Topcon America 5434 Wireless Excavator System User Manual X 22 Installation and Calibration Manual

Topcon America Corporation Wireless Excavator System X 22 Installation and Calibration Manual

Contents

Installation Manual

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POSITIONING SYSTEMSX-22Excavator Indicate SystemInstallation and Calibration ManualPart Number 7010-1019Rev A©Copyright Topcon Positioning Systems, Inc.June, 2011All contents in this manual are copyrighted by Topcon. All rights reserved. The information contained herein may not be used, accessed, copied, stored, displayed, sold, modified, published, distributed, or otherwise reproduced without express written consent from Topcon.
ECO#4152Terms and ConditionsThank you for buying this Topcon product. This manual has been prepared to assist you with the care and operation of the product and its use is subject to these Terms and Conditions and those more fully set forth in the Operator’s/User’s Manual.Usage and SafetyThis product is designed for use by professionals. Always use safety precautions when operating this or any Topcon product.CopyrightsAll information contained in this Manual is the intellectual property of, and copyrighted material of TPS. All rights are reserved. You may not use, access, copy, store, display, create derivative works of, sell, modify, publish, distribute, or allow any third party access to, any graphics, content, information or data in this Manual without TPS’ express written consent and may only use such information for the care and operation of your Product. The information and data in this Manual are a valuable asset of TPS and are developed by the expenditure of considerable work, time and money, and are the result of original selection, coordination and arrangement by TPS.TrademarksX-22, Topcon, and Topcon Positioning Systems are trademarks or registered trademarks of TPS. Other product and company names mentioned herein may be trademarks of their respective owners.Disclaimer of WarrantyEXCEPT FOR SUCH WARRANTIES AND LICENSES PROVIDED WITH THE PRODUCT, THIS MANUAL AND THE PRODUCT ARE PROVIDED “AS-IS”. TOPCON AND ITS DISTRIBUTORS SHALL NOT BE LIABLE FOR TECHNICAL OR EDITORIAL ERRORS OR OMISSIONS CONTAINED HEREIN; NOR FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES RESULTING FROM THE FURNISHING, PERFORMANCE OR USE OF THIS MATERIAL OR THE PRODUCT.Please see the Operator’s/User’s Manual for detailed information on warranties and the license agreement which may apply to the Product.License AgreementUse of any computer programs or software supplied by Topcon or downloaded from the Topcon website in connection with the Product implies acceptance of the Terms and Conditions here and in the Operator’s/User’s Manual.Please see the Operator’s/User’s Manual for detailed information on warranties and the license agreement which may apply to the Product.
P/N 7010-1019TOCiTable of ContentsChapter 1Introduction .......................................................... 1-1System Components ........................................................ 1-1Chapter 2Installation and Calibration ................................. 2-1Getting Started ................................................................. 2-1Step 1: Charge the Sensors ........................................ 2-1Step 2: Attach the Brackets ....................................... 2-2Bracket for Boom Sensor ................................... 2-2Bracket for Arm (Stick) Sensor with Laser Detector ................................................. 2-5Bracket for Bucket Sensor .................................. 2-6Bracket for Tilt Bucket Sensor (Optional) ......... 2-10Step 3: Attach the Mast for the PitchRollCompass ... 2-13Step 4: Attach the X-22 Display ............................... 2-15Step 5: Measure the Excavator .................................. 2-17Step 6: Entering the Sensors on the X-22 Display .... 2-17Step 7: Attach the Sensors to the Excavator ............. 2-19Step 8: Calibrate the Sensors ..................................... 2-23Calibrating the Boom Sensor .............................. 2-23Calibrating the ArticBoom Sensor (Optional) .... 2-23Calibrating the PitchRollCompass ...................... 2-23Calibrating the Stick Sensor ............................... 2-24Calibrating the Bucket Sensor ............................ 2-24Calibrating the Tilt Bucket Sensor (Optional) .... 2-25Step 9: Measure and Calibrate the Buckets ............... 2-25Finding Your Way Around the Software ......................... 2-26Tracking .................................................................... 2-26Wizards ..................................................................... 2-26How to Return to the Main Menu ............................. 2-27Before You Start to Dig ................................................... 2-28
Table of ContentsX22 Installation and Calibration ManualiiCheck that X-22 is Measuring Correctly ................... 2-28Backup ....................................................................... 2-28Applications ............................................................... 2-28Arm (Stick) Sensor with Laser Detector ................... 2-29Handling Damaged Sensors ....................................... 2-29Important Information On Use ......................................... 2-30Charger ...................................................................... 2-30Sensors ....................................................................... 2-31X-22 Display and Power Supply ............................... 2-32Machine and Bucket Measurements ................................ 2-32Measure Additional Buckets ............................... 2-42Chapter 3Troubleshooting .................................................. 3-1Appendix ASpecifications ...................................................... A-1X-22 Sensor ...................................................................... A-1WEEE Directive ............................................................... A-2Appendix BSafety Warnings ................................................... B-1General Warnings ............................................................. B-1Sensor Warnings .............................................................. B-2Usage Warnings ............................................................... B-3Appendix CWarranty Terms ................................................... C-1
P/N 7010-1019Chapter 11-1IntroductionCongratulations on your new X-22 System.System ComponentsMeasuring and installation equipment is also available separately (not shown).
X-22 Installation and Calibration ManualNotes:1-2
P/N 7010-1019Chapter 22-1Installation and CalibrationGetting StartedBefore you can start using your X-22 System for excavation, you need to set it up. Read on to find out how to install X-22 on your excavator in nine simple steps.Step 1: Charge the SensorsThe first thing you must do is charge the sensors for several hours (i.e. overnight). The charger’s LEDs may briefly turn on and off as the sensors go through their charging cycle. This is normal. Leave the sensors on the charger to ensure a full charge. If the batteries are completely flat, it takes around 12 hours to charge them fully. Make sure the contacts on the charger and the sensors are free of debris before charging. Figure 2-1. Battery Charger
X-22 Installation and Calibration Manual2-2Step 2: Attach the BracketsAttach the aluminum brackets using the self-tapping screws provided. The drill and bit for the screws are also included. The drill is 4.6 mm and the screws Taptite M5x10 have a recessed head.A weld plates can be purchased separately, if drilling is not possible.Bracket for Boom SensorThe bracket for the boom sensor must be attached to the side of the boom that faces the cab. Figure 2-2. Boom Sensor Bracket LocationNOTICERub a little grease or oil onto the screws before screwing them in.NOTICEWhen determining the location of the sensor brackets, make sure you allow room to install and uninstall the sensors onto the brackets.
Installation and CalibrationP/N 7010-1019 2-3The bracket for the boom sensor must be attached to a face of the boom that does not slant in relation to the boom bolt. The following picture shows how the boom is widest down by the boom bolt and gets narrower towards the center. The bracket must not therefore be attached in this area. Figure 2-3. Do Not Install Bracket on Slanted Area of BoomThe bracket for the ArticBoom sensor should be attached to the articulated (extended) boom, if the machine has one, in the same way.
X-22 Installation and Calibration Manual2-4It makes no difference to the wireless communication or angle measurements for the sensors whether the bracket for the boom sensor is positioned as shown in Figure 2-4,Figure 2-4. Boom Sensor Bracket Orientationor as shown in Figure 2-5.Figure 2-5. Boom Sensor Bracket Orientation
Installation and CalibrationP/N 7010-1019 2-5Bracket for Arm (Stick) Sensor with Laser DetectorThe bracket for the arm (stick) sensor must be attached to the side of the arm (stick) that faces the cab.Position the bracket so that the sensor is roughly vertical when the laser hits it. Take care not to attach the bracket too high on the arm (stick) to avoid problems with getting the laser beam to hit the sensor.Figure 2-6. Arm (Stick) Sensor Bracket LocationNOTICEAttach the bracket for the arm sensor with the spring clips at the top so that the sensor slides in from above.
X-22 Installation and Calibration Manual2-6Bracket for Bucket SensorThe best place to attach the bracket for the bucket sensor depends on the size of the excavator and if the joints are tight or loose.It is easiest to make X-22 measure accurately if the bucket sensor is attached directly on the bucket/quick coupler. This is especially the case if the joints are loose. Alternative 1: The inside of the quick coupler/bucket If the excavator is large enough, the bracket for the bucket sensor can be attached on the inside of the quick coupler/bucket. Attach the bracket on the part of the quick coupler/bucket closest to the cab.Figure 2-7. Quick Coupler/Bucket Bracket Location - InsideNOTICEFully extend and retract the bucket cylinder before fitting and make sure that the bracket and the sensor do not meet any obstructions.
Installation and CalibrationP/N 7010-1019 2-7 Alternative 2: The outside of the quick coupler/bucket The bracket for the bucket sensor can also be attached on the outside of the quick coupler / bucket. Attach the bracket on the part of the quick coupler/bucket closest to the cab. Figure 2-8. Quick Coupler/Bucket Bracket Location - OutsideNOTICEIf the bucket sensor is attached on the inside of the quick coupler/bucket, the sensor direction of the bucket sensor must be changed from Normal to Reverse. Select Main Menu Setup Hardware  Sensors and mark the bucket sensor. Then select Details. Select Sensor direction and press Edit.
X-22 Installation and Calibration Manual2-8Alternative 3: The inside of the control arm (dog-bone) If the excavator is large enough and the joints are tight, the bracket for the bucket sensor can be attached on the inside of the control arm (dog-bone). Attach the bracket on the control arm closest to the cab.Figure 2-9. Inside of Control Arm (Dog-bone)NOTICEFully extend and retract the bucket cylinder before fitting and make sure that the sensor do not meet any obstructions.NOTICEIf the bucket sensor is attached on the inside of the control arm (dog-bone), the direction of the bucket sensor must be altered from Normal to Reverse. Select Main Menu Setup Hardware  Sensors and mark the bucket sensor. Then select Details. Select Sensor direction, and press Edit.
Installation and CalibrationP/N 7010-1019 2-9Alternative 4: The outside of the control arm (dog-bone) If the excavator is too small to fit the bracket with the bucket sensor on the inside of the control arm and the joints are tight, the bracket can be attached on the outside of the control arm. Attach the bracket on the control arm closest to the cab.Figure 2-10. Outside of Control Arm (Dog-bone)NOTICEFully extend and retract the bucket cylinder before fitting and make sure that the sensor do not meet any obstructions.NOTICEAttach the bracket with the spring clips on the left so that the sensor slides into the bracket from the left.
X-22 Installation and Calibration Manual2-10Bracket for Tilt Bucket Sensor (Optional)The bracket for the tilt bucket sensor must be attached so that the sensor rotates sideways or lengthways.Alternative 1: Sideways When the tilt bucket sensor is installed sideways, the long axis of the sensor is used to measure how much the bucket is tilted to the side. Figure 2-11. Sideways InstallationFigure 2-12. Sideways InstallationNOTICEThe long axis must move as shown in the pictures below when the bucket is tilted to the side, or else the sensor will not measure correctly.
Installation and CalibrationP/N 7010-1019 2-11Example of sideways installation on a tilt bucket:Figure 2-13. Sideways Installation
X-22 Installation and Calibration Manual2-12Alternative 2: Lengthways When the tilt bucket sensor is installed lengthways, the short axis of the sensor is used to measure how much the bucket is tilted to the side. Note that the short axis must move as shown in the pictures below when the bucket is tilted to the side, or else the sensor will not measure correctly. Figure 2-14. Lengthways InstallationFigure 2-15. Lengthways Installation
Installation and CalibrationP/N 7010-1019 2-13Example of lengthways attachment:Figure 2-16. Lengthways InstallationStep 3: Attach the Mast for the PitchRollCompassA mast is supplied with X-22 for the PitchRollCompass sensor. We recommend mounting the mast on the back of the machine’s counterweight. Position the bracket on top of the mast, parallel with the tracks of the machine.The optional welding mast ring (sold separately) is to be welded to the machine. Bolts and nuts are supplied with the mast. When the
X-22 Installation and Calibration Manual2-14mast ring is in place, attach the aluminium bracket firmly to the mounting ring with the M8x30 Allen screws provided. Figure 2-17. Mast and Mast Ring InstallationNOTICEPosition the mast (or mast ring) so that it holds the mast steady and vertical on the excavator.
Installation and CalibrationP/N 7010-1019 2-15Step 4: Attach the X-22 DisplayYou can easily attach the X-22 Display to the side window in the cab using the suction cup provided. Clean the glass before attaching the suction cup. This prevents air from getting into the suction cup. Figure 2-18. X-22 Display - Side ViewNOTICECheck regularly that the suction cup is firmly attached and take it off when it is not being watched.
X-22 Installation and Calibration Manual2-16The X-22 Display’s on/off switch is on the bottom of the unit.Figure 2-19. X-22 Display FeaturesOn/OSwitchUSB Port for CoordinatorPower Cable ConnectorRAM MountCoordinator SlotBottom ViewBack View
Installation and CalibrationP/N 7010-1019 2-17Step 5: Measure the ExcavatorTurn the X-22 Display on and select Main menu Setup Excavators New to enter your excavator.Figure 2-20. Create a New MachineLater in this manual you will find a list of the measurements you need to take. Use it for reference and making notes while measuring. You will find a tape measure in the case.Step 6: Entering the Sensors on the X-22 DisplayOnce the sensors are fully charged and have been taken out of the charger, they have to be entered on the X-22 Display. Select Main menu Setup Hardware Sensors. If the sensors have been entered already they are listed on the screen.Select New and enter all the sensors one by one if they are not already entered. Entering a new sensor can take few minutes.NOTICEIt is important to measure the excavator accurately. If the dimensions are wrong, X-22 will not measure as accurately as it should.
X-22 Installation and Calibration Manual2-18Each sensor has a unique serial number, which can be found on the back of the sensor preceded by “SN:”. It is important to keep the serial numbers of all the sensors for reference, and we recommend making a note of them in the table below. It is not possible to communicate with the sensor without the serial number.NOTICEIt is important to take all the sensors out of the charger before starting to enter them on the X-22 Display. The radio for the sensors is switched off when they are in the charger. Sensor Serial NumberBoomArm (Stick)BucketPitchRollCompassArticBoomTilt Bucket
Installation and CalibrationP/N 7010-1019 2-19Figure 2-21. Serial Number LabelStep 7: Attach the Sensors to the ExcavatorNow you are ready to attach the sensors to the excavator. Slide the boom sensor into the bracket you have attached to the boom, the arm (stick) sensor into the bracket on the arm and the bucket sensor into the bracket on the control stick. If you have a PitchRollCompass sensor, an ArticBoom sensor, and/or a Tilt sensor, then attach them in the same manner.
X-22 Installation and Calibration Manual2-20Figure 2-22. Install Sensors onto BracketsNOTICEThe sensors only go into the brackets one way. Slide the sensor into the bracket with the charging pins on the sensor pointing away from the bracket.
Installation and CalibrationP/N 7010-1019 2-21Slide the PitchRollCompass sensor into the bracket on top of the mast. If needed, loosen the fastening screws of the mast base, and rotate the mast until sensor is pointing straight ahead. Then tighten the fastening screws so that the mast stays in this position.Figure 2-23. PitchRollCompass Sensor Orientation
X-22 Installation and Calibration Manual2-22Figure 2-24. PitchRollCompass Sensor Orientation
Installation and CalibrationP/N 7010-1019 2-23Step 8: Calibrate the SensorsThe sensors should now be in position on the excavator. Press Start digging in the Main Menu and you are asked to calibrate the sensors. Follow the on-screen instructions. Calibrating the Boom SensorAttach one magnet in the center of the boom bolt and another in the center of the stick bolt. Then thread the line through the spirit level, pull it tight, and secure the ends to the magnets. When the spirit level is level, the boom is level.Calibrating the ArticBoom Sensor (Optional)If the excavator has an articulated (extended) boom, the boom sensor is calibrated by positioning the boom vertically, and the ArticBoom sensor is calibrated by positioning the articulated boom horizontally. Calibrating the PitchRollCompassPark the excavator on a horizontal surface and position the superstructure so that it is parallel to the tracks, following the on-screen instructions.Then rotate the superstructure slowly.NOTICEIt is important to calibrate the sensors accurately. If calibration is not done correctly, X-22 will not measure as accurately as it should. The most accurate sensor calibration is achieved by using a rotating laser, theodolite or a total station instead of the spirit level and plumb line provided.
X-22 Installation and Calibration Manual2-24Calibrating the Stick SensorAttach a magnet in the center of the stick bolt and hang a plumb line from it. When the plumb bob is still and the line passes through the center of the bucket bolt, the stick is vertical.Figure 2-25. Calibrating the Arm (Stick) SensorCalibrating the Bucket SensorHow the bucket sensor is to be calibrated depends on how the sensor has been attached:On the inside or outside of the control arm (dog-bone) Attach a magnet in the center of each bolt at the ends of the control arm (dog-bone). Pull the line with the spirit level on it tight and attach the ends to the magnets. The spirit level shows when the control stick is level.
Installation and CalibrationP/N 7010-1019 2-25Figure 2-26. Calibrate Control Arm (Dog-bone) SensorDirectly on the quick coupler / bucket If the bucket sensor has been attached directly on the quick coupler / bucket, the sensor is calibrated by positioning the bucket vertically.Calibrating the Tilt Bucket Sensor (Optional)If the excavator has a tilt bucket, the tilt bucket sensor is calibrated by positioning the tilt bucket horizontally. Follow the on-screen instructions.Step 9: Measure and Calibrate the BucketsThe final step is to measure and enter the excavator’s buckets.
X-22 Installation and Calibration Manual2-26To enter the excavator’s buckets, select Main Menu Setup BucketsNew.Each bucket also has to be calibrated. Follow the instructions on the X-22 Display.The bucket teeth/blade can be worn down and become shorter with time. In this case the bucket radius should be measured again and the bucket recalibrated.Finding Your Way Around the SoftwareButtons and lists that are displayed on screen can both be pressed. TrackingYou can see where you are in the software right at the top of each screen. If, for example, you press Setup in the Main Menu followed by Excavators, Main menu > Setup > Excavators is displayed at the top of the screen.WizardsWhen you press New to enter a new excavator, a new bucket or a new sensor, a wizard starts up and guides you through everything you have to do. You can see how far you have progressed in the wizard in the top right-hand corner of the screen.NOTICEIt is important to measure the buckets accurately. If the dimensions are wrong, X-22 will not measure as accurately as it should.
Installation and CalibrationP/N 7010-1019 2-27Wizards also start up when you select the type of digging work.How to Return to the Main MenuTo return to the previous menu, press the Back button in the bottom left-hand corner, as shown in Figure 2-27. If you are following a wizard, you can also go back a step by pressing Back button. If you press Back several times, you ultimately return to the Main Menu.Figure 2-27. Press the Bottom Left Button to Return to Main MenuNOTICERefer to the X-22 User’s Manual for more information on using the X-22 software.
X-22 Installation and Calibration Manual2-28Before You Start to DigCheck that X-22 is Measuring CorrectlyOnce you have X-22 ready for digging work, we recommend checking that the system is measuring as accurately as it should. This can be done by running through the verification routine. The first time you press Start digging in the Main Menu, you are asked to verify the calibration. Otherwise, you can start the verification routine from the menu in the digging window by pressing CheckVerify.If the system is not measuring as accurately as it should, a dimension or calibration value is probably wrong. In the menu in the digging window, press Check Troubleshooting, X-22 helps you identify the problem and rectify it. BackupOnce you have checked that X-22 is measuring correctly, we recommend making a backup copy of all the data you have entered on the X-22 Display. 1. Plug a USB memory stick into the X-22 Display.2. Select Main Menu  Setup Hardware Computer Backup/ImportBackup.3. Press Start backup to save the measurements for all excavator(s) and bucket(s), sensor serial numbers, etc. to the memory stick. ApplicationsYou can perform a wide range of digging work with X-22. In the user manual, you will find an overview of the different types of work and how X-22 can be used.
Installation and CalibrationP/N 7010-1019 2-29Arm (Stick) Sensor with Laser DetectorYou should be aware that the laser detector of the arm (stick) sensor has some limitations. It is designed for rotary lasers with laser diodes of 1mW or more, and 630nm wavelength (visible red light). It cannot be guaranteed that the laser detector will work with other rotary lasers, nor if the sun shines directly onto it.If you are unable to get the laser detector of the stick sensor to work properly, you can use a machine detector instead. Do the following:1. Attach the machine detector next to the stick sensor. Mark its position so that you can attach it on the exact same place if you have to take it off again.2. Measure the center of the machine detector just like you did with the stick sensor. 3. Select Main MenuSetupHardwareSensors. 4. Select Stick with laser, and press Details. The two measurements specifying the center of the laser detector are at the bottom of the list displayed on the screen. Edit and enter the measurements of the machine detector instead.5. Continue to dig and use the machine detector to reference instead of the laser detector of the stick sensor. Make sure that “Laser” is selected as “Reference” of the project you are working on, and reference when the laser beam hits the center of the machine detector.Handling Damaged SensorsThere is a powerful lithium battery in every sensor. It is just inside the cover bearing the serial number, so it is well protected by the sensor housing and the aluminium bracket when the sensor is on the excavator.If in spite of this a sensor is seriously damaged, be careful. If a sensor is so badly damaged that the lithium battery is punctured or squashed, there might be a risk of explosion, fire or injury.Damaged sensors are special waste and must be handled accordingly.
X-22 Installation and Calibration Manual2-30Important Information On UseThis section describes how the equipment should be handled. If the guidelines are not followed, there might be a risk of explosion, fire, injury or damage to the equipment.ChargerThe charger is for indoor use only. Avoid moisture. Batteries charge faster at lower temperatures, but the sensors must never be charged at temperatures below 0°C (32°F).Operating temperature 0°C to +35°C35°F to +95°FNot waterproofFor indoor use onlyNOTICENever put wet sensors in the charger.NOTICEMake sure the contacts on the sensors and the charger are free of debris before charging.
Installation and CalibrationP/N 7010-1019 2-31SensorsThe sensors are waterproof, but are not designed for digging in water. The wireless connection does not work in water either, so remove the bucket sensor and stick sensor if you intend to dig in water.Operating temperature -20°C to +60°C-4°F to +140°FCharging temperature +5°C to +35°C-41°F to +95°FStorage temperature -20°C to +35°C-4°F to +95°FOperating time approx. 4 weeks on one chargeNOTICENever expose the sensors to temperatures above 100°C (212°F), or there might be a risk of explosion. NOTICETake the sensors off when using a pick hammer.
X-22 Installation and Calibration Manual2-32X-22 Display and Power SupplyThe kit contains a power cable for the X-22 Display with a cigarette lighter plug, which can be used for both 12V and 24V supply.Machine and Bucket MeasurementsOn the next several pages there are pictures illustrating all excavator and bucket measurements that must be taken. Refer to these pictures and make a note of the dimensions beside them while taking the measurements.You will find more pictures showing each measurement in greater detail on the X-22 Display, if you press Details as shown in Figure 2-28 on page 2-33. We recommend looking through the pictures on the X-22 Display first and familiarizing yourself with the various measurements before starting to measure.Operating temperature 0°C to +50°C35°F to +122Storage temperature -20°C to +70°C35°F to +158°FNot waterproof
Installation and CalibrationP/N 7010-1019 2-33Figure 2-28. Entering Measurements
X-22 Installation and Calibration Manual2-34Machine Dimension MeasurementBoom 1 Articulated boomMachine Dimension MeasurementArm (Stick) 2
Installation and CalibrationP/N 7010-1019 2-35Machine Dimension MeasurementControl Arm (Dog-bone)3 Machine Dimension MeasurementBucket bolt to control arm bolt 4
X-22 Installation and Calibration Manual2-36Machine Dimension MeasurementArm (Stick) axis to control arm (dog-bone) bolt 5Machine Dimension MeasurementLink 6
Installation and CalibrationP/N 7010-1019 2-37Machine Dimension MeasurementRoll length 7Machine Dimension MeasurementHeight to boom pin 8
X-22 Installation and Calibration Manual2-38Machine Dimension MeasurementPitch length 9Machine Dimension MeasurementBucket Web 10
Installation and CalibrationP/N 7010-1019 2-39Machine Dimension MeasurementBucket Front 11Machine Dimension MeasurementBucket Width 12
X-22 Installation and Calibration Manual2-40 Machine Dimension MeasurementBucket bolt to tilt axis 13Machine Dimension MeasurementBucket tip to tilt axis 14
Installation and CalibrationP/N 7010-1019 2-41Machine Dimension MeasurementBucket bolt to laser sensor 15 Machine Dimension MeasurementArm (Stick) axis to laser sensor 16
X-22 Installation and Calibration Manual2-42Measure Additional BucketsName of Bucket:Bucket Dimension MeasurementWeb 10 Front 11Width 12Bucket bolt to tilt axis 13Bucket tip to tilt axis 14Name of Bucket:Bucket Dimension MeasurementWeb 10 Front 11Width 12Bucket bolt to tilt axis 13Bucket tip to tilt axis 14
Installation and CalibrationP/N 7010-1019 2-43Name of Bucket:Bucket Dimension MeasurementWeb 10 Front 11Width 12Bucket bolt to tilt axis 13Bucket tip to tilt axis 14Name of Bucket:Bucket Dimension MeasurementWeb 10 Front 11Width 12Bucket bolt to tilt axis 13Bucket tip to tilt axis 14
X-22 Installation and Calibration ManualNotes:2-44
P/N 7010-1019Chapter 33-1TroubleshootingIn this section you will find answers to the following questions:The X-22 Display is not responding, what should I do?....... page 3-1The sensors are not responding, what should I do?...............page 3-1A sensor is damaged, what should I do?..............................page 3-1How do I recalibrate a sensor?...........................................page 3-1The system is not measuring accurately, what should I do?..page 3-2The compass is measuring incorrectly, what should I do?.....page 3-2The laser sensor is not working, what should I do?...............page 3-2The X-22 Display is not responding, what should I do?Most X-22 problems can be solved by turning the X-22 Display off and on.The sensors are not responding, what should I do?If you are having problems making contact with the sensors, proceed as follows: Turn the X-22 Display off and put all the sensors in the charger for a few minutes. The sensors will then be reset while they are being charged. Take all the sensors out of the charger and turn the X-22 Display back on.A sensor is damaged, what should I do?You can obtain a new sensor by contacting your dealer. Delete the damaged sensor from the X-22 Display before entering the new one.
X-22 Installation and Calibration Manual3-2How do I recalibrate a sensor?If you have already calibrated the sensors and want to recalibrate one, proceed as follows: Select Main menu Setup Hardware Sensors and highlight the sensor you want to calibrate. Select Details. Then select Calibrated and press Change. The system is not measuring accurately, what should I do?If the system is not measuring accurately, a dimension or calibration value is probably wrong. Select Verify from the menu in the digging window, and press Troubleshooting. X-22 will then help you identify the problem and rectify it. Follow the on-screen instructions.The compass is measuring incorrectly, what should I do?The compass in the PitchRollCompass sensor is magnetic and has to be calibrated in order to measure correctly. Therefore try recalibrating the compass to see if this helps. Select Main Menu Setup Hardware Sensors PitchRollCompass Details. Then select Calibrated, and press Change.If you want to check how well the compass is calibrated, you can select Main MenuSetupHardwareSensors PitchRollCompassVerify. When the machine is stationary and the superstructure is rotated, the compass measurements should ideally form a perfect circle with the center at the origin.In certain special circumstances the magnetic compass can be disrupted so much that it should not be used. In this situation the heading on the screen can change even if the machine is at a complete standstill. If this happens, the compass should be turned off. Select Main menu Setup Hardware Sensors and highlight the PitchRollCompass sensor. Select “Details”. Then select “Compass on” and press “Change”. All the software functions that use the
TroubleshootingP/N 7010-1019 3-3heading measurements from the compass will now disappear and you will have to keep track of the heading yourself.In situations where there are large fluctuations in the magnetic field around the machine all the time, the compass calibration will not be able to compensate for the disturbances. An example of such a situation is if the machine is close to a railway line that is in use: Trains are surrounded by a strong magnetic field, which will badly disrupt the compass measurements whenever a train goes past. In this case the heading displayed on the screen could change even if the machine is at a complete standstill.Working in the vicinity of high-voltage cables can also cause problems for the magnetic compass. The laser sensor is not working, what should I do?The laser sensor may have problems detecting the laser beam in strong sunlight, particularly if the sun is shining straight into the photoelectric cell. If this happens, the amount of sunlight hitting the cell will have to be reduced by turning the sensor away from the sun, for example. If the laser sensor is exposed to strobe lighting, a rotating flashing light or the like, the sensor may be misled into thinking that it has detected the laser.If the laser sensor does not respond to the laser beam at all, even at close range, the photoelectric cell has probably been damaged. In this case you will have to contact your dealer to have the sensor replaced.
X-22 Installation and Calibration ManualNotes:3-4
P/N 7010-1019 A-1SpecificationsX-22 SensorThe following section provides specifications for the X-22 Sensor. Table A-1. X-22 Sensor General SpecificationsGeneral DetailsEnclosure Xenoy CL 100 PolycarbonateResistant to hydraulic fluids, diesel and UV exposureIP67Color Topcon YellowDimensions W: 112 mm x H: 48 mm x D: 68 mmW: 4.4 in. x H: 1.89 in. x D: 2.68 in.Weight 230g (standard sensor)0.5 lbs.Battery Operating time: Up to four weeks with normal useMaterial: Lithium-ion polymerNominal capacity: 5600mAhCharging time: OvernightExpected battery life: Beyond 3 yearsOperating temperature-20°C to +60°C-4°F to +140°FCharging temperature+5°C to +35°C-41°F to +95°FStorage temperature -20°C to +35°C-4°F to +95°FRadio Range: Over 50m (164 ft) line-of-sightFrequency: 2.4 GHz license-free ISM-bandProprietary packet radio protocolConnectors 2 charging pins (6V DC input, no polarity)
X-22 Installation and Calibration ManualA-2X-22 DisplayThe following section provides specifications for the X-22 Fanless 8.9” WSVGA TFT Multifunctional Touch Panel PC. Table A-2. X-22 Sensor General SpecificationsDisplay ScreenLCD Size 8.9”Display Type WSVGA TFTResolution 1024 x 600Color 256KPixel Pitch 0.1905mm (H) x 0.189mm (V)Luminance 220cd/m²Contrast Ratio 500Viewing Angle 50 (U), 60 (D), 70 (L), 70 (R)Response Time 30msBacklight LEDTouch Screen 5-Wire ResistiveLight transmission 80%Touch Interface USB Onboard Touch InterfaceSystemCPU Onboard AMD Geode LX800 @ 0.9W 500MHz with 128K L2 Cache CPUCooling Method Passive CPU HeatsinkSystem Chipset AMD Geode LX800/ CS5536System Memory Onboard 512MB DDR MemorySSD One CF Socket by IDE Secondary Slave Channel Supports Type I/II Compact Flash Card
P/N 7010-1019 A-3Rear Panel I/OSerial Port 1 x RS-232, 1 x RS-232 or Optional RS-422/ 485Ethernet 2 x RJ-45 (Realtek RTL8101L LAN)WIFI Optional USB WiFi 802.11 b/g (Occupies One USB Port)VGA 1 x DB-15Audio Line-out, Mic-inUSB 2 x USB 2.0Mouse & K/B 1 x PS/2 Keyboard ConnectorEnvironment & MechanicalColor Front Panel Black; Rear Panel BlackMounting Wall/ Stand/ VESA 75mm x 75mmPower Input 100 ~ 250Vdc/ 47 ~ 63HzPower Output +12Vdc/ 5A (60W)Operating Temperature-10°C ~ 60°C14°F to +140°FStorage Temperature-20°C ~ 70°C-4°F to +158°FRelative Humidity 10% to 95% @ 40°C, Non-condensingDimension W: 225mm x H: 139mm x D: 38.9mmW: 8.86 in. x H: 5.47 in. x D: 1.53 in.Weight 1.26Kgs (2.78 lbs.)Table A-2. X-22 Sensor General Specifications (Continued)
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P/N 7010-1019Appendix BB-1Safety WarningsGeneral Warnings1. Read and become familiar with the machine manufacturer’s operating instructions, including safety information, before installing or using your Topcon equipment.2. Use extreme caution on the jobsite. Working around heavy construction equipment can be dangerous.3. DO NOT attach system brackets while the machine is running.4. DO NOT allow any X-22 system component to limit the visibility of the operator.5. Use Ty-wraps, to keep hoses and wires secured and away from possible wear or pinch points.6. Use eye protection whenever welding, cutting, or grinding is being done on the machine.7. Protect yourself at all times, and wear protective clothing, when working on or near hydraulic lines. Avoid direct exposure to your eyes when using laser control.8. Use appropriate welding precautions and practices when welding. After welding, all paint all affected areas with a rust inhibitor.CAUTIONDO NOT stare into the laser beam or view the beam directly with optical equipment.WARNINGDO NOT weld near hydraulic lines or on any equipment when in operation.
X-22 Installation and Calibration ManualB-29. 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.10. Keep the carrying case dry at all times.If moisture does enter the carrying case, leave it open and allow it to thoroughly dry before storing any components.Sensor Warnings NOTICEDisconnect all Topcon system electrical cables prior to welding on the machine.NOTICEAll mounting bracket welds must be secure and strong to prevent sensor equipment from vibrating excessively or from becoming detached at the weld during operation.NOTICEDO NOT allow moisture to get inside the case. Moisture trapped in the case can adversely affect components.DANGERNever attempt to open the X-22 sensors! Lithium-Ion batteries can be dangerous if mishandled!DANGERDo not incinerate or heat battery pack above 212 degrees fahrenheit (100 degrees celsius). Excessive heat can cause serious damage and possible explosion.
P/N 7010-1019 B-3Usage Warnings WARNINGTampering with the batteries by end users or non-factory authorized technicians will void the battery’s warranty.• Do not attempt to open the sensors.• Do not disassemble the sensor.• Do not charge in conditions different than specified.• Do not use other than the specified battery charger.• Do not short circuit.• Do not crush or modify.CAUTIONIf this product has been dropped, altered, transported or shipped without proper packaging, or otherwise treated without care, erroneous measurements may occur.The owner should periodically test this product to ensure it provides accurate measurements.Inform Topcon immediately if this product does not function properly.CAUTIONOnly allow authorized Topcon warranty service centers to service or repair this product.
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P/N 7010-1019Appendix CC-1Regulatory InformationThe following sections provide information on this product’s compliance with government regulations for use.FCC ComplianceThis 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, and2. This device must accept any interference received, including interference that may cause undesired operation.This equipment has been tested and found to comply with the limits for a digital device, pursuant to Part 15 of the FCC rules. These limits are designed to provide reasonable protection against harmful interference in residential installations. This equipment generates, uses, and can radiate radio frequency energy, and if not installed and used in accordance with the instructions, may cause harmful interference to radio communications. However, there is no guarantee that interference will not occur in a particular installation.If this equipment does cause interference to radio or television equipment reception, which can be determined by turning the equipment off and on, you are encouraged to try to correct the interference by one or more of the following measures:• Reorient or relocate the receiving antenna.• Move the equipment away from the receiver.• Plug the equipment into an outlet on a circuit different from that to which the receiver is powered.• Consult the dealer or an experienced radio/television technician for additional suggestions.
X-22 Installation and Calibration ManualC-2FCC ComplianceThis equipment complies with FCC radiation exposure limits set forth for uncontrolled equipment and meets the FCC radio frequency (RF) Exposure Guidelines in Supplement C to OET65. This equipment has very low levels of RF energy that it deemed to comply without maximum permissive exposure evaluation (MPE). But it is desirable that it should be installed and operated with at least 20cm and more between the radiator and person’s body (excluding extremities: hands, wrists, feet and ankles). 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, and2. This device must accept any interference received, including interference that may cause undesired operation.This equipment has been tested and found to comply with the limits for a digital device, pursuant to Part 15 of the FCC rules. These limits are designed to provide reasonable protection against harmful interference in residential installations. This equipment generates, uses, and can radiate radio frequency energy, and if not installed and used in accordance with the instructions, may cause harmful interference to radio communications. However, there is no guarantee that interference will not occur in a particular installation.If this equipment does cause interference to radio or television equipment reception, which can be determined by turning the equipment off and on, the user is encouraged to try to correct the interference by one or more of the following measures:• Reorient or relocate the receiving antenna.• Move the equipment away from the receiver.CAUTIONAny changes or modifications to the equipment not expressly approved by the party responsible for compliance could void your authority to operate such equipment.
P/N 7010-1019 C-3• Plug the equipment into an outlet on a circuit different from that to which the receiver is powered.• Consult the dealer or an experienced radio/television technician for additional suggestions. Federal Communication Commission Declaration of Conformity (DoC) StatementModel No: HiPer IICAUTIONAny changes or modifications to the equipment not expressly approved by the party responsible for compliance could void your authority to operate such equipment.Trade Name TopconResponsible Party Topcon PositioningSystems, Inc.Address7400 National Drive,Livermore, CA 94550Telephone No +925-245-8300
X-22 Installation and Calibration ManualC-4Canadian Emission Labeling RequirementsThis equipment complies with IC radiation exposure limits set forth for uncontrolled equipment and meets RSS-102 of the IC radio frequency (RF) Exposure rules. This equipment has very low levels of RF energy that it deemed to comply without maximum permissive exposure evaluation (MPE). But it is desirable that it should be installed and operated with at least 20cm and more between the radiator and person’s body (excluding extremities: hands, wrists, feet and ankles). 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 undesired operation of the device.2. To reduce potential radio interference to other users, the antenna type and its gain should be so chosen that the equivalent isotropically radiated power (e.i.r.p.) is not more than that permitted for successful communication.3. This Class B digital apparatus meets all requirements of the Canadian Interference-Causing Equipment Regulations.Cet appareil numérique de la classe B respecte conform a la norme NMB-003 du Canada.IC RF Radiation Exposure StatementThis installer of this device must ensure that the antenna is located or pointed such that it dose not emit RF field in excess of Health Canada limits for the general population; consult Safety Code 6, obtainable from Health Canada’s website at www.hc-sc.gc.ca/rpb.
P/N 7010-1019 C-5Community of Europe ComplianceThe product described in this manual is in compliance with the R&TTE and EMC directives from the European Community.European Community Declaration of Conformity with R&TTE Directive 1999/5/ECThe following standards were applied: (R&TTE Directive 1999/5/EEC) • EN 301 489-1 V1.8.1 (2008-04)• EN 301 489-17 V1.3.2 (2008-04)• EN 300 328 V1.7.1 (2006-10)• EN 60950-1:2001 + A11:2004The following CE mark is affixed to the device:
X-22 Installation and Calibration ManualC-6Declaration of Conformity with Regard to the R&TTE Directive 1999/5/ECesky [Czech](Topcon) tímto prohlašuje, že tento (HiPer II) je ve shod se základními požadavky a dalšími píslušnými ustanoveními smrnice 1999/5/ES.Dansk [Danish] Undertegnede (Topcon) erklærer herved, at følgende udstyr (HiPer II) overholder de væsentlige krav og øvrige relevante krav i direktiv 1999/5/EF.Deutsch [German] Hiermit erklärt (Topcon) dass sich das Gerät (HiPer II) in Übereinstimmung mit den grundlegenden Anforderungen und den übrigen einschlägigen Bestimmungen der Richtlinie 1999/5/EG befindet.Eesti [Estonian] Käesolevaga kinnitab (Topcon) seadme (HiPer II) vastavust direktiivi 1999/5/EÜ põhinõuetele ja nimetatud direktiivist tulenevatele teistele asjakohastele sätetele.English Hereby, (Topcon) declares that this (HiPer II) is in compliance with the essential requirements and other relevant provisions of Directive 1999/5/EC.Español [Spanish] Por medio de la presente (Topcon) declara que el (HiPer II) cumple con los requisitos esenciales y cualesquiera otras disposiciones aplicables o exigibles de la Directiva 1999/5/CE. [Greek] Français [French] Par la présente (Topcon) déclare que l'appareil (HiPer II) est conforme aux exigences essentielles et aux autres dispositions pertinentes de la directive 1999/5/CE.csdadeeteneselfr
P/N 7010-1019 C-7Italiano [Italian] Con la presente (Topcon) dichiara che questo (HiPer II) è conforme ai requisiti essenziali ed alle altre disposizioni pertinenti stabilite dalla direttiva 1999/5/CE.Latviski [Latvian] Ar šo (Topcon) deklar, ka (HiPer II) atbilst Direktvas 1999/5/EK btiskajm prasbm un citiem ar to saisttajiem noteikumiem.Lietuvi [Lithuanian] Šiuo (Topcon) deklaruoja, kad šis (HiPer II) atitinka esminius reikalavimus ir kitas 1999/5/EB Direktyvos nuostatas.Nederlands [Dutch] Hierbij verklaart (Topcon) dat het toestel (HiPer II) in overeenstemming is met de essentiële eisen en de andere relevante bepalingen van richtlijn 1999/5/EG.Malti [Maltese] Hawnhekk, (Topcon) , jiddikjara li dan (HiPer II) jikkonforma mal-tiijiet essenzjali u ma provvedimenti orajn relevanti li hemm fid-Dirrettiva 1999/5/EC.Magyar [Hungarian] Alulírott, (Topcon) nyilatkozom, hogy a (HiPer II) megfelel a vonatkozó alapvetõ követelményeknek és az 1999/5/EC irányelv egyéb elõírásainak.Polski [Polish] Niniejszym, (Topcon) , deklaruj, e (HiPer II) spenia wymagania zasadnicze oraz stosowne postanowienia zawarte Dyrektywie 1999/5/EC.Português [Portugues](Topcon) declara que este (HiPer II) está conforme com os requisitos essenciais e outras disposições da Directiva 1999/5/CE.Slovensko [Slovenian](Topcon) izjavlja, da je ta (HiPer II) v skladu z bistvenimi zahtevami in ostalimi relevantnimi doloili direktive 1999/5/ES.Slovensy [Slovak](Topcon) týmto vyhlasuje, že (HiPer II) spa základné požiadavky a všetky príslušné ustanovenia Smernice 1999/5/ES.itlalinlmthuplptslda
X-22 Installation and Calibration ManualC-8WEEE DirectiveFollowing information is for EU-member states only:The use of the symbol below indicates that this product may not be treated as household waste. By ensuring this product is disposed of correctly, to help prevent potential negative consequences for the environment and human health, which could otherwise be caused by inappropriate waste handling of this product. For more detailed information about the take-back and recycling of this product, please contact a supplier where you purchased the product or consult. Suomi [Finnish](Topcon) vakuuttaa täten että (HiPer II) tyyppinen laite on direktiivin 1999/5/EY oleellisten vaatimusten ja sitä koskevien direktiivin muiden ehtojen mukainen.Svenska [Swedish] Härmed intygar (Topcon) att denna (HiPer II) står I överensstämmelse med de väsentliga egenskapskrav och övriga relevanta bestämmelser som framgår av direktiv 1999/5/EG.fisv
P/N 7010-1019Appendix DD-1Warranty TermsTPS laser and electronic positioning equipment are guaranteed against defective material and workmanship under normal use and application consistent with this Manual. The equipment is guaranteed for the period indicated, on the warranty card accompanying the product, starting from the date that the product is sold to the original purchaser by TPS’ Authorized Dealers.1During the warranty period, TPS will, at its option, repair or replace this product at no additional charge. Repair parts and replacement products will be furnished on an exchange basis and will be either reconditioned or new. This limited warranty does not include service to repair damage to the product resulting from an accident, disaster, misuses, abuse or modification of the product.Warranty service may be obtained from an authorized TPS warranty service dealer. If this product is delivered by mail, purchaser agrees to insure the product or assume the risk of loss or damage in transit, to prepay shipping charges to the warranty service location and to use the original shipping container or equivalent. A letter should accompany the package furnishing a description of the problem and/or defect.The purchaser’s sole remedy shall be replacement as provided above. In no event shall TPS be liable for any damages or other claim including any claim for lost profits, lost savings or other incidental or consequential damages arising out of the use of, or inability to use, the product.1. The warranty against defects in a Topcon battery, charger, or cable is 90 days.
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Topcon Positioning Systems, Inc.7400 National Drive, Livermore, CA 94550800∙443∙4567 www.topconpositioning.comISO 9001:2000FM 68448X-22 Installation and Calibration ManualP/N: 7010-1019 Rev A 06/11 ©2011 Topcon Positioning Systems, Inc. All rights reserved. No unauthorized duplication.

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