3YSTEM&IVEs

#ONTROL"OX
FOR-OTOR'RADERAND$OZER

EXIT
VALVE:
DEADBA
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BLADE D 3 GPS MO ENTER
TIME C
ON D
RESET
EEPRO ST. 50 LPS MO E ON
M DE
ON
ADVAN
CED FE
ATURES

4ECHNICAL2EFERENCE-ANUAL
 P O S I T I O N I N G S Y S T E M S

System Five™
9164 Control Box
for Motor Grader and Dozer

Technical Reference
Manual

Part Number 7010-0377

Rev C

©Copyright Topcon Positioning Systems, Inc.

January, 2010

All contents in this manual are copyrighted by Topcon. All rights reserved.
The information contained herein may not be used, accessed, copied, stored,
displayed, sold, modified, published, distributed, or otherwise reproduced
without the express written consent from Topcon.
ECO#3541
 TOC

Table of Contents
Chapter 1
Introduction .......................................................... 1-1
9164 Control Box Front Panel Controls .......................... 1-2
Accessing the Technician’s Menu ................................... 1-3

Chapter 2
Application Codes ................................................ 2-1
Dozer Application Code r1.60 ........................................ 2-1
Motor Grader Application Code r1.60 ............................ 2-2

Chapter 3
Technician’s Menu Selections ............................ 3-1
Selecting the Valve Type ................................................. 3-1
Valve Types ..................................................................... 3-2
Valve Offsets ................................................................... 3-6
Dither ............................................................................... 3-7
Dither Frequency ............................................................. 3-8
Maximum Current ........................................................... 3-9
Current Hysteresis ........................................................... 3-11
PWM Frequency .............................................................. 3-12
Boost (Dozer Only) .......................................................... 3-14
Deadband ......................................................................... 3-17
Blade Time Constant ....................................................... 3-18
GPS Mode ........................................................................ 3-19
LPS Mode ........................................................................ 3-20
Reset EEPROM ............................................................... 3-21
Mainfall Cutout (Motor Grader Only) ............................. 3-22
Mainfall Comp. (Motor Grader Only) ............................. 3-23
Smartlink (Motor Grader Only) ....................................... 3-24
Bump Amount (Motor Grader Only) ............................... 3-25

P/N 7010-0377 i
Table of Contents

Appendix A
Komatsu Pilot Machine Settings ........................ A-1

ii 9164 Control Box Technical Reference Manual

 Preface

Preface
Thank you for purchasing this Topcon product. The materials
available in this Manual (the “Manual”) have been prepared by
Topcon Positioning Systems, Inc. (“TPS”) for owners of Topcon
products, and are designed to assist owners with the use of the
receiver and its use is subject to these terms and conditions (the
“Terms and Conditions”).

NOTICE Please read these Terms and Conditions carefully.

Terms and Conditions

USE This product is designed to be used by a professional. The user
should have a good knowledge of the safe use of the product and
implement the types of safety procedures recommended by the local
government protection agency for both private use and commercial
job sites.
COPYRIGHT All 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 receiver. 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.

P/N 7010-0377 iii

Preface

TRADEMARKS System Five™, 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 WARRANTY EXCEPT FOR ANY
WARRANTIES IN AN APPENDIX OR A WARRANTY CARD
ACCOMPANYING THE PRODUCT, THIS MANUAL AND THE
RECEIVER ARE PROVIDED “AS-IS.” THERE ARE NO OTHER
WARRANTIES. TPS DISCLAIMS ANY IMPLIED WARRANTY
OF MERCHANTABILITY OR FITNESS FOR ANY
PARTICULAR USE OR PURPOSE. TPS 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 RECEIVER. SUCH
DISCLAIMED DAMAGES INCLUDE BUT ARE NOT LIMITED
TO LOSS OF TIME, LOSS OR DESTRUCTION OF DATA, LOSS
OF PROFIT, SAVINGS OR REVENUE, OR LOSS OF THE
PRODUCT’S USE. IN ADDITION TPS IS NOT RESPONSIBLE
OR LIABLE FOR DAMAGES OR COSTS INCURRED IN
CONNECTION WITH OBTAINING SUBSTITUTE PRODUCTS
OR SOFTWARE, CLAIMS BY OTHERS, INCONVENIENCE, OR
ANY OTHER COSTS. IN ANY EVENT, TPS SHALL HAVE NO
LIABILITY FOR DAMAGES OR OTHERWISE TO YOU OR ANY
OTHER PERSON OR ENTITY IN EXCESS OF THE PURCHASE
PRICE FOR THE RECEIVER.
LICENSE AGREEMENT Use of any computer programs or software
supplied by TPS or downloaded from a TPS website (the “Software”)
in connection with the receiver constitutes acceptance of these Terms
and Conditions in this Manual and an agreement to abide by these
Terms and Conditions. The user is granted a personal, non-exclusive,
non-transferable license to use such Software under the terms stated
herein and in any case only with a single receiver or single computer.
You may not assign or transfer the Software or this license without
the express written consent of TPS. This license is effective until
terminated. You may terminate the license at any time by destroying

iv 9164 Control Box Technical Reference Manual

 Terms and Conditions

the Software and Manual. TPS may terminate the license if you fail to
comply with any of the Terms or Conditions. You agree to destroy the
Software and manual upon termination of your use of the receiver.
All ownership, copyright and other intellectual property rights in and
to the Software belong to TPS. If these license terms are not
acceptable, return any unused software and manual.
CONFIDENTIALITY This Manual, its contents and the Software
(collectively, the “Confidential Information”) are the confidential and
proprietary information of TPS. You agree to treat TPS’ Confidential
Information with a degree of care no less stringent that the degree of
care you would use in safeguarding your own most valuable trade
secrets. Nothing in this paragraph shall restrict you from disclosing
Confidential Information to your employees as may be necessary or
appropriate to operate or care for the receiver. Such employees must
also keep the Confidentiality Information confidential. In the event you
become legally compelled to disclose any of the Confidential
Information, you shall give TPS immediate notice so that it may seek a
protective order or other appropriate remedy.
WEBSITE; OTHER STATEMENTS No statement contained at the
TPS website (or any other website) or in any other advertisements or
TPS literature or made by an employee or independent contractor of
TPS modifies these Terms and Conditions (including the Software
license, warranty and limitation of liability).
SAFETY Improper use of the receiver can lead to injury to persons or
property and/or malfunction of the product. The receiver should only
be repaired by authorized TPS warranty service centers. Users should
review and heed the safety warnings in an Appendix.
MISCELLANEOUS The above Terms and Conditions may be
amended, modified, superseded, or canceled, at any time by TPS. The
above Terms and Conditions will be governed by, and construed in
accordance with, the laws of the State of California, without reference
to conflict of laws.

P/N 7010-0377 v
Preface

Manual Conventions
This manual uses the following conventions:
Example Description

FileExit Click the File menu and click Exit.

Connection Indicates the name of a dialog box or screen.
Frequency Indicates a field on a dialog box or screen, or a tab
within a dialog box or screen.
Enter Press or click the button or key labeled Enter.

Further information to note about the configuration,

NOTE maintenance, or setup of a system.

Supplementary information that can help you

TIP configure, maintain, or set up a system.

Supplementary information that can have an affect

NOTICE on system operation, system performance,
measurements, or personal safety.

Notification that an action has the potential to

CAUTION adversely affect system operation, system
performance, data integrity, or personal health.

Notification that an action will result in system

damage, loss of data, loss of warranty, or personal
WARNING
injury.

vi 9164 Control Box Technical Reference Manual

 Chapter 1

Introduction
This manual covers the 9164 Control Box Technician’s Menu for
Dozer and Motor Grader application code r1.60.
The Technician's Menu contains additional System Performance
Settings not available to the operator (end user) in the System
Performance Menu.
These settings allow the user to override default settings of System
Five™ to improve System Five performance in certain situations.
These settings are not, however, meant to be changed by the operator.

Access to the Technician’s menu is intended for,

NOTICE and should be limited to, Topcon qualified dealer
and field service technicians. Any changes to the
factory default settings without a thorough
understanding to their effects on System Five™
may cause adverse consequences to System Five
accuracy and operation.

P/N 7010-0377 1-1

Introduction

9164 Control Box Front Panel

Controls

1. Selection Buttons
2. LCD Display
3. Grade Adjustment LEDs
4. Rotary Knobs
5. Power Switch
6. Grade Adjustment Direction Arrows

1-2 9164 Control Box Technical Reference Manual

 Accessing the Technician’s Menu

Accessing the Technician’s

Menu
1. Power up the 9164 Control Box and press the Setup selection
button on the Main Menu screen.

3D
3D-MC 3D-MC
Control LPS GPS Setup
MAIN MENU

2. Use the Rotary Knob to highlight Beeper.

EXIT ENTER

ADJUST VALVE OFFSETS ADJUST LED BRIGHTNESS

SET POINTS SYSTEM TEST
MEASUREMENT UNIT SMARTLINK OFF
CHECK HOURMETERS BEEPER ON

3. Press and hold the Enter button for approximately five seconds
until you hear a rapid series of beeps, and then release the Enter
button to display the Advanced Features screen.
Dozer Advanced EXIT ENTER
Features Screen
VALVE: GPS MODE ON
DEADBAND 3 LPS MODE ON
BLADE TIME CONST. 50
RESET EEPROM

ADVANCED FEATURES

For Motor Grader, once you enter the Advanced Features

screen, use the rotary knob to select Advanced Features and
press Enter to display more selections.

P/N 7010-0377 1-3

Introduction

Motor Grader EXIT ENTER

Advanced VALVE: GPS MODE ON
Features DEADBAND 1 LPS MODE ON
Screens BLADE TIME CONST. 999 BUMP AMOUNT 1
MAINFALL CUTOUT 7MAR ADVANCED FEATURES

ADVANCED FEATURES

EXIT ENTER
MAINFALL COMP. ON
SMARTLINK 0
RESET EEPROM

ADVANCED FEATURES

1-4 9164 Control Box Technical Reference Manual

 Chapter 2

Application Codes
The following charts describe the Technician’s Menu Selections and
the factory settings for Dozer and Motor Grader application code
r1.60.

Dozer Application Code r1.60

Table 2-1. Dozer Code Chart

Menu Selection Factory Setting Range

Valve Type No Valve Solenoid Sink, Solenoid Source,
Prop. Sink, Prop. Source, Servo,
Danfoss, Prop. PWM Sink,
Prop. PWM Source, Joystick,
John Deere CAN,
Komatsu CAN, No Valve
Valve Offsets 0 0-999
Dither 4 0-31
Dither Frequency 45Hz 0.0Hz-12.5Hz
Maximum Current 3.05 Amps 0.0 Amps - 4.80 Amps
Current Hysteresis 6% 1.5%-12.0%
PWM Frequency 448Hz 2Hz-1708Hz
Adj Joystick 50/50 35-65
Elev Boost Amplitude 0% 0-999
Elev Boost Duration 0 mS 0-500 mS
Slope Boost Amplitude 0% 0-999
Slope Boost Duration 0 mS 0-500 mS
Raise Boost Only Off On/Off
Deadband 3 mm 0-30 mm
Blade Time Constant 50 20-60
Reset EEPROM NA Yes, Exit (No)
GPS Mode On On/Off
LPS Mode On On/Off

P/N 7010-0377 2-1

Application Codes

Motor Grader Application Code

r1.60
Table 2-2. Motor Grader Code Chart

Menu Selection Factory Setting Range

Valve Type No Valve Solenoid Sink, Solenoid
Source, Proportional Sink,
Proportional Source,
Servo, Danfoss,
Proportional PWM Sink,
Proportional PWM
Source, Komatsu CAN,
CAT CAN, John Deere
CAN, No Valve
Valve Offsets 0 0-999
Dither 4 0-31
Dither Frequency 45Hz 0.0Hz-12.5Hz
Maximum Current 1.75 Amps 0.0 Amps - 4.80 Amps
Current Hysteresis 6% 1.5%-12.0%
PWM Frequency 448Hz 2Hz-1708Hz
Deadband 3 mm 0-30 mm
Blade Time Constant 50 20-60
Mainfall Cutout 7 0-10
GPS Mode On On/Off
LPS Mode On On/Off
Bump Amount 1 1-25
Mainfall Comp On On/Off
Smartlink 0 0-10
Reset EEPROM NA Yes, Exit (No)

2-2 9164 Control Box Technical Reference Manual

 Chapter 3

Technician’s Menu
Selections
Selecting the Valve Type
1. To display the Setup Valve screen, use the rotary knob to
highlight Valve, and press Enter.
EXIT ENTER
VALVE: GPS MODE ON
DEADBAND 3 LPS MODE ON
BLADE TIME CONST. 50
RESET EEPROM

ADVANCED FEATURES

2. To display all possible valve types, highlight Valve: and press

Enter.
EXIT ENTER
VALVE: N.A. MAXIMUM CURRENT
ADJUST VALVE OFFSETS CURRENT HYSTERISIS
ADJUST DITHER PWM FREQ.
ADJUST DITHER FREQ. ADJUST JOYSTICK

SETUP VALVE

P/N 7010-0377 3-1

Technician’s Menu Selections

3. Press the More button to display additional valve types.

EXIT MORE ENTER
JOYSTICK NO VALVE
JOHN DEERE CAN DANFOSS
CAT CAN PROP. PWM SINK
KOMATSU CAN PROP. PWM SOURCE

VALVE TYPE
EXIT MORE ENTER
SOLENOID SINK SERVO
SOLENOID SOURCE DANFOSS
PROP. SINK PROP. PWM SINK
PROP. SOURCE PROP. PWM SOURCE

VALVE TYPE

NOTE
Joystick is only available for dozers.

4. Select a valve type and press Enter to allow the Control Box to
configure its outputs to drive the selected valve type. The selected
valve type appears in the Setup Valve screen. If you select Exit,
no change is made to the valve type and you will be returned to
the Setup Valve screen.

See “Valve Types” on page 3-2 for a complete

NOTE
description of each valve type.

Valve Types
Listed below are brief descriptions of the selections found in the
Valve Type Screen:

Joystick (Dozer Only)

The Joystick valve type is a PWM output for the Topcon Joystick
Interface Box used on dozers.

3-2 9164 Control Box Technical Reference Manual

 Valve Types

John Deere® CAN

The John Deere CAN valve type is for IGC Dozers, 764 HSD, and
GP Motor Grader.

CAT® CAN
The CAT CAN valve type is for M Graders.

Komatsu® CAN
The Komatsu CAN valve type is for D155 Dozers.

No Valve
No Valve disables all valve outputs.

Solenoid Sink
Solenoid valves have only two positions; open or closed. Full voltage
is applied at a constant frequency (typically around 4-6 Hz). The
length of time (duty cycle) that the valve stays open is determined by
the amount of error (distance from grade).
Sink means that there is a constant +voltage applied to the coil. The
ground is switched by the valve driver for control.

Solenoid Source
Solenoid valves have only two positions; open or closed. Full voltage
is applied at a constant frequency (typically around 4-6 Hz). The
length of time (duty cycle) that the valve stays open is determined by
the amount of error (distance from grade).
Source designation means that the coil is always grounded. The
+voltage is switched by the valve driver for control.

Proportional Sink (Current Controlled)

A proportional valve has a spool cut that allows for an infinite
number of positions, allowing variable flow rates. As the grade error
increases, the spool can open up further to increase flow.

P/N 7010-0377 3-3

Technician’s Menu Selections

In Proportional Sink mode, the control box monitors the current level
at the coil. As the error (distance from grade) changes, the current
needed to finely position a proportional spool is varied. The control
box may then switch the available voltage on and off in order to
maintain the proper current level. The output frequency is limited,
but not controlled.
With Proportional Sink, the coil is always connected to +voltage, and
that the -ground is switched for control.

Proportional Source (Current Controlled)

With Proportional Source is similar to Proportional Sink, but the coil
is always grounded and the +voltage is switched for control.

Servo
A Servo valve is similar to a proportional valve in that a variable
amount of flow is produced through variable current. The difference
is that a servo valve contains a torque motor that drives the internal
mechanism. There is no source or sink, because the conductors will
swap from positive to negative depending on the direction called for
by the grade error. Only the raise and lower conductors are needed
for this mode.

The PWM frequency is fixed at 488Hz. Adjusting

NOTE
the frequency setting has no effect.

Danfoss
The Danfoss valve is a proportional valve, but it contains its own
electronics to drive a coil. Our control box constantly powers the
electronic package. A third connection (always the raise conductor)
sends a signal equal to half of the available voltage. The signal
voltage raises or lowers (typ. from 25% to 75%) to make a correction.

Current Limit and Frequency have no effect in

NOTE
Danfoss mode.

3-4 9164 Control Box Technical Reference Manual

 Valve Types

Proportional PWM Sink

PWM mode is an option carried over from System Four. Instead of
monitoring and regulating the current in the coil, we simply apply
voltage in an open loop configuration. The frequency remains
constant (adjustable) and the duty cycle is varied dependent on the
amount of grade error. One of the drawbacks of PWM mode is the
inconsistency of valve offsets due to changes in the resistance of the
coil and varying machine voltage. As the coil heats and cools
throughout the day, the resistance will change.
With Proportional PWM Sink, the coil is always connected to
+voltage, and that the -ground is switched for control.

Proportional PWM Source

Proportional PWM Source is similar to Proportional PWM Sink, but
the coil is always grounded. The +voltage is switched for control.

P/N 7010-0377 3-5

Technician’s Menu Selections

Valve Offsets
Valve Offsets are a calibration where the control box learns the
minimum signal it must give to a valve to make oil flow. Offsets that
are too low have the effect of “hanging up” a control system. Offsets
that are too high have the effect of overshooting, or not being able to
make fine corrections.
1. To display the Setup Valve screen, use the rotary knob to
highlight Valve and press Enter.
2. Select Adjust Valve Offsets and press Enter.
EXIT ENTER
VALVE: N.A. MAXIMUM CURRENT
ADJUST VALVE OFFSETS CURRENT HYSTERISIS
ADJUST DITHER PWM FREQ.
ADJUST DITHER FREQ. ADJUST JOYSTICK

SETUP VALVE

3. Press the button above a valve channel to activate the valve drive
you wish to adjust. Use the rotary knob to increase the signal
amount, and adjust the setting so that movement is just
detectable.

If you change the maximum current, you may need

NOTE to readjust the valve offsets (see Maximum Current
Selection).

For Motor Grader only, pressing the Auto button

NOTE
automatically adjusts the valve offsets.

EXIT RAISE LOWER AUTO RAISE LOWER ENTER

0 0 0 0
LEFT RIGHT
ADJUST VALVE OFFSETS

3-6 9164 Control Box Technical Reference Manual

 Dither

Dither
Dither is a technique used to make proportional control valves
respond quickly and repeatedly. Any time the coil is energized, there
is a continuous low frequency pulse given to overcome the stiction
(static friction) of the spool against the valve body. The Adjust
Dither setting controls the amplitude of the pulse given to the valve.
If the amplitude is too high, the hydraulic system will react to the
pulsed signal and the operator will feel the disturbance. If the setting
is too low, control will be difficult, since the spool will be less likely
to make smaller corrections. Dither is only active in proportional
modes. The default setting is correct for all Topcon supplied valves.
1. To display the Setup Valve screen, use the rotary knob to
highlight Valve and press Enter.
2. Select Adjust Dither and press Enter.
EXIT ENTER
VALVE: N.A. MAXIMUM CURRENT
ADJUST VALVE OFFSETS CURRENT HYSTERISIS
ADJUST DITHER PWM FREQ.
ADJUST DITHER FREQ. ADJUST JOYSTICK

SETUP VALVE

3. Use the rotary knob to set the valve dither value and press Enter
to save the setting, or press Exit to cancel and return to the
previous screen.
EXIT ENTER
USE THE KNOB TO SET
THE AMOUNT OF VALVE
DITHER 4
ADJUST DITHER

P/N 7010-0377 3-7

Technician’s Menu Selections

Dither Frequency
In addition to dither amplitude, the dither frequency, or the speed of
the pulse, may be adjusted. The default of 45Hz. will work with any
Topcon valve. Some proportional valves respond to faster or slower
frequencies than Topcon supplied valves. If the frequency is too low,
pulsing may be felt. Dither is not active in Solenoid, Danfoss and
Servo modes.
Dither
Frequency

Current

Dither
Amplitude Current

1. To display the Setup Valve screen, use the rotary knob to

highlight Valve and press Enter.
2. Select Adjust Dither Freq. and press Enter.
EXIT ENTER
VALVE: N.A. MAXIMUM CURRENT
ADJUST VALVE OFFSETS CURRENT HYSTERISIS
ADJUST DITHER PWM FREQ.
ADJUST DITHER FREQ. ADJUST JOYSTICK

SETUP VALVE

3-8 9164 Control Box Technical Reference Manual

 Maximum Current

3. Then use the rotary knob to set the valve dither frequency in Hz.
and press Enter to save the setting, or press Exit to cancel and
return to the previous screen.
EXIT ENTER
USE THE KNOB TO SET
THE FREQUENCY OF
VALVE DITHER IN HZ 45.0
ADJUST DITHER FREQ

Maximum Current
Maximum Current is a necessary selection for use with Proportional
Current modes. The figure below explains the basic Ohms’ Law
formulas:

E
Voltage = Current x Resistance Voltage

Current = Voltage x resistance

I R
Resistance = Voltage Current
Current Resistance
(Amps) (Ohms)

Current is determined by the resistance of the coil (this changes with

temperature and the machine’s voltage). In proportional mode,
System Five regulates the current, which corrects for any temperature
changes. The main benefit of this is that valve offsets will not drift
with temperature.
By setting the Maximum Current consistent with the type of valve
and the available voltage, we can insure that the valve offset
calibration uses the full range of spool movement. A maximum
current that is too high results in valve offsets that are extremely low.
Likewise, a maximum current that is too low results in offsets that are
too high.

P/N 7010-0377 3-9

Technician’s Menu Selections

If proportional PWM mode is selected, System Five

NOTE will not regulate the current and the benefit of
compensating for coil resistance changes with
temperature will not be used. Proportional PWM
was used in System Four.

The Maximum Current setting only effects the

NOTE current overload protection in Proportional PWM
control.

1. Disconnect a valve coil, then measure the resistance across the

coil with a multimeter (Ohms). Ensure that the coil is rated for
the voltage of the machine.
2. Measure the machine voltage (Volts).
3. Divide the voltage by the resistance. The result is the maximum
current.
4. Use the rotary knob to select Maximum Current in the Setup
Valve Screen and press Enter.
EXIT ENTER
VALVE: N.A. MAXIMUM CURRENT
ADJUST VALVE OFFSETS CURRENT HYSTERISIS
ADJUST DITHER PWM FREQ.
ADJUST DITHER FREQ. ADJUST JOYSTICK

SETUP VALVE

5. Use the rotary knob to select the maximum current value (in
Amps) that most nearly matches the result. Press Enter to save
the setting, or press Exit to cancel and return to the previous
screen.
EXIT ENTER
0.00N.A.
VALVE: 1.75 3.05 4.13
MAXIMUM CURRENT
0.67 VALVE OFFSETS
ADJUST 2.00 3.27 4.34
CURRENT HYSTERISIS
1.04 DITHER 2.33
ADJUST 3.57
PWM FREQ. 4.60
1.31 DITHER FREQ.
ADJUST 2.57 3.78 4.80
ADJUST JOYSTICK

SETUP CURRENT
MAXIMUM VALVE

3-10 9164 Control Box Technical Reference Manual

 Current Hysteresis

Current Hysteresis
Current Hysteresis is used to maintain a given current level in the
valve coil; the available machine voltage is switched at a rate that will
maintain that level. The rate that the voltage is switched is
determined by a hysteresis band. This band is a percentage of current
above and below the chosen current setpoint. Voltage is turned on
until current reaches the upper end of the hysteresis band. Voltage is
then turned off until current reaches the lower hysteresis band. The
typical switching frequency will be between 200Hz. and 2000Hz.
The default setting is calculated to work with any standard Topcon
valve package.

Greater hysteresis band values result in slower

NOTE
switching frequencies.

1. To display the Setup Valve screen, use the rotary knob to

highlight Valve and press Enter.
2. Use the rotary knob to select Current Hysteresis in the Setup
Valve screen and press Enter.
EXIT ENTER
VALVE: PROP SINK MAXIMUM CURRENT
ADJUST VAVLE OFFSETS CURRENT HYSTERISIS
ADJUST DITHER PWM FREQ.
ADJUST DITHER FREQ. ADJUST JOYSTICK

SETUP VALVE

P/N 7010-0377 3-11

Technician’s Menu Selections

3. Use the rotary knob to set the current hysteresis percentage and
press Enter to save the setting, or press Exit to cancel and return
to the previous screen.

EXIT ENTER
1.5%
3.0%
6.0%
12.0%

CURRENT HYSTERESIS

PWM Frequency
Pulse Width Modulation, or PWM, is the older System Four method
of controlling a proportional valve. The frequency of the signal
remains constant, and the duty cycle, or “time on”, is varied to move
the spool to different positions for variable flow. This frequency may
be adjusted for different types of valves. System Four was set to
440Hz. The same adjustment may also be used for solenoid valve
settings.
The difference between solenoid mode and PWM mode is the
application of dither in the signal and the speed of the PWM signal.
Solenoid generally runs on a lower frequency than PWM.
1. To display the Setup Valve screen, use the rotary knob to
highlight Valve and press Enter.
2. Use the rotary knob to select PWM Freq. in the Setup Valve
screen and press Enter.

EXIT ENTER
VALVE: PROP SINK MAXIMUM CURRENT
ADJUST VAVLE OFFSETS CURRENT HYSTERISIS
ADJUST DITHER PWM FREQ.
ADJUST DITHER FREQ. ADJUST JOYSTICK

SETUP VALVE

3-12 9164 Control Box Technical Reference Manual

 PWM Frequency

3. Use the rotary knob to set the PWM frequency in Hz. and press
Enter to save the setting, or press Exit to cancel and return to the
previous screen.
EXIT ENTER
2 HZ 10 HZ 488 HZ 1464 HZ
4 HZ 12 HZ 732 HZ 1708 HZ
6 HZ 14 HZ 976 HZ
8 HZ 244 HZ 1220 HZ

PQM FREQ.

P/N 7010-0377 3-13

Technician’s Menu Selections

Boost (Dozer Only)

Boost values can improve performance of certain machine types in
some conditions, however, Topcon strongly recommends that these
values remain zero unless guided by a qualified Topcon technician.
Amplitude is a percentage of full-scale output with the same scaling
as valve offsets. For example, in prop current mode, if the max
current is set to 1.04 Amps, an amplitude setting of 500 would result
in 0.52 Amps output current.
Duration is how long the boost output remains active. For example, a
duration value of 50 would result in a duration of 50mS (0.05S).

Amplitude

Offset Value

Duration

Do not set amplitude valves lower than value

CAUTION offsets. For example, if the offsets are set to 400 the
boost amplitude must be set to 400 or above.
Setting boost amplitude below the offsets will result
in limiting hydraulic flow response.

1. To display the Boost screen, press the Setup selection button on

the Main Menu screen.

3D
3D-MC 3D-MC
Control LPS GPS Setup
MAIN MENU

3-14 9164 Control Box Technical Reference Manual

 Boost (Dozer Only)

2. Use the rotary knob to highlight Adjust Valve Offsets, and press
Enter.
EXIT ENTER

ADJUST VALVE OFFSETS ADJUST LED BRIGHTNESS

SET POINTS SYSTEM TEST
MEASUREMENT UNIT SMARTLINK OFF
CHECK HOURMETERS BEEPER ON

3. Press the Boost button.

EXIT RAISE LOWER BOOST RAISE LOWER ENTER

0 0 0 0
LEFT RIGHT
ADJUST VALVE OFFSETS

4. Use the rotary knob to select Elev Duration in milliseconds, and

press Enter.
EXIT ENTER
ELEV DURATION 0 RAISE BOOST ONLY: OFF
ELEV AMPLITUDE 0
SLOPE DURATION 0
SLOPE AMPLITUDE 0

VALVE BOOST

5. Use the rotary knob to set the elevation duration. Press Enter to
save the setting, or press Exit to cancel and return to the previous
screen.
EXIT ENTER

USE THE KNOB TO

ADJUST DURATION mS 0
ELEV DURATION

P/N 7010-0377 3-15

Technician’s Menu Selections

6. Repeat Steps 4 and 5 to set Elev Amplitude, Slope Duration,

and Slope Amplitude.
EXIT ENTER
ELEV DURATION 0 RAISE BOOST ONLY: OFF
ELEV AMPLITUDE 0
SLOPE DURATION 0
SLOPE AMPLITUDE 0

VALVE BOOST

See Appendix A for suggested machine-specific

NOTE
settings.

7. Use the rotary knob to select Raise Boost Only and press Enter
to toggle between Raise Boost Only: Off and Raise Boost
Only: On.
• Raise Boost Only: Off - Boost is applied to both elevation
raise and elevation lower.
• Raise Boost Only: On - Boost is applied only to elevation
raise.
8. Press Exit to save and return to the previous screen.
EXIT ENTER
ELEV DURATION 0 RAISE BOOST ONLY: OFF
ELEV AMPLITUDE 0
SLOPE DURATION 0
SLOPE AMPLITUDE 0

VALVE BOOST

3-16 9164 Control Box Technical Reference Manual

 Deadband

Deadband
Deadband controls the range of the on-grade indication LEDs on the
front of the Control Box. This setting does not control the hydraulic
deadband. The default of 3 mm indicates that the elevation may
move within 3 mm to either side of on-grade before the lights indicate
a correction.
Deadband also effects the LED’s in slope mode.
1. Use the rotary knob to highlight Deadband in the Advanced
Features screen and press Enter.

EXIT ENTER
VALVE GPS MODE ON
DEADBAND 3 LPS MODE ON
BLADE TIME CONST. 50
RESET EEPROM

ADVANCED FEATURES

2. Use the rotary knob to set the elevation deadband in millimeters

and press Enter to save the setting, or press Exit to cancel and
return to the previous screen.

EXIT ENTER
USE THE KNOB TO ADJUST THE
DEADBAND OF YOUR DISPLAY IN
MILLMETERS. (1MM = .003 FEET) 3
DEADBAND

P/N 7010-0377 3-17

Technician’s Menu Selections

Blade Time Constant

Blade Time Constant, or BTC, determines the speed at which the
control box realizes a change in slope when communicating with the
slope sensor. A small BTC makes the control box realize the slope
change very quickly. Accuracy is increased, but corrections can be
quick and choppy with the ability to overshoot. A larger BTC makes
the control box realize the change slowly, decreasing response, but
providing a smoother correction.
Values should range between 20 and 60, with a default of 50
providing the optimum value. The BTC value is stored in the slope
sensor, and not in the control box.
1. Use the rotary knob to highlight Blade Time Const. in the
Advanced Features screen and press Enter.

EXIT ENTER
VALVE GPS MODE ON
DEADBAND 3 LPS MODE ON
BLADE TIME CONST. 50
RESET EEPROM

ADVANCED FEATURES

2. Use the rotary knob to set the blade time constant and press Enter
to save the setting, or press Exit to cancel and return to the
previous screen.

EXIT ENTER

50
BLADE TIME CONST.

3-18 9164 Control Box Technical Reference Manual

 GPS Mode

GPS Mode
The GPS Mode selection either removes or allows user access to 3D-
MC GPS Mode in the control box. Turning GPS Mode OFF removes
the 3D-MC GPS selection from the control box’s Main Menu.
1. Use the rotary knob to select GPS Mode in the Advanced
Features screen and press Enter.

EXIT ENTER
VALVE GPS MODE OFF
DEADBAND 3 LPS MODE ON
BLADE TIME CONST. 50
RESET EEPROM

ADVANCED FEATURES

2. Use the Enter button to toggle between GPS Mode On or Off.

3. Press Exit to save and return to the previous screen.

The control box’s Main Menu changes to reflect

NOTE
the GPS Off setting, as shown below.

3D
3D-MC
Control LPS Setup
MAIN MENU

P/N 7010-0377 3-19

Technician’s Menu Selections

LPS Mode
The LPS Mode selection either removes or allows user access to 3D-
MC LPS Mode in the control box. Turning LPS Mode OFF removes
the 3D-MC LPS selection from the control box’s Main Menu.
1. Use the rotary knob to select LPS Mode in the Advanced
Features screen and press Enter.

EXIT ENTER
VALVE GPS MODE ON
DEADBAND 3 LPS MODE OFF
BLADE TIME CONST. 50
RESET EEPROM

ADVANCED FEATURES

2. Use the Enter button to toggle between LPS Mode On or Off.

3. Press Exit to save and return to the previous screen.

The control box’s Main Menu changes to reflect

NOTE
the LPS Off setting, as shown below.

3D-MC
Control GPS Setup
MAIN MENU

3-20 9164 Control Box Technical Reference Manual

 Reset EEPROM

Reset EEPROM
Resetting the EEPROM restores the control box to its factory default
settings. This should only be used when reinstalling the control box
onto a completely different machine, or after loading a different type
of application software. The EEPROM (E-squared) memory is the
nonvolatile memory that keeps track of all machine settings. Loading
a new version of the same application code does not affect the
EEPROM memory.

Resetting the EEPROM will reset the system’s

NOTICE valve offset and gain settings. Offsets and gains
must be reentered prior to operating the system.

1. Use the rotary knob to select Reset EEPROM in the Advanced

Features screen and press Enter.

EXIT ENTER
VALVE GPS MODE ON
DEADBAND 3 LPS MODE ON
BLADE TIME CONST. 50
RESET EEPROM

ADVANCED FEATURES

2. Press Yes to reset the EEPROM, or press Exit to cancel and

return to the previous screen.

EXIT YES
ARE YOU SURE?
PRESSING "YES" WILL OVERWRITE ALL VALUES
SAVED IN PERMANENT MEMORY WITH STANDARD
DEFAULT VALVUES.

ADJUST DITHER FREQ

EXIT

ALL VALUES IN PERMANENT MEMORY HAVE BEEN

SET TO FACTORY DEFAULTS. YOU MUST SET THESE
VALUES FOR YOUR PARTICULAR APPLICATIONS.

ADJUST DITHER FREQ

P/N 7010-0377 3-21

Technician’s Menu Selections

Mainfall Cutout
(Motor Grader Only)
Mainfall Cutout shuts off automatic control when quick jerky
machine movement, caused by rough terrain or sudden starts and
stops, is detected by the mainfall sensor, reducing gouging while
grading.
Mainfall Cutout values range between 0 and 10. A Mainfall Cutout
value of 0 turns this feature off. A value of 1 is the most sensitive,
and a value of 10 is the least sensitive.
1. Use the rotary knob to highlight Mainfall Cutout in the
Advanced Features screen, and press Enter.

EXIT ENTER
VALVE: GPS MODE ON
DEADBAND 1 LPS MODE ON
BLADE TIME CONST. 999 BUMP AMOUNT 1
MAINFALL CUTOUT 7 ADVANCED FEATURES

ADVANCED FEATURES

2. Use the rotary knob to set the mainfall cutout value and press
Enter to save the setting, or press Exit to cancel and return to the
previous screen.

EXIT ENTER

7
MAINFALL CUTOUT

3-22 9164 Control Box Technical Reference Manual

 Mainfall Comp. (Motor Grader Only)

Mainfall Comp.
(Motor Grader Only)
Mainfall Comp. allows the user to disable the mainfall sensor.
Selecting On enables the mainfall sensor. Selecting Off disables the
sensor.
The default setting is On.
1. Use the rotary knob to highlight Advanced Features in the
Advanced Features screen, and press Enter.

EXIT ENTER
VALVE: GPS MODE ON
DEADBAND 1 LPS MODE ON
BLADE TIME CONST. 999 BUMP AMOUNT 1
MAINFALL CUTOUT 7MAR ADVANCED FEATURES

ADVANCED FEATURES

2. Highlight Mainfall Comp., and press Enter to toggle mainfall

comp. On or Off.
EXIT ENTER
MAINFALL COMP. ON
SMARTLINK 0
RESET EEPROM

ADVANCED FEATURES

3. Press Exit to save and return to the previous screen.

P/N 7010-0377 3-23

Technician’s Menu Selections

Smartlink (Motor Grader Only)

Smartlink links the elevation sensor to the slope sensor. As the
elevation of the blade changes, the signal sent to the slope sensor
increases, allowing a smoother elevation and slope correction.
Smartlink values range between 0 and 10. The higher the value, the
greater the coupling of the elevation and slope sensor.

1. Use the rotary knob to highlight Advanced Features in the

Advanced Features screen, and press Enter. Highlight
Smartlink and press Enter.

EXIT ENTER
VALVE: GPS MODE ON
DEADBAND 1 LPS MODE ON
BLADE TIME CONST. 999 BUMP AMOUNT 1
MAINFALL CUTOUT 7MAR ADVANCED FEATURES

ADVANCED FEATURES

EXIT ENTER
MAINFALL COMP. ON
SMARTLINK 0
RESET EEPROM

ADVANCED FEATURES

2. Use the rotary knob to set the smartlink value and press Enter to
save the setting, or press Exit to cancel and return to the previous
screen.

EXIT ENTER

0
SMARTLINK

3-24 9164 Control Box Technical Reference Manual

 Bump Amount (Motor Grader Only)

Bump Amount
(Motor Grader Only)
Bump Amount allows the user to adjust the number of Control Box
rotary knob clicks applied to the setpoint with each Smart Knob
button press. For example, a bump amount value of 5 applies 5 rotary
knob clicks with each press of the Smart Knob button.
Bump amount values range between 1 and 25. The default value is 1.
1. Use the rotary knob to highlight Bump Amount in the
Advanced Features screen, and press Enter.

EXIT ENTER
VALVE: GPS MODE ON
DEADBAND 1 LPS MODE ON
BLADE TIME CONST. 999 BUMP AMOUNT 1
MAINFALL CUTOUT 7MAR ADVANCED FEATURES

ADVANCED FEATURES

2. Use the rotary knob to set the bump amount value and press
Enter to save the setting, or press Exit to cancel and return to the
previous screen.

EXIT ENTER

1
BUMP AMOUNT

P/N 7010-0377 3-25

Technician’s Menu Selections

Notes:

3-26 9164 Control Box Technical Reference Manual

 Item Fixed or Settings for D155 Settings for D85 Settings for D65
Adjustable
Type Proportional Proportional Proportional
Fixed Current Current Current

P/N 7010-0377
Drive Fixed Source Source Source
Max Current Fixed 1.04 A 1.04 A 1.04 A
Advanced
Dither {% of FS} Fixed 15 15 15
Valve Settings
PWM freq Setting is not Setting is not Setting is not
Fixed necessary. necessary. necessary.
Settings
Hysterisis Fixed 6.0% 6.0% 6.0%
Dither freq. Fixed 90.0 Hz 90.0 Hz 90.0 Hz
Deadband {mm} Adjustable* 10 3 3
SmartLink Fixed 0 0 0
Advanced
Blade Time Constant Adjustable* 45 45 45
Settings
Mainfall Cut-Out Fixed 0 0 0
Switch Type Fixed SIMPLE SIMPLE SIMPLE
Boost Duration Elev Fixed 120 60 70
Valve Boost Boost Amplitude Elev Fixed 600 500 500
Parameters Boost Duration Slope Fixed 110 65 50
Boost Amplitude Slope Fixed 600 550 500
Raise Left (Upward) Adjustable** 400~580 400~580 400~580
Lower Left (Downward) Adjustable** 400~580 400~580 400~580
Valve Offsets
Raise Right Adjustable** 400~580 400~580 400~580
Lower Right Adjustable** 400~580 400~580 400~580
Elevation Adjustable*** 40~70 40~70 40~70
Gain
Slope Adjustable*** 3~15 3~15 3~15
* Recommended Initial Settings. Refer to the TOPCON manual for details.
** These Settings depend on the individual machine.
Appendix A

*** These settings depend on the operator's work style, type of soil/ gravel, etc.
Komatsu Pilot Machine

A-1
Komatsu Pilot Machine Settings

Notes:

A-2 9164 Control Box Technical Reference Manual

 Index

Index
A G
Adjust Valve Offsets 3-15 GPS Mode 3-19
Advanced Features Screen 1-3 ground 3-3

B H
Blade Time Constant 3-18 hydraulic deadband 3-17
Boost 3-14 hysteresis band 3-11
Bump Amount 3-25
J
C John Deere® CAN 3-3
CAT® CAN 3-3 Joystick 3-2
coil 3-4
Current Hysteresis 3-11
K
Komatsu® CAN 3-3
D
Danfoss 3-4
Deadband 3-17
L
Dither 3-7 LPS Mode 3-20
Dither Frequency 3-8
Dozer Application Code 2-1 M
Dozer Code Chart 2-1, 2-2
duty cycle 3-5 Mainfall Comp. 3-23
Mainfall Cutout 3-22
Maximum Current 3-9
E Motor Grader Application Code 2-2
EE memory 3-21
Elev Amplitude 3-16 N
Elev Duration 3-15
No Valve 3-3
non-volatile memory 3-21

F O
frequency 3-3
OhmsLaw 3-9
Front Panel 1-2
open loop 3-5

P/N 7010-0377 Index

Index

P
Proportional PWM Sink 3-5
Proportional PWM Source 3-5
Proportional Sink 3-3
Proportional Source 3-4
PWM 3-12
PWM Frequency 3-12

R
Raise Boost Only 3-16
Reset EEPROM 3-21

S
Servo 3-4
Smartlink 3-24
Solenoid Sink 3-3
Solenoid Source 3-3

V
valve offset calibration 3-9
Valve Offsets 3-6
Valve Type 3-1
voltage 3-3

Index 9164 Control Box Technical Reference Manual

 Topcon Positioning Systems, Inc.
7400 National Drive, Livermore, CA 94550
800∙443∙4567 www.topconpositioning.com

C UPDATE FOR R1.60; ADD CAN VALVE STYLES 3541

B UPDATE FOR DOZER CODE R1.4 2559
RELEASE, UPDATE FOR MTGR CODE R1.4;
A 1860
ADDED INFOR FOR DOZER CODE R1.3
REV DESCRIPTION ECO

System Five™ 9164 Control Box for Motor Grader and Dozer Technical Reference Manual
P/N: 7010-0377 Rev C 1/10
©2010 Topcon Positioning Systems, Inc. All rights reserved. No unauthorized duplication.