Wheel Angle Sensor Kit Installation

Wheel Angle Sensor Kit Installation Item Component Part Number Qty 1. WAS Bracket Kit 200-0247-02 1 2. WAS Assembly Kit 200-0468-01 1 3. Instruction Guide 602-0401-01 1 602-0401-01-A

Overview Always shut down the vehicle when working around the steering axle or pivot point when installing or adjusting the Wheel Angle Sensor components. The steering mechanism could move suddenly and unexpectedly and cause severe injury or death. These instructions provide the procedure for installing the Wheel Angle Sensor on a custom installation that is not supported by an existing vehicle specific Wheel Angel Sensor Installation Kit. This manual provides general guidelines, specifications, and some examples of other Wheel Angle Sensor installations for reference so that an installation can be accomplished that is safe and performs satisfactorily. The Wheel Angle Sensor sends feedback to the AutoSteer system to give it the relative position of the steering axle, pivot point, or other steering mechanism so the AutoSteer system can better predict how far and fast to turn. Note: This installation requires the installer to cut the standard length of rods to specific lengths to work on the vehicle. It is always the responsibility of the installer to verify the rod lengths will work for their particular installation. The manufacturer is not responsible for damage caused by incorrectly installed Wheel Angle Sensors. The installer takes responsibility for all risks from damage and injury when installing a Wheel Angle Sensor on a vehicle. Supported Vehicles The following models have been confirmed to be compatible with this Wheel Angle Sensor Kit: Supported Make, Models, and Year Model was First Released Page Custom Vehicle Installation... 3 2 Wheel Angle Sensor Installation Guide

Custom Vehicle Installation Wheel Angle Sensor Installation Guidelines To ensure a quality installation that is safe and reliable, use the following guidelines to make decisions on the proper way and place to install the Wheel Angle Sensor. These are guidelines only. In certain situations, it may not be possible to follow all of them, however try to minimize deviating from these guidelines as much as possible. Every deviation has the potential to cause the Wheel Angle Sensor not perform as well as it should. A poorly performing Wheel Angle Sensor will decrease AutoSteer performance, especially during challenging driving conditions such as high speed operations and loose or slippery soil conditions. 1. Install the Wheel Angle Sensor in a protected position to avoid damage from tall crops or other debris. 2. Avoid installing the Wheel Angle Sensor on top of the steering axle or any place where a person may accidentally step on it while servicing the vehicle. Bent or damaged sensor rods will cause the Wheel Angle Sensor to lose calibration and thus performance will be degraded. If necessary build a protective cage around the Wheel Angle Sensor assembly to prevent damage. 3. Avoid installing the Wheel Angle Sensor on components which can move or rotate independently of the steering mechanism such as the steering cylinders or tie rods with ball joints. If the Wheel Angle Sensor must be connected to one of these, verify that they do not move when the steering mechanism is turned. 4. The Wheel Angle Sensor bracket must be well secured to the vehicle to avoid changes in position after the steering calibration has been completed. Build brackets so that when they are installed they are held by multiple bolts or one bolt and a solid stop to ensure the brackets cannot move after they have been installed. If the bracket slides after installation and calibration, the calibration will no longer be valid. 5. The Wheel Angle Sensor should be mounted on the non-movable part of the steering mechanism and the Linkage Rod connected to the movable part to protect the cable from damage. Note: The best place to mount the Wheel Angle Sensor is on the back side of the steering axle if possible. Figure 1 Example of Good Wheel Angle Sensor Installation Shield Over Wheel Angle Sensor for Protection Wheel Angle Sensor Mounting Bracket and Linkage Mounting Bracket Mounted Solid Wheel Angle Sensor Mounted Behind Axle Wheel Angle Sensor Installation Guide 3

6. If custom building Wheel Angle Sensor brackets, they should be made with 3/16" (5 mm) metal to ensure that the brackets are sturdy and will not flex during normal operational conditions. 7. It is recommended to paint the Wheel Angle Sensor brackets after building them to make the installation look professional. 8. The Wheel Angle Sensor MUST be mounted with the potentiometer on the top to avoid water intrusion into the Wheel Angle Sensor Block. Note: This guideline must not be ignored. Figure 2 Potentiometer Mounted on Top of Wheel Angle Sensor Potentiometer Wheel Angle Sensor Block 9. The Wheel Angle Sensor should be mounted so that it's rotation matches the rotation of the steering axle. 10. The movement read by the Wheel Angle Sensor should be directly proportional to the movement of the steering axle. Figure 3 Wheel Angle Sensor Motion Pivot Point Matches Steering Axle Pivot Point 4 Wheel Angle Sensor Installation Guide

11. The mounting brackets and the linkage arms should be positioned so that the motion from center to right equals the motion from center to left. If the angels for left and right are not equal, line acquisition performance may be less than optimum. 12. The linkage arms need to have enough clearance to rotate freely from a full left to a full right turn without coming into contact with any other parts of the vehicle. Figure 4 Left to Center Movement is Equal to Right to Center 13. When the steering mechanism is in the straight ahead position, the Wheel Angle Sensor Rod should be in line with the potentiometer connector. Figure 5 Wheel Angle Sensor Rod In-line with Connector when Steering Mechanism is Straight Ahead Potentiometer Connector Wheel Angle Sensor Rod Wheel Angle Sensor Installation Guide 5

14. To make fine adjustments to the potentiometer angle, loosen the two screws securing the potentiometer to the Wheel Angle Sensor Block and rotate the potentiometer. 15. To avoid damage to the potentiometer, NEVER rotate beyond the travel stops (approximately140 degrees). 16. The travel stops are marked by the screws holding the potentiometer sensor to the top of the Wheel Angle Sensor block. These screws MUST stick out the bottom of the Wheel Angle Sensor assembly and the Allen heads should be on the top of the sensor. The long screws prevent the sensor from being accidentally over extended by hand when the Wheel Angle Sensor Rod is connected. Verify these screws are installed correctly and the Wheel Angle Sensor Rod moves back and forth freely between the two screws at the bottom of the Wheel Angle Sensor block. Figure 6 Wheel Angle Sensor Potentiometer Screws Allen Heads of Screws Wheel Angle Sensor Rod Screws out the Bottom as Travel Stops 17. Adjust the Linkage Arms so that the when the steering mechanism travels from the full left to the full right positions, the potentiometer reaches near the minimum and maximum readings. This can be determined by connecting one lead of an Ohm meter to pins A or C of the potentiometer and the other lead to pin B. At the maximum turn in one direction it should not be below 1.5 Kilo-Ohms and at the maximum turn in the opposite direction it should not be above 6.1 Kilo-Ohms. There must be at least 3.5 Kilo-Ohms of difference between the minimum and maximum measurements. Figure 7 Adjust Linkages so Wheel Angle Sensor Reaches Maximums Must be at least 3.5 Kilo-Ohms or 95 Degrees between Full Left and Full Right 6 Wheel Angle Sensor Installation Guide

18. The linkage rods will most likely need to be cut in order to allow for proper adjustments. Prior to cutting them, verify the linkage rods lengths will work by checking them at the full left and right positions. Use the lock nuts on the Linkage Rod and the Wheel Angle Sensor Rod to act as a test marker for the connection point at the various angles. Once the lengths of the rods have been determined, cut the rods so that the ball joint will connect at that location. Note: Never cut the linkage rods until the lengths have been tested for fit and so that the system meets the guidelines above. 19. Once the linkage rods have been cut, adjust the lengths of the Linkage Rod and the Wheel Angle Sensor Rod but DO NOT connect them yet. With the rods disconnected and moved to a safe position, turn the steering mechanism to the maximum left position and then verify that the linkage rods can be connected without damaging anything. 20. After testing the maximum left position, DISCONNECT the linkage rods and then turn the steering mechanism to the maximum right position. Again verify that the rods can be connected without damaging anything. 21. Once it has been verified that the linkage rods will not be damaged, they can be connected to each other permanently. Slowly turn the steering mechanism manually from the full right to full left position, watching the assembled Wheel Angle Sensor closely. Be sure to do this slowly the first time to verify that they do not bind or come in contact with anything. Note: Never turn the steering mechanism with the AutoSteer system or manually with the linkage rods connected, until their lengths have been verified manually or the Wheel Angle Sensor could be damaged. 22. Tighten all screws, bolts and, nuts after the Wheel Angle Sensor has been installed and tested. 23. Route the Wheel Angle Sensor cable from the ECU to the Wheel Angle Sensor in a safe position away from moving or hot parts and protected from crop residue or debris. Note: Verify that the cable is routed so that when the axle moves up or down in uneven soil conditions that the cable is not stretched or broken. 24. Secure the Wheel Angle Sensor cable with cable ties along the route. Note: Be sure to secure the Wheel Angle Sensor cable to the bracket as close to the Wheel Angle Sensor connector as possible to make sure the connector is not holding all the weight. Wheel Angle Sensor Installation Guide 7

Figure 8 Secure Wheel Angle Sensor Cable Close to Potentiometer Cable Tie Close to Potentiometer 25. If the Wheel Angle Sensor is ever moved or changed after it has been calibrated, the system will need to be calibrated again to take into account any changes. Overview The Generic Wheel Angle Sensor kit includes a number of common parts that will allow an installer a way to build custom brackets to mount the Wheel Angle Sensor. The parts provided are separated into two sections, the Wheel Angle Sensor assembly and the Wheel Angle Sensor Bracket kit. The Wheel Angle Sensor assembly contains the primary Wheel Angle Senor and Linkage Rods required for all installs. The Wheel Angle Sensor Bracket kit contains generic brackets that can be used or modified to mount the Wheel Angle Sensor. Figure 9 and Figure 10 show a diagram of what the parts look like that are included in the two sub-kits. Table 1 and Table 2 list the part descriptions as well as part numbers of the individual components in each of the kit. Use these parts lists for reference when reading this install guide. 8 Wheel Angle Sensor Installation Guide

Wheel Angle Sensor Assembly Kit Figure 9 Wheel Angle Sensor Assembly Kit Parts (PN 200-0468-01) Table 1 Wheel Angle Sensor Assembly Kit Parts List (PN 200-0468-01) Item Component Part Number Qty 1. Wheel Angle Sensor Assembly 200-0015-01 1 2. Linkage Assembly 200-0155-01 1 3. Nut, 3/8" 24 x 1-3/4 ZP 518-0016-01 1 4. Nut, Hex Jam 3/8" 24 x 7/32" SS 510-0028-01 2 Wheel Angle Sensor Installation Guide 9

Wheel Angle Sensor Bracket Kit Figure 10 Wheel Angle Sensor Bracket Kit Parts (PN 200-0247-02) Table 2 Wheel Angle Sensor Bracket Kit Parts List (PN 200-0247-02) Item Component Part Number Qty 1. Bracket, WAS Universal 202-0158-01 1 2. Bracket, Linkage Universal 202-0157-01 1 3. Bolt, 3/8" 16 x 2" Hex GR 5 ZP 512-0012-01 2 4. Bolt, 3/8" 16 x 1-1/4" Hex GR 5 ZP 512-0006-01 2 5. Washer, Flat 3/8" ZP 516-0001-01 8 6. Nut, Locknut 3/8" Nylon Insert 518-0001-01 4 7. Clamp, 1-1/2" x 5/16" Muffler 200-0106-01 1 Wheel Angle Sensor Install Kit Examples The following Figures provide examples of existing Wheel Angle Sensor install kits for known vehicle types. These examples can be used to show the variety of ways the Wheel Angle Sensor can be installed and the various custom brackets that have been made to allow the Wheel Angle Sensor to be installed. Along with the bracket kit drawings, actual Figures showing the kits installed on the actual vehicle will also help visualize how they are used. 10 Wheel Angle Sensor Installation Guide

Figure 11 Example 1 Drawing Figure 12 Example 1 Installed on Vehicle Wheel Angle Sensor Installation Guide 11

Figure 13 Example 2 Drawing Figure 14 Example 2 Installed on Vehicle 12 Wheel Angle Sensor Installation Guide

Figure 15 Example 3 Drawing Figure 16 Example 3 Installed on Vehicle Wheel Angle Sensor Installation Guide 13

Figure 17 Example 4 Drawing Figure 18 Example 4 Installed on Vehicle Install Wheel Angle Sensor Brackets The Wheel Angle Sensor needs to be connected to two points on the vehicle s steering mechanism. One point is stationary and the other point moves as the steering mechanism turns from right to left. Follow this general procedure to attach the Wheel Angle Sensor Brackets and Wheel Angle Sensor. 14 Wheel Angle Sensor Installation Guide

Install Wheel Angle Sensor Brackets 1. Locate a good Wheel Angle Sensor mounting position on the vehicle. 2. Start by attaching a custom built Wheel Angle Sensor Mounting Bracket to the stationary part of the steering mechanism. 3. Attach the Wheel Angle Sensor to the Wheel Angel Sensor Bracket with the two 3/8" x 5/8" bolts and flat washers. Note: Verify that the wire connector is facing the correct direction for your installation before attaching the Wheel Angle Sensor to the bracket. 4. Tighten the bolts with a 9/16" ratchet wrench. 5. Attach the custom built Linkage Rod Mounting Bracket to the moving part of the steering mechanism. 6. Tighten all bolts holding the brackets in place. Cut the Wheel Angle Sensor Rods to Length The Wheel Angle Sensor rods are 12" (305mm) long. These rods may need to be cut with a hack saw or other cutting device to the proper length to allow the linkage rods to allow the Wheel Angle Sensor to achieve the maximum number of counts as the steering wheel is turned from full right to full left. Wheel Angle Sensor Installation Guide 15

Note: Due to the variability of the possible mounting positions, axle options, and wheel angle stops on the vehicle, it is the responsibility of the installer to verify the lengths are correct for each individual installation prior to cutting the rods. Failure to verify the fit on your specific vehicle may cause damage to the Wheel Angle Sensor components or vehicle when the steering wheel is turned. This damage is not covered by warranty. Always verify the clearances prior to permanently cutting and connecting the Wheel Angle Sensor Rods to the Wheel Angle Sensor Brackets. Note: Prior to cutting the rods, always mark the rods and temporarily connect them to the Wheel Angle Sensor Brackets. Manually position the steering mechanism at the full left and right positions and verify that if the rods were cut to the suggested lengths, nothing will be damaged. DO NOT CUT THE RODS UNTIL THE FIT IS VERIFIED. Note: Secure the rods in a vice or other device while cutting. Protect the threads so they are not damaged. It is advisable to attach a nut on the side of the metal rod that is going to be kept in order to clean the threads after the cut has been made. Clean the ends of the threaded rods using a file and verify the threads are still good after cutting them. Note: The Wheel Angle Sensor Assembly kit provides a coupler nut and extra jam nuts that allows the installer to joint two pieces of linkage rod together if the installation requires a linkage more than 12" (305mm) long. Generally, one rod will need to be cut off and the cut off portion can be attached to the other piece to make it longer. Additional linkage rod can also be ordered from your AutoSteer dealer. Assemble the Linkage Rod Hardware After cutting the Linkage Rods to the proper lengths the ball joints and other hardware must be attached and prepared for the installation. Note: Never connect and turn the steering mechanism with the Linkage Rods connected until the fit has been verified. Assemble the Linkage Rod Hardware 1. Attach a jam nut to the end of the Wheel Angle Sensor Rod. 2. Connect the Eye Connector to the end of the Wheel Angle Sensor Rod. Eye Connector Jam Nut 16 Wheel Angle Sensor Installation Guide

Assemble the Linkage Rod Hardware 3. Attach a jam nut to each end of the Linkage Rod. 4. Attach the ball joints to both ends of the linkage arm. Note: The bolts for the ball joints can be positioned so they are going in the same direction or in opposite directions. It will depend on how the brackets were designed and line up on each particular installation. Ball Joint Jam Nuts Ball Joint Coupler Nut 5. In required, two lengths of linkage rod can be extended using a coupler nut and two jam nuts as shown. Jam Nuts Note: DO NOT PERMANENTLY CONNECT THE RODS TOGETHER UNTIL THE FIT IS VERIFIED. Attach Wheel Angle Sensor and Linkage Rods The Wheel Angle Sensor Linkage Rod will be attached to the Wheel Angle Sensor and the Linkage Rod will be attached to the Linkage Rod Bracket. Do not attach the Wheel Angle Sensor Rod to the Linkage Rod until the fit has been confirmed and the steering mechanism has been manually checked at the full right and full left positions. Follow the general procedure below to complete the installation. Example Figures of each step are shown for reference. Wheel Angle Sensor Installation Guide 17

Attach Wheel Angle Sensor and Linkage Rods Lock Nut Flat Washer 1. Attach the Wheel Angle Sensor Rod to the Wheel Angle Sensor with the screw, washer, and lock nut that came with the assembly. 2. Verify that the rod points in the correct direction. Note: It is important that the flat washer goes on the screw head side and NOT the nut side when attaching the arm. Allen Screw Head 3. Tighten the screw on the Wheel Angle Sensor shaft with a 1/8 Allen wrench and a 3/8 open end wrench. Note: The screws holding the potentiometer sensor to the top of the metal block should stick out from the bottom of the Wheel Angle Sensor assembly (shown by arrows). The Allen head should always be on the top of the sensor. The screws stick out on the bottom to prevent the sensor from being accidentally over extended by hand. Verify these screws are installed correctly and the Wheel Angle Sensor Rod moves back and forth freely between the two screws at the bottom of the Wheel Angle Sensor block. 4. Attach the linkage rod to the linkage bracket. The lock washer should be attached to this connection. 5. Tighten the ball joint to the bracket with a 1/2" and 9/16 open end wrenches. Note: Do not attach the Wheel Angle Sensor Rod to the Linkage Rod at this time. Make sure they are disconnected until after the maximum right and maximum left stops have been verified not to damage the assembly. 18 Wheel Angle Sensor Installation Guide

Attach Wheel Angle Sensor and Linkage Rods 6. With the linkage rods disconnected, start the vehicle and manually turn the steering wheel so that the vehicle will travel straight ahead when moving. 7. Temporarily attach the Wheel Angle Sensor Rod and Linkage Rod together. 8. Rotate the Wheel Angle Sensor potentiometer on top of the mounting block so that the plastic wire connector is parallel to the Wheel Angle Sensor Rod. 9. After the potentiometer has been adjusted, tighten the potentiometer screws with a 3/8 wrench and 5/32 Allen wrench. Adjust the orientation of Potentiometer sensor so that the wire connector is parallel to Wheel Angle Sensor Rod when wheels are straight ahead Rods connected with vehicle steering system positioned to drive Straight Ahead 10. Disconnect the linkage rods and then turn the steering wheel manually so the steering mechanism is turned to the full left position. Note: The vehicle may need to be driven a short distance in order to get the steering system to move to the full left position. 11. Reattach the linkage assembly and verify that the sensor and linkage rods will not be damaged. Adjust the rod lengths as necessary. 12. Disconnect the linkage rods and turn the steering wheel manually so the steering mechanism is turned to the full right position. Note: The vehicle may need to be driven a short distance in order to get the steering system to move to the full right position. 13. Reattach the linkage assembly and verify that the sensor and linkage rods will not be damaged. Adjust the rod lengths as necessary. Wheel Angle Sensor Installation Guide 19

Attach Wheel Angle Sensor and Linkage Rods 14. Repeat Step 6 through Step 13 until the rod lengths have been adjusted and the potentiometer is centered to get the maximum sensor movement. 15. The maximum movement is reached when the Wheel Angle Sensor Rod will sweep from approximately 3/16 (5mm) from both bolt heads when the steering mechanism is turned to the maximum right and left positions. Note: An Ohm meter can also be used to determine if there is enough sensor movement. Connect the Ohm meter to pins A and B of the Wheel Angle Sensor. Measure the Ohm reading at the maximum left and right position. After subtracting the smaller number from the larger number, there should be at least a 3.5 Kilo-Ohms change. The reading should also never go below 1.5 or higher than 6.1 Kilo-Ohms as this is reaching the limits of the potentiometer and could damage the sensor. Potentiometer Screw Stops Full Left Movement Range Full Right Wheel Angle Sensor as Seen from the Bottom 16. Once all the adjustments are complete, tighten all lock nuts and bolts on the Linkage and Wheel Angle Sensor Rods. A 1/2 and two 9/16 wrenches are required to tighten all the connections. 20 Wheel Angle Sensor Installation Guide