Hydraulic Kit Installation Guide Item Component Part Number Qty 1. HOSE 5/8 X 48" -8F X -12F 90 DEG ORFS F451TC-JSJ9081210-48 2 2. HOSE 1/4" X 48" -4F X -6F ORFS F451TC-JCJC040604-48 1 3. HOSE 5/8 X 72" -8F X -10M ORFS F451TC-JSJ0081010-72 2 4. HOSE 5/8 X 120" -8F X -10F 90 DEG ORFS F451TC-JSJ9081010-120 1 5. ADAPTER - RUN TEE -12 ORFS 12 R6LO-S 1 602-0491-01 REV A 2014-02
Item Component Part Number Qty 6. ADAPTER RUN TEE -16 ORFS 16 R6LO-S 1 7. ADAPTER REDUCER -16F X -12M ORFS 16-12 TRLON-S 1 8. ADAPTER -10 ORFS SWIVEL NUT ELBOW 10 C6LO-S 1 9. VALVE SHUTTLE SAE -6 ASH-06-2 1 10. ADAPTER ELBOW -6 ORB X -6 ORFS 6 C5OLO-S 2 11. ADAPTER STRAIGHT -6 ORB X -6F ORFS 6 F65OL-S 1 12. HOSE 5/8 X 120" -8F X -10F 45 DEG ORFS F451TC-JSJ7081010-120 1 13. ADAPTER -10 ORFS 45 DEG ELBOW 10 V6LO-S 1 14. ADAPTER, F-M, STREET ELBOW, 1/4" 1/4 CD 1 15. TAPE TEFLON 1/2" x 520" 511-0001-01 1 16. KIT CABLE TIE HOSE ID 200-0467-01 1 17. INSTALLATION MANUAL 602-0491-01 1 500-0016-04 Hydraulic Valve Kit 2 1 Item Component Part Number Qty 1. Valve High Flow Assembly 500-0016-04 1 2. Pressure Transducer 500-0274-02 1 2 Hydraulic Kit Installation Guide
Tools 500-0186-01 Kit This list consists of special tools required to complete the installation. A complete set of common installation tools is assumed. Allen Hex Key 1/4 11/16 open wrench 16mm open wrench Allen Hex Key 3/16 5/8 open wrench 17mm open wrench Allen Key 5/32 9/16 open wrench (2x) 18mm open wrench Allen Hex Key 1/8 1/2 open wrench 19mm open wrench 15/16 open wrench 7/16 open wrench 22mm open wrench 7/8 open wrench 1/2 12 point ratchet wrench 24mm open wrench 13/16 open wrench 15/16 socket wrench 32mm open wrench 3/4 open wrench 13mm open wrench 22mm socket wrench Breaker bar for socket wrench Hacksaw with steel cutting blade 30mm socket wrench #1 Phillips screwdriver Wire cutter small Cleaning rags #2 Phillips screwdriver Cleaning brush Ten Foot Ladder Tape measure (12ft minimum) Hydraulic Kit Installation Guide 3
Overview These instructions provide the procedure for installing the Novariant hydraulic system for the supported vehicles listed below. There may be some variations in the vehicles depending on the vehicles options. Note: Only technicians trained for hydraulic valve installations should perform the installation procedures in this guide. If the vehicle requires a hydraulic steering valve to be installed, ensure a trained technician is available for the installation. Supported Vehicles The following models have been confirmed to be compatible with this Hydraulic Installation Kit: Supported John Deere Models (Non-AT Ready) 9100, 9120 9200, 9220, 9230 9300, 9320, 9330 9400, 9420, 9430 9520, 9530 9620, 9630 4 Hydraulic Kit Installation Guide
This kit is for installation on these models only. If your vehicle is a different model, contact your dealer for the correct installation kit. Note: Only technicians trained for hydraulic valve installations should perform the installation procedures in this guide. If the vehicle requires a hydraulic steering valve to be installed, ensure a trained technician is available for the installation. Steering Valve Installation Procedure Overview 1. Install the AutoSteer valve bracket and valve on the tractor. 2. Connect the seven hoses between the valve and the tractor. 3. Check for oil leaks. 4. Perform a functional test to confirm correct valve operation. Hydraulic Kit Installation Guide 5
Install the Valve Bracket Install the Valve Bracket Steering Valve Mounting Holes 1. Install the AutoSteer valve is on the tractor frame right side. A valve bracket is secured to the tractor using the bolts provided in your kit. 2. Tighten the two mounting bolts. 3. Install the valve in the position shown here. AutoSteer Valve Note: the valve bracket has extra holes enabling different valve mounting positions. Use these alternate bracket positions as necessary to clear the vehicle or accessories previously installed. 4. Secure the valve onto the bracket in the position shown using three 3/8 allen screws, washers and nuts. 5. 5. Tighten the three 3/8 allen screws. 6 Hydraulic Kit Installation Guide
Connect the Hydraulic Hoses The Steering Valve must be connected to the various hydraulic ports on the vehicle to integrate with the steering system on the vehicle. Various hydraulic fittings and hoses are used to do this. This section provides an overview of how the Steering Valve will be connected to the vehicle. Hose Connection Diagram Figure 3 shows all the hydraulic connections prior to attaching to the Steering Valve. Use this diagram to identify the hoses prior to removing them. Figure 3 Hydraulic Connection Diagram Hydraulic Hose Connection Procedure The hoses must be connected in the order provided in this installation manual to ensure that all the connections can be accessed and tightened properly. Refer to the hose diagram in Figure 3 for information on connecting the correct hydraulic hose to the correct ports on the vehicle and Steering Valve. Hydraulic Kit Installation Guide 7
Note: Verify all the hoses and fittings are in the correct orientation shown in the figures prior to tightening them. Failure to put them in the proper orientation may cause the hoses to be damaged or not reach the intended connection. The hydraulic hose connection procedures are contained in the following sub-sections: Connect the Vehicle Hydraulic Hose. Connect the AutoSteer Valve Hoses Connect the Steering Cylinder Hoses Connect the Pressure Transducer Connect the Vehicle Hydraulic Hoses Connect the Vehicle Hydraulic Hoses 1. Install a large tee to the original return line coming from the remotes and connect the AutoSteer return hose to this tee. Note: The AutoSteer valve shares the pressure, return, and load sense lines used for vehicle remotes (SCV). 2. Install a tee on a the original pressure line going to the remotes and connect the AutoSteer pressure hose to this tee. 3. Install the AutoSteer shuttle valve as shown here. Note: The center port connects to the Load Sense hose on the tractor. One side port connects to the Steel Load sense line coming from the remotes. The other side port connects to the thin hose coming from LS on the AutoSteer valve. 4. Secure the hoses with nylon cable ties. Note: Keep the hose ends capped during the installation to avoid contamination. Note: Do not allow the hoses to contact the rotating drive shaft between the engine and the transmission. Secure the hoses away from the drive shaft using cable ties. 5. Tighten all fittings. 6. Confirm that all swivel nuts are tight. Pressure Line Tee AutoSteer Valve Tank Tee Shuttle Valve 8 Hydraulic Kit Installation Guide
Connect the AutoSteer Valve Hydraulic Hoses Connect the AutoSteer Valve Hydraulic Hoses Left Steer Cylinder Connection Right Steer Cylinder Connection Attach steer IN/OUT hoses to the hydraulic valve. Vehicle Orbitrol Right Steering Unit Connection Vehicle Orbitrol Left Steering Unit Connection Connect the Steering Cylinder Hoses Note: Refer to Figure 3 and the Hydraulic Hose Connection Overview for information on how to connect the hoses. The hoses must be connected in the correct order for best fit and ease of installation. Connect the Steering Cylinder Hoses 1. Locate the steering hoses connected to one of the steering cylinders on the vehicle right side. Right Steer Cylinder Port Note: The tee adapter shown on the right side of this illustration is the Left-Steer port on the cylinder. The tee adapter shown on the left side of this figure is the Right- Steer port on the cylinder. This cylinder is located on the right side of the tractor. The next illustration shows a closeup of the cylinder connections. Left Steer Cylinder Port Hydraulic Kit Installation Guide 9
Connect the Steering Cylinder Hoses 2. Disconnect the Orbitrol steering hose from the tee adapter on the right turn cylinder port. 3. Connect a 72 inch extension hose from the end of this Orbitrol steering hose to the "SR" port on the AutoSteer Valve. 4. Route the hose in a secure location with sufficient hose slack to enable tractor articulation without hose stress. Note: Route the hose so that it does not get pinched when the wheels turn from full left to full right. 5. Secure this hose to an existing hole under the frame using heavy duty cable ties. Note: Secure the hose so that is does not drop down below the frame and does not touch the drive shaft shield. Use several cable ties to secure the hose in a safe position. 6. Connect a long 120 inch hose with a 45 degree elbow between the right turn cylinder port and the "R" port on the AutoSteer valve. 7. Route the hose in a secure location with sufficient hose slack to enable tractor articulation without hose stress. 8. Disconnect the Orbitrol steering hose from the tee adapter on the left turn cylinder port. 9. Connect a 72 inch extension hose from the end of this Orbitrol steering hose to the "SL" port on the AutoSteer Valve. 10. Route the hose in a secure location with sufficient hose slack to enable tractor articulation without hose stress. Run Tees Left Steering Steer Out Connection Right Steering Steer Out Connection 11. Connect a long 120 inch hose with a 90 degree elbow between the left turn cylinder port and the "L" port on the AutoSteer valve. 12. Route the hose in a secure location with sufficient hose slack to enable tractor articulation without hose stress. 13. Tighten the hose fittings. Vehicle Articulation Pivot Point Hose Slack Loop Hose Slack Loop 10 Hydraulic Kit Installation Guide
Connect the Pressure Transducer 500-0186-01 Kit Connect the Pressure Transducer Pressure Transducer Port 1. Locate the Steering Valve TRANS port. 2. Apply 2-3 turns of Teflon tape to the NPT adapter thread before installing the adapter on the valve. Thread the pressure transducer onto the adapter. The pressure transducer does not require Teflon tape because it uses an O.-ring seal. Do not over tighten. Note: Use a ¼ NPT elbow adapter when required to mount the transducer closer to the valve. Install the Pressure Transducer on the Steering Valve TRANS port. Note: Do not over tighten the Pressure Transducer. Pressure Transducer Connector 3. Connect the valve harness to the pressure transducer. Push the connector until the latch locks onto the transducer. To remove the cable, lift the tab on the latch and pull the connector. 4. Connect the Steering Valve 4-pin connector and 10-pin connectors to the SA Module Harness. Note: Secure the Pressure Transducer cable and connector with cable ties in a protected position. Hydraulic Kit Installation Guide 11
Hydraulic Installation Checklist 1. Valve bracket bolts are tight. 2. Mounting screws securing the valve are tight. 3. Pressure hose is connected to correct AutoSteer Valve port and the vehicle pressure line. 4. Tank hose is connected to correct AutoSteer Valve port and the vehicle Tank line. 5. The Shuttle Valve is properly connected to the vehicle and AutoSteer load sense ports. 6. The ORBITROL Left Steer (steer in) hose is connected correctly at both ends. 7. The ORBITROL Right Steer (steer in) hose is connected correctly at both ends. 8. The Left Steer (steer out) hose is connected correctly at both ends. 9. The Right Steer (steer out) hose is connected correctly at both ends. 10. Pressure transducer installed and tight. 11. Check that all hose fittings are tight. 12. Check hose routing and ensure cable ties are on all hoses. 13. Ensure all hoses are clear of moving parts, such as the drive shaft and front axle shaft. 14. SAM harness is connected to the two valve connectors. 15. Ensure the hoses do not interfere with vehicle operation. Post System Installation Procedures This section provides information in the following sub-sections: Hydraulic Leak Test Create New Vehicle Pressure Relief Valve Adjustment Procedure Once the entire AutoSteer system, including the Display and Display Harnesses, have been installed on the vehicle, the procedures and notes provided in this section must be followed to complete the installation and prepare the vehicle for full AutoSteer capabilities. Note: Always perform these steps after the complete installation or system damage may occur and/or poor performance may occur. DO NOT START THE VEHICLE BEFORE PERFORMING A LEAK TEST. Hydraulic Leak Test On completion of installing the entire AutoSteer system including the Roof Module and Display, the system needs to be checked for leaks. Follow the procedure below to check for leaks. High-Pressure Fluid Hazard Read and understand the vehicle s user manual before installation. Wear hand and eye protection while performing hydraulic system maintenance. Relieve hydraulic system pressure before servicing the hydraulic system. 12 Hydraulic Kit Installation Guide
Prior to starting the vehicle, verify all people and equipment are clear from around the vehicle and the AutoSteer system is powered down. The vehicle could move unexpectedly and cause injury or death to bystanders. Note: The following steps need to be performed after the complete AutoSteer system has been installed, the AutoSteer System has powered up (BUT NOT THE VEHICLE), and the vehicle has been created in the AutoSteer system. After the entire AutoSteer system installation has been completed, the system needs to be checked for leaks. Follow the procedure below to check for leaks. Note: If an oil leak is noticed during any part of this test, immediately shut down the vehicle and repair the leak. 1. Clear any bystanders away from the vehicle. 2. Put the vehicle into Park and/or set the park brake to prevent the vehicle from moving. 3. Turn the vehicle over for a few seconds and if the vehicle starts, immediately shut it down. 4. Walk around the vehicle and check all the hydraulic fittings that were opened. Look for any oil leaks. 5. Once any leaks have been repaired, or if none are found, start the vehicle again and let it run at a low idle. 6. Take the vehicle out of Park and/or remove the parking brake. Turn the steering wheel manually to the right and left stops two or more times to get any air out of the hoses. 7. Confirm the vehicle turns in the correct direction when the steering wheel is turned manually. 8. Confirm the steering system behaves the same as it did prior to installing the AutoSteer System. Measure the times it takes to manually turn the steering wheel from full left to right and full right to left and compare to the times recorded before the installation. If the times are different, determine why there is a difference and repair. 9. Put the vehicle back into Park and/or reset the parking brake. Shut down the vehicle, walk around it again, and check for any hydraulic leaks. 10. Once any leaks have been repaired, or if none are found, start the vehicle again and let it run at a low idle. 11. Take the vehicle out of Park and/or remove the parking brake and leave the vehicle running. 12. Power up the AutoSteer system and navigate to the steering components test screen. If the safety screen requirements have been met, press the Continue or Accept button. 13. Press the Hard Right and the Hard Left buttons several times to force the Steering Valve to turn the steering wheels or steering mechanism to the full right and full left positions and get the air out of the lines. 14. Verify that the vehicle turns in the correct direction it is commanded. Measure the time it takes the AutoSteer System to turn the steering wheel from full left to right and full right to left and compare to the times recorded to the times for manual movement. It should not take more than 3 to 4 seconds to go from lock to lock. Note: If the wheels turn in the wrong direction, the hoses were attached to the wrong ports on the Steering Valve or to the incorrect steer lines. The steer hoses need to be switched. 11. Power down the Display, put the vehicle into Park and/or reset the parking brake, and shutdown the vehicle. 12. Once again check the vehicle for hydraulic leaks and repair any that are found. Hydraulic Kit Installation Guide 13