Installation OnTrac2+ GPS Assisted Steering System Manual PN: 602-0208-02-A
Copyright Copyright 2012. All rights reserved. This document is copyrighted and all rights are reserved. Information in this document is subject to change without notice and does not represent a commitment on the part of Novariant. The document may not, in whole or in part, be copied, photocopied, reproduced, translated, or reduced to any electronic medium or machine-readable form without prior consent, in writing, from Novariant. Technical Support Refer to your owner's manual for technical support information. Contact Information Refer to your owner's manual for contact information. ii OnTrac2+ GPS Assisted Steering System
Table of Contents Table of Contents Chapter 1 Overview... 1 Safety Information.......................................................... 2 Safety Instructions......................................................... 2 Warning Statements........................................................ 3 Caution Statements........................................................ 5 Installation Procedure Overview................................................ 6 Special Tool Requirements.................................................... 6 OnTrac2+ GPS Assisted Steering System Components Diagram...................... 7 Installation Kit Components................................................... 8 OnTrac2+ Main Hardware Kit................................................ 8 OnTrac2+ Switch Kit....................................................... 9 Chapter 2 MDU3 Installation... 11 MDU3 Installation Overview.................................................. 11 MDU3 Installation Procedure................................................. 12 Install the Main Gear on the Steering Wheel.................................... 12 Attach the Anti-rotation Pin................................................. 18 Install the MDU3......................................................... 19 Chapter 3 Universal Bracket Installation... 21 Universal Bracket Installation Kit Overview..................................... 22 Universal Bracket Installation Procedure........................................ 23 Chapter 4 ECU4 Installation... 27 ECU4 Installation Overview.................................................. 27 ECU4 Orientation.......................................................... 27 ECU4 Installation Procedure................................................. 29 Chapter 5 Cable Harness Installation... 31 Safety Notes............................................................... 31 Cable Harness Connections Overview.......................................... 32 Cable Harness Installation Procedure........................................... 33 Chapter 6 Care and Maintenance... 37 Chapter 7 Troubleshooting... 39 LED Indicators............................................................. 39 Diagnostics................................................................ 40 Appendix A CNH Fit Kit Installation...41 CNH Fit Kit Overview....................................................... 41 Supported Vehicles......................................................... 41 CNH Fit Kit Components Overview............................................ 42 Installation Notes........................................................... 43 CNH Fit Kit Installation Procedure............................................. 44 Install the Mechanical Drive Unit............................................ 44 Install the Column Bracket................................................. 46 Install the Anti-rotation Pin................................................. 47 Install the Shift Lever..................................................... 49 Installation Manual iii
Table of Contents iv OnTrac2+ GPS Assisted Steering System
1 Overview This chapter contains the following sections: Safety Information Installation Procedure Overview OnTrac2+ GPS Assisted Steering System Components Diagram Installation Kit Components Installation Manual 1
Overview Safety Information The manufacturer disclaims any responsibility for damage or physical harm caused by failure to adhere to the following safety requirements: Safety Instructions Read these safety instructions and the user's instructions thoroughly, and follow the instructions. Only an operator who is fully authorized to drive the tractor can make use of the OnTrac2+ GPS Assisted Steering System. The operator must not exceed the safe speed limit for the terrain it is operating on. An operator must always be conscious of his actions when operating the OnTrac2+ GPS Assisted Steering System. When installing the OnTrac2+ Assisted Steering System do not force the components as this can result in the components being damaged. Always follow the instructions in the installation; operation; and maintenance manual Only an authorized party should install the OnTrac2+ GPS Assisted Steering System. Always carry out an inventory of the components delivered to ensure all the correct components are present. Never use replacement components. Only use original components. If there are any questions regarding the safe operation of the OnTrac2+ GPS Assisted Steering System or the instructions in the manuals do not hesitate to always contact the responsible expert. Always use the correct tools to install the OnTrac2+ GPS Assisted Steering System. Caution must be taken when installing the OnTrac2+ GPS Assisted Steering System to prevent injury. Do not use or operate the OnTrac2+ GPS Assisted Steering System in unsafe weather conditions. Do not use or operate the OnTrac2+ GPS Assisted Steering System if the terrain is unsafe. It is not allowed for an unauthorized person to use or operate the OnTrac2+ GPS Assisted Steering System. Before starting work activities, the operator must have sufficient knowledge of procedures how operate the OnTrac2+ GPS Assisted Steering System in a safe manner. When installing the OnTrac2+ GPS Assisted Steering System, all safety precautions must be taken into account and it should not be used if there are any parts loose, missing or damaged. Only an operator who has been trained or is experienced may operate the OnTrac2+ GPS Assisted Steering System. Before using the OnTrac2+ GPS Assisted Steering System all functions must be checked and controlled for their correct working order. When there is any doubt, do not take any risks always consult an expert. Before operating the OnTrac2+ GPS Assisted Steering System, control all functions of the Presence Switch and confirm the settings to ensure it functions correctly. Turning the OnTrac2+ GPS Assisted Steering System on and off must always happen consciously following the correct prescribed procedures. If an abnormal phenomenon presents itself, for example excessive vibrations noise, then immediately turn off the OnTrac2+ GPS Assisted Steering System and consult a responsible expert. When the OnTrac2+ GPS Assisted Steering System is being cleaned or when maintenance takes place, it must be totally turned off and free of any electrical currents. The operator of the OnTrac2+ GPS Assisted Steering System must have complete knowledge about how to react in case of emergency. A trained expert must always carry out maintenance or repairs on the OnTrac2+ GPS Assisted Steering System. During repair or replacement of components on the OnTrac2+ GPS Assisted Steering System only original components must be used. Always wear correct prescribed personal protection equipment during the use or cleaning or maintenance of the OnTrac2+ GPS Assisted Steering System. Always use the recommended cleaning materials and accessories when the OnTrac2+ GPS Assisted Steering System is cleaned. 2 OnTrac2+ GPS Assisted Steering System
Overview Every unsafe condition or situation on the OnTrac2+ GPS Assisted Steering System must be reported to the responsible persons. Do not leave or place objects on or in the area of the OnTrac2+ GPS Assisted Steering System. Warning Statements As the operator of the vehicle, you are responsible for its safe operation. The GPS steering system is not designed to replace the vehicle s operator. WARNING To prevent the vehicle from running over a person, you must never leave the vehicle while the GPS steering system is engaged. WARNING To understand the potential hazards associated with the operation of the OnTrac2+ GPS Assisted Steering System, read the provided documentation before installing the GPS steering system on a vehicle. WARNING Movement of the Electronic Control Unit (ECU4) relative to the vehicle may cause erratic steering and sudden loss of vehicle control while in AutoSteer mode. Always keep the Electronic Control Unit (ECU4) firmly secured to the vehicle. Do not operate your OnTrac2+ system with a loose ECU4. WARNING To prevent the accidental engagement of steering and loss of vehicle control while driving on roads, turn the MDU3 power switch to the OFF position or remove the MDU3 from the steering column. Never drive on roads or in public areas with the GPS steering system turned on. Installation Manual 3
Overview WARNING The OnTrac2+ GPS Assisted Steering System is solely intended for agricultural use. The systems should only be used with agricultural vehicles and should not be used with any other type of vehicle or for any other purposes. Unapproved applications may result in loss of vehicle control resulting in injury or death. 4 OnTrac2+ GPS Assisted Steering System
Overview Caution Statements The manufacturer disclaims any responsibility for damage or physical harm caused by failure to adhere to the following safety requirements: CAUTION The GPS steering system does not detect obstacles in the vehicle s path. The operator must observe the path being driven in order to avoid obstacles. CAUTION When engaged, the GPS steering system controls only the steering of the vehicle. The operator must control the speed of the vehicle. CAUTION To avoid possible damage to electronic circuits caused by electrostatic discharge, never touch the contacts on the ECU4 electrical connectors at any time. CAUTION Make sure the assembly does not interfere with any of the vehicle control levers on the steering column. CAUTION Make sure that the main gear race has properly engaged the three rollers before closing latch. If the race is not engaged properly, you risk damaging the MDU3 and steering wheel while the OnTrac2+ GPS Assisted Steering System is operating. Installation Manual 5
Special Tool Requirements Installation Procedure Overview Note: For vehicle-specific installation tips, please consult the OnTrac2+ GPS Assisted Steering System Supported Vehicle List, which is available from your local dealer. Note: Tighten all screws, bolts, nuts, and cable connections after the final assembly of the Steering System on the vehicle. The installation steps are listed below. Follow them in order: 1. Display Installation. Refer to the documentation that came with your display. 2. Install the Mechanical Drive Unit (MDU3). 3. Install the Anti-Rotation Bracket. 4. Install the Electronic Control Unit (ECU4). 5. Install the Cable Harness. Special Tool Requirements This list consists of special tools required to complete the installation. A complete set of common installation tools is assumed. 7/64'' Allen Wrench 5/32'' Allen Wrench 1/4'' Open Wrench 1/4'' Nut Driver Torque wrench 0 to 20 lbf-in (0 to 2 Nm), for 5/32'' hex bit Loctite 242 or equivalent 6 OnTrac2+ GPS Assisted Steering System
Special Tool Requirements OnTrac2+ GPS Assisted Steering System Components Diagram Figure 1-1 Overview of the Main Components in the Vehicle s Cab Display MDU3 (Integrated with the steering wheel) ECU4 (On cab floor) Installation Manual 7
Special Tool Requirements Installation Kit Components This section describes the OnTrac2+ components required for a typical installation. The installation kit is organized into a main kit that contains a switch kit subassembly. The Switch Kit contains the hardware that enables you to switch the OT2+ system between vehicles. OnTrac2+ Main Hardware Kit The typical OnTrac2+ installation requires the components shown in Figure 1-2. Figure 1-2 OnTrac2+ Installation Kit Table 1-1 OnTrac2+ Installation Kit Components Item Component Part Number Qty 1. Mechanical Drive Unit (MDU3) 200-0463-08 (AL 200-0463-07) 2. OnTrac2+ Switch Kit (see OnTrac2+ Switch Kit on page 9) 126-0009-04 (AL 126-0009-05) 1 1 3. Anti-rotation Pin 510-0160-02 1 4. ECU4 200-0610-01 1 8 OnTrac2+ GPS Assisted Steering System
Special Tool Requirements Item Component Part Number Qty 5. ECU4 Power/Data Harness 201-0517-02 1 6. Installation Manual 602-0208-02 1 7. Quick Reference Guide 602-0300-01 1 OnTrac2+ Switch Kit The Switch Kit components shown in Figure 1-3 enable you to switch the OT2+ system between vehicles. Note: An anti-rotation bracket that fits your vehicle steering column is required to complete the OnTrac2+ installation. This bracket varies by vehicle model and must be purchased separately. Contact your OnTrac2+ dealer for a list of supported vehicles and available bracket kits. Figure 1-3 OnTrac2+ Switch Kit Components Installation Manual 9
Special Tool Requirements Table 1-2 OnTrac2+ Installation Kit Components Item Component Part Number Qty 1. Upper Ring 402-0019-02 1 2. 5.75 x 0.50 Spacer 402-0024-03 1 3. 5.75 ID x 0.25 Spacer 402-0024-04 1 4. Ring Cap Assembly 200-0522-05 (AL 200-0522-04) 1 5. Main Gear Assembly 200-0621-01 1 6. Hardware Kit 200-0635-01 1 7. Cable, Mechanical Drive Unit Kit to ECU4 201-0518-01 1 Note: You may purchase additional switch kits from your dealer. Additional switch kits enable you to move the OnTrac2+ system easily and quickly between two or more vehicles. The switch kit includes all the parts that will remain permanently attached to each vehicle. Contact your dealer for further details. 10 OnTrac2+ GPS Assisted Steering System
2 MDU3 Installation This chapter contains the following sections: MDU3 Installation Overview MDU3 Installation Procedure MDU3 Installation Overview The MDU3 installation process is described below. A detailed procedure for each step is described in the following sections of this chapter. 1. Install the Main Gear on the Steering Wheel. 2. Attach the Anti-rotation Pin. 3. Install the MDU3. Installation Manual 11
MDU3 Installation Overview MDU3 Installation Procedure Refer to Installation Kit Components on page 8 to identify the parts used in this section. Install the Main Gear on the Steering Wheel The goal of this section is the installation of the main gear on the steering wheel. A completed installation is shown in Figure 2-1. Through the use of switch kits, main gears can be installed and left on multiple vehicles allowing the user to move the MDU3. Note: Certain CNH vehicle models require the installation of spacer rings between the main gear and the steering wheel column. See Appendix A for details. Figure 2-1 Completed Main Gear Installation 12 OnTrac2+ GPS Assisted Steering System
MDU3 Installation Overview Install The Main Gear around the Steering Column Note: The installation of the main gear on the steering wheel does NOT require removing the steering wheel from the vehicle. 1. Remove 2 hex screws from the Smaller section of the Main Gear as shown in Figure 2-2. Figure 2-2 Main Gear Hex Screws 2. Remove the smaller section by pulling downwards as shown in Figure 2-3. Note: Tolerances are tight; pull directly downwards on smaller section. Figure 2-3 Main Gear Exploded View Installation Manual 13
MDU3 Installation Overview 3. Install the larger section under steering wheel around steering column. Install with the gear side on the top, closest to the steering wheel as shown in Figure 2-4. Figure 2-4 Installed Main Gear Note: Weave the gear around the steering wheel spokes if necessary; certain steering columns may be too thick for the gear opening. 4. Reinstall the smaller section using care to push directly upwards on the sector, because it is a very tight fit. Note: To facilitate the fit between the two gear sections, you may apply a drop of oil or apply a thin film of grease to the two alignment pins before mating the gear sections. 5. Reinstall and secure the 2 hex screws. At this point the main gear is assembled around the steering column below the steering wheel as shown in Figure 2-4. The gear is free to move around and must be now clamped to the steering wheel. Note: If you are installing a universal anti-rotation bracket on a CNH vehicle, a CNH fit kit may be required to move the steering away from the instrument panel. Contact your OnTrac2+ dealer for details. Examine Steering Wheel and Column Examine the steering wheel underside to determine if a spacer is necessary. A steering wheel with a soft covering material usually requires installation of a spacer to avoid interference with the MDU3 housing. Install Spacer (If Needed) Install the spacer around the steering column between the steering wheel and the main gear as shown in Figure 2-5. Flex the plastic spacer as needed to clear the steering wheel spokes as shown in Figure 2-6. The large chamfer on the outside diameter of the spacer ring should be facing the main gear as shown in Figure 2-5. 14 OnTrac2+ GPS Assisted Steering System
MDU3 Installation Overview Note: Two spacers with different thicknesses are included in the kit. Select the thinnest spacer that provides sufficient clearance between steering wheel and MDU3. Figure 2-5 Wheel with Spacer Chamfer Alignment Spacer Figure 2-6 Spacer Flexing Install the Clamp Ring The gear is free to move around and must be now clamped to the steering wheel. This procedure will install and center the ring gear for typical 3 spoked, normal shaped steering wheels. Installation Manual 15
MDU3 Installation Overview 1. Place the clamp ring on top of the steering wheel and install a minimum of 6 hex screws. Install a screw on each side of every spoke keeping the screws as close to the spokes as possible. At this stage keep the screws fairly loose to allow for centering. See Figure 2-7. Note: Two lengths of screws are provided in the kit to support different thicknesses of steering wheel spokes. Select the shorter of the two screws that still provides full thread engagement. Figure 2-7 Clamp Ring 2. With the main gear clamped loosely, rotate and move the gear until 3 screws touch the spokes evenly. Figure 2-8 shows the main gear rotated counter-clockwise until three of the mounting screws touch the steering wheel spokes evenly. Figure 2-8 Main Gear Centered The red circles indicate which screws are touching the spokes. 3. Check the installation by rotating the steering wheel and watching for off-center movement of the main gear. Repeat the centering process as necessary. 4. Tighten the screws with an Allen key. Torque to 6 lbf-in (0.7 Nm). Tighten the screws in a cross-pattern (as opposed to tightening each screw in a clockwise or counter-clockwise order). 16 OnTrac2+ GPS Assisted Steering System
MDU3 Installation Overview Note: Do not over-tighten the clamp ring screws. 5. Check the installation again after tightening by rotating the steering wheel and watching for off-center movement of the main gear. Repeat the centering process as necessary. 6. Snap the plastic cover over the top ring as shown in Figure 2-9. Figure 2-9 Plastic Cover Ring Plastic Cover Ring Installation Manual 17
MDU3 Installation Overview Attach the Anti-rotation Pin 1. Chose the desired MDU3 orientation. The MDU3 can be mounted in any orientation the user chooses. Consider the following when choosing an orientation: Ease of installing anti-rotation bracketry Access to the Power Switch Avoid locations where a knee could accidently press the power switch. Avoid blocking the vehicle's steering column controls and indicators. Cable routing with minimal obstruction in the cab 2. Based on your preferred orientation, choose one of three locations for the Anti-rotation Pin as shown in Figure 2-10. Figure 2-10 Anti-rotation Pin Locations Three O clock Position Nine O clock Position Anti-rotation Pin Installed in the Bottom Position 3. Apply Loctite 242 or equivalent medium strength thread locker to the anti rotation pin threads. Note: Loctite 242 is not supplied with the OnTrac2+ GPS Assisted Steering System. 4. Install the anti-rotation pin and tighten to 40 in.lbs (4.5 N.m.) using a 1/4'' wrench or flat screwdriver. Note: The anti-rotation pin must always be kept tight to avoid breakage or separation. Periodically check the anti-rotation pin and confirm that it is tight. A large coin can be used as a screwdriver to temporarily tighten the anti-rotation pin if the correct tools are not readily available. 18 OnTrac2+ GPS Assisted Steering System
MDU3 Installation Overview Install the MDU3 This procedure describes the installation and alignment of the MDU3 to the Main Gear. 1. Open the MDU3 release latch as shown in Figure 2-11. Figure 2-11 MDU3 Release Latch Release Latch 2. Fit the MDU3 around the Main Gear so that the three MDU3 rollers align on the Main Gear race as shown in Figure 2-12. Note: The plastic cover on the MDU3 can be used as a guide to fit the bottom portion of the MDU3 to the V-rollers. Figure 2-12 MDU3 Alignment Rollers Main Gear Race Installation Manual 19
MDU3 Installation Overview 3. Ensure that the main gear race has properly engaged the three rollers before closing latch. See Figure 2-12. CAUTION Make sure that the main gear race has properly engaged the three rollers before closing latch. If the race is not engaged properly, you risk damaging the MDU3 and steering wheel while the OnTrac2+ GPS Assisted Steering System is operating. 4. Rotate the MDU3 manually to ensure smooth rolling. 5. Continue to the Universal Bracket Installation chapter. 20 OnTrac2+ GPS Assisted Steering System
3 Universal Bracket Installation This chapter contains the following sections: Universal Bracket Installation Kit Overview Universal Bracket Installation Procedure The universal anti-rotation bracket is available through your dealer. It should be used for vehicles that are not supported with a custom vehicle-specific bracket. Consult your OnTrac2+ dealer for a list of all available anti-rotation brackets. An Anti-rotation bracket is required to complete the OnTrac 2+ installation. Note: You may require a different bracket kit depending on your specific vehicle. Contact your dealer for details. Note: If your are installing a vehicle specific anti-rotation bracket, skip this section of the manual and refer to the installation instructions provided with your vehicle-specific bracket kit. Installation Manual 21
Universal Bracket Installation Universal Bracket Installation Kit Overview To complete your OnTrac2+ installation and prevent the rotation of the MDU3 (Mechanical Drive Unit), an anti-rotation bracket must be mounted to the vehicle steering column just below the steering wheel. This chapter provides instructions for installing a universal bracket kit that is available as an accessory through your AutoSteer dealer. Many other brackets are available to fit specific vehicles models and can be ordered through your AutoSteer dealer. Contact your dealer for details and availability for your vehicle model. The typical universal bracket kit includes the components shown in Figure 3-1. Figure 3-1 Universal Bracket Kit 6 1 5 2 3 4 Table 3-1 Universal Bracket Installation Kit Components Item Component Part Number Qty 1. Flange Bearing 522-0001-01 1 2. Fifth Wheel Slider 203-0218-01 1 3. Front Bracket 202-0216-01 1 4. Back Bracket ( V shape) 202-0232-01 1 5. Clamping screws. Machine Screw Phillips 1/4-20 x 4" (Washers, Lock Washers and Nuts) 514-0088-01 4 6. Bolts 5/16-18 x 3/4" (Slider Attaching Bolts) 512-0029-01 2 22 OnTrac2+ GPS Assisted Steering System
Universal Bracket Installation Universal Bracket Installation Procedure Note: The MDU3 is attached to the steering wheel prior to installation of the bracket kit. 1. Make sure that you have all of the required parts. See Figure 3-1. 2. Attach front bracket to the fifth wheel slider bracket using the two bolts (slider attaching bolts). See Figure 3-2. Tighten finger tight. Note: The slider will require adjustment once installed on the steering column. Figure 3-2 Fifth Wheel Slider Attachment Front Bracket Fifth Wheel Slider Installation Manual 23
Universal Bracket Installation 3. Place the flange bearing assembly over anti-rotation pin. Note: It is important that the anti-rotation pin is placed through the flange bearing before attaching the back bracket. Figure 3-3 Slide Flange Bearing Anti-rotation Pin 4. Attach the back bracket to the front bracket using the four machine screws clamping the steering column between the front and back brackets. Figure 3-4 Attaching the Brackets Clamping Screws 24 OnTrac2+ GPS Assisted Steering System
Universal Bracket Installation 5. Tighten the clamping assembly. CAUTION Make sure the assembly does not interfere with any of the vehicle control levers on the steering column. 6. Adjust the position of the fifth wheel slider so the flange bearing is approximately in the middle of the anti-rotation pin and tighten the bolts (Slider attaching bolts). Figure 3-5 Fifth Wheel Slider Adjustment 7. The bracket installation is complete. Continue to the ECU4 Installation chapter. Installation Manual 25
Universal Bracket Installation 26 OnTrac2+ GPS Assisted Steering System
4 ECU4 Installation This chapter contains the following sections: ECU4 Installation Overview ECU4 Orientation ECU4 Installation Procedure ECU4 Installation Overview The ECU4 contains instruments that control steering performance while the vehicle is in motion in the field. Refer to Installation Kit Components on page 8 to identify the parts used in this chapter. ECU4 Orientation For your OnTrac2+ GPS Assisted Steering System to operate correctly, we recommend mounting the ECU4 in a flat, level position on the floor of the vehicle. Note: Do not mount the Electronic Control Unit (ECU4) in an upright position in the cab. Installation Manual 27
ECU4 Orientation 1. Make sure you install the ECU4 in one of the four recommended orientations. Refer to Figure 4-1 and Figure 4-2 for details. Figure 4-1 ECU4 Mounting Orientations (Top Down Views) Front of Vehicle Figure 4-2 Incorrect ECU4 Mounting Orientations Front of Vehicle 28 OnTrac2+ GPS Assisted Steering System
ECU4 Orientation ECU4 Installation Procedure 1. Install the ECU4 on a flat, level and rigid surface such as the floor in you vehicle cab. Choose a position that does not interfere with vehicle controls, seat or cab entry and exit. Figure 4-3 ECU Position on Cabin Floor Front 2. Secure the flat bracket in one of the four recommended orientations using appropriate screws (not provided). The bracket has two hole sizes and will accept M6, M8, M10, 1/4, 5/16 or 3/8 mounting screws. If you plan to drill holes in the cab, check for the presence of cables, hoses or other sensitive equipment on the opposite side of the plate before drilling. Figure 4-4 Secure the ECU4 Bracket to the Cabin Floor Installation Manual 29
ECU4 Orientation 3. Secure the ECU4 to the flat bracket using the four (#8-32) screws provided. Tighten using a 1/4 nut driver, or alternatively a flat screwdriver. The ECU4 has open slots on one side so you may first pre-install two screws before attaching the unit. To remove you may simply loosen two screws on one side and remove the other two screws. Figure 4-5 ECU Position on Cabin Floor 30 OnTrac2+ GPS Assisted Steering System
5 Cable Harness Installation This chapter contains the following sections: Safety Notes Cable Harness Connections Overview Cable Harness Installation Procedure Safety Notes Note: The vehicle must be powered Off during the installation of the cable harness. Note: To prevent the system from any unexpected shut down while operating, check the cable insulation and cable connections to the other instruments. Route the cables away from all sharp edges to prevent control wires from being pulled hard or damaged. Installation Manual 31
Safety Notes Cable Harness Connections Overview The typical Cable Harness installation includes the components shown in Figure 5-1. For a detailed cable connection procedure, see Cable Harness Installation Procedure on page 33. Figure 5-1 Cable Harness Installation - Overview 2 1 6 5 3 4 7 Table 5-1 Cable Harness Installation Components Item. Description Part Number Part Number (AL) 1. User Display Varies by Display Varies by Display 2. User Display Cable Harness Varies by Display Varies by Display 3. Battery Power Cable (Not included with this kit) 201-0488-01 4002026-12 4. MDU3 to ECU4 Cable Harness 201-0518-01 N/A 5. ECU4 Power/Data Harness 201-0517-02 N/A 6. Electronic Control Unit (ECU4) 200-0610-01 N/A 7. Mechanical Drive Unit (MDU3) 200-0463-08 200-0463-07 32 OnTrac2+ GPS Assisted Steering System
Safety Notes Cable Harness Installation Procedure The OnTrac2+ GPS Assisted Steering System cable harness installation steps are described below. Follow them in order, referring to Figure 5-1 as necessary. This procedure assumes that you have connected your Display to your Display Harness and Power. Refer to your Display documentation for further information. 1. Connect the MDU3 to ECU4 Cable Harness 30 pin connector to the ECU4 and tighten the connector screw using a 1/4 nut driver. Tighten to 15 to 20 in-lbs (1.7 to 2.2Nm). Use only the recommended nut driver and do not over tighten. Figure 5-2 Attach MDU3 to ECU4 Cable Harness 30 pin connector to the ECU4 2. Connect the ECU4 Power/Data Harness 18 pin connector to the ECU4 and tighten the connector screw using a 1/4 nut driver. Tighten to 15 to 20 in-lbs (1.7 to 2.2Nm). Use only the recommended nut driver and do not over tighten. Figure 5-3 Attach the ECU4 Power/Data Harness 18 pin connector to the ECU4 Installation Manual 33
Safety Notes 3. Connect the MDU3 to ECU4 Cable Harness to the MDU3. Figure 5-4 Connect the MDU3 to ECU4 Cable Harness to the MDU3 34 OnTrac2+ GPS Assisted Steering System
Safety Notes 4. Connect ECU4 Power/Data Harness to the Display Cable Harness. Press the spring latch to mate the connectors. See Figure 5-6. To open, press the spring latch and separate the connectors. Figure 5-5 Connect ECU4 Power/Data Harness to the Display Cable Harness To Display Cable Harness CAN connector for other controllers Figure 5-6 ECU4 Power/Data Harness to Display Cable Harness Connector Installation Manual 35
Safety Notes 5. Connect the ECU4 Power/Data Harness to the Power Cable Harness. Figure 5-7 Connect ECU4 Power/Data Harness to the Power Cable Harness To Power Cable Harness 6. Verify that the locking features on the connectors are secured. 7. Power ON your Display and your MDU3. 8. Check the green power indicator on the MDU3. 9. Check the flashing green power indicator on the ECU4. 10. When the hardware installation is complete, proceed to system calibration. Refer to your Display User Manual. 36 OnTrac2+ GPS Assisted Steering System
6 Care and Maintenance This chapter describes the required care and maintenance for your OnTrac2+ system. Should you require repair services, spare parts or warranty, contact your OnTrac2+ dealer. Only the factory or an authorized service center has the correct parts and training necessary to service your OnTrac2+ system. Keep the anti-rotation pin tight at all times. Check the anti-rotation pin every 250 hours of operation or every six months, whichever occurs first, and tighten as necessary. Do not operate the OnTrac2+ unit if the anti-rotation pin is loose. Keep the anti-rotation bracket well secured to the steering column at all times. Check the anti-rotation bracket every 250 hours of operation or every six months, whichever occurs first, and confirm that it is secure and all fasteners are tight. Tighten as necessary. Keep the Electronic Control Unit (ECU4) and associated brackets well secured to the vehicle at all times. Verify that the ECU4 is secure every 250 hours of operation or every six months, whichever occurs first, and tighten as necessary. Do not operate the OnTrac2+ system if the ECU4 is not well secured. A detached ECU4 may cause sudden loss of vehicle control while in AutoSteer mode. Do not expose your Mechanical Drive Unit (MDU3) to water or rain. Store the MDU3 in a protected location. On open platform tractors, remove it from the vehicle when not in use. Check all cables and electrical connectors every six months. Secure any loose cables using cable ties. Clean the outside surfaces of your Mechanical Drive Unit and the three guide rollers using a damp cloth. Do not apply spray cleaners, spray waxes, liquids or lubricants such as WD-40. The use of any liquid cleaning agent or lubricant may damage the internal components of your Mechanical Drive Unit and will void the factory warranty. Always clean the main gear and main gear race (see Figure 2-4 and Figure 2-12) with a damp cloth to remove dust before installing the MDU3 to the steering wheel. This is especially important when moving the MDU3 between vehicles. The Mechanical Drive Unit is manufactured with sealed bearings and self lubricating components and does not require lubrication. Do not apply oil, grease or spray lubricants. Note: Any attempt to open the Mechanical Drive Unit (MDU3) or Electronic Control Unit (ECU4) will void the factory warranty. Installation Manual 37
Care and Maintenance 38 OnTrac2+ GPS Assisted Steering System
7 Troubleshooting This chapter contains the following sections: LED Indicators Diagnostics LED Indicators The ECU4 has been designed with 4 LEDs that indicate the status of the ECU4 as well as provide some basic troubleshooting information. Figure 7-1 shows the front panel of the ECU4. Table 7-1 provides definitions for the different LEDs and colors. Figure 7-1 Front Panel of ECU4 Installation Manual 39
Diagnostics Table 7-1 ECU4 Icon Definitions Green Icons Description Orange Icons Description Solid green indicates that the system is receiving power and it is in an operational mode. Solid orange indicates a fault, most likely a communication error. Flashing green indicates that the ECU4 is communicating to the GPS steering system via the CAN connection. Solid orange indicates that new software is being loaded. Do not turn the ECU4 power OFF while this light is orange. When green, a left steering command is being sent to the actuator. Orange indicates a fault error code. When green, a right steering command is being sent to the actuator. Orange indicates a fault error code. Diagnostics Power LED does not Turn ON Check all cable connections and verify that they have all been properly connected. Verify that the Display has powered ON. Check the fuses on the main harness. Right and Left LEDs are Blinking but do not Steer the Vehicle This indicates a bad actuator on the MDU3 or possibly a bad cable. Verify that the cables are properly connected to the actuators and there are no shorts. Verify that the actuators are working. Right and Left LEDs do not Blink when a Steer Right or Steer Left Command is Sent This indicates that a steering command is not being sent to the ECU4. Verify the GPS steering system settings, especially vehicle type, and verify that system is set up properly. Use the system diagnostics screens to manually command the MDU3 to turn the steering wheel right and left. Determine if the unit is communicating with GPS steering system as indicated by the blinking green communications LED. If not, check the cable for problems. System is Unresponsive and does not Steer Verify that the green power LED is turned ON. If not determine why the system is not powered up. Determine if the Communications LED is flashing. If not, check all cables and settings on the GPS steering system. E1 or E2 LEDs are Solid Orange These LEDs indicate a fault condition. Contact your dealer or technical support if these LEDs are on. 40 OnTrac2+ GPS Assisted Steering System
A CNH Fit Kit Installation This appendix contains the following sections: CNH Fit Kit Overview Supported Vehicles CNH Fit Kit Components Overview Installation Notes CNH Fit Kit Installation Procedure CNH Fit Kit Overview The CNH Fit kit is designed for installing the OnTrac2+ Mechanical Drive Unit (MDU3) on vehicles that require a bracket configuration different from the one shipped with the OnTrac2+ GPS Assisted Steering System kit. The CNH Fit kit prevents interference between the MDU3 set-up and the other parts of the vehicle steering column. Supported Vehicles The CNH Fit kit shall only be installed on approved vehicles. For a complete list of approved vehicles, please contact your dealer. The following list of Case IH and New Holland vehicles are supported: Case IH MX Magnum Case IH STX Steiger Case IH STX Quadtrac Case IH SPX Sprayers Case IH FLX Floaters with Surveyor Cab New Holland TJ New Holland TG New Holland T7000/8000 Series Installation Manual 41
Supported Vehicles CNH Fit Kit Components Overview The typical Vehicle Fit Kit (P/N 126-0008-01), includes the components shown in Figure 1. Figure 1 CNH Fit Kit 3 4 1 2 Table 1 CNH Fit Kit Components Item Component Part Number Qty 1. Shift Lever 203-0109-01 1 2. Bracket Kit 200-0424-02 1 3. Shim 202-0269-01 4 4. Socket Head Screw, 10-24 x 2", SS 514-0163-01 8 5. Socket Head Screw, 10-24 x 2.5" (Not Shown) 514-0165-01 8 42 OnTrac2+ GPS Assisted Steering System
Installation Notes Figure 2 provides an overview of the bracket kit components: Figure 2 Bracket Kit Components 1 2 3 4 Note: An alternate set-up is provided with this kit. Select and use the set-up that best fits your vehicle steering column configuration. Table 2 Item Bracket Kit Components Description 1. Flange Bearing Hole (for anti-rotation pin. Part of Universal Bracket Installation Kit) 2. Muffler Clamp 3. Fifth Wheel Slider 4. Fifth Wheel Slider Bolts Installation Notes The following instructions should be used only as a supplement to the main body of this manual. The instructions that follow are generic. For details about the installation and calibration of your OnTrac2+ GPS Assisted Steering System specific to your vehicle, contact your dealer. Installation Manual 43
CNH Fit Kit Installation Procedure The OnTrac2+ GPS Assisted Steering System may not perform well if you have excessive wear in the steering linkage and joints. Tighten all screws, bolts, nuts, and cable connections after the final assembly of the kit on the vehicle. To install the steering kit on your vehicle, you need a standard tool set. CNH Fit Kit Installation Procedure The installation steps are listed below: 1. Install the Mechanical Drive Unit. 2. Install the Column Bracket. 3. Install the Anti-rotation Pin. 4. Install the Shift Lever. Install the Mechanical Drive Unit 1. Install the MDU3 onto the steering column. See MDU3 Installation on page 11. Note: For the CNH fit kit, we recommend the MDU3 orientation shown in Figure 8-1. Figure 8-1 Recommended MDU3 Orientation 44 OnTrac2+ GPS Assisted Steering System
CNH Fit Kit Installation Procedure Note: Do not use the plastic spacer ring provided with the main OnTrac2+ GPS Assisted Steering System installation kit. Note: If there is interference between the steering wheel spokes and the main gear, proceed with step 2 before securing the main gear to the clamp ring. 2. Remove the peel-off paper from the inner surface of the shims and place one shim between each steering wheel spoke and the main gear. See Figure 8-2. Figure 8-2 Shim Installation Shim Installation Manual 45
CNH Fit Kit Installation Procedure Install the Column Bracket 1. Install the column bracket onto the vehicle s steering column as shown in Figure 8-3 and Figure 8-4. The elements of the column bracket surround the steering column to prevent the Mechanical Drive Unit from rotating while the system operates. Note: You may have to push down the rubber boot on some specific steering columns to install the column bracket correctly. See Figure 8-4. Figure 8-3 Bracket Installation Figure 8-4 Column Bracket Installation Pushing Down the Rubber Boot 46 OnTrac2+ GPS Assisted Steering System
CNH Fit Kit Installation Procedure 2. Loosen the two fifth wheel slider bolts. You will need to adjust the height of this element later. Refer to Install the Anti-rotation Pin on page 47 for details. 3. Align the two column bracket s nuts with the muffler clamp holes to fasten the bracket s elements together. Note: If the U-bolt option is not appropriate for your vehicle, install the straight-bolt option provided with this kit. Refer to Install the Mechanical Drive Unit on page 44 for details. Install the Anti-rotation Pin The anti-rotation pin is part of the Mechanical Drive Unit (MDU3). It prevents the MDU3 from rotating around the steering column when the OnTrac2+ GPS Assisted Steering System operates. We strongly recommend the use of Loctite 242 (or equivalent) on the anti-rotation pin threads. Note: Loctite 242 not supplied by the manufacturer. 1. The anti-rotation pin can be set at three different locations on the MDU3. Choose the location for the anti-rotation pin that best fits your vehicle steering column configuration. See Figure 8-5. 2. Fix the Mechanical Drive Unit anti-rotation pin to the flange bearing hole as shown in Figure 8-5. 3. Adjust the height of the fifth wheel slider so it matches the height of the anti-rotation pin. 4. Align the anti-rotation pin to the flange bearing hole and adjust the fifth wheel slider. Installation Manual 47
CNH Fit Kit Installation Procedure 5. Tighten the two fifth wheel slider bolts. Figure 8-5 MDU3 Anti-rotation Pin Positions Three O clock Position Nine O clock Position Bottom Position Figure 8-6 Anti-rotation Pin Attachment Anti-rotation Pin Flange Bearing Hole Fifth wheel slider Fifth Wheel Slider Bolts (2x) 48 OnTrac2+ GPS Assisted Steering System
CNH Fit Kit Installation Procedure Install the Shift Lever Note: The lever comes with a spare set screw and a small metal sleeve. 1. Remove the old lever from the steering column. Keep the set screw. 2. Place the sleeve in the set screw hole on the lever. Install the new lever as shown. Secure with the set screw. See Figure 8-7. Figure 8-7 Shift Lever Installation 3. Refer to the main body of this manual to complete the installation. Installation Manual 49
CNH Fit Kit Installation Procedure 50 OnTrac2+ GPS Assisted Steering System