AutoSteer Installation Guide

AutoSteer Installation Guide John Deere JD-9860 STS Combine Harvester Covers AutoSteer (IK#180-0051-01 Rev A) installation on the following combine models having single cylinder rear axle: JD-9650 STS 4WD & 2WD JD-9750 STS 4WD & 2WD JD-9560 STS 4WD & 2WD JD-9660 STS 4WD & 2WD JD-9760 STS 4WD & 2WD JD-9860 STS 4WD & 2WD PN: 602-0007-01, 8.25.2004, Rev 1.1 1

Introduction This installation guide specifies the correct mounting positions for all the AutoSteer brackets and hardware on the machine. This guide is an internal company engineering document and should not be used by AutoFarm installers or customers because it does not include important safety warnings and step-by-step procedures. AutoFarm installers and customers should refer to the appropriate customer install guide for complete installation instructions. Consult an AutoFarm Wheeled Tractor Installation Manual for full details on cable connections, AutoSteer system startup and calibration. 2

Installation Kit Overview JD-9860 STS 4WD Combine Harvester Roof Array Brackets Wheel Angle Sensor Monitor Bracket Hydraulic Hoses & Adapters Cab Box Bracket AutoSteer Valve HOSES NOT SHOWN TO TRUE LENGTH Valve Bracket Relief Valve, DPS2 Valve Drain Plate & Orifice Cable Routing Hardware AutoSteer Steering Cable Install Guide 3 P#180-0051-01 Rev. A 08/2004

Location of AutoSteer Installation Points Valve Bracket with Autosteer Valve, Relief Valve & DPS2 Valve & Orifice on Left Side Roof Array on Bolts Over Cab Monitor on Right Side Window Frame Wheel Angle Sensor on Rear Axle Cab Box on Cab Wall Panel JD-9860 STS 4WD Combine 4

Roof Array Installation Mount the roof array brackets over the two front bolts on the cab roof. Use large OD washers as spacers and replace original bolts with longer bolts (M12x1.75x50mm). Note: Older John Deere combines might require the longer metric bolts (M12x1.75x80mm) and a longer spacer bushing or additional spacer washers because the bolt holes on the cab roof are deeper. 5

Roof Array Brackets Roof Array mounts here with two 5/8 bolts Hole for M12 bolt to mount on cab roof Note: These brackets mount the roof array 12 above the cab roof for a better view of the sky over the grain tank and should provide good GPS performance under most conditions. Combines equipped with extra high grain tank extensions ( greedy boards ) might require special roof array brackets to position the GPS antennas higher above the cab for a better view of the sky. 6

Roof Array Brackets Mounting Position Over Cab Roof Array with GPS and Radio Antennas 5/8 Bolts, Washer & Nuts (two on each side) Warning: To avoid collisions with low objects and shock hazard, the roof array must be removed from the cab roof before transporting the combine on a truck or trailer and before entering low buildings or driving under low structures and power lines. Spacer for Combines with Deeper Hole (Newer combines use a pile of washers as a spacer.) Longer Bolts (M12 Metric) Brackets 7

Roof Array Brackets Detail Roof Array Bracket Use aprox. 10 washers as spacers. On older combines use longer aluminum spacer bushing. Thread on Cab Roof 8

Roof Array Fully Assembled over Cab Brackets should lie flat touching the cab roof for stability. You can use a soft material (ex: rubber or plastic sheet) as a spacer between the ends of the brackets and the cab roof if necessary. 9

Routing Antenna Cables The antenna cables must be routed away from the roof array and across the cab roof to the right rear side of the cab before going down to the cab entry hole. Secure the cables with cable ties and clamps to avoid excessive movement of the cables. Excess cable can be wrapped into a role inside the cab and secured with cable ties. Note: In this picture the roof array is not mounted on the elevated 12 brackets that help obtain a better view of the sky over the grain tank. The cables can be secured to the brackets using cable ties as necessary. Radio whip antenna GPS L1 antenna Roof Array (without brackets) Antenna Cables (3 GPS + 1 Radio) FRONT GPS L1 antenna GPS L1/L2 antenna Cab Roof 10

Monitor Bracket Installation 1. Mount monitor bracket on two holes on window frame. 2. Remove plastic side panel to have access to back of hole for the nut. 3. Insert one or two washers as spacers between the bracket and the window frame at each bolt if required. Remove this plastic panel to gain access behind window frame. If you just bend the panel forward it might be sufficient. 11

Monitor Bracket Assembly Monitor Bracket that Mounts on Right Side Window Frame Monitor Slider Adjustable Bracket for Monitor Height Mounting Bolts 3/8-16 with Nuts & Washers (These bolt the bracket to the window frame.) Note: An optional long steel reinforcement plate can be supplied with your installation kit. This plate will mount behind the window frame and will be secured by the two main bracket mounting bolts. The part has a curve to pass over ashtray nuts on newer combines. 12

Monitor Bracket Assembly Extra Washers (to use as spacers as needed) Main Bracket (that mounts on window frame) Curve (to fit reinforcement plate over the ashtray welded nuts on newer combines) 13

Monitor Bracket Installed Warning: Do not cover this Emergency Exit pull tab that should remain visible and accessible after the installation is completed. Monitor arm slider will mount on this slider bracket Remove ashtray here on newer combines. 14

Monitor Arm Installed Remove one arm from the monitor arm assembly so that the monitor is mounted on only one arm. 15

Monitor Mounted You can move this bracket up and down to change monitor height. The best height might be lower than the height shown in this picture. UP DOWN 16

Installing the Cab Box The Cab Box is installed on the right side of the cab against the back wall. M6 flat head screws (4X) Remove the original plastic bin and its steel bracket from the cab wall. The four M6 screws that secure the bin will be used to mount the Cab Box bracket to the cab wall. The bin will no longer be used unless you install it in another position. Note: Remove this ashtray before installing the monitor bracket. Driver Seat 17

Installing the Cab Box Cab Box Slider Note: First mount the bracket onto the cab wall then mount the slider onto the bracket. Threaded holes (8x) for mounting the slider onto the bracket. There are two sets of four holes so you can choose the height of the cab box. The holes are slanted at an angle so that the Cab Box follows the angle of the right side cab Wall. 10-32x1/4 screws for mounting the cab box slider onto the bracket. Cab Box Bracket Chamfered holes for mounting bracket to cab wall using the four original M6 flat head screws 18

Cab Box Bracket Installed 1. Remove these two screws before sliding the Cab Box onto the bracket. 2. Use the two screws to secure the Cab Box after it is mounted on bracket. Bracket Mounted to the Cab Wall 19

Cab Box Installed 1. Mount the bracket to the cab wall using the four original M6 screws. 2. Mount the cab box slider on the cab box bracket using four small screws. 3. Slide the cab box into the slider. Driver Seat Note: The cab box mounting plate can be mounted on other side of cab box so that the ON/OFF switch and door face the driver. Position of Cab Box after Installation 20

Cable Entry into Cab Warning: Before drilling any holes check the other side of the panel for cables and other parts that can be damaged by the drill. Left Side of Cab 1. Cut a 1-3/4 hole in this panel with a hole saw and insert the rubber grommet for allowing the cable entry into the cab. The GPS antenna cable and the steering cable will go through the grommet. 2. Seal the space in the grommet around the cables with foam or silicone rubber to avoid dust entering the cab. 21

Steering Cable Connections Connects to the AutoSteer valve on left side of machine Connects to GPS Steering Controller (Cab Box) in the cab. Steering Cable Connects to the AutoSteer valve on Left side of machine Note: If necessary, you can extract more wheel angle sensor cable from the main steering cable in order have sufficient cable length to reach the wheel angle sensor on the rear axle. To extract the cable you will have to cut open some cable ties on the black protective cable cover. Close the protective cover and replace the cable ties after extracting the necessary cable length. Connects to the wheel angle sensor on rear axle. 22

Cable Routing Hardware 1. Secure all loose cables and hoses with the cable ties and clamps provided. 2. Route cables and hoses clear of moving parts and sources of heat. 3. Use the rubber grommet to protect cables at entry hole on cab wall. Rubber Grommet for Cable Entry Clamps Short Cable Ties Long Cable Ties 23

Wheel Angle Sensor (4WD Axle) (on single cylinder axle) Note: On 2WD combines with a single steering cylinder, the installation of the wheel angle sensor follows the same guidelines shown here. On combines equipped with two steering cylinders, you can choose to use a special wheel angle sensor bracket that mounts on the cylinder. Consult AutoFarm for further details WAS bracket mounts here with a long ¾ or 20mm bolt & nut through the axle. You can use any convenient hole on inner or outer axle as long as linkage arms are aligned (see WAS assembly drawing) 4WD Axle (single steering cylinder) End of linkage rod mounts on bracket on this tie rod using a 1-1/2 muffler clamp to secure to tie rod. 24

Wheel Angle Sensor Assembly Shield to Protect Sensor from Debris Cable Connector Wheel Angle Sensor ( pot sensor ) Adjust this arm length to get between 3400 and 3600 counts from hard left to hard right turn. Cut to length as needed. Wheel Angle Sensor Bracket. Can also be rotated 90 degrees to horizontal position if necessary for better alignment of linkage arms. Ball Joints (2X) This bolt mounts the bracket to the rear axle using one of the existing holes Linkage Arm U-Bolt Clamp (1-1/2 muffler clamp) Tie Rod Bracket Note: Exact mounting position can be different from figure above depending on type of axle and what side you choose for mounting. 25

2WD Axle Note: Assembly on 4WD rear axles is the same as 2WD, but you must keep linkages and stay clear of hydraulic hoses going out to the wheel hub traction motor. (grease lines normally not found on machine) Wheel Angle Sensor Bracket These four holes allow mounting the bracket in a vertical or horizontal position while keeping the wheel angle sensor in the vertical position. Allows different bracket positions. Long Bolt Rear 2WD Axle 26

Wheel Angle Sensor Assembled After final assembly, the wheel angle sensor should look similar to the figure shown. The exact mounting position can be different depending on the axle type and axle tread width. The wheel angle sensor cable should be routed in a protected position over the axle and secured with cable ties to avoid damage from the crop residue (especially corn). All the nuts and bolts must be tightened after final assembly. Linkage Rods Protective Shield Goes Here Wheel Angle Sensor 27

Warning: Refer to AutoFarm hydraulic diagram and hose drawing before installing the Autosteer valve and hoses on the combine. Improper or inverted installation of hoses on the pressure relief valve can result in severe pump damage from over pressure. The pressure relief valve must be correctly installed, tested and adjusted before turning on the AutoSteer Cab Box. 28

Hose Connections on AutoSteer Valve MAIN AUTOSTEER VALVE HOSE TO LEFT STEER CYLINDER HOSE TO RIGHT STEER CYLINDER HOSE FROM RIGHT MANUAL STEER PRESSURE ADJUSMENT SCREW ON RELIEF VALVE CARTRIDGE RELIEF VALVE JD-9860 STS COMBINE Hose Kit #500-128-01 Rev. 2 CONNECTS TO PUMP PRESSURE OUTLET HOSE FROM LEFT MANUAL STEER CONNECTS TO FILTER OIL RETURN TO TANK DRAIN THE ORIGINAL MANUAL STEERING PRESSURE HOSE CONNECTS HERE TO GET OIL FOR MANUAL STEERING RETURN 2X3 STEEL FRAME ON LEFT SIDE OF COMBINE JUST ABOVE CYLINDER WINDOWS AUTOFARM 08-20-2004 PRESSURE LOAD SENSE DPS2 VALVE (OPEN CENTER PRESSURE CONTROL) Optional orifice goes here to eliminate chatter DPS2 Cartridge (40/80/160 psi) DRAIN ORIFICE (JIC) 0.022 or 0.031 CONNECTS TO PUMP SUCTION 29

Valve Bracket 1. Mount the valve bracket on this 2 x3 frame member on left side of combine (STS models). Use the three square U-bolts to secure bracket on the frame. You might have to move existing hoses in order to mount the bracket. The hoses should come out the right side of the bracket towards back of machine. 2. Route all the AutoSteer hoses along here to the pump and filter up near the engine and the steer hoses down to the rear axle. Do not route the hoses near moving or hot parts such as pulleys and belts. 30

AutoSteer Open Center Hydraulic Assembly Warning: The correct connection of hoses to this relief valve is the most important step in the hydraulic installation. Connecting the hoses inverted or on the wrong port will cause immediate severe pump damage on the combine from over pressure when engine is turned on. Connect pressure hose coming from pump or attenuator here. Connect tank return hose to here (this hose actually goes to the filter which is on the return oil path). Install ORFS damper orifice (0.031 ) here to eliminate chatter if necessary. Drain Orifice JIC (0.022 or 0.031 ) 31

Adjusting the AutoFarm Pressure Relief Valve Before Installing AutoSteer After Installing AutoSteer 1. Connect a pressure gauge with a long (25ft) hose to the diagnostic port (small quick coupler with rubber cap) on the steering oil pump. The recommended pressure gauge is a 5000psi or at least 3500psi with liquid fill. A long hose will allow pressure measurements from inside the combine cab while driving. You will need a female diagnostic coupling (Aeroquip FD-90 series or equivalent) to connect your hose to the diagnostic port on the pump. 2. Turn on the engine to the working engine speed (ex: 2300rpm) and manually steer the wheels to a hard right or hard left position. 3. Measure the steering pressure while trying to turn the wheels against the stops. 4. The pressure that you measure is the relief pressure of the original pressure relief valve on the combine steering system. Write down the measured pressure for latter reference. A typical pressure reading for a John Deere combine will be around 2800-2900 psi. Attention: The AutoSteer relief valve protects the steering oil pump against excessive oil pressure and must be correctly installed and adjusted in order to prevent damage to the pump. Always check the relief valve installation and adjust the relief pressure before turning on the AutoSteer main power switch on the Cab Box. Improper relief valve installation or inverted hose connections will cause overpressure and immediate severe damage to the steering oil pump when the engine is turned on. 1. Connect a pressure gauge to the diagnostic port on the steering oil pump (see picture to identify the test port). 2. Turn on the engine to working engine speed (ex: 2300rpm) and manually steer the wheels to a hard right or hard left position. 3. Measure the steering pressure while trying to turn the wheels against the stop. 4. Turn the adjustment screw on the AutoSteer relief valve counter clockwise until you notice a significant drop in the pressure reading while turning the wheels against the stop. This will 5. If the relief valve is correctly installed you will notice that the maximum pressure can be adjusted on the AutoSteer relief valve. If the relief valve is not working you will notice that the pressure reading does not change when you turn the adjustment screw. You might also get a zero pressure reading if the other hoses are not connected correctly. Certify that the relief valve adjustment screw is working before proceeding. 6. Turn the wheels against the stop and turn the adjustment screw on the AutoFarm relief valve until the measured pressure is 100psi below the maximum pressure that you measured before installing the AutoSteer system. The final adjustment of the AutoSteer relief valve will be done after the AutoSteer system is fully functional while steering the machine in AutoSteer mode. (this is explained latter in this installation guide). 32

AutoSteer Valves (Open Center) Relief Pressure Adjustment Screw Hoses Going to Steering Cylinder on Rear Axle Relief Valve Main AutoSteer Valve DPS2 Pressure Control Valve 33

AutoSteer Valve Assembled The excess cable harness should be secured with cable ties in a convenient and protected location The valve bracket is secured to the combine frame with three square U-Bolts supplied with the kit. 34

Pressure and Return Hose Connection Points Steering Pump (used only for steering and gear case lubrication) Gearcase This end of the steering pressure hose will be removed from here and connected directly to the Tee on the DPS2 valve on AutoSteer valve bracket. A new hose will connect this pump outlet to a tee on the pressure relief valve on the valve bracket. This elbow on pump suction will be replaced by a special reworked -12 elbow that has a -4 adapter for the AutoSteer tank drain hose coming from the orifice on AutoSteer system. 35

Steering Pump Hose Connection Test port coupler for connecting a pressure gauge to measure oil pressure during relief valve adjustment. Steering Oil Pump Main Suction Hose from Gearcase Reservoir to Steering Oil Pump Note: Use A 5000psi pressure gauge to adjust AutoSteer relief valve pressure. Adjust relief pressure to about 2900 psi or about 50 psi above the manual steering relief pressure. Drain hose coming from AutoSteer orifice to drain the load sense pressure. Reworked tee with a -4 ORFS hose connector on the side to receive the drain hose from AutoSteer system 36

Return from Relief Valve 1. Remove this hose end and insert a tee supplied with hose kit. 2. Re-connect this hose to the tee. 3. Connect the return hose coming from the AutoSteer relief valve to this tee. When the relief valve opens, it will dump oil to the oil filter which is in the return oil path before it lubricates the gear case. 37

Connecting the Steer Hoses to the Steering Cylinder Note: The connections follow the same idea on the other side, but one side has -6 hose fittings and the other side has -8 hose fittings. Single steering cylinder found on most John Deere STS 4WD & 2WD combines. This hose will connect to the AutoSteer steer in hose. Steer out hoses will connect here directly to the steering cylinder. 38

Routing Hoses Secure all the hoses with cable ties to avoid movement and keep away from moving parts on combine. Note: Loose hoses can cause hydraulic chatter. 39

Final Pressure Relief Valve Adjustment The pressure relief valve must be adjusted again after the AutoSteer system has been installed and is fully functional. The objective is to adjust the AutoSteer relief pressure to a value 100 psi above the original steering relief pressure. Follow the steps below: 1. Drive the combine at working engine speed (ex: 2300 rpm) at a very low speed and make a hard left or hard right turn against the stops in the AutoSteer steering calibration mode. 2. Observe the maximum steering pump pressure when the wheels hit the stops. 3. Adjust the maximum pressure (turn the screw on the relief valve) so that it is 100 psi above the maximum pressure that you measured before installing the AutoSteer system. For example, if you measured a 2800 psi relief pressure before installing AutoSteer, then you must adjust the AutoSteer relief pressure to 2900 psi. If the AutoSteer relief valve is correctly adjusted, it will only open when the combine is in AutoSteer mode. During normal manual steering the original steering relief valve will open before the AutoSteer relief valve. Note: The Autosteer relief valve must not be adjusted to exactly the same pressure as the original steering relief valve because hydraulic instability and audible chatter can develop. Note: To check if the original relief valve is working during manual steering, you can make a hard right or hard left turn against the wheel stops while driving with manual steering. If the original relief valve is working you will hear or feel the noise from the relief valve that is built into the steering unit under the cab. 40

The following pages are extra instructions for covering special installations or different combine models. 41

Special Instructions for Double Cylinder Rear Axles Some John Deere combines such as the JD-9660 CTS 4WD can be equipped with a different rear axle that has two external steering cylinders. AutoFarm offers a special wheel angle sensor kit for mounting the wheel angle sensor directly on one steering cylinder as shown above. You can choose to mount the wheel angle sensor on either the right side or left side steering cylinder. The linkage arm length should be adjusted to get between 3400 and 3600 counts. Note: The wheel angle sensor has a protective shield that is not shown. It mounts with two bolts on the two 3/8 threads that exist on the black wheel angle sensor body. The shield protects the sensor from flying debris at the back of combine. Wheel Angle Sensor Cable Threads for Mounting Shield Rod Wheel Angle Sensor Bracket Longer bolt (3/8-16 x 2) mounts bracket on rod end U-bolt (2-1/8 Muffler Clamp) This should really be a ball joint (picture is wrong) Steering Cylinder. One on each side of rear axle. Rod Bracket 42

Calibration and Tuning Notes tbd 43

Notes This is a preliminary version of the AutoSteer JD- 9860 STS installation guide. This guide is published by engineering as a technical reference for company employees and will be updated with new pictures and information as it becomes available. Note: AutoSteer installation on John Deere CTS model combines (JD-9560 CTS & JD-9660 CTS) requires a different installation kit (uses different valve bracket & hoses) and a different installation guide. Last Update: 08-23-2004 44