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Trimble GCS900 Grade Control System for
Grading Applications
Version 11.20
Revision A
Part Number 59002-06-ENG
December 2009 F
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C WARNING – This alert warns of a potential hazard which, if not avoided, can cause severe
injury.
Warnings
C WARNING – Do not operate this system unless you are fully trained on this equipment and
end-use equipment.
Maintenance of hydraulic hoses, fittings, and valves must be done by qualified service
personnel only. If inspection and service of hydraulic hoses, fittings, and valves is required, the
inspection and service should be performed at machine lubrication and service intervals.
Staring into a laser beam when a laser transmitter is operating may damage your eyes. To
avoid injury, do not look into the laser beam when it is in operation. For more information, refer
to the documentation that came with your laser.
The cutting edge of the machine may move without warning when automatic controls are on.
These sudden movements could cause injury to anyone near the cutting edge, or damage to
the machine. Always put the system in manual and engage the machine's park brake before
you leave the machine, or when somebody is working near the cutting edge.
When the cutting edge is not in operation, leaving it in the air could cause injury to you or
others, or damage to the machine. Always place the cutting edge on the ground when it is not
in use.
As the system equipment may extend beyond the extents of the cutting edge, operating the
machine close to people and objects could cause injury to them or damage to the machine or
system equipment. Maintain adequate clearance from people and objects when operating the
machine.
The cutting edge may move abruptly during hydraulic valve calibration. To avoid injury, make
sure the machine's park brake is engaged, and the calibrations are supervised by an operator
in the machine cab. Maintain adequate clearance from people and objects during the hydraulic
valve calibration.
C WARNING – Disconnect the negative battery terminal before commencing any welding.
Ensure that power is removed from the system by disconnecting the power input cable(s).
Failure to follow this warning may result in electric shock.
C WARNING – Ensure that all valve module connectors are correctly connected. Failure to do so
can result in personal injury from crushing, and permanent damage to the hydraulic system.
3 Machine Components . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.1 Machine configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.1.1 Optional components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.1.2 Additional components for conventional guidance . . . . . . . . . . . . . . 26
3.1.3 Additional components for 3D guidance . . . . . . . . . . . . . . . . . . . 27
3.1.4 Data radios . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
3.2 Machine-specific installation kits . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3.3 Device settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
9 Measure Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
9.1 Measure-up worksheet: bulldozer / scraper . . . . . . . . . . . . . . . . . . . . . 98
9.2 Measure-up worksheet: motor grader . . . . . . . . . . . . . . . . . . . . . . . 100
9.3 Preparing for measure-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
9.4 General guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
9.4.1 Optional mast measurements for conventional guidance systems . . . . . . 103
9.4.2 Electric mast measurements . . . . . . . . . . . . . . . . . . . . . . . . . 103
9.4.3 A-frame measurement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
9.5 Preparing the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
9.5.1 Bulldozers and scrapers . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
9.5.2 Motor graders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
9.6 Mast measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
9.6.1 Taking the measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
9.6.2 Standard mast measurements . . . . . . . . . . . . . . . . . . . . . . . . . 107
9.6.3 Additional measurements for an electric mast . . . . . . . . . . . . . . . . 108
9.7 Blade / cutting edge dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
9.7.1 Bulldozer / scraper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
1
Installation Workflow 1
If this message appears, then you must enter the A-frame machine measurement
before you can continue to use 2D guidance.
For more information, see 9.7, Blade / cutting edge dimensions.
2
Preparing for an Installation 2
Allow a full day for two experienced people to do the installation or more time for
inexperienced installers. The actual time taken will depend on the site, when you can
get access to the machine, and how long you have to wait for other tradespeople.
2.2 Tools
Make sure that you have the following tools available:
2.4.2 Temperature
The sensors give accurate guidance within their specified operating temperature
range. For optimum performance, do not mount the sensors near:
• Hydraulic lines
• Turbo chargers
• Exhaust systems
• Oil reservoirs
Some machines pressurize the instrument cluster area to distribute conditioned air. If
you drill the mounting brackets to these panels, make sure that you reseal these areas.
B Tip – Use a moist cloth or wet-wipe to clean the control box screen. Do not use your fingers –
you could scratch the screen.
2.4.4 Water
Certain system components, such as the control box, are sealed against water splash.
Other components are sealed against total water immersion. However you must take
care when selecting mounting locations.
Potential sources of water include:
• Condensation
• Rain
• Snow
• Ground water thrown up by passing vehicles or wheels
• Vehicle-washing systems (for example, waterblasters)
3
Machine Components 3
These machine types ... Support this guidance type ... Which requires these components ...
• Bulldozer Blade slope AS400 blade slope sensor
• Motor grader
• Bulldozer Lift/lift Two LR410 laser receivers
• Motor grader
• Bulldozer Cross slope Cross slope sensor group:
• Motor grader • AS400 blade slope sensor
• AS400 mainfall sensor
• RS400 blade rotation
Bulldozer Lift plus blade slope • AS400 blade slope sensor
• LR410 or SR300 laser receiver with PM400
power module
Motor grader Lift plus cross slope • Cross slope sensor group (see above)
• LR410 or SR300 laser receiver with PM400
power module or ST300 or ST400 sonic tracer
These machine types ... Support this guidance type ... Which requires these components ...
• Bulldozer/Scraper 1 x GPS, cab mounted • 1 x GPS receiver
• Motor grader • A data radio
1 x GPS, mast mounted • 1 x GPS receiver
• A data radio
• Fixed or electric mast and PM400 power module
2 x GPS • 2 x GPS receivers
• A data radio
• Fixed or electric masts and PM400 power module
• Bulldozer 1 x UTS • UTS target
• Motor grader • A data radio
• Fixed mast or electric mast and PM400 power
module
Bulldozer 3D plus blade slope • 1 x GPS receiver or UTS target
• A data radio
• Fixed or electric mast and PM400 power module
• AS400 blade slope sensor
3D plus cross slope • 1 x GPS receiver or UTS target
• A data radio
• Fixed or electric mast and PM400 power module
• AS400 blade slope sensor
• AS400 mainfall sensor
• RS400 blade rotation
Motor grader 3D plus cross slope • 1 x GPS receiver or UTS target
• A data radio
• Fixed or electric mast and PM400 power module
• AS400 blade slope sensor
• AS400 mainfall sensor
• AS400 blade pitch sensor
• RS400 blade rotation
For this device... This data ... Is stored in the ... Notes
VM4xx valve modules Valve calibration Machine file
RS400 rotation sensor Angle calibration Sensor Recalibrate the sensor of you move or
swap it.
EM400 electric mast Height offset Machine file
AS400 sensor Angle calibration Sensor
ST300/ST400 Bench N/A Sonic tracers bench when they are
sonic tracers powered up, but the system also
restores the last bench point
LB400 Lightbar Position Lightbar After removal, return each lightbar to the
Invert Machine file same position. Otherwise, you must set
Scale or tolerance display file the lightbar connections again.
See 10.6, Lightbar Connections
CB430 control box Settings Machine and display files
MS9xx GPS receivers The .cfg site Control box design folder When you load a design, the control box
configuration file or data card root directory sends the .cfg file to the GPS receiver .
To send a .cfg file from the data card, see
10.10, GPS Receiver Configuration
Machine radio Network and Machine file The control box automatically sets the
frequency settings network number in the machine radio.
So, if you swap radios, the control box
will set the network number that was
configured for the previous radio, onto
the current radio.
See 10.1, Using the Setup menus
4
Installing the Main Harness Assembly 4
ATTENTION – Do not use a tool, such as pliers, to tighten a harness or component connector
C as this could damage the connector. Always hand-tighten the connectors.
ATTENTION – Do not cut off any left over cabling, as this could affect system performance.
C Bundle, tie wrap and store any extra cabling in a convenient place on the machine.
Once you have installed the cables, you must check the installation. For more
information, see 11.1, Validating the cabling installation.
Figure 4.4 shows the cabling for a bulldozer automatic system with dual GPS
receivers.
< =
A1
> ?
@
<
>
? @
D
A C
B
=
>
<
GPS receiver
Fixed C
mast
Quick disconnect
bracket
Laser receiver and/or
B AS400 sensor connector
GPS receiver
A To rear harness
Figure 4.4 Bulldozer automatic system with dual GPS receivers (continued over page)
LB400 lightbars
H
Radio modem
F
MAN K
I J
D N CAN bus terminator
G
PM400
L
M
To front harness
D Lightbar harness cable (P/N 54438) I Ignition switched & battery unswitched
E Valve cable: power cable (P/N 54486-xx)
without load sense (P/N 0395-9610) J Remote switch cable (P/N 0395-9254-xxx)
with load sense (P/N 0395-2610) K Cab harness cable (P/N 54020)
F Switched power cable w/o PM400 (P/N 57726-xx) L Radio cable (P/N 0395-9470-xxx)
G PM400 power module (P/N 0395-5020) M Rear harness cable (P/N 0395-9010)
H PM400 power cable (P/N 0395-9130-xxx) N Reversing buzzer connector
Figure 4.8 shows the cabling for an motor grader automatic system with UTS and
sideshift.
< >
?
@
=
?
=
<
>
@
<
=
A
>
@
UTS target
G
To rear harness
C
CAN bus
terminator
E
AS400 mainfall sensor
Unused connector
D Quick disconnect bracket
A Blade slope sensor cable (P/N 0793-0210-xxx) E Elevation sensors Y-cable (P/N 0395-9090-xx)
B Cross slope sensor Y-cable (P/N 0395-1590-xx) F Mainfall sensor cable (P/N 0395-1870-xx)
C UTS cable (P/N 0312-0990) G Front harness cable (P/N 0395-9800)
D Electric mast cable (P/N 0793-3350)
Figure 4.8 Motor grader automatic system with UTS and sideshift (continued over page)
Lightbars
G H
P
I
Q
To front harness U
L
N N
O
T
Radio modem
M
S R
G Power cable without PM400 (P/N 57726-xx) N CAN bus terminator (P/N 2114-2116)
H Power module cables (P/N 0395-9130-xxx) O Unused connector
I PM400 power module (P/N 0395-5020) P Lightbar harness cable (P/N 54438)
J Valve modules cables (P/N 0395-9610-xxx) or Q Cab harness cable (P/N 57335)
valve cable with load sense (P/N 0395-9620-xxx) R Sideshift remote switch cable (P/N 57636-xx)
K VM420 valve modules S Remote switch cable (P/N 57545-xx)
L Rear harness cable (P/N 0395-9810) T Ignition switched & battery unswitched
M Data radio cable (P/N 0395-9470-xxx) power (P/N 54486-xx)
U Reversing buzzer connector
C CAUTION – If you connect the system’s ground (negative) connection to the negative terminal
of the battery, and attempt to start the machine with the master disconnect switch open (or if
the machine has a defective master disconnect switch or battery ground cable), then the starter
current will flow through the system from a component ground on the chassis to the battery
terminal. This will damage the system.
To avoid damaging the system, you must connect the system’s ground (negative) connection
to the frame of the machine, not the negative terminal of the battery.
B Tip – While you are connecting the power, place a “Machine under service, do not turn on”
tag on the battery isolation switch.
6. Connect the black and white wires of the power cable to a suitable grounding
lug on the machine chassis.
=
<
>
?
@ A
B
>
24 V+
C
D
E F
< Switched power to machine B Two ground wires (black and white)
= Blue wire C Master disconnect switch
> Fuses D Machine batteries
? Cab harness E Voltage protection diode
@ Green wire F Ground lug on machine chassis
A Run relay
2. Connect the cable to the grounding point. Use the provided washer and nut to
secure the diode to either:
– A hole in the machine frame. For thin metal, drill a 9.525 mm (0.375 in)
hole; for thick metal, drill an 8.43 mm (0.332 in) hole and then tap the
hole with a 3/8 – 24 tap.
– The supplied square block (welded directly to the machine frame).
Note – To ensure that the diode comes in complete contact with the metal
surface, remove any existing paint. To keep the mounting surface from
rusting and the diode from loosening, make sure that you apply rust
prevention paint after you have secured the diode.
3. Torque the nut to:
– 14 N⋅m (125 lb-in) without lubricant
– 12.5 N⋅m (110 lb-in) lubricated
4. Use the provided nut to connect the lug end of the voltage protection diode
cable to the grounded negative (–) terminal of the battery.
5. Verify that all wire connections are correct and tight.
6. Replace the battery isolation master key. Turn the key to the on position.
Fuses
24 V+ Master disconnect switch
Black wires
Ground lug on chassis
5
Welding and Fitting Tasks 5
Note – For the optimum performance of dual GPS systems, Trimble recommends that
you mount the masts on the left and right sides of the machine.
Motor grader
>
< = ?
D CB A @
Push-arm bulldozer
?
>=
<
@
B
D
<
@ A
D B
C
Scraper
> A
=
?
E
C WARNING – Disconnect the negative battery terminal before commencing any welding.
Ensure that power is removed from the system by disconnecting the power input cable(s).
Failure to follow this warning may result in electric shock.
Cutting edge
Machine centerline
2. Assemble the angle mast mount and check that the rotating bracket is in the
correct position.
3. When you are satisified that is everything is correct, weld the mount securely:
Upper section
Lower section
Mount
4. Take a note of the bolt hole number you use on the upper section: 1 is nearest
the front of the machine; 7 is nearest to the operator’s cab.
You will enter this number into the system at a later time.
Bolt the blade pitch sensor bracket to the underside of the rotating bracket: use the
bolts that secure the mast to the rotating bracket.
The following image shows a quick disconnect bracket mounted on a motor grader:
4. Check that the bracket is square to the blade. Adjust as required to make
lengths A and B equal:
Blade
A B
5. Once you confirm the measurements, secure the bracket to the blade.
If using bolts, torque the mounting bolts to 20 ± 2 N·m (15 ± 1.5 lbf ft). Secure
with Blue Loctite.
Use one of the following methods to install the valve/power module bracket:
Option 1
1. Attach new weld bosses to the cab. Make sure that the weld bosses match the
hole patterns in the bracket.
2. Fix the bracket to the bosses.
Option 2
Fix the bracket to existing weld bosses.
If you use weld bosses with existing fixtures, you may have to use longer bolts
than those in the kit.
Option 3
Weld the bracket directly to the machine.
• The mounting tube clamp and the adjustable mast mount of the mast connect to
the same mount, as shown below:
ATTENTION – If you do not install the sideshift stop, you must inform the operator of the
C potential for the rotating bracket mount to come into contact with another part of the machine.
Position the sideshift stop so that the rotating bracket mount is at least 50 mm (2 in)
from the part of the machine that the mount would otherwise contact.
To install the sideshift stop:
1. Tack weld the sideshift stop to the cutting edge.
2. Check that the position of the sideshift stop is suitable. Adjust if necessary.
3. Securely weld the sideshift stop.
2. Bolt the data radio onto the data radio bracket. Ensure the mounting screws are
all fitted with washers and lock washers.
3. Use the rubber shock mount kit to bolt the data radio bracket to the adapter
plate. The bolts are included with the adapter plate.
4. Secure with Loctite.
The following image shows the SNRx10 mounted on the machine cab:
6
Installing the Cab Components 6
In this chapter: Note – To mount the valve module onto the same
bracket as the power module, use the dual
Q The control box module mounting bracket (P/N 0395-9170).
Q Remote switches
Q Towed scraper raise / lower switch
Q Valve module
Q Power module
Q Lightbars
Q Radios
Q Reversing buzzer
RAM mount
Control box
Pole bracket
1. Use the M5 screws and flat washers to attach the ball mount to the control box.
2. Use the M10x40 screws, washers, split lock washers and nut plate or hex nuts
to attach the pole bracket to the cab.
3. Fasten the RAM mount to the pole bracket.
4. Insert the ball mount into the RAM mount socket and fasten.
5. Connect the control box cable from the harness cable to the control box.
B Tip – The control box is easy to remove from the RAM mount. To prevent vandalism or theft,
remove the control box at night.
For more information, refer to the instructions supplied with the control box
assembly.
Note – If it is not practical to mount the remote switch on the blade control
lever, you can make a custom mount.
2. Route and secure the remote switch cable.
3. Connect the cable to the remote switch connector on the rear harness cable.
4. Finish the install. See 6.2.3, Complete the remote switch installation.
So the operator can activate the switches with the thumb and index finger, orient the
switches in towards the console:
Note – Before you mount a remote switch, make sure that the position is suitable for
the operator.
5. Insert the pins into the back of the blank Deutsch connector. See Figure 6.1.
3 = Black 10 = Black 2 11
4 = Black 9 = Black 4 9
5 = White 8 = Red
6 = Red 7 = White
5 8
6 7
Note – If you orient the switch outwards from the
console, you must reverse the red and white wires.
6 7
Check that this switch ... Affects this side of the By ...
blade...
Left auto/manual Left Going into Auto or Inactive
Right auto/manual Right Auto mode
2. Cable tie the remote switch assembly cables to each lever. Ensure that the
cables do not adversely affect lever operation.
3. The remote switch assembly kit contains a set of stickers; each sticker indicates
a different control lever operation. Place an appropriate sticker onto each
remote switch assembly.
Use hook and loop tape to install the switch in the machine cab, adjacent to the
machine controls.
To connect the switch to the system harness:
1. Cut the 6-pin connector off the end of the raise/lower switch cable.
2. Insert the six crimped wires into the back of the 8-pin remote switch connector
cap (P/N 0395-9230) supplied with the rear harness. See Figure 6.3.
1 = Empty 8 = Black
2 = Red 7 = Empty
1 8
3 = Green 6 = Brown
4 = Blue 5 = White 2 7
3 6
4 5
3. Connect the newly formed 8-pin connector to the system rear harness.
6.6 Lightbars
To attach the lightbar directly to a suitable surface in the cab, use one of the
following:
• the supplied nuts, washers, and bolts
• double-sided tape
• hook and loop tape
To determine where to mount the lightbars, see 5.13, Lightbar brackets.
6.7 Radios
Before you connect any of the radios, make sure that the radio brackets are installed
correctly. See 5.14, Radio brackets.
Once you have connected the radio, use a cable tie to bundle any extra cable.
SNRx10 only
1. Plug the 8-socket connector on the radio cable (P/N 0395-9470-xx) into the
SNRx10 radio modem.
2. Connect the 12-pin connector on the radio cable to the black rooftop radio
connector.
The SNRx10 radio modem installed on the machine cab:
For more information, refer to the SNRx10 Radio Modem User Guide.
SNM930 only
1. Plug the 24-socket connector on the SNM930 interface cable (P/N 71330-xx)
into the SNM930 cellular modem.
2. Connect the interface cable to the black rooftop radio connector.
2. Plug the 12-pin Deutsch connector on the third-party radio cable into the
standard 12-socket radio connector on the main harness:.
Third-party radio
J2
Note that the physical connection of the flying lead black and red wires are machine
dependent. As there is no polarity, both wires perform the same function.
See Figure 6.4.
Flying lead
Red
Black
1 1
2 2
J2 Black Active terminator (J1)
3 3
4 4
Red
Reversing buzzer
Machine power flying lead Machine power
O
Machine reverse switch
Buzzer
O
O
Buzzer
Machine reverse switch
O
Reversing buzzer
Machine ground Machine ground flying lead
Parallel – Correct Parallel – Correct
Machine power
Buzzer
O
O
Series – Incorrect
7
Installing the Fixed Components 7
In this chapter:
=
< >
The following image shows the rotation sensor mounted on a pivot point at the back
of the blade:
< = >
?
4. Connect the cable to the AS400 blade slope sensor. See Figure 7.1.
5. Tie the cable every 300 mm (12 in) to keep it free from damage.
The following image shows the blade slope sensor in the rear circle pocket:
3. Place the rotation sensor on the modified lid. Make sure that the:
– sensor arm fits into the recessed groove
– connector faces towards the rear of the machine
4. Use the provided screws and nylon bushings to secure the rotation sensor to the
modified lid.
Fit the nylon bushings into the groove on the rotation sensor:
5. Bolt the drive arm bracket to the inside frame of the circle so that the drive arm
fits securely over the rotation sensor.
6. Use the supplied shoulder bolt to attach the drive arm to the mounting bracket.
7. Position the drive arm near to the center of the drive arm mounting slot. To
install it, use one bolt; secure it firmly but not tight.
8. Connect the rotation sensor cable to the sensor.
9. Open the Diagnostics dialog and view the output from the sensor.
If the value is:
– within ± 32° of zero go to Step 17.
– outside the 32° go to Step 10.
10. Taking care not to move the drive arm relative to the sensor body, disconnect
the sensor cable and remove the rotation sensor from the lid.
11. Loosen the allen screw on the drive arm:
12. Place material, such as a folded business card, under the drive arm to space the
arm from the sensor. This gives the sensor drive arm some clearance when you
tighten the allen screw again.
13. Reconnect the rotation sensor cable.
14. Use a screwdriver to rotate the shaft until the the Diagnostics dialog shows
that the sensor output is within ± 32° of zero:
15. Tighten the allen screw on the drive arm and recheck the reading.
16. Repeat Step 3 to Step 7 to reattach the rotation sensor to the hydraswivel lid.
17. Slowly rotate the sensor and observe the the Diagnostics dialog for the sensor
output.
18. When the reading is within ± 32° of zero, install the second mounting arm bolt
and tighten both bolts:
19. Recheck the sensor rotation angle value on the control box.
Angle riser
Rotating bracket
Mount
8
Installing the Removable Sensor
Components 8
In this chapter:
ATTENTION – To avoid damage to the electric mast and/or shock mounts, make sure that you
C tighten all bolts to the specifications outlined below.
1. For a:
– bulldozer, position the shock mount on the mounting plate and use the
supplied grade 8 bolts and washers to attach it.
– motor grader, position the shock mount or vertical riser on the rotating
bracket and use the supplied grade 8 bolts and washers to attach it.
2. Torque the bolts to 305 N·m (225 lbf ft).
3. Remove the two bolts that attach the clamp to the upper cross bracket of the
shock mount.
4. Position the electric mast on the lower U-bracket of the shock mount and use
the supplied bolt and washer to bolt the mast onto the U-bracket.
Re-install the clamp onto the cross bracket.
5. Check that the mast is properly installed onto the shock mount.
6. Torque the mast bolt to 205 N·m (151 lbf ft).
7. Torque the clamp bolts to 8 N·m (6 lbf ft).
8. Remove the two 13 mm (1⁄2 in) bolts that secure the U-bracket to the lower part
of the shock mount and apply Loctite to them.
9. Reinstall the two bolts to the U-bracket and tighten to 54 N·m (40 lbf ft).
Note – Before you replace a mast with a laser receiver, disconnect the GPS receiver.
Reconnect the receiver once you complete the replacement.
1. Ensure that the base of the laser receiver and the top of the mast mount are free
from dirt.
2. Position the laser receiver on the mast mount so that it is square to the blade,
and the connector faces backwards.
3. Use the supplied bolt and lock washer to secure the laser receiver.
B Tip – When securing the bolt, apply some anti-seize compound to the bolt thread.
<
>
@
< Laser receiver
= Laser receiver coil cable P/N 0793-0860
> Electric mast
? Electric mast coil cable P/N 0793-3350
@ Quick disconnect bracket P/N 0791-0940
ATTENTION – To ensure system accuracy, you must fully insert the mast or laser receiver into
C the GPS mounting bracket.
> >
<
@
?
?
Adapter sleeve
9
Measure Up 9
Date:
Measurement units:
Machine name:
Date:
Measurement units:
Machine name:
ATTENTION – The bottom section of the rotating bracket has two bolt holes; you can use either
C of these to attach the top section to the bottom. However, you must choose one or the other
and use only that one - you cannot take measurements for both and then swap between them.
Note – You do not have to measure to the very tip of the moldboard, however,
you must measure to the same point at each end of the moldboard.
4. Compare the two measurements. If they are not equal, rotate the blade slightly.
5. Repeat Step 3 and Step 4 until the two measurements are equal.
6. Mark the rotating part of the circle where it lines up with the fixed part of the
circle. Make the mark prominent enough to see from the cab:.
Now, whenever you need to rotate the blade to zero, align the chisel mark with
the fixed part of the circle.
• If you do not use a measure-up tool, make the height measurements to either:
– the top of the mast (remove the mounting brackets and/or collars).
– the joint between the radome and the lower housing of the GPS receiver:
ATTENTION – The Measure height to option in the Mast Measurements dialog defaults to
C Measure-up tool.
If you do not use a measure-up tool, make sure that you select the correct Measure height to
option. If you select the wrong option, this can introduce a substantial vertical error into the
positioning information that the system provides. See 10.4.1, Mast measurements.
Bulldozer Scraper
B B
B
C C C
Motor grader
B B
C C
If the mast leans towards the blade tip, the measurement is negative.
Note – Take either the Edge H/V or Edge Angle measurements - you do not need both.
Edge H/V:
• Cutting edge horizontal distance: I
• Cutting edge vertical distance: K
Edge Angle:
• Cutting edge height: J
• Cutting edge angle: L
L
K
J
K
L
GCS900 Grade Control System for Grading Applications Installation Manual 111
9 Measure Up
• Blade height: F
• Blade width between tips: G
• Distance between lift rams: H
F H
9.8.1 Bulldozer
O N
GCS900 Grade Control System for Grading Applications Installation Manual 113
9 Measure Up
Guidance point
N
Front of blade
H x
A = Horizontal distance from cutting edge bolts back to left GPS receiver
H = Horizontal distance from cutting edge bolts to front of blade
C = Distance in from left blade tip
A
Straight edge
GCS900 Grade Control System for Grading Applications Installation Manual 115
9 Measure Up
Straight edge
Centerline
2. Mark the bottom edge of the mounting bracket at each 90° interval:
B Tip – When you mount the measure-up tool, make sure that the measurement units you prefer
to work in are on the horizontal surface.
To use the measure-up tool efficiently, take the measurements in this order:
a. Back from cutting edge bolts
b. Above cutting edge bolts
c. In from left/right blade tip
For dual antenna systems, where the tops of the masts are the same distance back
from the cutting edge bolts, this is a safe and quick way to align the measure-up tool:
1. Slide the measure-up tool onto the top of the mast you want to measure.
2. Point the measure-up tool at the other mast.
3. Mark the mast you are measuring, in line with the 90° marks on the bracket.
4. For measurements a and b, to rotate the bracket until it points straight forward,
align the marks on the bottom of the bracket with each mark on the mast.
GCS900 Grade Control System for Grading Applications Installation Manual 117
9 Measure Up
5. For c, to rotate the bracket another 90°, align the marks on the bottom of the
bracket with the next mark on the mast.
4. Secure a plumb line from one of the notches in the measure-up tool so that the
plumb line hangs just in front of the cutting edge bolts.
5. Record the measurement beside the notch you secure the plumb line to.
6. Measure the distance from the plumb line to the center of the cutting edge
bolts:
7. Subtract the value taken in Step 6 from the value taken in Step 5.
GCS900 Grade Control System for Grading Applications Installation Manual 119
9 Measure Up
B Tip – To align the measure-up tool, sight along the tool to the other mast:
2. Secure a plumb line from one of the notches on the measure-up tool, so that the
plumb line hangs just out from the end of the blade.
3. Record the measurement beside the notch you secure the plumb line to.
4. Measure the distance from the tip of the blade to the intersection of the steel
framing square and the plumb line:
5. Subtract the value measured in Step 4 from the measurement taken in Step 3.
Note – If the center of the mast is outside the blade tip, the measurement is
negative.
10
Setup Menus 10
C CAUTION – If you lack experience with the GCS900 Grade Control System, when you are in
Manager mode be careful not to accidentally change any system settings.
To validate the rotation sensor mounting position, check that the rotation sensor
values:
• do not change when you tilt the blade
• increase when you move the right hand blade tip forward.
If the value decreases, invert the mounting direction.
Once you have configured all of the settings, the Finished page appears:
4. To save the system settings, press Finish. The summary page appears.
5. Check the summary page to ensure that the settings match your system type.
10.3 Units
1. From Setup Menu – Installation, select Units:
• For systems that do not use a mast, the blade dimensions page of the Machine
Dimensions wizard appears:
ATTENTION – Valid machine measurements are critical to system operation. Make sure that
C you enter all of the required measurements for your system type.
2. Press 7. If the mast uses a rotating bracket, the Bolt Holes page appears:
If required, select the bolt holes that you are using and press 7.
3. The Mast Measurements page appears:
ATTENTION – Make sure that you select the correct Measure height to option.
C If you select the wrong option, this can introduce a substantial error into the guidance
information that the system provides. For more information, see 9.6, Mast measurements.
2. Check the LED pattern on the lightbars to see if they correspond to the dialog.
If they do not, for each lightbar that is wrong, do the following:
Connect this lightbar to the harness Then press this If the LEDs light up at the wrong end, then
(disconnect others) ... softkey ... press this softkey ...
Left/Vertical Set A Invert A
Center/Horizontal Set B Invert B
Right Set C Invert C
3. Press \.
To configure this Enter this number into the Enter the same number into the ...
radio ... Machine Radio Configuration dialog ...
SNR900 A network between 1-40 GPS base radio (via the base station radio
SNR910 display)
SNR2400/ A channel between: Internal UTS radio (via the face plate)
SNR2410 • 1-12 for the ATS600
• 31-60 for the SPSx30
SNR410 Refer to the documentation supplied with your radio
Notes – 1. If your site uses both GPS and UTS positioning systems with 900 MHz
radios, then the GPS radios and each UTS radio must use different
networks.
2. If you have a dual band SNRx10 radio, assign a network ID to both radio
modules so that you can switch between radio bands if necessary.
The list that appears on the first page of the wizard varies according to the sensors
that are connected to the harness. The following table describes the calibration
options for each machine:
For this machine ... These list items may appear ...
• Bulldozer Mainfall, blade slope and rotation sensors
• Motor Grader Note – You can calibrate the above sensors collectively, or individually;
you only need to calibrate them once.
Blade slope sensor
Blade pitch sensor
Blade rotation sensor
Mainfall sensor
Electric masts
Linked EM400 calibration
Mill/Cold planer Drum slope sensor
Other Blade slope sensor
Linked EM400 calibration
As a guideline, the default values for the SNR900 or SiteNet 450 are:
– Baud rate: 38400
– Parity: None
For the SNM930 cellular modem
To receive VRS corrections, set Yes in the GGA field of the External VRS
Device group.
Note – To receive VRS corrections, the MS99x GPS receivers require version
3.9x or later firmware.
The dialog lists all of GPS receiver configuration files in the root directory of
the data card.
The CMRs softkey displays which CAN bus the system is currently using to
relay information between the GPS receivers.
2. Select the correct .cfg file and press \. A message appears:
Loading. Please wait ...
3. Once the file loads, Setup Menu – Configuration appears. Check that the GPS
configuration file was correctly sent:
a. Measure and enter all the machine measurements.
b. Calibrate all the sensors.
c. Position the cutting edge on a known point and compare the coordinates
that appear on the control box with the known coordinates of the point.
11
Validation and Troubleshooting 11
Check the continuity between this pin on the And this pin on the missing component ...
control box ...
K (CAN0 Hi) C
J (CAN0 Lo) D
At this harness connector ... Check CAN0 Hi at pin ... Check CAN0 Lo at pin ...
Data radio 4 5
ATS / UTS target C D
Valve module C D
Electric mast C D
Laser receiver C D
AS400 angle sensor C D
RS400 rotation sensor C D
11.8 No power
Where there appears to be no power present on the system, check that:
• power is connected correctly; use a multimeter to trace the voltage from the
source through all the components of the system
• all fuses are working
• all the pinouts are connected correctly
If you suspect that a component is faulty, swap in a known good component
and then re-check the machine power.
If the control box does not power up:
1. Remove the main harness connector from the control box.
2. On the power circuit between the battery and the control box, check the:
– connections to battery positive and chassis ground: tighten any loose
connections, and re-check the control box.
– fuses on the switched and/or unswitched positive power flying leads:
replace any blown fuses, and re-check the control box.
– power cables and connectors between the battery and the control box.
3. Ensure that battery voltage is present at pins D and F on the control box
connector. See Figure 11.1.
If the control box is receiving power, suspect a faulty control box. Swap in a
known good control box and then re-check the machine power and control box.
W A
V B
C
U X
j Y
T i D
k Z
S h r m a E
R g F
q n b
P p G
f
Pin Function Pin Function
N e d c H
A SPARE N/C X IGNITION / WAKE UP INPUT
M J
B SWITCH INPUT 0 L K Y SWITCH INPUT 1
C SWITCH INPUT 3 Z SWITCH INPUT 6
D BATT + a RCA LINE OUT Hi
E SWITCH COMMON GROUND b RCA LINE OUT Lo
F BATT – c CDL Lo
G SPARE N/C (Not Connected) d CDL Hi
H SWITCH INPUT 4 e CAN1 BUS SHIELD
J CAN0 Lo f RS232-0 RTS
K CAN0 Hi g RS232-0 CTS
L CAN1 Hi h RS232-0 RXD
M CAN1 Lo i RS232-0 TXD
N RS232-2 TXD j RADIO SWITCH
P RS232-2 RXD k SWITCH INPUT 2
R RS232-2 GND m BATT–
S RS232-1 GND n AWAKE GROUND
T RS232-1 RXD p AWAKE
U RS232-1 TXD q RS232-0 GROUND
V SWITCH INPUT 5 r SPARE N/C (Not Connected)
W BATT +
A
Radio Declarations A
In this chapter:
C CAUTION – The use of this radio equipment requires individual authorization for outdoor
operation in Latvia.
Language Declaration
English Hereby, Trimble Navigation, declares that this 2.4 GHz Spread Spectrum Radio Transceiver,
SNR2400, is in compliance with the essential requirements and other relevant provisions of
Directive 1999/5/EC.
Finnish Trimble Navigation vakuuttaa täten että 2.4 GHz Spread Spectrum Radio Transceiver, SNR2400,
Suomi tyyppinen laite on direktiivin 1999/5/EY oleellisten vaatimusten ja sitä koskevien direktiivin muiden
ehtojen mukainen.
Dutch Hierbij verklaart Trimble Navigation dat het toestel 2.4 GHz Spread Spectrum Radio Transceiver,
Nederlands SNR2400, in overeenstemming is met de essentiële eisen en de andere relevante bepalingen van
richtlijn 1999/5/EG
Bij deze verklaart Trimble Navigation dat deze 2.4 GHz Spread Spectrum Radio Transceiver,
SNR2400, voldoet aan de essentiële eisen en aan de overige relevante bepalingen van Richtlijn
1999/5/EC.
French Par la présente Trimble Navigation déclare que l'appareil 2.4 GHz Spread Spectrum Radio
Francais Transceiver, SNR2400, est conforme aux exigences essentielles et aux autres dispositions
pertinentes de la directive 1999/5/CE
Par la présente, Trimble Navigation déclare que ce 2.4 GHz Spread Spectrum Radio Transceiver,
SNR2400, est conforme aux exigences essentielles et aux autres dispositions de la directive
1999/5/CE qui lui sont applicables
Swedish Härmed intygar Trimble Navigation att denna 2.4 GHz Spread Spectrum Radio Transceiver,
Svensk SNR2400, står I överensstämmelse med de väsentliga egenskapskrav och övriga relevanta
bestämmelser som framgår av direktiv 1999/5/EG.
Danish Undertegnede Trimble Navigation erklærer herved, at følgende udstyr 2.4 GHz Spread Spectrum
Dansk Radio Transceiver, SNR2400, overholder de væsentlige krav og øvrige relevante krav i direktiv
1999/5/EF
German Hiermit erklärt Trimble Navigation, dass sich 2.4 GHz Spread Spectrum Radio Transceiver,
Deutsch SNR2400, in Übereinstimmung mit den grundlegenden Anforderungen und den anderen
relevanten Vorschriften der Richtlinie 1999/5/EG befindet". (BMWi)
Hiermit erklärt Trimble Navigation die Übereinstimmung des Gerätes 2.4 GHz Spread Spectrum
Radio Transceiver, SNR2400, mit den grundlegenden Anforderungen und den anderen relevanten
Festlegungen der Richtlinie 1999/5/EG. (Wien)
Greek ΜΕ ΤΗΝ ΠΑΡΟΥΣΑ Trimble Navigation ΔΗΛΩΝΕΙ 2.4 GHz Spread Spectrum Radio Transceiver,
Ellhnikdz SNR2400, ΕΥΜΜΟΡΦΩΝΕΤΑΙ ΠΡΟΣ ΤΙΣ ΟΥΣΙΩΔΕΙΣ ΑΠΑΙΤΗΣΕΙΣ ΚΑΙ ΤΙΣ ΔΟΙΠΕΣ ΣΧΕΤΙΚΕΣ
ΔΙΑΤΑΞΕΙΣ ΤΗΣ ΟΔΗΓΙΑΣ 1999/5/ΕΚ
Italian Con la presente Trimble Navigation dichiara che questo 2.4 GHz Spread Spectrum Radio
Italiano Transceiver, SNR2400, è conforme ai requisiti essenziali ed alle altre disposizioni pertinenti
stabilite dalla direttiva 1999/5/CE.
Spanish Por medio de la presente Trimble Navigation declara que el 2.4 GHz Spread Spectrum Radio
Español Transceiver, SNR2400, cumple con los requisitos esenciales y cualesquiera otras disposiciones
aplicables o exigibles de la Directiva 1999/5/CE
Portuguese Trimble Navigation declara que este 2.4 GHz Spread Spectrum Radio Transceiver, SNR2400, está
Portuguese conforme com os requisitos essenciais e outras disposições da Directiva 1999/5/CE.
A.1.1 Notices
Class B Statement – Notice to Users. 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 radio frequency energy and, if not installed and used in accordance with the
instructions, may cause harmful interference to radio communication. 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:
• Reorient or relocate the receiving antenna.
• Increase the separation between the equipment and the receiver.
• Connect the equipment into an outlet on a circuit different from that to which
the receiver is connected.
• Consult the dealer or an experienced radio/TV technician for help.
Changes and modifications not expressly approved by the manufacturer or registrant
of this equipment can void your authority to operate this equipment under Federal
Communications Commission rules.
This Class B digital apparatus complies with Canadian ICES-003.
Cet appareil numérique de la classe B est conforme à la norme NMB-003 du Canada.
The SNR2400 operates in the 2400 to 2483.5 MHz frequency band (2400 to 2454
MHz in France). It contains a transmitter module that is certified for unlicensed use in
this band as a transmitter pursuant to 47 C.F.R. §§ 15.247 Subpart C of Part 15 of
FCC Rules regarding Spread Spectrum Systems for the United States.
License-free operation in Canada is covered by RSS-210 of Industry Canada; in the
European Union is covered by harmonized standard EN 300 328; in Australia and
New Zealand by gazetted standard AS/NZS 4771:2000.
B
Towed Scraper Installations B
3. Connect the 10-pin connector of the John Deere valve cable assembly
(P/N 0793-1030) to the machine harness connector.
4. Connect the 9-pin connector of the John Deere valve cable assembly to the 9-
socket connector of the John Deere direct connect valve cable (P/N 57765).
5. Connect the 6-pin connector of the John Deere direct connect valve cable to the
6-socket connector of the VM415 valve module.
Diag slot
6. To select a laser system, operate the right-turn signal lever until LAS appears
on the display screen.
7. Briefly turn on the HAZARD switch. CAL appears, signifying calibration.
Note – If it does not receive a signal change within 30 seconds, the control
system enters SUS (suspend) mode. To return the tractor to calibrate mode,
briefly turn on the hazard switch and then turn it off again.
8. Make sure the system is in Active Control (AC) mode. To put the hydraulic
system into AC, move the hydraulic paddle switch into its downward detent
position and then release it:
If the tractor moves out of AC, it goes into External Command (EC) mode. If
this happens, repeat Step 8.
9. Once the calibration is complete, turn off the tractor ignition switch and then
return the diagnostic fuse to the spare fuse slot.
7. Rotate the Selector knob to highlight the center icon (right pointing arrow) on
the right side of the screen.
8. Press the Left Arrow switch. The 30-second timer starts.
9. To put the tractor hydraulic system into Active Control (AC), move the
hydraulic paddle switch into its downward detent position and then release it.
If the tractor moves out of AC mode, it goes into External Command (EC)
mode. To put the system back into AC mode, repeat Step 9.
Note – If the system does not receive a signal change within 30 seconds, it
enters SUS (suspend) mode. To restart the 30 seconds, press the Left Arrow
switch.
3. Connect the other 6-pin connector of the Case direct connect valve cable to the
6-socket connector of the VM415 valve module.
Enter button
Drive knob
Right arrow button
4. The Translator ECM screen shows if the Class 3 option is present and enabled:
Note – If the option is not enabled, the screen displays “ISO 11783 Class 3 is
Disabled”.
If the Translator ECM is present, but not enabled:
1. Turn the Menu selection knob to the Diagonal icon.
8-socket connector
9-socket connector
To validate the install, check that the CLASS 3 option is enabled. See Validate the
machine, page 154.
0395-9130
Challenger direct
connect cable
58559
0395-9030
5. Press the Right arrow button to highlight the Stationary Override window, and
then rotate the Adjustment knob to highlight ENABLE.
Note – Every time you turn off the tractor and then turn it back on again, you
must repeat this step.
6. Press the rocker switch for the required remote valve.
A > Red A
B > Blue B
C > Green C
D > White D
E > Brown E
F > Black F
G > Gray G
H > Orange H
N/U I
N/U J
Top view
Red A of valve wiring
White B 1
Black C White
Red
Green D
N/U E
F 3 Black
Solid 2
buss N/U G
bar
H Green
Front
Rear
Front
A Top view
Red
B of valve wiring
White
Black C 1
Green D White
Red
Red E
White F
Black Black
G 3
2
Green H
Green
Rear
A > Black A
B > Brown B
C > Red C
D > N/U D
E > N/U E
F > Orange F
G > Yellow G
H > Green H
Red I
Black J
1 >
2 >
N/U A
N/U B
N/U C
N/U D
N/U E
Orange F
Yellow G
Black H
Rear
Front
Orange A
Yellow B
Black C
N/U D
N/U E
Orange F
Yellow G
Black H
Rear
bench The process of aligning the machine blade position (Northing, Easting, and/or
Elevation) to a benchmark. The bench calibration offsets your machine position to
that of the benchmark, improving accuracy and providing a point that you can
return to later for accuracy checks.
CAN Controller Area Network. A system used for communications between electronic
devices.
cross slope The average grade or slope of a parcel or area expressed as a percentage of vertical
difference in elevation to the horizontal distance. A level surface has a cross slope
of zero.
data card The plug-in, removable storage card which holds all the design and system files.
detent A mechanism that temporarily keeps one part in a certain position relative to that
of another, and can be easily released by applying force to one of the parts.
firmware Software stored in flash memory. Firmware runs the GCS900 system.
GNSS Global Navigation Satellite System. The standard generic term for satellite
navigation systems that provide autonomous geo-spatial positioning with global
coverage.
GPS Global Positioning System. A technique that uses satellite technology to calculate
an accurate three-dimensional position.
A GPS system consists of a space segment (up to 24 NAVSTAR satellites in six
different orbits), the control segment (five monitor stations, one master control
station and three upload stations), and the user segment (GPS receivers).
LED Light Emitting Diode. A small, bright (usually colored) light used in electronic
componentry.
lightbar A bar or unit of LEDs that guide you when using the system. Lightbars give
cut/fill or left/right guidance depending on how they are set up.
GCS900 Grade Control System for Grading Applications Installation Manual 161
Glossary
pitch The forward and aft grade (or mainfall) of the machine.
radome A dome like shell transparent to radio-frequency radiation, used to house a radar
antenna.
softkeys on the screen keys associated with physical front panel keys. The operation
performed by a softkey varies depending on the current screen. A softkey on the
screen is controlled by a hard key that is adjacent to it on the front panel. Press the
hard key to activate the softkey.
VRS Virtual Reference Station. Trimble's VRS™ networks use RTK solutions from the
Trimble RTKNet software to provide high-accuracy, real-time kinematic (RTK)
GNSS positioning for wider areas.
162 GCS900 Grade Control System for Grading Applications Installation Manual
Index
A motor grader 37
scraper 31
above cutting edge bolts 107, 119 calibration and configuration settings 28
calibration, sensors 130
CB430 control box
B install custom post 50
back from cutting edge 115 installation 68
back from cutting edge bolts 107, 118 pinout information 138
bench test 22 connector failure, dust 21
blade dimensions 109 control box, CB430 pinout information 138
blade pitch sensor bracket 55 Control Box’s Radio Port 133
blade pitch sensor, installation 88 cutting edge dimensions 109
blade slope sensor
installation, bulldozer 82
installation, motor grader 84 D
blade slope sensor bracket 58
dialogs
bracket installation
Calibrate Mainfall Sensor 133
blade pitch sensor bracket 55
Calibrate Rotation Sensor 132
blade slope sensor 58
Calibrate Sensors 130
lightbars 62
Calibrate Slope Sensor 131
mainfall sensor 59
Control Box’s Radio Port 133
quick disconnect assembly 56
GPS Receiver Configuration 134
rotating bracket 52
Lightbar Connections 128
scraper mast mount 55
Machine Dimensions 125
sonic tracer mount 61
Machine Name Error 15
vale module/power module 60
Machine Radio Configuration 129
bulldozer
Machine Settings 123
install harness cable 31
Select Radio Band 128
system components 48
Setup Menus
system diagram 35
Configuration 122
Installation 122
Units 124
C diode, over-voltage protection 44
cab or body mounted systems, receiver position 114 direction indicator, installation 78
cable installation distance between lift rams 112
bulldozer 31
ignition switched power 43
machine power 43, 46 E
motor grader 37
electric mast measurements 103, 108
planning 18
electric mast, installation 90
power module 46
environmental factors 20
routing harnesses 30
ergonomics 20
scraper 31
external VRS device 133
validation 136
cables
bulldozer 31
H L
harness cable routing 30 laser receiver installation
height (to top of lower housing) 114 LR400/LR410 92
SR300 91
Lightbar Connections 128
I lightbars
install brackets 62
ignition switched power cabling 43 install lightbars 75
in from left blade tip 116
in from left/right blade tip 107, 120
installation M
angled riser on fixed mast 88
blade pitch sensor 88 machine body dimensions 113
blade slope sensor machine configurations 26
bulldozer 82 Machine Dimensions 125
motor grader 84 Machine Name Error 15
CB430 control box 68 machine power, cabling 43, 46
direction indicator 78 Machine Settings 123
electric mast 90 mainfall sensor
environmental factors 20 installation, motor grader 87
GPS receiver 93 mainfall sensor bracket 59
harness cable mainfall sensor installation, bulldozer 83
bulldozer 31 manager mode 122
motor grader 37 mast lean back 109
scraper 31 mast lean in from blade tip 108
laser receiver measure-up
LR400/LR410 92 above cutting edge bolts 107, 119
SR300 91 back from cutting edge 115
lightbars 75 back from cutting edge bolts 107, 118
mainfall sensor, bulldozer 83 blade dimensions 109
mainfall sensor, motor grader 87 cab or body mounted systems 114
mounting plates 51 cutting edge dimensions 109
operational considerations 20 distance between lift rams 112
power module 75 height (to top of lower housing) 114
radio modem 64 in from left blade tip 116
radio, SNRx10 76 in from left/right blade tip 107, 120
remote switches 70 machine body dimensions 113
reversing buzzer 78 marking the motor grader circle 104
rotating angle bracket on fixed mast 88 mast lean back 109
rotation sensor, bulldozer 82 mast lean in from blade tip 108
W
water, preventing seepage 21