Ag Leader OnTrac3 MDU-G4 User manual

OnTrac3
MDU-G4 Installation Manual
Ag Leader PN 2006237 Rev. A
NOVARIANT 602-0567-01-A

© 2014 Ag Leader Technology
2202 South Riverside Drive
Ames, Iowa 50010 USA

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Table of Contents
MDU-G4
Introduction...............................................................................................................3
Legal Disclaimer.......................................................................................................3
Safety Information ....................................................................................................4
Safety Instructions...............................................................................................4
Warning Alerts.....................................................................................................5
Caution Alerts......................................................................................................6
Installation Requirements.........................................................................................6
Standard Tool Requirements..............................................................................6
Vehicle Requirements.........................................................................................6
Technical Support.....................................................................................................7
Vehicle Inspection ....................................................................................................7
Components
Supported Models ....................................................................................................8
OnTrac3 Main Hardware Kit.....................................................................................8
MDU-G4 Switch Kit...................................................................................................8
OnTrac3 Installation
MDU-G4 Installation Procedure..............................................................................10
Install the Main Gear on the Steering Wheel ....................................................10
Examine Steering Column and Steering wheel...........................................11
Install Spacer (If Needed).......................................................................12
Install the Top Ring......................................................................................12
Attach the Anti-Rotation Pin.........................................................................14
Install the MDU-G4......................................................................................15
Universal Bracket Installation.................................................................................16
Universal Bracket Installation Kit Overview............................................................16
Universal Bracket Installation Procedure................................................................17
ECU-S1 Installation................................................................................................19
ECU-S1 Orientation ..........................................................................................19
ECU-S1 Installation Procedure...............................................................................19
Cable Harness Installation
Cable Harness Connections Overview...................................................................21
Cable Harness Installation Procedure....................................................................22
On/Off Switch .........................................................................................................23
Care and Maintenance...........................................................................................23

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MDU-G4
ONTRAC3
MDU-G4
INTRODUCTION
The MDU-G4 mechanical drive unit is a high performance steering actuator designed to provide high
precision steering when coupled to a GPS automated steering system. The MDU-G4 was designed for
ease of installation, portability between vehicles and a long service life. The MDU-G4 uses a reliable
high torque DC motor and a robust and simple gear drive for fast and responsive steering under all field
steering conditions. The unique split gear design and quick-release latch makes for an easy installation
that does not require the removal of the steering wheel so you gain time and are also able to easily
transfer your OnTrac3 between vehicles.
This manual provides the basic information and overview of the installation procedure for installing the
MDU-G4 steering actuator on a vehicle. Read this manual prior to beginning the installation as this
manual provides the cautions and warnings that need to be recognized and understood prior to installing
or operating an OnTrac3 system.
This manual provides the instructions for the installation of the components that come with this OnTrac3
installation kit. The installation is broken down into specific sections that may refer to sub-kit assemblies
that are part of this kit. These sub-kits will come with their own instructions so refer to those when
directed for information on installing the sub-kit parts.
Prior to operating and installing the OnTrac3 system, be sure to read and understand the Steering
Controller Operator’s Manual that comes with the Steering Controller system. That manual provides the
instructions on how to operate the OnTrac3 system as well additional safety information.
LEGAL DISCLAIMER
Note: Read and follow ALL instructions in this manual carefully before installing or operating the
OnTrac3 system.
Note: Take careful note of the safety information in the Safety Information section of this manual
and the additional safety messages provided throughout this manual and any other supplemental
material provided.
The manufacturer disclaims any liability for damage or injury that results from the failure to follow the
instructions, cautions, and warnings set forth herein.
Please take special note of the following warnings:
1. There is NO obstacle avoidance system included with the manufacturer’s product. The owner must
always have a human present in the operator’s seat of the vehicle when the OnTrac3 system is in use to
look for obstacles including people, animals, trees, ditches, buildings, etc. and take control of the vehicle
to manually avoid them if necessary.
2. The OnTrac3 system does NOT control the speed of the vehicle. The operator must always adjust the
speed of the vehicle manually so that it is operated at a safe speed that will not cause the vehicle to roll
over or go out of control.

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3. The OnTrac3 system will take over control of the vehicle’s steering system when the OnTrac3 system
is activated during: Testing, calibration, tuning, and automatic steering operations. The vehicle’s steering
axles, tracks, articulation point, or wheels may move unpredictably when activated. Prior to starting the
vehicle and/or activating the OnTrac3 system, verify that all people and obstacles are clear of the vehicle
to prevent death, injury, or damage to property.
4. Use of the OnTrac3 system is NOT permitted while the vehicle is on public roads or in public areas.
Verify that the system is powered OFF before driving on roads or in public areas.
SAFETY INFORMATION
SAFETY INSTRUCTIONS
Read these safety instructions and the user's instructions thoroughly, and follow the instructions.
• Only an operator who is fully authorized to drive the tractor can make use of the OnTrac3 GPS Assisted
Steering System.
• The operator must not exceed the safe speed limit for the terrain it is operating on.
• An operator must always be conscious of his actions when operating theOnTrac3 GPS Assisted Steering
System.
• When installing the OnTrac3 Assisted Steering System do not force the components as this can result in
the components being damaged.
• Always follow the instructions in the installation; operation; and maintenance manual.
• Only an authorized party should install the OnTrac3 GPS Assisted Steering System.
• Always carry out an inventory of the components delivered to ensure all the correct components are
present. Never use replacement components. Only use original components.
• If there are any questions regarding the safe operation of the OnTrac3 GPS Assisted Steering System or
the instructions in the manuals do not hesitate to always contact the responsible expert.
• Always use the correct tools to install the OnTrac3 GPS Assisted Steering System.
• Caution must be taken when installing the OnTrac3 GPS Assisted Steering System to prevent injury.
• Do not use or operate the OnTrac3 GPS Assisted Steering System in unsafe weather conditions. Do not
use or operate the OnTrac3 GPS Assisted Steering System if the terrain is unsafe.
• It is not allowed for an unauthorized person to use or operate the OnTrac3 GPS Assisted Steering System.
• Before starting work activities, the operator must have sufficient knowledge of procedures how operate
the OnTrac3 GPS Assisted Steering System in a safe manner.
• When installing the OnTrac3 GPS Assisted Steering System, all safety precautions must be taken into
account and it should not be used if there are any parts loose, missing or damaged.
• Only an operator who has been trained or is experienced may operate the OnTrac3 GPS Assisted
Steering System.
• Before using the OnTrac3 GPS Assisted Steering System all functions must be checked and controlled
for their correct working order. When there is any doubt, do not take any risks always consult an expert.
• Before operating the OnTrac3GPS AssistedSteering System, control all functionsof the Presence Switch
and confirm the settings to ensure it functions correctly.
•Turningthe OnTrac3 GPS AssistedSteeringSystemonandoffmustalways happenconsciouslyfollowing
the correct prescribed procedures.

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• If an abnormal phenomenon presents itself, for example excessive vibrations noise, then immediately turn
off the OnTrac3 GPS Assisted Steering System and consult a responsible expert.
• When the OnTrac3 GPS Assisted Steering System is being cleaned or when maintenance takes place, it
must be totally turned off and free of any electrical currents.
• The operator of the OnTrac3 GPS Assisted Steering System must have complete knowledge about how
to react in case of emergency.
• A trained expert must always carry out maintenance or repairs on the OnTrac3 GPS Assisted Steering
System.
• During repair or replacement of components on the OnTrac3 GPS Assisted Steering System only original
components must be used.
• Always wear correct prescribed personal protection equipment during the use or cleaning or maintenance
of the OnTrac3 GPS Assisted Steering System.
• Always use the recommended cleaning materials and accessories when the OnTrac3 GPS Assisted
Steering System is cleaned.
• Every unsafe condition or situation on the OnTrac3 GPS Assisted Steering System must be reported to
the responsible persons.
• Do not leave or place objects on or in the area of the OnTrac3 GPS Assisted Steering System.
WARNING ALERTS
The OnTrac3 system installer and manufacturer disclaim any responsibility for damage or physical harm
caused by the 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: After the installation of the OnTrac3 system, verify that all the screws, bolts, nuts, and cable
connections are tight. Verify that all the cables have been secured to prevent them from being
damaged.
WARNING: To understand the potential hazards associated with the operation of a OnTrac3
equipped vehicle, read the provided documentation prior to installing or operating the OnTrac3
system.
WARNING: To prevent accidental death or injury from being run over by the vehicle or automated
motion of the steering system, never leave the vehicle’s operator seat with the OnTrac3 system
engaged.
WARNING: Movement ofthe Electronic Control Unit (ECU) relative to thevehicle may cause erratic
steering and sudden loss of vehicle control while in AutoSteer mode. Always keep the ECU firmly
secured to the vehicle. Do not operate your OnTrac3 system with a loose ECU.
WARNING: To prevent accidental death or injury from being run over by the vehicle verify that area
around the vehicle is clear of people and obstacles before startup, calibration, tuning, or use of the
OnTrac3 system.

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WARNING: To prevent the accidental engagement of the OnTrac3 system and loss of vehicle
control while driving on roads, turn the OnTrac3 power switch to the OFF position or remove the
OnTrac3 from the steering column. Never drive on roads or in public areas with the OnTrac3
system powered up.
WARNING:TheOnTrac3GPSAssistedSteering System issolelyintendedforagriculturaluse.The
systems should only be used with agricultural vehicles and should not be used with any other type
of vehicle or for any other purposes. Unapproved applications may result in loss of vehicle control
resulting in injury or death.
CAUTION ALERTS
The Steering system installer and manufacturer disclaim any responsibility for damage or physical harm
caused by the failure to adhere to the following safety requirements:
CAUTION: The OnTrac3 system does not detect obstacles in the vehicle’s path. The vehicle
operator must observe the path being driven and take over steering manually if an obstacle must
be avoided.
CAUTION: The OnTrac3 system does not control the speed of the vehicle. The operator must
manually adjust the speed of the vehicle to keep the vehicle safely under control.
CAUTION: Toavoidpossibledamageto electronic circuits causedbyelectrostaticdischarge,never
touch the contacts on the ECU electrical connectors at any time.
CAUTION: Make sure the assembly does not interfere with any of the vehicle control levers on the
steering column.
CAUTION: Make sure that the main gear race has properly engaged on the three rollers before
closing latch. If the race is not engaged properly, you risk damaging the OnTrac3 and steering
wheel while the OnTrac3 GPS Assisted Steering System is operating.
INSTALLATION REQUIREMENTS
STANDARD TOOL REQUIREMENTS
The installer is assumed to have a complete set of common installation tools including:
• 7/64'' Allen Wrench
• 5/32'' Allen Wrench
• 1/4'' Open Wrench
• 1/4'' Nut Driver
• Torque wrench 0 to 20 lbf-in (0 to 2 Nm), for 5/32'' hex bit
VEHICLE REQUIREMENTS
Prior to installing the OnTrac3 system, verify the following items on the vehicle:

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• The vehicles steering system is in good working order. Drive the vehicle to verify this prior to beginning
the installation. There should be no play in the steering and the vehicle should turn proportionally the
same to the left and right.
• The vehicle’s electrical system and battery must be in good working order.
• The vehicle should be fully cleaned before installing the OnTrac3 system. A clean vehicle will improve the
overall installation and cable routing
If any issues are discovered with the vehicle, they must be repaired prior to beginning the OnTrac3
installation by a qualified service person for the vehicle.
Note: This installation manual, vehicle specific installation manuals, and sub-kit manuals contains
valuable information for servicing the OnTrac3 system. After the installation is complete, store all of
these manuals in a safe place for future reference.
TECHNICAL SUPPORT
Contact your Ag Leader Dealer or Ag Leader Technology for technical support.
Telephone: [phone]
Email: [email protected]
VEHICLE INSPECTION
Prior to installing the OnTrac3 system, confirm that the vehicle and the vehicle’s steering system are in
good working order by driving it around. In addition, verify the following items:
• Verify that you can turn the steered wheels from lock to lock.
• Record the time it takes to turnthe vehicle’s steering mechanism (ex.steering axle, articulationpoint) from
full left to full right and then record the time to go from full right to full left as fast as you can manually.
This will be used later to ensure steering performance is okay.
• Verify the vehicle steers straight and does not pull to one side when driving in a straight line.
• Verify that there are no oil leaks.
• Check for loose or worn steering components.
If any part of the vehicle is not in working order, have the system serviced by a qualified technician prior
to beginning the OnTrac3 installation procedure.

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COMPONENTS
SUPPORTED MODELS
These instructions provide the suggested procedure for installing the OnTrac3 system on qualified
vehicles for the easiest installation and best performance. This product is compatible with most vehicles
with a three spoke steering wheel with hydrostatic power steering.
Note: The installer can install the AutoSteer system differently than how the manufacturer suggests;
however the components that are called out in this manual may not fit properly or the lengths of
cables may not be long enough with alternative mounting solutions. If the installer modifies the
installation procedure, it is the responsibility of the installer to ensure all the components will work and
that any component with specific orientation and mounting requirements are met.
ONTRAC3 MAIN HARDWARE KIT
This section describes the components required for a typical installation. The installation kit is organized
into a main kit that contains a “switch kit” subassembly. The Switch Kit contains the hardware that
enables you to switch the OnTrac3 system between vehicles
The sub-kits that are required for the installation of the OnTrac3 system are provided in this section. Use
this section to verify that all the sub-kits and parts required for the installation are available.
Note: All part numbers provided in this manual are subject to change without notice. They are
provided as a reference at the time of this writing. Always verify that the part numbers are still valid
from your AutoSteer dealer if spare parts need to be ordered.
MDU-G4 SWITCH KIT
The Switch Kit components enable the operator to move the OnTrac3
between vehicles.
Note: An anti-rotation bracket that fits your vehicle steering column is required tocomplete the MDU-
G4 installation. This bracket varies by vehicle model and must be purchased separately. Contact
your OnTrac3 dealer for a list of supported vehicles and available bracket kits.

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C
OMPONENTS
Item Component Part Number
1 MDU-G4 4100971
2 Steering Wheel (Switch) kit 126-0041-01
3 Anti-Rotation Pin, assembly 200-0752-01
4 Installation Guide MDU-G4 602-0546-01
5 Operator’s Manual OnTrac3 602-0559-01
6 OnTrac3 Control Unit 4100970
7 MDU-G4 Harness 201-0603-01
8 OnTrac3 Control Unit Harness 201-0605-01
9 OnTrac3 Control Unit Bracket 200-0627-02

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ONTRAC3 INSTALLATION
MDU-G4 INSTALLATION PROCEDURE
Refer to Installation Kit Components in the Components section to identify the parts used in this section.
INSTALL THE MAIN GEAR ON THE STEERING WHEEL
The goal of this section is the installation of the main gear on the steering wheel. A completed installation
is shown in
Through the use of switch kits, main gears can be installed and left on multiple vehicles allowing the user
to move the MDU-G4
Install the Main Gear around the Steering Column
1. Remove the 2 hex screws from the Smaller
section of the Main Gear.
2. Remove the Smaller section by pulling
downwards.
Note: Tolerances are tight, pull directly downwards on the smaller section.

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3. Install the larger section under the
steering wheel around the steering
column.Installwith the gearsideonthetop
side, closest to the steering wheel.
Note: Weave the gear around the steering wheel spokes if necessary, certain columns may be too
thick for the gear opening.
4. Reinstall the smaller section using care to push directly upwards on the sector, this is a very tight fit.
Note: To facilitate the fit between the two gear sections, you may need to apply a drop of oil to assist
in aligning the two gear sections.
5. Reinstall and secure the 2 hex screws. At this point the main gear is assembled around the steering
column below the steering wheel. The gear is free to move around and must now be clamped to the
steering wheel.
Examine Steering Column and Steering wheel
Examine the steering wheel underside to determine if a spacer is necessary. A steering wheel with a soft
covering material usually requires installation of a spacer to avoid interference with the MDU-G4
housing. Flat steering wheels also require the addition of a spacer to prevent interference between the
steering wheel and MDU-G4 when the wheel is turned.

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Install Spacer (If Needed)
Install the spacer around the steering column
between the steering wheel and the main gear. Flex
the plastic spacer as needed to clear the steering
wheel spokes. The large chamfer on the outside
diameter of the spacer ring should be facing the main
gear..
Note: Two spacers with different thicknesses are included in the kit. Select the thinnest spacer that
provides the sufficient clearance between the steering wheel and the MDU-G4
Install the Top Ring
1. The gear is free to move around and must be now clamped to the steering wheel. This procedure will
install and center the ring gear for typical 3 spoke shaped steering wheels.
2. Place the top ring on top of the steering wheel and install a minimum of 6 hex screws. Install a screw
on each side of every spoke keeping the screws as close to the spokes as possible. At this stage keep
the screws fairly loose to allow for centering.
Note: Two lengths of screws are provided in the kit to support different thicknesses of the steering
wheel spokes. Select the shorter of the two screws that still provides full thread engagement.

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3. With the main gear clamped loosely, rotate and
move the gear until 3 screws touch the three
spokes evenly. Rotate the main gear counter-
clockwise until three of the mounting screws touch
the steering wheel spokes evenly. This procedure
will help to automatically centerthe gear under the
steering wheel.
4. Check the installation by rotating the steering
wheel and watching for off-center movement of the
main gear. Repeat the centering process as
necessary.
5. Tighten the screws with an Allen key. Torque to
6 in-lb (0.7 Nm). Tighten the screws in a cross-
pattern (as opposed to tightening each screw in a
clockwise or counter-clockwise order).
Note: Do not over-tighten the top ring screws. This may cause the ring gear to warp or damage the
steering wheel spokes.
6. Check the installation again after tightening by rotating the steering wheel and watching for off-center
movement of the main gear. Repeat the centering process as necessary.

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7. Snap the plastic cover over the top ring.
Attach the Anti-Rotation Pin 1. Choose the desired MDU-G4 orientation.
The MDU-G4 can be mounted in any
orientation the user chooses. Consider the
following when choosing an orientation:
•Ease of installing anti-rotation bracket.
•Access to the Power Switch.
•Avoid locations where a knee could
accidently press the power switch.
•Avoid blocking the vehicle's steering
column controls and indicators.
•Cable routing with minimal obstruction in
the cab.
2. Based on your preferred orientation,
choose one of three locations for the Anti-
rotation Pin.

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Assemble the anti-rotation pin by inserting the long screw
through the metal sleeve provided.
Install the anti-rotation pin under the MDU-G4 in one of
the three positions and tighten to 100 in.lbs (11.3 Nm)
using the 3/16” hex key (Allen key) provided.
Note: The anti-rotation pin must always be kept tight to avoid breakage or separation. Periodically
check the anti-rotation pin and confirm that it is tight. Always tighten to the specified torque.
Install the MDU-G4 This procedure describes the installation of the MDU-G4 to the
Main Gear
1. Open the MDU-G4 release latch.
2. Fit the MDU-G4 around the Main Gear so that the three
MDU-G4 rollers align on the Main Gear race.
Note: The plastic cover on the MDU-G4 canbe used as a guide to fit the bottomportion of the MDU-
G4 to the V-rollers

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3. Ensure that the main gear race has properly
engaged the three rollers before closing latch.
4. Rotate the MDU-G4 manually to ensure
smooth rolling operation.
UNIVERSAL BRACKET INSTALLATION
The universal anti-rotation bracket is provided with the OnTrac3 kit. It should be used for vehicles that
are not supported with a custom vehicle-specific bracket. Consult your OnTrac3 dealer for a list of all
available anti-rotation brackets. An Anti-rotation bracket is required to complete the MDU-G4 installation.
Note: A different bracket may be required depending on your specific vehicle. Contact your
AutoSteer dealer for details
Note: If you are installing a vehicle specific anti-rotation bracket, skip this section and refer to the
instruction manual provided with your vehicle specific anti-rotation bracket kit.
UNIVERSAL BRACKET INSTALLATION KIT
OVERVIEW
To complete your MDU-G4 installation and prevent the rotation of the MDU-G4, an anti-rotation bracket
must be mounted to the vehicle steering column just below the steering wheel. This chapter provides
instructions for installing a universal bracket kit that is available as an accessory through your dealer.
The typical universal bracket kit includes the following components:

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UNIVERSAL BRACKET INSTALLATION PROCEDURE
Note: Note: The MDU-G4 is attached to the steering wheel prior to installation of the bracket kit.
Item Component Part Number Qty
1 Flange Bearing 522-0001-01 1
2 Fifth Wheel Slider 203-0218-01 1
3 Front Bracket 202-0216-01 1
4 Back Bracket (‘V’ shape) 202-0232-01 1
5Clamping screws. Machine Screw Phillips 1/4 - 20 x 4" (Washers, Lock
Washers and Nuts) 514-0088-01 4
6Bolts 5/16 -18 x 3/4" (Slider
Attaching Bolts) 512-0029-01 2

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1. Make sure that you have all of the required parts.
2. Attach front bracket to the fifth wheel slider bracket
using the two bolts (slider attaching bolts). See Figure 32
Tighten finger tight.
Note: The slider bracket will require adjustment once installed on the steering column.
3. Place the flange bearing assembly over anti-rotation
pin.
Note: It is important that the anti-rotation pin is placed through the flange bearing before attaching
the Fifth Wheel Bracket
4. Attachthe backbracketto thefront bracket usingthe
four machine screws clamping the steering column
between the front and back brackets.