conditions The rugged IP56 enclosure is designed for harsh environments The control panel is powered from a cradle based on a sophisticated induction solution while data is transferred wirelessly via infrared between the cradle and the control panel Leica Geosystems recommends to use the MMB1300 Cradle for control panel Cradle will be used throughout this manual PowerGrade control panel N Warning Product Overview a b b C d h a Graphical display e Menu key b Grade indication led s f Function keys c Left side sensor setup g Enter key d Right side sensor setup h Speaker This product may be installed on building machinery only by an appropriately trained and qualified specialist PowerGrade Product Overview PowerGrade 8 N Warning Unauthorized modification of machines by mounting the product may alter the function and safety of the machine Precautions Follow the instructions of the machine manufacturer If no appropriate instruction is
32. sor setup keys are used to choose the type of sensor that the system should run with and to find and set the reference point for that sensor The left and right hydraulic channel has four sensor setup keys each Ua Auto Manual key D up key down key sensor select key The system can also be fitted with an External Multi Switch This switch has three keys on it One Auto Manual key Red and a set of up and down keys green These keys have the same function as the corre sponding keys on the control panel PowerGrade 13 Product Overview PowerGrade 14 External switch for Toggle the master switch to AUTO to enable automatic control on all Dozer channels selected on the control panel Toggling the master switch to MAN places all channels in manual control regardless of selection on the control panel 2 Operation 2 1 Select the Input Source Sensor selection 1 Push the left or right key to open the sensor selection menu Following screen appears Laser 0 5 m i Adjust Fea F3 Adjust Operation PowerGrade 15 Operation PowerGrade 16 2 Use the 4 keys to scroll through the available sensors a If the sensor is connected and active it will show up in black b If it s not connected or inactive it will show in red and a red cross will show up on the screen if that sensor is selected 2 8cm 0 5 seek Fe seek oWap 3 Highlight the sensor that Is goin
33. ss slope by inversing the actual target cross slope For example 2 3 gt 2 3 e Level 2 Swap the cross slope by inversing the actual target cross slope and swap the side of the motorgrader that is controlled by ultrasonic By pressing F4 SWAP the actual target slope will be inversed Requirements Two Tri Sonic sensors must be connected and the system must be in motor grader mode Move the motorgrader to a flat level ground Set the moldboard level with the machine Select slope on left side and sonic on right side Choose ground mode for the Tri Sonic Manually set the cross slope of the blade to level Set the height for the right sonic by pressing and holding F3 SEEK for 2 sec Mm KN WN FH 6 Press F1 SWAP and the sensors will switch sides 7 Set the height for the left sonic by pressing and holding SEEK for 2 sec The machine is now ready for the final grade following the previously pass It is possible to have different heights and mode settings for the two Tri Sonic sensors PowerGrade 31 Operation 2 5 Laser Sensor PowerGrade 32 Using the Laser Sensor The Laser Sensor is used to measure the elevation of the blade This is done by measuring the distance from where the laser beam is hitting the laser and the centerline on the Laser Sensor When the Laser Sensor detects a laser beam this is indicated on the display by a red line through the laser icon If at some
34. t is placed on the machine 21 Operation PowerGrade 22 5 Enter the Tri Sonic menu First press the key then press the Adjust function key Tri1 sonic Adjust F F3 F4 Select between the different modes e Ground Mode e Edge Mode e Stringline Press the D or key to toggle between the modes Once selected press the eI key Following screens will appear by pressing the up N or down L af Enter key to toggle between the screens dd E Tri Sonic Tri Sonic Tri Soanic ad Hr Tri Sonic Tri Sonic Tri Soanic Teat Time Error ESC FT r a e Teat Time Error EC Stringline describes the window where the Tri Sonic will work within certain range All readings outside of this range will be ignored Sideshift works only with the modes Edge and Stringline 6 Go to the Sideshift menu option and set it to Yes 7 Press both 4 and keys simultaneously to set the control panel in seek mode 8 Check that the height is approximately 40 70 cm Operation PowerGrade 23 Operation PowerGrade 24 9 Press both D and keys simultaneously and keep them pressed for three seconds to set the reference height 10 Press the right e key to set the machine in Auto Mode 11 Press the Side A M function key to enable the automatic sideshift control _T 0cm 1 0 4 Cauro Famosa TO _ ee side A seek seek SUap 2 3 1 Mounting the Tri Sonic CE The dire
35. to anticipate and avoid operational hazards The person responsible for the product must ensure that all users understand these directions and adhere to them PowerGrade 43 Safety Directions 4 2 Permitted use Adverse use N Warning PowerGrade 44 Intended Use e Determine the position of a dozer grader blade or excavator bucket e Calculate the distance between the blade bucket and a reference model surface line or point e Automatic adjustment of a dozer grader hydraulic system in order to match the blade to the reference model e Use of the product without instruction e Use outside of the intended limits e Disabling safety systems e Removal of hazard notices e Opening the product using tools for example screwdriver unless this is specifically permitted for certain functions e Modification or conversion of the product e Use after misappropriation e Use of products with obviously recognizable damages or defects e Use with accessories from other manufacturers without the prior explicit approval of Leica Geosystems e Inadequate safeguards at the work site for example working on roads e Controlling of machines moving objects or similar monitoring application without addi tional control and safety installations Adverse use can lead to injury malfunction and damage It is the task of the person responsible for the equipment to inform the user about hazards and how to counteract them
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