GPS AutoSteer System Hardware Installation Manual
Contents
1. Locate the mounting bracket on the left rear side of the vehicle See Figure 3 3 Figure 3 3 SA Module Mounting Location gt SA Module Bracket Mounting Location 32 AutoSteer System Mount the SA Module 2 Start two of the SA Module mounting screws into the mounting bracket on the opposite side of the L bracket 3 Attach the SA Module bracket to the vehicle frame with a 3 8 x 1 1 2 bolt flat washers and nut from the installation kit See Figure 3 4 Tighten the bracket with a 9 16 wrench and 9 16 socket and ratchet Figure 3 4 SA Module Bracket Installed Mounting Bolt 4 Attach the SA Module to the bracket with the connector facing the rear with the two other screws provided in the installation kit Tighten the screws with a 2 Philips screwdriver See Figure 3 5 Figure 3 5 SA Module Attached to the Bracket Hardware Installation Manual 33 Mount the SA Module 34 AutoSteer System Roof Module Installation The Roof Module Installation chapter contains information in the following sections e Safety Notes Roof Rail Installation Procedure Safety Notes e The AutoSteer system must be powered OFF when installing or removing the Roof Module The Roof Module must always be firmly secured to the Roof Rail using the hardware provided whenever the vehicle is in operation to prevent the Roof Module from releasing from its bracket and falling The Roof Module must be removed when transporting the ve2. 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 all leaks have been repaired or if none are found start the vehicle again and let it run at a low idle Hardware Installation Manual 53 Hydraulic Leak Check Note If an oil leak is noticed during any part of this test immediately shut down the vehicle and repair the leak Note The entire vehicle will rotate on the tracks when the steering wheel is turned Make sure the vehicle will not strike anything or anyone before continuing If necessary move the vehicle to an open area 6 Take the vehicle out of Park and or remove the park brake Turn the steering wheel manually to the right and left stops two or three times to get any air out of the hoses 7 Confirm that the vehicle rotates in the correct direction and that the vehicle steers the same as it did before the system was installed 8 Put the vehicle back into Park and or reset the park brake Shut down the vehicle walk around it again and check for any hydraulic leaks 9 Once the leaks have been repaired or if none are found start the vehicle again and let it run at a low idle 10 Take the vehicle out of Park and or remove the park brake Move the vehicle to an open flat area and leave the vehicle in park 11 Power up the AutoSteer display 12 Power up the User display and navigate to the Hydraulic Valve window from the Steer
3. Connection 3 If necessary cut a slot in the rubber grommet and then replace the rubber grommet and close the rear window 4 Secure the Main Cable Harness cables to the rear of the vehicle See Figure 6 8 Figure 6 8 Route Cables on Back of Vehicle wt ee b h y L 2 K hn 4 A i gt s Q S Hardware Installation Manual 47 Main Cable Harness 5 Neatly coil excess cables and secure with cable ties See Figure 6 9 Figure 6 9 Coil and Secure Excess Cables Coil Excess Cable and Secure 48 AutoSteer System Main Cable Harness Main Cable Harness Connections Inside Cab Figure 6 10 shows the Main Cable Harness connections used inside the cab Table 6 1 shows the functions of the Main Cable Harness cab connectors Refer to your display s User Manual for instructions on connecting the main cable harness connections shown to the correct ports and harnesses on the user display and display cables Figure 6 10 Main Cable Harness Cab Connections CAN OUT e gt IS e 4 oe ie gt 4 x 2 re Set SAM DATA Table 6 1 Cab Main Cable Harness Connector Functions DISPLAY ETH Display Ethernet Port RJ 45 DISPLAY COMM Display Communication Port DB 9 VEHICLE POWER 12 Volt Power Supplied by Display Harness Hardware Installation Manual 49 Main Cable Harness Power Supply Connection The following sub sections describe basic instructions for connecting the Aut
4. Rees 41 Installation Procedure uyo susu som Aan acti errada 41 Chapter 6 Connecting System Gables uu u un un aaa baa 43 SA Module Harness breast dde des adds did adi 43 SA Module Connect dada tarros diia 43 Steine Valve COnnecuoms u y E AAA AAA tees 44 Mam Cable Tisi pe SS a suu y id a ii Sante es 45 Root Modilew 2 l u L eds t pico aba 45 SA Module Harness Connections 4 Main Cable Harness Connections Inside Cab 49 Power Supply CONNEC ON Aisa Bieta ie bea eae AS e 50 Calo POWER Connec s desmadre pe rara h at 50 Battery Power OnneciOn2 lt 74 4eicdauus touts subi issuu idas ia 51 Chapter 7 Post Installation Procedures and Information 53 Create New VehHi l6uss u sussusupahuya usa id cda 393 Fy draulic Leak Chcok ss cd a a io da 53 Chapter 8 Final Hardware Installation Checklist Final Hardware Installation Checklist Hydraulic Installation Checklist AutoSteer Performance Checklist GPS AutoSteer System Installation Overview The Installation Overview chapter information is provided in the following sections e Installation Kit Overview e Sub Assemblies o Steering Valve Kit Components e Hose Kit Components e Bracket Kit Components Pre Installation Vehicle Tests Installa
5. are secured with cable ties GSS Installation Checklist ob oe ee J Steering Valve is installed and all fasteners are tight All hose fittings are tight All hoses are routed and secured with cable ties Vehicle has been checked for hydraulic leaks after the installation Manual steering is normal after the AutoSteer installation AutoSteer Performance Checklist 1 2 cat Sy E A oe 56 Complete AutoSteer system calibration Complete AutoSteer system tuning Line acquisition performance is good On line steering performance is good Manual override kick out is working Temperature sensor is working Record Temperature Sensor reading after idling engine for 10 minutes Check that Manual Steering speed is the same as before the installation AutoSteer System eS cl L P fe 1 0 E keeli OUUU O L Temp
6. vetada id da ae a uhuy ee A te Pee Ae os eae 8 Chapter 2 Steering Valve Installation u u uu suu uuu ade 9 Steering Valve Installation Procedure OvervIeW 9 Prepare the Steering Valve for Installation 10 Install the Stennes Val e ass Socket ees ated A ha a ane aa hukaq 13 Eydraulic Hose OVEIVIEWS andina aes eae See ee td 15 Steen Valve POr OYES Was cl usss ea whet eae ke ous Sai 15 Hose Connection ONGPVISW ua uwa AE a ee eo eaten 16 Hydraulic Hose Connection Procedure 18 Attach Hoses to the Steenne Valye u 2 ulus loyca uu ususiy beg hes 18 Attach Hoses to the Vehicle Connections 23 Hydraulic Installation Checklist 30 Chapter 3 SA Module Installation uu uu is 31 SA Module Mounting Orientation 31 Mount the S A Modules zu avian a Cie de das latas Da bes Ae eee ees 32 Chapter 4 Root Module Installation 35 S NO CS eee oe sine asua aa wa eee he ae eee ee s du ba G ase heey 35 Roof Rail Installation Procedure 36 Chapter 5 Display Installati lgllyuy 2 usus uksi u Supap susu Skapukasaqaykigukastukusspakhasasyi 41 nfrogdiie Ipu Sauce aa SY Suha paw ARO De Caw a bid
7. Drive the vehicle and confirm that it steers straight and the vehicle turns proportionally to the left and right Check the steering system hydraulic hoses and connections to ensure there are no oil leaks The vehicle electrical system and battery must be in good working order The vehicle should be fully cleaned before installing the AutoSteer system A clean vehicle will improve the overall installation and cable routing and will also reduce the chance for oil contamination when the hydraulic connections are opened Hardware Installation Manual vii Important Information This installation manual contains valuable information for servicing the AutoSteer system After the installation is complete store this manual in a safe place for future reference Note Verify that all screws bolts nuts hose connections and cable connections are tight after the final installation of the AutoSteer system on the vehicle Technical Support Refer to your owner s manual for technical support information Contact Information Refer to your owner s manual for contact information Copyright 2009 All Rights Reserved viii AutoSteer System Table of Contents Chapter 1 installation OVeEIWIEW icon icono naaa 1 stalan on KIC COVEN Ward dde 2 SUDAASSEMIDIIGS 4 wwe ea baad tamawa au wb amo saat asua ultu DEAE A 2 Pre Installation Y eticle Test as 62024 ener tone 4 A isa 5 Installation Procedure Outline 2 4 05 022 050 assi sacd 7 Cable Didera
8. Follow the procedure below to prepare the valve for installation 1 Place the Steering Valve on a flat surface identify the pressure transducer port and remove the protective port plug with a pliers or flat screwdriver See Figure 2 1 Figure 2 1 Identify the Pressure Transducer Port Pressure Transducer Port 10 AutoSteer System Steering Valve Installation Procedure Overview 2 Wrap Teflon tape two times around the threaded side of the street elbow provided with the kit 3 Attach the street elbow to the pressure transducer port and tighten with a 3 4 wrench Point the elbow away from the valve body as shown in Figure 2 2 Figure 2 2 Street Elbow Attached Street Elbow Attached 4 Wrap Teflon tape around the threads of the pressure transducer two times 5 Attach the pressure transducer to the street elbow and tighten with a 3 4 wrench 6 Tighten the pressure transducer until the pins match the connector so the wire will stay near the Steering Valve as shown in Figure 2 3 and Figure 2 5 Note Verify the pins match up correctly Do not force the connection Figure 2 3 Pressure Transducer Connectors Pressure Transducer Pins Pressure Transducer Connector Hardware Installation Manual 11 Steering Valve Installation Procedure Overview 7 Attach the rubber gasket over the pressure transducer connector then attach the pressure transducer connector to the pressure transducer and then secure the connection wi
9. GPS AutoSteer System Hardware Installation Manual Supported Vehicles Cat Challenger 35 45 55 PN 602 0214 01 A LEGAL DISCLAIMER Note Read and follow ALL instructions in this manual carefully before installing or operating the AutoSteer system Note Take careful note of the safety information in the Safety Information section and throughout this manual The manufacturer disclaims any liability for damage or injury that results from failure to follow the instructions and warnings set forth herein Please take special note of the following warnings 1 There is NO obstacle avoidance system included in the manufacturer s product Therefore users must always have an operator on the equipment when the AutoSteer system is In use to look for any obstacles including people animals trees ditches buildings etc 2 During installation of the AutoSteer system and during the Calibration and Tuning processes the vehicle will pivot from side to side on its tracks Be sure that all people and obstacles are clear of the vehicle before installation calibration and tuning or use of the AutoSteer system 3 Use of the AutoSteer system is NOT permitted while the vehicle is on public roads or in public areas Ensure that the sys tem is OFF before driving on roads or in public areas ll AutoSteer System Special Requirements Tools This list consists of the tools required to complete the installation The installer is assumed to h
10. Hose 8 90 Deg ORFS x 8F ORFS Hardware Installation Manual 17 Hydraulic Hose Connection Procedure Hydraulic Hose Connection Procedure Note Due to the limited space in the Steering Valve port area the hoses should be connected in the order provided by this installation manual to reduce installation problems Refer to the hose diagram in Figure 2 11 and Table 2 1 and Table 2 2 for information on connecting the correct hydraulic hose to the correct ports on the vehicle and Steering Valve High Pressure Fluid Hazard Read the Owner s Manual before installation Wear hand and eye protection while performing hydraulic system maintenance Relieve hydraulic system pressure before servicing the hydraulic system Attach Hoses to the Steering Valve 1 Prepare the hydraulic hoses in the kit by attaching the proper colored cable ties to the ends of the hoses as described in Table 2 2 2 Attach the 90 degree connector of the Steer In Right hose to the STIN1 port on the Steering Valve 3 Position the hose as shown in Figure 2 12 and tighten the connection with a 15 16 wrench Figure 2 12 STIN1 Hose Connection STIN1 Connected 18 AutoSteer System Hydraulic Hose Connection Procedure Attach the 90 degree connector of the Steer In Left hose to the STIN2 port on the Steering Valve Leave the connection loose for the time being Attach the 90 degree connector of the Steer Out Right hose to the STOUT port on the Steering Val
11. SS I5 FEOWIDED INSTALLED OW THE WALVE Table 1 2 Steering Valve Kit Components PN 153 0007 01 SA Module Harness Cat 201 0162 02 Assembly Kit Common 200 0497 02 EN Valve Assembly Cat 500 0010 02 Cable Routing Hardware Cat 35 45 55 200 0121 01 SA Module Bracket Assembly 200 0190 01 Hardware Installation Manual 3 Installation Kit Overview 6 Kit RAM Mount Base with Screws 200 0508 01 8 Atento Switch Ore Label 603 0074 01 SA Module Assembly Wheeled 200 0206 01 Temperature Sensor Kit Cat 200 0119 01 Hose Kit Components Figure 1 3 Hose Kit Components PN 500 0022 02 a ae Table 1 3 Hose Kit Components PN 188 0012 01 Hose 1 2 x 78 8F 90 Degree x 8F ORFS 502 0006 02 Hose 1 2 x 78 8F 90 Degree x 8M ORFS 502 0007 02 Adapter Run Tee ORFS F M M 8 506 0004 01 E Adapter Run Tee ORFS F M M 6 506 0003 01 Adapter 45 Degree Elbow ORFS 8 506 0027 01 4 AutoSteer System Pre Installation Vehicle Tests 6 Adapter Expander 8M x 6F ORFS 506 0061 01 Tape Teflon 1 2 x 520 511 0001 01 8 Adapter 90 Degree Elbow ORFS 8 506 0013 01 9 Kit Cable Tie Hose ID 200 0467 01 Bracket Kit Components Figure 1 4 Bracket Kit Components PN 152 0021 01 Table 1 4 Hose Kit Components PN 188 0012 01 Display Bracket Assembly 200 0469 02 Installation Guide 602 0214 01 Washer Flat M16x30x3 517 0007 01 Pre Installation Vehicle Tests The vehicl
12. ave a complete set of common installation tools 15 16 socket and ratchet 15 16 open wrench sena O A Hardware Installation Manual ili Safety Information Warning Alerts The AutoSteer system installer and manufacturer disclaim any responsibility for damage or physical harm caused by failure to adhere to the following safety requirements As the operator of the vehicle you are responsible for its safe operation The steering system is not designed to replace the vehicle s operator Note Verify that all screws bolts nuts hose connections and cable connections are tight after the final installation of the AutoSteer system on the vehicle To avoid electrical shock hazards remove the Roof Module from the vehicle before driving under low structures or low electrical power lines Ensure that you are in a stable position on the vehicle platform when installing or removing the Roof Rail and Roof Module so you do not fall To prevent accidental death or injury from being run over by the vehicle never leave the vehicle s operator chair with the AutoSteer system engaged IV AutoSteer System High Pressure Fluid Hazard Read the Owner s Manual before installation Wear hand and eye protection while performing hydraulic system maintenance Relieve hydraulic system pressure before servicing the hydraulic system To understand the potential hazards associated with the operation of AutoSteer equipment read the pro
13. e s steering system must be in good working condition prior to the installation of the AutoSteer System Verify the existing steering system 1s operating correctly by performing the tests listed below in a wide open area Note The steering system test requires a relatively large area Ensure you have enough room to perform the test before beginning Hardware Installation Manual 5 Pre Installation Vehicle Tests 1 Drive the vehicle in a low gear and slowly turn the steering wheel all the way to the left The vehicle should steer to the left at a steadily increasing rate until it is making a sharp left turn 2 Drive the vehicle in a low gear and slowly turn the steering wheel all the way to the right The vehicle should steer to the right at a steadily increasing rate until it is making a sharp right turn 3 On flat terrain drive the vehicle in a straight line in a low gear and release the steering wheel The vehicle and steering wheel should spring back to the center position and continue to drive straight after releasing the wheel without drifting right or left Note The vehicle and steering wheel should return to the center position and continue to drive straight after releasing the wheel without drifting right or left 4 Ask the vehicle driver or owner if they have experienced any vehicle steering problems The operator should report no steering problems If the vehicle passes the four tests proceed with the AutoSteer system insta
14. e 2 20 Attach Tank Hose Original Tank Hose Tank Hose Connection 6 ORFS to 8 ORFS to Hose Adapter Run Tee Hardware Installation Manual 25 Hydraulic Hose Connection Procedure 9 Tighten all hose connections and adapters with 13 16 7 8 and 15 16 wrenches 10 Disconnect the Orbitrol Steer Left hose from the diagnostic port fitting with 3 4 and 15 16 wrenches 11 Attach the Steer In Left hose from the Steering Valve to the Orbitrol Steer Left hose Tighten fittings with 7 8 and 15 16 wrenches See Figure 2 21 Figure 2 21 Attach Steer In Left Hose Orbitrol Steer Left Hose Steer In Left Hose Diagnostic Port Fitting J E a gt ele 1 io b e w gl y I 3 w mL ved gt AER NA 12 Disconnect the Orbitrol Steer Right hose from the pressure test port with 3 4 and 15 16 wrenches 13 Attach the Steer In Right hose from the Steering Valve to the Orbitrol Steer Right hose Tighten fittings with 7 8 and 15 16 wrenches See Figure 2 22 Figure 2 22 Attach Steer In Right Hose Orbitrol Steer Right Hose im A Ghi e ka y I o e ae ff x Steer In Right Hose Ly ye w J Diagnostic Port Fitting 26 AutoSteer System Hydraulic Hose Connection Procedure 14 Attach the Steer Out Right hose to the steer right diagnostic port adapter Tighten the hose with 3 4 and 15 16 wrenches 15 Attach the Steer Out Left hose to the steer left diagnostic p
15. e been installed on the vehicle the procedures and notes provided in this chapter must be followed to complete the installation and prepare the vehicle for full AutoSteer capabilities Create New Vehicle Once the entire system has been installed the operator must first create a new vehicle profile This configures the system so that the user display can properly communicate with the various sensors and components on the vehicle Follow the procedure below to create a new vehicle 1 Ensure that the vehicle is still in Park and or the park brake is set to prevent the vehicle from moving 2 Ensure the vehicle is off Do not start the vehicle yet 3 Power up the AutoSteer system 4 Follow the instructions provided in the user display s user manual to create a new vehicle Note Do not start the vehicle until after the Hydraulic Leak Test has been performed on the vehicle After the vehicle has been created shut down the AutoSteer system prior to starting the vehicle Hydraulic Leak Check On completion of installing the entire AutoSteer system including the Roof Module and user display the system needs to be checked for leaks Follow the procedure below to check for leaks 1 Clear any bystanders away from the vehicle If there is a hydraulic leak they could be injured Put the vehicle into Park and or set the park brake to prevent the vehicle from moving 2 3 Turn the vehicle over for a few seconds and if the vehicle starts
16. edure Hydraulic Installation Checklist Before starting the vehicle after installing the valve and hoses verify the following to prevent damage to the vehicle or oil spills 1 2 3 The mounting bolts that secure the valve to the frame are tight The P hose is connected to correct port on Steering Valve and vehicle pressure port The T hose is connected to correct port on Steering Valve and vehicle tank port Note If the Pressure and Tank hoses are reversed the vehicle could possibly turn unexpectedly when the AutoSteer is engaged Double check these connections to make sure they are correct The STINI steer hose is connected to the correct port on the Steering Valve and attached to the steer right line from the orbitrol The STIN2 steer hose is connected to the correct port on the Steering Valve and attached to the steer left line from the orbitrol The STOUT steer hose is connected to correct port on the Steering Valve and the steer right port on the vehicle The STOUT2 steer hose is connected to correct port on the Steering Valve and the steer left port on the vehicle 6 7 8 9 The Pressure Transducer has been installed and tightened The Temperature Sensor has been installed and tightened 10 All other hose fittings are tight 11 Checked that all hose and cables have been routed so they will not be damaged by moving parts or foreign objects 30 Prior to starting the vehicle verify all people and equi
17. es es Tp CO Install the Main Cable harness 10 Install the display using a RAM mount arm 11 Connect the Main Cable harness to the display harness Power DB9 serial RJ 45 Note Instructions for connecting the vehicle kit cables to the display can be found in the display owner s manual 12 Verify that all connectors are properly coupled and secured 13 Start the vehicle and check for oil leaks 14 Power ON the AutoSteer system 15 Calibrate the vehicle 16 Tune the vehicle 17 Verify that the AutoSteer system has been installed properly and operates satisfactorily Hardware Installation Manual 7 Installation Procedure Outline Cable Diagram Mid Of 3100 VS Mid Ob Mid EDILO LUZ SSAINHVH 10100 S Mid EL JTA IVA 444d 1LS0 LN Md F 19159N3 310M34 J 10100 41004 Mid L v lV 3 101004 V5 dJM0d 31000 Ys H13 31000 100d SFT 1 COW 3004 d das Lon mn ss w a CNidt Nidf i i 0 92t0 LUZ SSAINYTH V IV HITA 44MOd q IDIH A Hid E HNOS AY 1dSs10 Nid B H14 AY 1d510 SFT TJA IVA LYI GG ONY GF GE LYI welbeig SIP2 AATONNOE AD dH1 1N3534d34 ANI 03HS50 Aejdsip 0 ssewey a q WIE J3auun3 0 JENUELU S daun Aejdsip Jasn yya papiaosd SUOIINIISUI 20 0 J AFIdSIO JOVEN adj ajay AutoSteer System steering Valve Installation The Steering Valve Installation chapter informat
18. gure 6 4 Attach Data and RJ 45 Connector to Roof Module Ethernet Connector Roof Module Connector 2 Route the Roof Module data cable to the back of the cab Secure the cable to the roof with a metal wire clamp and to the underside of the roof with a cable tie See Figure 6 5 Loosen the bolt on the roof with a 15mm socket and ratchet Figure 6 5 Route Cable to Left Rear Pos gt gt E y Metal Wire Clip Cable Tie to Filter Hinge Under the Lip of Cab Hardware Installation Manual 45 Main Cable Harness Route the cable down the left side cab post There is nothing to attach the cable to the cab post on the bottom To hold the harness a cable tie must be looped through the space between the fender and the cab and wrapped around the square tubing below the fender Open the rear window and remove the wire access rubber grommet See Figure 6 6 Figure 6 6 Remove Rubber Grommet 5 Route the Main Cable Harness into the cab through the wire access port 46 AutoSteer System Main Cable Harness SA Module Harness Connections 1 Route the Main Cable Harness s SA Module data and SA Module power cables out the back window where the Roof Module harness was routed in 2 Connect the 12 pin data and 2 pin power connectors between the Main Cable Harness and the SA Module harness near the SA Module See Figure 6 7 Figure 6 7 Connect SA Module Data and Power Connectors 2 Pin Power Connection 12 Pin Data
19. hicle at speeds above 30 mph 48 km h e Ensure you are In a stable position on the vehicle platform when removing the Roof Module so that you do not fall or drop the Roof Module e Use a ladder to install the AutoSteer Roof Rail Ensure that you are in a stable position on the vehicle platform when installing or removing the Roof Rail and Roof Module so that you do not fall Hardware Installation Manual 35 Roof Rail Installation Procedure Roof Rail Installation Procedure 1 Place the ladder as close as possible to the side of the cab 2 Locate the two bolts on top of the cab shown in Figure 4 1 Remove the bolts with a 21mm socket and ratchet Note Leave the rubber gasket on top of the roof Figure 4 1 Mounting Bolts Location gt Mounting Bolt Locations 3 Place two M16 flat washers on both rubber gaskets See Figure 4 2 Figure 4 2 Place Flat Washers on Rubber Gasket aa 36 AutoSteer System Roof Rail Installation Procedure 4 Place the Roof Rail on top of the washers and center it over the cab 5 Attach the Roof Rail using the bolts removed earlier and tighten it securely with a 21mm socket and ratchet See Figure 4 3 Figure 4 3 Attach Quick Attach Rail 6 Attach the three antennas to the proper antennas connections on the Roof Module See Figure 4 4 Note Hand tighten the connections Do not over tighten Figure 4 4 Attach the Antennas Hardware Installatio
20. ing Components window 13 Command the vehicle to turn Right and then Left a few times The vehicle should rotate in the direction it is commanded If the vehicle rotates in the wrong direction the hoses were attached to the wrong ports on the valve and need to be switched 14 Power down the AutoSteer display put the vehicle back into Park and or reset the park brake and shutdown the vehicle 15 Once again check the vehicle for hydraulic leaks and repair any that are found 54 AutoSteer System Final Hardware Installation Checklist This Final Hardware Installation Checklist contains the verifications steps necessary after the installation of the AutoSteer system Note The Final Hardware Installation Checklist is on the back of this page Fill in the checklist after the installation is complete You should keep a copy of this checklist for future reference when servicing the AutoSteer system Customer Name Location Address Contact Information Machine Model Year Serial AutoSteer Installation Kit Part Number NOTES Name of Installer Date Installed Hardware Installation Manual 55 Final Hardware Installation Checklist Final Hardware Installation Checklist 1 So Se eS ee A User Display Bracket Installed and all fasteners are tight User Display Installed Roof Rail is installed and all fasteners are tight SA Module is installed and all fasteners are tight All cable ends are connected All cables
21. ion is provided in the following sections Steering Valve Installation Procedure Overview Prepare the Steering Valve for Installation Install the Steering Valve Hydraulic Hose Overviews e Steering Valve Port Overview Hose Connection Overview Hydraulic Hose Connection Procedure Attach Hoses to the Steering Valve Attach Hoses to the Vehicle Connections Hydraulic Installation Checklist Note Only technicians trained for hydraulic valve installations should perform the installation procedures in this chapter If your vehicle requires a hydraulic Steering Valve to be installed ensure a trained technician is available for the installation Steering Valve Installation Procedure Overview AS SP A Prepare the Steering Valve for installation on the vehicle Install the Steering Valve on the vehicle Connect the six hoses between the Steering Valve and the vehicle Check for oil leaks Perform a manual functional test to confirm correct valve operation High Pressure Fluid Hazard Read the Owner s Manual before installation Wear hand and eye protection while performing hydraulic system maintenance Relieve hydraulic system pressure before servicing the hydraulic system Hardware Installation Manual 9 Steering Valve Installation Procedure Overview Prepare the Steering Valve for Installation Prior to installing the Steering Valve onto the vehicle an elbow and pressure transducer must be attached to the valve
22. l is connected to the STIN2 port The STOUTI port is then connected to the steer right port on the vehicle and the STOUT2 port is connected to the steer left port on the vehicle Table 2 2 shows the list of hoses provided by the installation kit The kit also provides colored cable ties To ensure the correct hose is attached to the correct port on both sides attach the colored cable tie shown in the table to each end of the hose listed prior to beginning the installation It is also recommended that the existing hoses and ports on the vehicle are also labeled with the colored cable tie that the new hoses will be attaching to before disconnecting the hoses to prevent a mix up The numbers in Figure 2 11 and Table 2 2 correspond to the Item Numbers for each hose provided in Table 1 2 If the number has a after it it means that there are multiple hoses with the same length and fittings 16 AutoSteer System Install the Steering Valve Figure 2 11 Caterpillar 35 45 and 55 Hose Connections STEERING ORBITROL AUTOSTEER VALVE T L A a EL CO PRESSURE z fi TRANSDUCER SENSOR TEMPERATURE P PRESSURE T TANK IRETURN PRESSURE HYDRAULIC DISPLACEMENT CONTROL VALVE Table 2 2 Color Codes for Hydraulic Hoses PP Red 1 1 1 2 x 78 Hose 8 90 Deg ORFS x 8F ORFS 1 2 x 78 Hose 8 90 Deg ORFS x 8F ORFS 2 2 1 2 x 78 Hose 8 90 Deg ORFS x 8F ORFS 1 3 1 2 x 78 Hose 8 90 Deg ORFS x 8F ORFS 1 2 x 78
23. llation If the vehicle fails one or more of the tests the steering system must be evaluated by a Caterpillar dealer and repaired if necessary Possible causes of steering problems Incorrect track tension Hydraulic problem Note The Steering Valve controls the steering of the vehicle by changing the oil flow in the steer lines The amount of oil used to control the vehicle s turn is very small On some higher hour vehicles it is possible that the vehicle may have excessive internal leakage in the steering system that will not allow the Steering Valve to build up enough flow to control 6 AutoSteer System Installation Procedure Outline the steering Though the AutoSteer system will not work it is possible that manual steering work adequately in this situation If after installing the AutoSteer system the system does not steer and all troubleshooting procedures have been followed it may be necessary to have the system pressure and flow checked by an Caterpillar dealer service technician Installation Procedure Outline 1 Verify that all components have been received Note Steps 2 3 4 and 8 are skipped if installing an electric steering actuator such as OnTrac II Install the Hydraulic Valve Assembly Install the Hydraulic Hoses Install the SA Module Install the Roof Rail on the cab roof Install the Roof Module on the Roof Rail Install the Monitor Mounting bracket in the cab Install the SA Module harness Se a
24. n Manual 37 Roof Rail Installation Procedure 7 Place the Roof Module on the Roof Rail 8 Remove the locking pin from the Roof Rail See Figure 4 5 Note Press the button on the end of the handle to allow the pin to be removed Figure 4 5 Removing the Locking Pin Locking Pin Button 9 Adjust the Roof Module position on the rail 10 Re insert the locking pin to lock the Roof Module onto the vehicle See Figure 4 6 Figure 4 6 Locking Pin Inserted Locking Pin 38 AutoSteer System Roof Rail Installation Procedure 11 The Roof Module is now installed See Figure 4 6 Figure 4 7 Roof Module Installed Hardware Installation Manual 39 Roof Rail Installation Procedure 40 AutoSteer System Display Installation The Display Installation chapter contains information in the following sections e Introduction e Installation Procedure Introduction This chapter provides the instructions for installing the RAM mount ball in the cab so that the user display can be attached later Refer to your display s User Manual for instructions on installing the display Note If the holes shown for mounting the display are being used by another piece of equipment other mounting locations can be used However for best performance and ease of use use the holes shown in the installation manual Installation Procedure 1 Locate the accessory mounting bracket holes on the front right corner cab post If nece
25. nection e Cab Power Connection e Battery Power Connection SA Module Harness SA Module Connection 1 Connect the SA Module harness to the SA Module See Figure 6 1 Figure 6 1 shows an example SA Module not attached to a vehicle and is to be used as a reference on how the SA Module harness connector attaches to the SA Module Figure 6 1 Connecting SA Module Connector Bottom of SA Module Cable Connector Locking Mechanism in Open Position Latch Hardware Installation Manual 43 SA Module Harness 2 Close the cable connector locking mechanism as shown in Figure 6 2 Figure 6 2 SA Module Connector closed Locked Position Closed U Steering Valve Connections 1 Route SA Module harness s 4 pin and 10 pin cable to the Steering Valve along the rear of the vehicle and then along the right side with the newly installed hose connections 2 Connect the 4 pin and 10 pin connectors to the Steering Valve jumper cable See Figure 6 3 Figure 6 3 Hydraulic Valve Connections p SA Module Harness Connectors _ gt gt 3 Neatly coil any excess cable and secure with cable ties 4 Replace the side panel between the tracks and the cab on the vehicle that was removed at the beginning of the installation 44 AutoSteer System Main Cable Harness Main Cable Harness Roof Module 1 Attach the Main Cable Harness s Roof Module connector and Ethernet connector to the Roof Module See Figure 6 4 Fi
26. oSteer system to available vehicle power sources Cab Power Connection e Battery Power Connection Note Refer to your display user manual before connecting the AutoSteer system to vehicle power The AutoSteer Main Cable Harness must be connected to a 3 pin 12V power source Your display user manual provides specific instructions for connecting power to the AutoSteer system and specifies the appropriate vehicle power source Cab Power Connection 1 Locate the cab console right side 12V power outlet See Figure 6 11 2 Use this 12V accessory power connector if the display manual specifies connecting to power inside the cab Figure 6 11 Cab 12V Power Outlet Cab Power Connection 50 AutoSteer System Main Cable Harness Battery Power Connection 1 Locate the vehicle battery See Figure 6 12 2 Connect to the vehicle battery if the display manual specifies a direct battery connection Figure 6 12 Vehicle Battery Location Note A battery cable is provided with the AutoSteer system when a direct battery connection is required Hardware Installation Manual 5 1 Main Cable Harness 52 AutoSteer System Post Installation Procedures and Information The Post Installation Procedures and Information chapter provides information in the following sections e Create New Vehicle Hydraulic Leak Test Calibration and Tuning Notes Once the entire AutoSteer system including the user display and display harnesses hav
27. ort adapter Tighten the hose with 3 4 and 15 16 wrenches See Figure 2 23 Figure 2 23 Attach Steer Out Hoses A Steer Left Diagnostic Port Fitting Steer Out Left Hose Steer Out Right Hose Steer Right Diagnostic Port Fitting 16 Disconnect the existing Pressure line from the fitting at the pump with 3 4 7 8 and 15 16 wrenches 17 Attach a 8 ORFS run tee to the fitting 18 Connect the existing pressure line to the end of the tee 19 Attach a 90 degree 8 ORFS elbow to the tee port and point towards the front of the machine Hardware Installation Manual 27 Hydraulic Hose Connection Procedure 20 Attach the Pressure hose from the Steering Valve to the elbow and tighten all connections with a 15 16 wrench See Figure 2 24 Figure 2 24 Pressure Hose Connected Pressure Hose from Steering Valve 90 Degree Elbow Existing Pressure Line Run Tee 21 Organize and secure the hoses using cable ties in the side compartment so they cannot be damaged See Figure 2 25 Figure 2 25 Secure Hoses on Side a gt gt S d lt De 28 AutoSteer System Hydraulic Hose Connection Procedure 22 Organize and secure the hoses under the vehicle going to the Steering Valve using heavy duty cable ties Attach the hoses to the existing metal lines See Figure 2 26 Figure 2 26 Secure Hoses to Bottom of Vehicle Existing Metal Lines Hardware Installation Manual 29 Hydraulic Hose Connection Proc
28. pment are clear from around the vehicle and the AutoSteer system is powered down The vehicle could turn unexpectedly and cause injury or death to bystanders Note Before powering up the AutoSteer system move the vehicle to a flat wide open area where if the vehicle does begin to spin it will not damage anything AutoSteer System SA Module Installation The SA Module Installation chapter contains information in the following sections SA Module Mounting Orientation Mount the SA Module SA Module Mounting Orientation The SA Module can also only be mounted in certain orientations Figure 3 1 shows the correct mounting positions and Figure 3 2 shows the improper mounting positions Figure 3 1 Correct SA Module Mounting Orientations Ly t rem de lak ot x i 5 o p w s y a vr A O a yo TY o b Figure 3 2 Incorrect SA Module Mounting Orientations aii S al q O O I eS h Hardware Installation Manual 31 Mount the SA Module Mount the SA Module Due to the variety of options available on vehicles and the possible configuration differences 1t may be necessary to install the SA Module in a location other than the example shown here If an alternative location is required choose a location where the SA Module can be protected from damage from moving parts or crop debris and excessive moisture from weather and cleaning equipment 1
29. ssary remove any protective screws or covers from the cab post See Figure 5 1 Figure 5 1 Identify the Bracket Mounting Holes e g e 4 Pe i at Pij y ae a s Mounting Holes for User Display Bracket Hardware Installation Manual 41 Installation Procedure 2 Attach the user display bracket to the mounting holes with the two longer M10 x 35mm bolts and washers that are included with the installation kit See Figure 5 2 Tighten the bracket with a 17mm socket and ratchet The bracket should angle back towards the side window Figure 5 2 Monitor Bracket Installed Bracket Bolts 3 Attach the RAM mount ball to mounting bracket using the four 10 32x3 4 Phillips screws and lock nuts provided Tighten using a 3 8 wrench and 2 Philips screwdriver Figure 5 3 Mounted Display Bracket IS tl y b i ip P d A RAM Mount Base Note Refer to the user display manual for the remaining user display specific installation instructions 4 Replace the side panel between the tracks and the cab on the vehicle that was removed at the beginning of the installation 42 AutoSteer System Connecting System Cables The Connecting System Cables chapter provides information in the following sections e SA Module Harness e SA Module Connection Steering Valve Connections e Main Cable Harness e Roof Module e SA Module Harness e Main Cable Harness Connections Inside Cab e Power Supply Con
30. tallation kit shown in Figure 2 8 Tighten the bolts with a 9 16 wrench and 9 16 socket and ratchet Figure 2 8 Steering Valve Mounted Mounting Bolts 3 The Steering Valve is now mounted 14 AutoSteer System Install the Steering Valve Hydraulic Hose Overviews Steering Valve Port Overview The Steering Valve has six ports that need to be connected to the vehicle s hydraulic system The ports on the left side of the valve are shown in Figure 2 9 and the ports on the bottom of the valve are shown in Figure 2 10 Figure 2 9 Left Side Ports on Steering Valve di WA ee ON LI a Figure 2 10 Bottom Ports on Steering Valve ee eee Oy l il A jl Hardware Installation Manual 15 Install the Steering Valve Table 2 1 shows a description and the fitting types and sizes of each of the ports on the Steering Valve Table 2 1 Steering Valve Port Functions and Fitting Sizes eooo eee as STOUTI Steer Right out to Vehicle 8 ORFS STIN2 Steer Left from Orbitrol 8 ORFS STOUT2 Steer Right out to Vehicle 8 ORFS Hose Connection Overview Figure 2 11 shows an overview on how the hose connections are to be attached The P port is teed into the main steering pressure line The T port is teed into the main steering tank line The existing steer lines are disconnected from the vehicle ports and the steer right line from the orbitrol is connected to the STIN1 port and the steer left line from the orbitro
31. th the screw Tighten the screw with a 1 Phillips screwdriver See Figure 2 4 Figure 2 4 Pressure Transducer Connector Detail Note The pressure transducer kit may come with an alternative rubber gasket Either one can be used but ensure that one is installed Failure to use the rubber gasket will allow moisture to get into the sensor and cause it to fail 8 The Steering Valve is ready to install and should look similar to Figure 2 5 Figure 2 5 Pressure Transducer Attached A x ED A 3 4 Pressure Transducer and Cable Attached 12 AutoSteer System Install the Steering Valve Install the Steering Valve The Steering Valve is installed on the inside of the vehicle s frame ahead of the cab on the right side of the vehicle Figure 2 6 shows the mounting location from the outside The valve is attached directly to the frame Figure 2 6 Caterpillar 35 45 and 55 Steering Valve Mounting Location e Steering Valve Mounting Location 1 Locate the two existing bolt holes from the inside of the of the right side frame under the engine area as shown in Figure 2 7 Figure 2 7 Steering Valve Mounting Location F J aN a A AA AN DUDS 7 77 Wy 3 Rear of the Vehicle is this Direction QN Steering Valve Mounting Bolt Holes Hardware Installation Manual 13 Install the Steering Valve 2 Attach the Steering Valve with the two 3 8 x 4 bolts washers and nuts provided with the ins
32. tion Procedure Outline Cable Diagram This installation guide describes the installation of the AutoSteer system on several models of Caterpillar track vehicles The AutoSteer installation kit PN 188 0023 01 is used on the following models Caterpillar Track 35 45 and 55 models The vehicle specific sub assemblies for the vehicle series are listed in Table 1 1 Note If you are installing an electric steering wheel actuator such as OnTrac II skip the Steering Valve SA Module and SA Module Harness installation information in this book and refer to your electric steering product manual for further instructions Hardware Installation Manual 1 Installation Kit Overview Installation Kit Overview This Installation Kit Overview section is divided into sub sections for each of the three sub assemblies as shown in Figure 1 1 The components in each sub assembly are described in the following sections Figure 1 1 Installation Kit Components PN 188 0023 01 1 Table 1 1 Installation Kit Components PN 188 0023 01 Steering Valve Kit Cat Hose Kit Cat 35 45 55 06 2004 Brackets Kit Cat 35 45 55 Sub Assemblies This vehicle installation kit contains the following components Steering Valve Kit Components Hose Kit Components Bracket Kit Components 2 AutoSteer System Installation Kit Overview Steering Valve Kit Components Figure 1 2 Steering Valve Kit Components PN 153 0007 01 VALVE HARME
33. uds will hold the panel from falling When the nuts are removed be careful to not allow the panel to fall Hardware Installation Manual 23 Hydraulic Hose Connection Procedure 2 Identify the ports and hoses that the Steering Valve will be connected to See Figure 2 18 Figure 2 18 Vehicle Hose Attachment Points Tank Hose _ Hose Connects Directly to Hydraulic Housing Steer Right Hose re y lt gt re E Steer Left Hose P d r f f m ee f a q ms aj E T Y y Y re L k 4 NW m 7 hs gt mam NS F ie i g t at 1 i t i Fi H t Y Pressure Hose 3 Mark the existing steer left and steer right hoses with the colored cable ties provided with the kit to prevent them from being mixed up The hose ends should be labeled the same color as the Steer In Left and Steer In Right hoses are The existing ports would be labeled the same color as the Steer Out Left and Steer Out Right hoses are colored 24 AutoSteer System Hydraulic Hose Connection Procedure 4 Disconnect the exiting Tank line with 13 16 and 3 4 wrenches See Figure 2 19 oe ey n Figure 2 19 Tank Line Disconnected Attach a 6 ORFS run tee to the existing fitting Attach the original hose to the end of the run tee Attach a 8 ORF to 6 ORFS hose adapter to the end of the Tank hose from the Steering Valve Attach the Tank hose to the tee port See Figure 2 20 Figur
34. ve Leave the connection loose for the time being Attach the 90 degree connector of the Steer Out Left hose to the STOUT2 port on the Steering Valve Leave the connection loose for the time being Adjust the angles of the 90 degree hose connections as shown in Figure 2 13 and then tighten the three connectors with a 15 16 wrench k Figure 2 13 STIN2 STOUT1 STOUT2 Hose Connection STIN2 Connected STOUT2 Connected STOUT1 Connected mi I M ee y A dies ne ku F a To simplify the installation of the Tank hose remove the solenoid from the left side of the valve with a 3 4 wrench Hardware Installation Manual 19 Hydraulic Hose Connection Procedure 9 Attach the 90 degree connector of the Tank hose to the T port on the Steering Valve Point the hose connection downward and tighten the connection with a 15 16 wrench as shown in Figure 2 14 Figure 2 14 Tank Hose Connection iS Solenoid Removed Tank Hose 10 Reattach the solenoid valve and tighten only to 4 6 ft lbs 5 8 nm with a torque wrench Verify that it is attached the correct way wires point towards the valve Note Do not over tighten the nut or the solenoid could be damaged 11 Assemble the temperature sensor assembly by attaching the temperature sensor to the probe Tighten the connection with 17mm and 21mm wrenches No Teflon is required for this connection as there is no oil pressure here 20 AutoSteer System H
35. vided documentation before installing the GPS steering system on a vehicle To prevent the accidental engagement of AutoSteer and loss of vehicle control while driving on roads shut down the AutoSteer system exit the program Never drive on roads or in public areas with the AutoSteer system turned on Hardware Installation Manual Caution Alerts The AutoSteer system installer and manufacturer disclaim any responsibility for damage or physical harm caused by failure to adhere to the following safety requirements The Roof Module must be removed when transporting or driving the vehicle at speeds above 30 mph 48 km h The Roof Module can possibly detach due to wind loads at higher speeds The AutoSteer system does not detect obstacles in the vehicle s path The operator must observe the path being driven in order to avoid obstacles When engaged the AutoSteer system controls only the steering of the vehicle The operator must control the speed of the vehicle The AutoSteer system must be powered OFF when installing or removing the Roof Module The Roof Module must always be firmly secured to the Roof Rail using the hardware whenever the vehicle is in operation to prevent the Roof Module from releasing from its bracket and falling vi AutoSteer System Vehicle Requirements The vehicle steering and hydraulic systems must be in good working order before installing the AutoSteer system Check for loose or worn parts
36. ydraulic Hose Connection Procedure 12 Attach the probe to the tee Before attaching the probe to the tee wrap the threads two times with Teflon tape Tighten the connections with 3 4 and 17mm wrenches See Figure 2 15 for the final assembly Figure 2 15 Temperature Sensor Assembly Temperature Sensor Probe Tee 13 Attach the temperature sensor assembly to the P port on the Steering Valve The temperature sensor should point upwards 14 Connect the temperature sensor connector of the Steering Valve harness to the temperature sensor 15 Attach a 90 8 ORFS degree elbow to the end of the temperature sensor assembly tee and point the elbow downward Hardware Installation Manual 2 1 Hydraulic Hose Connection Procedure 16 Attach the 90 degree connector of the Pressure hose to the elbow Tighten all connections with a 15 16 wrench See Figure 2 16 for an example of the final assembly Figure 2 16 Pressure Hose Connected Steering Valve Harness Temperature Sensor Connector Temperature Sensor Assembly 90 Degree Elbow Pressure Hose 22 AutoSteer System Hydraulic Hose Connection Procedure Attach Hoses to the Vehicle Connections 1 Locate the nuts and bolts holding the side panel to the right side of the vehicle between the tracks and the cab See Figure 2 17 Remove the nuts and bolts with a 1 2 socket and ratchet Remove Nuts and Bolts Holding Panel Note Remove the nuts last as the st
Download Pdf Manuals
Related Search