EZ-Steer 53345-60-ENG Installation Instructions

Transcription

Installation Instructions
EZ-Steer® Assisted Steering System
John Deere
Revision A
October 2008
Part Number 53345-60-ENG
*53345-60-ENG*
Q
6200 / 6300 / 6400
Q
6110 / 6210 / 6310 / 6410
Q
6120 / 6220 / 6320 / 6420
Q
6230 / 6330 / 6430
Q
7200 / 7400 / 7600
Q
7210 / 7410 / 7510 / 7610 / 7710 / 7810
Q
7220 / 7320 / 7420 / 7520
Q
7130 / 7230 / 7330 / 7430
Contact Information
Trimble Agriculture Division
10355 Westmoor Drive
Suite #100
Westminster, CO 80021
USA
[email protected]
www.trimble.com
www.EZ-Steer.com
Legal Notices
© 2004–2008, Trimble Navigation Limited. All rights reserved.
Trimble, the Globe & Triangle logo, and EZ-Steer are trademarks of
Trimble Navigation Limited, registered in the United States and in
other countries.
All other trademarks are the property of their respective owners.
This product is covered by the following patents: 6,198,992,
6,501,422, 6,703,973, 7,188,015, 7,200,490, 7,263,422, 7,360,623, and
7,363,132. Other patents are pending.
Release Notice
This is the October 2008 release (Revision A) of the <Document
Name>, part number 53345-60-ENG.
Limited Warranty Terms and Conditions
Product Limited Warranty
Subject to the terms and conditions set forth herein, Trimble
Navigation Limited (“Trimble”) warrants that this product and its
internal components (the “Product”) shall be free from defects in
materials and workmanship and will substantially conform to
Trimble’s applicable published specifications for the Product for a
period of one (1) year, starting from the earlier of (i) the date of
installation, or (ii) six (6) months from the date of original Product
shipment from Trimble.
Product Software
Product software, whether built into hardware circuitry as
firmware, provided as a standalone computer software product,
embedded in flash memory, or stored on magnetic or other media,
is licensed and not sold. If accompanied by a separate end user
license agreement, use of any such software will be subject to the
terms of such end user license agreement (including any differing
limited warranty terms, exclusions and limitations), which shall
control over the terms and conditions set forth in this limited
warranty).
Software Updates
During the limited warranty period you will be entitled to receive
such Fix Updates and Minor Updates to the Product software that
Trimble releases and makes commercially available and for which it
does not charge separately, subject to the procedures for delivery to
purchasers of Trimble products generally. If you have purchased the
Product from an authorized Trimble distributor rather than from
Trimble directly, Trimble may, at its option, forward the software Fix
Update or Minor Update to the Trimble distributor for final
distribution to you. Major Upgrades, new products, or substantially
new software releases, as identified by Trimble are expressly
excluded from this update process and limited warranty. Receipt of
software updates shall not serve to extend the limited warranty
period.
For purposes of this warranty the following definitions shall apply:
(1) “Fix Update” means an error correction or other update created
to fix a previous software version that does not substantially
conform to its published specifications; (2) “Minor Update” occurs
when enhancements are made to current features in a software
program; and (3) “Major Upgrade” occurs when significant new
features are added to software, or when a new product containing
new features replaces the further development of a current product
line. Trimble reserves the right to determine, in its sole discretion,
what constitutes a significant new feature and Major Upgrade.
Warranty Remedies
If the Trimble Product fails during the warranty period for reasons
covered by this Limited Warranty and you notify Trimble of such
failure during the warranty period, Trimble at its option will repair
OR replace the nonconforming Product, OR refund the purchase
price paid by you for the Product, upon your return of the Product
to Trimble in accordance with Trimble's standard return material
authorization procedures.
How to Obtain Warranty Service
To obtain warranty service for the Product, please contact your Trimble
dealer. Alternatively, you may contact Trimble to request warranty service at
+1-408-481-6940 (24 hours a day) or e-mail your request to
[email protected]. Please be prepared to provide:
– your name, address, and telephone numbers
– proof of purchase
– this Trimble warranty card
– a description of the nonconforming Product including the model number
– an explanation of the problem.
The customer service representative may need additional information from
you depending on the nature of the problem.
Warranty Exclusions and Disclaimer
This Product limited warranty shall only apply in the event and to the extent
that (i) the Product is properly and correctly installed, configured, interfaced,
maintained, stored, and operated in accordance with Trimble's applicable
operator's manual and specifications, and; (ii) the Product is not modified or
misused. This Product limited warranty shall not apply to, and Trimble shall
not be responsible for defects or performance problems resulting from (i) the
combination or utilization of the Product with hardware or software
products, information, data, systems, interfaces or devices not made, supplied
or specified by Trimble; (ii) the operation of the Product under any
specification other than, or in addition to, Trimble's standard specifications
for its products; (iii) the unauthorized, installation, modification, or use of the
Product; (iv) damage caused by: accident, lightning or other electrical
discharge, fresh or salt water immersion or spray; or exposure to
environmental conditions for which the Product is not intended; or (v)
normal wear and tear on consumable parts (e.g., batteries). Trimble does not
warrant or guarantee the results obtained through the use of the Product.
NOTICE REGARDING PRODUCTS EQUIPPED WITH GPS TECHNOLOGY:
TRIMBLE IS NOT RESPONSIBLE FOR THE OPERATION OR FAILURE OF
OPERATION OF GPS SATELLITES OR THE AVAILABILITY OF GPS
SATELLITE SIGNALS.
THE FOREGOING LIMITED WARRANTY TERMS STATE TRIMBLE'S
ENTIRE LIABILITY, AND YOUR EXCLUSIVE REMEDIES, RELATING TO
PERFORMANCE OF THE TRIMBLE PRODUCT. EXCEPT AS OTHERWISE
EXPRESSLY PROVIDED HEREIN, THE PRODUCT AND ACCOMPANYING
DOCUMENTATION AND MATERIALS ARE PROVIDED “AS-IS” AND
WITHOUT EXPRESS OR IMPLIED WARRANTY OF ANY KIND, BY EITHER
TRIMBLE OR ANYONE WHO HAS BEEN INVOLVED IN ITS CREATION,
PRODUCTION, INSTALLATION, OR DISTRIBUTION, INCLUDING, BUT
NOT LIMITED TO, THE IMPLIED WARRANTIES OF MERCHANTABILITY
AND FITNESS FOR A PARTICULAR PURPOSE, TITLE, AND
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OF ALL OBLIGATIONS OR LIABILITIES ON THE PART OF TRIMBLE
ARISING OUT OF, OR IN CONNECTION WITH, ANY PRODUCT.
SOME STATES AND JURISDICTIONS DO NOT ALLOW LIMITATIONS ON
DURATION OR THE EXCLUSION OF AN IMPLIED WARRANTY, SO THE
ABOVE LIMITATION MAY NOT APPLY TO YOU.
Limitation of Liability
TRIMBLE'S ENTIRE LIABILITY UNDER ANY PROVISION HEREIN
SHALL BE LIMITED TO THE AMOUNT PAID BY YOU FOR THE
PRODUCT. TO THE MAXIMUM EXTENT PERMITTED BY APPLICABLE
LAW, IN NO EVENT SHALL TRIMBLE OR ITS SUPPLIERS BE LIABLE
FOR ANY INDIRECT, SPECIAL, INCIDENTAL OR CONSEQUENTIAL
DAMAGE WHATSOEVER UNDER ANY CIRCUMSTANCE OR LEGAL
THEORY RELATING IN ANYWAY TO THE PRODUCTS, SOFTWARE AND
ACCOMPANYING DOCUMENTATION AND MATERIALS, (INCLUDING,
WITHOUT LIMITATION, DAMAGES FOR LOSS OF BUSINESS PROFITS,
BUSINESS INTERRUPTION, LOSS OF DATA, OR ANY OTHER
PECUNIARY LOSS), REGARDLESS OF WHETHER TRIMBLE HAS BEEN
ADVISED OF THE POSSIBILITY OF ANY SUCH LOSS AND REGARDLESS
OF THE COURSE OF DEALING WHICH DEVELOPS OR HAS
DEVELOPED BETWEEN YOU AND TRIMBLE. BECAUSE SOME STATES
AND JURISDICTIONS DO NOT ALLOW THE EXCLUSION OR
LIMITATION OF LIABILITY FOR CONSEQUENTIAL OR INCIDENTAL
DAMAGES, THE ABOVE LIMITATION MAY NOT APPLY TO YOU.
PLEASE NOTE: THE ABOVE TRIMBLE LIMITED WARRANTY
PROVISIONS WILL NOT APPLY TO PRODUCTS PURCHASED IN THOSE
JURISDICTIONS, SUCH AS COUNTRIES OF THE EUROPEAN
ECONOMIC COMMUNITY, IN WHICH PRODUCT WARRANTIES ARE
OBTAINED FROM THE LOCAL DISTRIBUTOR. IN SUCH CASE, PLEASE
CONTACT YOUR TRIMBLE DEALER FOR APPLICABLE WARRANTY
INFORMATION.
Registration
To receive information regarding updates and new products, please
contact your local dealer or visit the Trimble website at
www.trimble.com/register. Upon registration you may select the
newsletter, upgrade or new product information you desire.
Notice to Our European Union Customers
For product recycling instructions and more information, please go
to:
www.trimble.com/ev.shtml
Recycling in Europe: To recycle Trimble WEEE, Call
+31 497 53 2430, and ask for the "WEEE Associate"
Or
Mail a request for recycling instructions to:
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c/o Menlo Worldwide Logistics
Meerheide 45
5521 DZ Eersel, NL
Safety Information
Always follow the instructions that accompany a Warning or Caution. The information
they provide is intended to minimize the risk of personal injury and/or damage to
property. In particular, observe safety instructions that are presented in the following
format:
C
C
WARNING – This alert warns of a potential hazard, which, if not avoided, can cause
severe injury.
CAUTION – This alert warns of a hazard or unsafe practice which, if not avoided, can
cause injury or damage.
Note – An absence of specific alerts does not mean that there are no safety risks involved.
ii.1
ii.2
Warnings
C
WARNING – When you are working on the vehicle’s hydraulic systems, vehicle
C
WARNING – If someone else attempts to drive the vehicle while you are working on or
C
WARNING – Agricultural chemicals can pose serious health risks. If the vehicle has
C
WARNING – Vehicle cabs can be quite high in the air. Falling from this height can
attachments that are suspended can drop. If you are working around the vehicle, you
could suffer serious injury if an attachment dropped on you. To avoid this risk, lower all
vehicle attachments to the ground before you begin work.
under it, you can suffer serious or fatal injuries. To avoid this possibility, install a lockout
box on the battery terminal to prevent the battery from being reconnected, remove the
key from the vehicle’s ignition switch, and attach a “Do not operate” tag in the cab.
been used to apply agricultural chemicals, steam clean the vehicle to remove any chemical
residue from the areas of the vehicle where you will be working.
cause broken bones and internal injuries. To avoid falling from the vehicle, when you
enter or exit the vehicle, face the vehicle and use the steps and handrails
Cautions
C
CAUTION – When the vehicle has been running, parts of the vehicle, including the engine
and exhaust, can become extremely hot. These hot parts can cause serious burns. To avoid
burns, allow hot machine parts to cool before you begin working on them.
C
CAUTION – The system installation may bring you into contact with chemical substances,
such as oil. These can cause poisoning. Wash your hands thoroughly after you have
finished working on the system.
C
CAUTION – Battery posts, terminals, and related accessories contain lead and lead
compounds. Lead poisoning can cause lowered intelligence and kidney problems. To
avoid ingesting lead, wash your hands thoroughly after touching the battery.
AgGPS Autopilot Automated Steering System Installation Instructions
3
4
C
CAUTION – Always wear protective equipment appropriate to the job conditions and the
nature of the vehicle. This includes wearing protective glasses when you use pressurized
air or water, and proper protective welders clothing if you want to complete any welding.
Avoid wearing loose clothing or jewelry that can catch on machine parts or tools.
C
CAUTION – Parts of the vehicle may be under pressure. To avoid injury from pressurized
parts, relieve all pressure in oil, air, and water systems before you disconnect any lines,
fittings, or related items. To avoid being sprayed by pressurized liquids, hold a rag over fill
caps, breathers, or hose connections when you remove them. Do not use your bare hands
to check for hydraulic leaks. Use a board or cardboard instead.
AgGPS Autopilot Automated Steering System Installation Instructions
Contents
Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Cautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Technical assistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Required components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts included . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hardware organization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Vehicle measurements for small frame 6x00/6x10/6x20/6x30 machines
Vehicle measurements for small frame 7x00/7x10/7x20/7x30 machines
Vehicle measurements for large frame 7x00/7x10 machines . . . . . . . .
Preparing the vehicle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Your comments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2
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. 8
. 8
. 8
. 9
. 9
. 9
10
10
10
10
Bracket Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Disassembling the steering column . .
Modifying the steering column covers .
Lower cover . . . . . . . . . . . . .
Middle cover . . . . . . . . . . . . .
Upper cover . . . . . . . . . . . . .
Installing the EZ-Steer bracket. . . . . .
Reassembling the steering column . . .
Additional information . . . . . . . . . .
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12
28
28
31
32
33
34
50
EZ-Steer Assisted Steering System Installation Instructions
5
Contents
6
CHAPTER
1
Introduction
Q
Technical assistance
Q
Required components
Q
Parts included
Q
Hardware organization
Q
Vehicle measurements for small
frame 6x00/6x10/6x20/6x30
machines
Q
Vehicle measurements for small
frame 7x00/7x10/7x20/7x30
machines
Q
Vehicle measurements for large
frame 7x00/7x10 machines
Q
Preparing the vehicle
Q
Installation process
Q
Your comments
1
This manual describes how to install the
Trimble® EZ-Steer® assisted steering system.
Even if you have used other Global
Positioning System (GPS) products before,
Trimble recommends that you spend some
time reading this manual to learn about the
special features of this product. If you are not
familiar with GPS, visit the Trimble website
(www.trimble.com) for an interactive look at
Trimble and GPS.
7
1
Introduction
Technical assistance
1. If you have a problem and cannot find the information you need in the product documentation,
contact Trimble technical support:
2. Go to the Trimble website (www.trimble.com).
3. Hover over the Support and Training link at the top of the screen. The list of Support and Training
options appears.
4. Click the Support A–Z List link. The list of products appears.
5. Scroll to the bottom of the list.
6. Click the Submit An Inquiry link. A form appears.
7. Complete the form and then click Send.
Required components
Kits required
Special tools required
EZ-Steer bracket kit: P/N 53059-60
#2 Phillips screwdriver (preferably ratchet-type)
¼" flat blade screw driver (or small chisel)
1
/8" flat blade screw driver
5
/16" (4 mm) hex wrench
5
/16" nut driver
13 mm wrench
1
/2" wrench
10 mm, 13 mm, and 27 mm deep sockets
3
/8" deep socket
Small snap ring pliers
6" or 8" half round double cut file
Dremel rotary drill with #561 bit
Parts included
Additional items in bracket kit
metal templates (quantity 2)
5
/16" x 1.5" carriage bolts (quantity 2)
6 mm flange head bolts (quantity 4)
¼" - 20 flange head bolts (quantity 4)
metal spacer (quantity 2)
8
Introduction
C
1
WARNING – THE EZ-STEER ASSISTED STEERING SYSTEM IS SOLELY INTENDED FOR AGRICULTURAL
USE IN AN OPEN FIELD ENVIRONMENT WITH AGRICULTURAL VEHICLES APPROVED BY THE
MANUFACTURER FOR USE WITH THE EZ-STEER SYSTEM, AND SHOULD NOT BE USED WITH ANY
OTHER TYPE OF VEHICLE OR FOR ANY OTHER PURPOSE.
Contact your local EZ-Steer system reseller or check www.EZ-Steer.com to confirm that the EZ-Steer
system has been tested and approved by the manufacturer for use with your vehicle make and
model. The EZ-Steer system should not be installed on a vehicle not approved by the manufacturer
for such use. Installation of the EZ-Steer system on an unapproved vehicle will invalidate the
product warranty.
Hardware organization
Platform kit
EZ-Steer T2 system
(part number 53059-60)
(For EZ-Guide 250 / 500
part number 62000-30)
Guidance system display type
(For EZ-Guide 50 / 150 Plus
part number 62000-10)
– EZ-Steer bracket
– Bolt kit (EZ-Steer bracket)
– Metal templates
– metal spacers
– EZ-Guide Plus® lightbar with integrated
GPS receiver
– EZ-Guide 250 lightbar with integrated
GPS receiver
– EZ-Guide 500 lightbar with integrated
GPS receiver
– EZ-Steer controller
– EZ-Steer motor
– Bolt kit (EZ-Steer motor)
– Cable kit
Vehicle measurements for small frame 6x00/6x10/6x20/6x30
machines
Item
Measurement
Steering wheel diameter
398 – 401 mm (15.7 – 15.8 inches)
Wheel base
2387 – 2438 mm (94 – 96 inches)
Antenna height
2616 – 2743 mm (103 – 108 inches)
Antenna to axle offset
1295 – 1397 mm (51 – 55 inches) ahead
Vehicle measurements for small frame 7x00/7x10/7x20/7x30
machines
Item
Measurement
398 – 401 mm (15.7 – 15.8 inches)
Wheel base (2WD)
2794 – 2844 mm (110 – 112 inches)
Wheel base (MFWD)
2641 – 2692 mm (104 – 106 inches)
Antenna height
2895 – 3048 mm (114 – 120 inches)
1371 – 1473 mm (54 – 58 inches) ahead
9
1
Introduction
Vehicle measurements for large frame 7x00/7x10 machines
Item
Measurement
398 mm (15.7 inches)
Wheel base
2844 – 2895 mm (112 – 114 inches)
Antenna height
2946 – 3098 mm (116 – 122 inches)
1371 – 1448 mm (54 – 57 inches) ahead
Preparing the vehicle
1. Park the vehicle on a hard, level surface.
2. Engage the park brake and then remove the ignition key.
3. On an articulated vehicle, install the articulation locks.
4. Remove all dirt and debris from the areas of the vehicle where the system is to be installed.
5. Open all kit boxes and lay all of the parts out on a clean workbench.
6. Check the contents of the boxes against the packing lists.
Note – The left and right sides of the vehicle are referenced while standing behind the vehicle, facing the
normal direction of travel.
Installation process
To install the EZ-Steer platform kit (P/N 53059-60) on the vehicle:
1. Prepare the vehicle.
2. Disassemble the steering column.
3. Modify the steering column housings.
4. Attach the EZ-Steer bracket to the steering column.
5. Reassemble the steering column.
6. Mount the EZ-Steer motor onto the bracket and adjust.
7. Mount the lightbar display, antenna and EZ-Steer controller.
8. Connect all cabling.
9. Connect power for the lightbar display and controller.
Note – These steps are described in greater detail below.
Your comments
Your feedback about the supporting documentation helps us to improve it with each revision. Email
your comments to [email protected].
10
CHAPTER
2
Bracket Installation
In this chapter:
Q
Disassembling the steering
column
Q
Modifying the steering column
covers
Q
Installing the EZ-Steer bracket
Q
Reassembling the steering
column
Q
Additional information
2
This chapter describes how to modify the
vehicle’s steering column to support the
EZ-Steer bracket.
11
2
2.1
Disassembling the steering column
STEP 1
Use a 13 mm wrench to disconnect
the battery cables from the
terminals.
STEP 2
Use a 1/8" flat blade screw driver to
remove the cap from the steering
wheel.
CAP ON
CAP REMOVED
12
2
STEP 3
Telescope the steering column fully
outward and then turn the lock knob
clockwise to lock it into place. Use a
13 mm deep socket to remove the
lock nut, knob, and washers.
STEP 4
Use a ¼" flat blade screw driver or a
small chisel to spread the tabs of the
star washer.
STEP 5
Use a 27 mm deep socket to remove
the large nut and star washer.
13
2
STEP 6
Lift the steering wheel off the
steering shaft.
STEP 7
Use a small pair of snap ring pliers to
remove the snap ring and the washer
that is under it.
STEP 8
Remove the 4 screws from the
underside of the lower instrument
cluster cover. Use either a #2 Phillips
screw driver or a 5/16" (4 mm) hex
wrench, depending on the type of
screw.
14
2
STEP 9
6x30 / 7x30 models
Use a 1/8" flat blade screw driver to
remove the glow plug indicator light.
Once removed, disconnect the light.
STEP 10
Remove the light switch knob by
pulling up on it.
15
2
STEP 11
Remove the top instrument cluster
cover by lifting the bottom edge and
then hinging it upwards.
6x00 / 6x10 / 6x20 / 7x20 / 7x30 MODELS
7x00 / 7x10 MODELS
16
2
STEP 12
Use a ratchet screwdriver with a #2
Phillips bit to remove the 2 screws
from the mid cover.
LEFT SCREW SHOWN
17
2
STEP 13
C
CAUTION – Use care when you
remove the 3-position light
switch connector. If you use too
much force, the switch may
break.
Unplug the hazard switch X, light
switch Y, and alarm Z (if equipped).
Z
Y
X
Z
Y
18
X
2
STEP 14
Phillips bit to remove the 2 screws
that secure the instrument cluster.
STEP 15
Disconnect cables and then remove
the display.
6x10 / 6x20 / 6x30 / 7x20 MODELS
19
2
7x00 / 7x10 MODELS
STEP 16
Use a 10 mm deep socket to remove
the 4 bolts from the lower instrument
cluster cover.
20
6x00 MODELS
2
STEP 17
6x00 / 6x20 / 6x30 /
7x20 / 7x30 models
Use a #2 Phillips screwdriver to
remove the left screw from the
windshield air duct. This will enable
you to remove the left side panel
later.
6x10 models
Use a #2 Phillips screwdriver to
remove both screws from the
windshield air duct. This will enable
you to remove both side panels later.
STEP 18
6x00 / 6x20 / 6x30 /
7x20 / 7x30 models
Use a #2 Phillips screwdriver and/or
a 5/16" nut driver to remove the
center floor panel and the left side
panel.
6x10 models
Use a #2 Phillips screwdriver and/or
a 5/16" nut driver to remove the
center floor panel and both the left
and right side panels.
6x00 / 6x10 / 6x20 / 6x30 / 7x30 MODELS
21
2
6x10 MODELS
7x00 / 7x10 MODELS
22
2
7x00 / 7x10 MODELS
7x00 / 7x10 MODELS
23
2
STEP 19
Extend the steering shaft fully
outwards and then lock it into place.
Remove the plastic corner shield X
(if it is equipped). Lift up the lower
cover Z.
X
From under the dash, pull out the
cables for the turn signal, windshield
wiper lever, and shuttle shift lever (if
equipped) Y.
Disconnect the cables.
Corner Shield - 6x10 / 6x20 /
6x30 / 7x20 / 7x30 MODELS
Y
6x20 / 6x30 / 7x20 / 7x30 MODELS
Z
6x20 / 6x30 / 7x20 / 7x30 MODELS
24
2
6x00 MODELS
6x10 models
Cable connectors can be located
behind either the right or left side
panels. Both locations are shown.
Note – Depending upon the round, 12pin connector’s location, you may have
to remove the ignition switch lock ring
and then relocate the switch.
6x10 MODELS
6x10 MODELS
25
2
6x10 MODELS
7x00 / 7x10 models
There are either 2 or 3 connectors,
depending on whether the vehicle is
equipped with a left hand
forward/reverse shuttle lever.
7x00 / 7x10 MODELS
26
2
STEP 20
Lift the column X off the steering
shaft and then remove the lower
cover Y.
X
Y
27
2
2.2
Modifying the steering column covers
This section describes how to cut the steering column covers to provide clearance for the metal
EZ-Steer system bracket that bolts to the steering column.
Lower cover
STEP 1
Use a Dremel rotary tool with a #561
bit to cut away the side wall as
shown.
BEFORE CUTTING
AFTER CUTTING
28
2
STEP 2
Use a Dremel tool with a #561 bit to
remove 1" of plastic as shown to
create space for the cabling. Cut
slowly.
1.0"
BEFORE BEGINNING
FRONT VIEW AFTER CUTTING
½"
REAR VIEW AFTER CUTTING
29
2
STEP 3
Smooth the cut edges using a 6" or 8"
half round double cut file.
30
1.0"
2
Middle cover
STEP 1
Place the provided middle cover
template over the middle cover, as
shown.
STEP 2
Use the template to mark the
rectangular shape on the cover.
TEMPLATE LOCATION
STEP 3
Use a Dremel rotary tool with a #561
bit and then cut the rectangular
shape out of the cover. Cut slowly.
AFTER CUTTING
STEP 4
Smooth the cut edges with a 6" or 8"
31
2
Upper cover
STEP 1
Place the provided upper cover
template over the upper cover, as
shown.
Step 2
Use the template to mark the
rectangular shape on the cover.
TEMPLATE LOCATION
STEP 3
Use a Dremel rotary drill with a #561
bit and then cut the rectangular
shape out of the cover. Cut slowly.
STEP 4
Smooth the cut edges with a 6" or 8"
32
AFTER CUTTING
2.3
2
Installing the EZ-Steer bracket
STEP 1
Fit the bracket to the right side of the
steering column. Temporarily install
two 6 mm flange head bolts and
ligthly torque each bolt using a
10 mm deep socket.
STEP 2
Install the U-bolt and then tighten
the two flange nuts X with a ½"
wrench.
STEP 3
Remove the 6 mm bolts Y again.
X Y
33
2
Reassembling the steering column
STEP 1
Install the modified lower steering
column cover and then extend the
steering shaft fully out. Use the round
knob to lock the shaft into place.
STEP 2
Tilt the steering column to its middle
position. Install the column onto the
steering shaft. Route the cables along
the shaft and under the lower cover.
34
2
STEP 3
Tilt the column fully down and then
lift the lower cover upwards and then
plug together the electrical
connections for the shuttle shift (if
equipped), turn signal, and
windshield wiper levers.
B
Tip – If possible, get someone
else to hold the lower cover in
place while you reconnect the
cables.
7x00/7x10 models
Route the cables under the dash to
the right side.
6x00 / 6x20 / 6x30 / 7x20 / 7x30 MODELS
The mating connectors for the turn
signal and the windshield wiper are
the same connector type and gender.
Match the connectors by wire color.
6x10 models
Route the cables under the dash to
the left and right sides. Reconnect
the round 12-pin connector and then
install the ignition switch and lock
ring.
The mating connectors for the turn
signal and the windshield wiper are
the same connector type and gender.
6x10 MODELS
Note – Match the connectors by wire
color.
35
2
STEP 4
6x10 / 6x20 / 6x30 /
7x20 / 7x30 models
Use a 10 mm deep socket to replace
the corner shield.
Corner Shield - 6x10 / 6x20 /
6x30 / 7x20 / 7x30 MODELS
STEP 5
Route the switch and instrument
cluster connectors up through the
left and right sides of the lower cover.
LEFT SIDE 6x00 / 6x10
6x20 / 6x30 / 7x20 / 7x30 MODELS
RIGHT SIDE 6x00 / 6x10 /
6x20 / 6x30 / 7x20 / 7x30 MODELS
36
2
LEFT SIDE
7x00 / 7x10 MODELS
RIGHT SIDE
7x00 / 7x10 MODELS
37
2
STEP 6
C
CAUTION – In this step, do not
overtighten the bolts or the
lower plastic cover may crack.
Install the provided spacer under the
left of the cover and then install the
four 6 mm bolts included with the
bracket kit. Tighten the bolts with a
10 mm deep socket.
STEP 7
Tilt the column fully down.
Reconnect the instrument cluster
display.
6x10 / 6x20 / 6x30 / 7x20 / 7x30 MODELS
38
2
7x00 / 7x10 MODELS
6x00 MODELS
STEP 8
Phillips bit to reinstall the 2 screws
that secure the instrument cluster
and then tighten them.
39
2
STEP 9
Tilt the column fully upwards.
Connect the hazard and working
light switches and alarm (if
equipped) to the middle cover.
STEP 10
Insert 2 long machine screws or hex
head cap screws into the bottom of
the lower cover.
STEP 11
Install the middle cover and then
tighten the 2 small screws.
B
Tip – Use a ratchet screw driver
with a #2 Phillips bit.
LEFT SCREW
40
2
RIGHT SCREW
STEP 12
Extend the steering column fully out.
Install the upper cover and the light
switch knob. Slide the rear of the top
cover over the vertical bracket arm
first. Insert the top cover’s 2 hinges
and then push the cover forward and
pivot the panel downward.
41
2
STEP 13
6x30 / 7x30 models
Reconnect and insert the glow plug
indicator light.
STEP 14
Use a #2 Phillips screwdriver or 5/16"
(4 mm) hex wrench to install the 4
long screws into the underside of the
lower cover.
STEP 15
Attach the bracket arm to the upper
cover with the ¼"-20 flange head
bolts included with the bracket kit.
Adjust the arm vertically to avoid
contact with the plastic cover. Use a
3
/8" deep socket to tighten the bolts.
42
2
STEP 16
Use a small pair of snap ring pliers to
reinstall the flat washer and lock ring
onto the steering shaft.
STEP 17
Place the steering wheel onto the
shaft. Install the star washer and nut.
Tighten the large nut. Bend the metal
tabs upwards to prevent the nut from
rotating loose.
STEP 18
Install the lock knob, flat washers,
and nut.
43
2
STEP 19
Install the steering wheel cap.
STEP 20
Place the motor onto the bracket
arm. Use the ¼"-20 x 1" long carriage
bolts and T-knobs provided to secure
it.
6x00 / 6x10 / 6x20 /
6x30 / 7x20 / 7x30 MODELS
44
2
7X00 / 7X10 models
Place ½" spacer between slotted arm
and motor. Use supplied ¼"-20 x 1 ½"
long carriage bolts.
7x00/7x10 MODELS
STEP 21
Adjust the motor until there is 1"–
1¼" of clearance between the
steering wheel ring and the motor
drive wheel.
STEP 22
Check the clearance between the
motor and the right hand windshield
wiper lever.
45
2
STEP 23
Pull the release pin - the motor will
have spring tension against the
steering wheel.
STEP 24
When the steering column is tilted
fully upwards, it may be necessary to
push in the lower cover to allow the
column to tilt down.
46
2
STEP 25
Replace the side panel and the center
floor cover.
6x00 / 6x10 / 6x20 / 6x30 / 7x20 / 7x30
MODELS
47
2
6x10 MODELS
7x00 / 7x10 MODELS
48
2
7x00 / 7x10 MODELS
7x00 / 7x10 MODELS
STEP 26
Replace the 2 screws in the
windshield air duct.
6x00 / 6x10 / 6x20 / 6x30 / 7x20 / 7x30
MODELS
49
2
STEP 27
Use a 13 mm wrench to reconnect
the cables to the battery.
2.4
Additional information
For additional support information, refer to the documentation on www.EZ-Steer.com.
50

EZ-Steer 53345-60-ENG Installation Instructions

Transcription

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