On-the-Go Yield Measurement On-the-Go Moisture Measurement Mapping and GPS Combine Compatibility Reference Manual

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2 On-the-Go Yield Measurement On-the-Go Moisture Measurement Mapping and GPS Combine Compatibility Reference Manual By purchasing a Grain-Trak on-the-go yield and moisture monitor, you have taken a major step toward better farm management by gathering the information required to make more informed decisions about your operation. The single most important step you can take to ensure smooth operation of your system is to take the time to read and fully understand the user manual. Please read the entire manual before beginning installation. If you have any questions during installation or operation of your Grain-Trak system please contact your dealer, or contact Micro- Trak at one of the numbers listed at the bottom of this page. Micro-Trak Systems Inc. is committed to one goal - to listen and respond to the needs of its customers. With the finest service support in the industry, you can be confident that you will receive the help you need to get your system up and running as quickly and smoothly as possible. Please take a few minutes now to complete and return the warranty registration card(s) for this system. Having your registration card(s) on file puts you on Micro-Trak s preferred customer list which entitles you to valuable technical support and other important information from Micro-Trak. Without your registration card(s) on file, it is difficult to provide you with timely information on important changes, updates, enhancements and new products. Please send your warranty registration card(s) in today. See the following page for important warranty information. (800) (507) Fax: trakmail@micro-trak.com P.O. Box East LeRay Avenue Eagle Lake, MN Copyright Micro-Trak Systems, Inc. Printed in the U.S.A. 2

3 Micro-Trak Warranty Micro-Trak (herein Seller ) warrants to the original purchaser (herein Buyer ) that, if any product or part of the product (herein part ) proves to be defective in material or workmanship, upon inspection and examination by Seller, within one (1) year from the original date-of-purchase, and is returned to Seller with dated proof-of-purchase, transportation prepaid, within thirty (30) days after such defect is discovered, Seller will, at their option and sole discretion, either repair or replace said part, except that the warranty for expendable parts, including but not limited to, light bulbs and batteries shall be thirty (30) days from the original date-of-purchase. Said warranty is valid only when the part has been installed, operated and maintained in strict accordance with the procedures outlined in the manual. Any damage or failure to said part resulting from abuse, misuse, neglect, accidental or improper installation or maintenance, unauthorized modification, use with other products or attributable to acts of God, as determined solely by the Seller, will invalidate the warranty. Said part will not be considered defective if it substantially fulfills the performance specification. Buyer shall be responsible for all maintenance services, if any, all in strict accordance with the procedures outlined in the manual. The warranty does not include labor, installation, replacement parts or repairs, delivery of replacement parts or repairs or time and travel. Said warranty is nontransferable. The foregoing warranty is exclusive and in lieu of all other warranties of merchantability, fitness for purpose and of any other type, whether express or implied. The Seller s liability, whether in contract, in tort, under any warranty, in negligence or otherwise, shall not exceed the return of the amount of the purchase price paid by the Buyer, and under no circumstance shall the Seller be liable for special, indirect or consequential damages. Seller neither assumes nor authorizes anyone to assume for it any other obligation or liability in connection with said part. No action, regardless of form, arising out of the transactions under this agreement may be brought by the Buyer more than one (1) year after the cause of action has occurred. Seller agrees to extend the term of the foregoing warranty period should the Buyer return completed warranty registration information, with dated proof-of-purchase, to the Seller within one (1) year from the original date-of-purchase. All conditions and limitations of said foregoing warranty, except the term of said foregoing warranty, shall apply. Said term shall be extended to a total of three (3) years from the original date-of purchase on display consoles and network communication modules, as defined by Seller, and said term shall be extended to a total of two (2) years from the original date-of-purchase on all other parts, except that the warranty for expendable parts, including but not limited to, light bulbs and batteries shall be thirty (30) days from the original date-of-purchase, and except that the warranty for parts manufactured by someone other than the Seller, including but not limited to, shut-off and control valves, DGPS receivers, memory cards and drives, mapping software, flowmeters and pressure sensors shall be one (1) year from the original date-of-purchase. Units under warranty should be sent prepaid, with dated proof-of-purchase, within 30 days of discovering defect, to the address below: MAIL and UPS: Micro-Trak Systems, Inc. Attn: Service Department P.O. Box East LeRay Avenue Eagle Lake, MN Extended Warranty Option It s simple! Just complete the registration for this product ONLINE at and we ll extend your warranty for up to three years*, at no additional charge. Registration information is for internal use only. * Some limitations apply. See warranty statement for details. At Micro-Trak Systems, we believe a product that delivers quality and performance at a low cost is what is needed to help today s operator and the operator of the future compete in the world mar ket. It is our goal to provide operators with a line of electronic equipment that will help build and maintain an efficient and profitable operation that can be passed on to future generations. We thank you for your purchase and hope that we can be of service to you in the future. Micro-Trak Systems, Inc. 3

4 Table of Contents Warranty... 3 Table of Contents... 4 Location of Serial and Version Numbers... 5 Grain-Trak Parts List Grain-Trak Parts List - OPTIONAL... 8 Installation Required Tools...9 Mounting the Display Console...10 Console Wiring...11 Power Cable/Electrical Installation...12 TNgs100 Module Installation...13 Magnetic Speed Sensor Installation...14 Range Remote Run/Hold Kit Installation Grain Flow Sensor Installation...17 IH Combines Models 1440, 1460, Models 1600 (All Models) and 2100 Series w/o Removable Inspection Door Case/IH Combines...23 Models 2100 Series with Removable Inspection Door...23 John Deere Combines Models 6620, 7720, 8820, 9400, 9500, Models 4400, 660, Gleaner Combines Models L2, M2, N5, N6, N7, R40, R50, R60, R70, R42, R52, R62, R Ford New Holland Combines...30 Models TR75, TR85, TR86, TR95, TR96, TR97, TR Cable Connection at the Grain Flow Sensor...31 DMC Moisture Sensor Kit Installation...32 Moisture Sensor Installation Template...33 All Calibration Purpose...34 Grain-Trak Display Console...35 Entering Calibration Values Conversion Table...37 Calibration Help Sheet Abbreviated (Abr) Calibration Selecting Base Abr Calibration Mode...52 Entering Calibration Values...52 Base Abr Calibration Steps Selecting Moisture Abr Calibration Mode...58 Entering Calibration Values...58 Moisture Abr Calibration Selecting Card Abr Calibration Mode...61 Entering Calibration Values...61 Card Abr Calibration Display Screens...62 Memory Card Recording Table...63 Operation Operation Display...64 Description of Displayed Information Zeroing Counters Purpose...69 Selecting the Counter Zeroing Mode...70 Console Zeroing Display Screens...71 Troubleshooting Care and Maintenance...72 General Console Error Messages Appendices Appendix A: Replacement Parts List...79 Appendix B: Installation Templates Appendix C: Conversion Tables...82 Appendix D: Fine-Tuning Wheel Circumference Value...83 Appendix E: Fine-Tuning Moisture Sensor Calibration Value...84 Appendix F: Fine-Tuning Grain Flow Sensor Calibration Value...85 Appendix G: Grain Flow Sensor Load Cell Replacement Procedure Appendix H: Grain-Trak Display Console...88 Appendix I: Record Formats

5 Location of Serial and Version Numbers Grain-Trak TNv440 Console Serial and version numbers for the Grain-Trak console are printed on decals attached to the back side of the console. Back of Console Patent Number Version Number Serial Number Model Number TNgs10 Module Serial and version numbers for the TNgs100 module are printed on decals attached to the top of the module. To of Module Serial Number Version Number Model number and Plug Connection Diagram CGS 10 Grain Flow Sensor The serial number for the grain flow sensor is printed on the decal attached to the load cell bar. Serial Number 5

6 Grain-Trak Parts List Grain-Trak Display Console (boxed separately) Console Mounting and Hardware Kit (poly bag) Grain Trak Console (1) Ground Wire (1) Mount Bracket and (2) Adjustable Console Knobs Cable Ties (10) TNgs 100 Grain Sensor Input Module (1) Hardware Bag Magnetic Speed Sensor Kit (poly bag) U Mounting Bracket (1) 4-pin 10 ft. (3m) Extension Cable Power Cable (poly bag) Cable Ties (5) Speed Sensor Bracket Grain-Trak Power Cable (1) Hardware Bag Magnets (2) 2 Amp Fuse Terminals & Fuse Holder (1) 3-pin 5 ft. (1.5m) Extension Cable 6

7 Grain-Trak Parts List (cont) CGS 300 Flow Sensor Kit Range Remote Run/Hold Kit (poly bay) Cable Ties (5) (1) Hardware Bag (2) Magnets w/foam Tape (2) Hairpin Cotter Fasteners Assorted Fasteners Cable Ties (20) Flow Sensor Mount Brackets available for (1) Hardware Bag John Deere , 9500, 9600 John Deere , 7720, 8820 Case/IH and 2100 Series IH , 1460, 1480 Ford/New Holland - TR 75, TR 85, TR 86 Ford/New Holland - TR 95, TR 96, TR 97, TR 98 Gleaner - All Models Universal Kit (Fits most other makes and models) (1) 5 ft. (1.5m) Remote Run/Hold Cable (1) 2-pin 5 ft. (1.5m) Extension Cable Remote Run/Hold Bracket (unassembled) 7

8 Optional Grain-Trak Parts List MS-100 Moisture Sensor Kit Radar Interface Kits with Y Cable DICKEY -John (Amp, Packard, Cannon and Ford) Magnavox Raven TRW Moisture Sensor Extender Brackets (2) Mounting Hardware Hose Clamps (3) Cable Ties (10) Suction Cup Console Mounting Kit Suction Cup Base Plate Adapter Plate Mounting Hardware 8

9 Installation Required Tools Installation of your CALC-AN-ACRE is basically a three-step pro ce dure. Each installation will vary somewhat, de pend ing on your type of equip ment. Allowances for these differences have been made through the de sign of flex i ble mount ing brackets and extra hard ware. Homemade 12-Volt Test Light Solder wires approximately 12 (.30 meters) long to casing and base of bulb. When testing for 12 volts touch casing wire to equipment frame. Tools Needed to Install MT-2400 Screwdrivers Pliers Set of Wrenches Wire Cutter Electric Drill and Bits Hacksaw 12-Volt Test Light Center Punch Bench Vise Hammer Torch Tape Measure Scissors Rivet Gun Sabre Saw w/metal Blade MT-101 Tester 12-volt Bulb GE 53 or equivalent 9

10 Installation (cont) Mounting the Display Console Installation of the Grain-Trak console may vary from combine to combine. When selecting an installation area, the location is very important. The console should be installed in an area that affords the most workable situation. It should be convenient to reach and highly visible to the operator. Do not install the console in a location that obstructs the view of the road or work area. Whenever possible, avoid locations that expose the console to direct sunlight, high temperatures or rain. After selecting the general location, install the U mounting bracket with the bolts provided to an area that will sufficiently support the console. Insert the console mount bracket into the U bracket. Install the carriage bolts from inside the console mount bracket through the console mount bracket, rubber washers and the U bracket. Install the mount knobs. Position the console over the alignment posts and push it firmly into the mounting assembly. The DualLock fasteners should snap together. Insert the mount into the brackets and screw the console adjustment knobs into place. Note: Micro-Trak offers a suction cup console mounting kit as optional equipment (see Optional Parts under the Grain-Trak Parts List). This kit provides an easy installation for the Grain-Trak console on the windshield or side window of the cab. If you are having difficulty finding a clean installation for the console, the suction cup kit is a quick, simple and versatile solution. Contact Micro-Trak for pricing and availability. Console Mount Bracket Angle Adjustment Knobs U Mounting Brackets Drill ¼ (7mm) holes for bolts, or 3/16 (5mm) holes for selftapping screws. Bolts Lockwashers and nuts U Mounting Brackets (side view) For best visibility, the bracket should be mounted and adjusted so that the console readout can be viewed at a slight angle. Line of Sight Console Alignment Posts Note: Some systems may use two L brackets in place of the U bracket for console mounting. U Mounting Bracket 10

11 Installation (cont) Console Wiring Make a ground wire approximately 8 long from the blue auxiliary wire provided. Strip the insulation from both ends of the wire. Attach a ring terminal on one end of the wire and a spade terminal on the other end. Attach a ring terminal end of the ground wire to the vehicle s chassis with a self-tapping screw (make sure there is good metal-to-metal contact). Attach the spade terminal end of the ground wire to one of the grounding tabs on the back of the console. Attach the console s ground wire to the other grounding tab. This ground helps protect the console from electrical interference from cellular phones, two-way radios, etc. NOTE: Extra mounting hardware (two nuts and two bolts) has been added to this mount kit for additional consoles to be horizontally mounted to the Grain-Trak. Grain-Trak Display Console Shroud Tower DualLock Fasteners I/O Cable to TNgs 100 Module or Data-Trak Console Ignition Power Cable Mutiple Console Mounting Holes (Two on each Side of Bracket) Grounding Tabs.250 Isulated Female Spade Connector * See Data-Trak Reference Manual for details. 11

12 Installation (cont) Power Cable/Electrical Installation Power for the system is typically plugged in at the I/O tower connector on the back of the console bracket. Plug the power cable into the left I/O tower connector on the console bracket and cut the connector off of the other end of the power cable. This end becomes a terminating connector and should be installed in the unused I/O shroud connector on the TNgs 10 module. Cut the wires off as close to the terminating connector as possible. DO NOT tape the wires together. This will short out the console. The Grain-Trak must be connected to a 12-volt DC electrical system. Using your test light, locate a terminal or wire connected to your ignition switch which is hot when the key is turned on and dead when the key is turned off. A 2 AMP fuse is included with the power cable provided. Strip the insulation from end of the power cables red and black wires and crimp on the terminals provided. Attach the RED lead of the power cable to the 12-volt HOT terminal. Attach the BLACK lead (ground) to a screw in the chassis. Be sure there is good metal-to-metal contact. Secure any cables with the cable ties provided. Power for the system may also be plugged in at the I/O shroud connector on the TNgs10 module. Follow the same instructions as listed above, except plug the terminating connector into the unused I/O tower connector on the console bracket. Ground Screw Ignition Switch or Terminal Controlled by Ignition Switch Power Cable Black red 12 Volt DC when Ignition is Turned On 2 Amp In-line Fuse (required for unprotected circuits) NOTE: Your Grain-Trak console is equipped with a nonvolatile memory that, unlike some systems, does not require a steady supply of electricity to retain daily totals and calibration values. The advantage of this type of memory is that it will not discharge your vehicle s battery. Use ONLY on 12-volt DC negative ground systems 12

13 Installation (cont) TNgs100 Module Installation The TNgs100 module serves as the central processor and connecting point of the system s sensors. The grain flow sensor, moisture sensor, speed sensor and remote run/hold sensor all plug into the module. All information from these sensors is processed by the TNgs100 module and sent to the console for display. The module is typically installed outside the cab. A single cable connects the module to the console. When mounting the TNgs10 module, select an easily accessible area away from excessive heat and moving parts. Generally, a location on the right-hand side of the cab is the most convenient. The module is mounted to an area under the cab with Dual Lock TM fasteners. Additional cables ties are provided to secure the module in place. After you have determined the best location for your installation, use rubber alcohol or other solvent to thoroughly clean the surface of dirt, oil and grease. Remove the backing from the Dual Lock TM fasteners on the module. Press the module firmly onto the mounting surface. Install a self-tapping screw in the frame close to the module to serve as a ground. Cut the blue ground wire on the module to the required length. Strip the insulation from the end of the ground wire attached to the module and crimp on a ring terminal. Attach the ground wire to the ground screw on the frame. Make certain that there is a good metal-to-metal contact. This ground helps protect the system from electrical interference from cellular phones, 2-way radios, etc. Route the 10 ft. (3m) 4-pin square extension cable between the console and the module. On most combines, there is an access panel on the right-hand side of the cab to route the cable from the module and the I/O shroud connector on the console. Press the module firmly into place on a flat, clean surface. Frame Ground Under the Cab Mount Side Mount 13

14 Installation (cont) Magnetic Speed Sensor Installation Most of the primary functions of Grain-Trak are based on pulses received from the magnetic speed sensor. Determine the best location for the magnet on the combine s drive shaft. This should be a location where the sensor bracket Cable Tie or Non-magnetic Hose Clamp (not provided) Drive Shaft If a Clamp is Used, Place the Adjusting Screw Between the Magnets. can be easily installed. The drive shaft on the right-hand side of the combine works well for most installations and keeps cable lengths at a minimum. Magnet - Long Dimension in Direction or Rotation 1 or 2 Magnets Sensor Magnet - Long Dimension in Direction or Rotation 3/8 Locking Nuts Speed Sensor on Drive Shaft L Bracket ¼ to ½ (6-13 mm) Space Attach the Bracket to the Frame with Bolts, self-tapping screws or hose clamps (not provided) Securing Cable Ties Lock Using rubbing alcohol or other solvent, thoroughly clean the area on the drive shaft where the magnets will be installed, so that it is free of dirt, oil and grease residue. Position the magnets on the drive shaft exactly opposite each other with the long dimension of the magnets in the direction of rotation. NOTE: If the magnets are not spaced evenly, the speed readings may be erratic. Secure magnets in place with a plastic cable tie. When you are certain that the magnets are placed evenly, you may use an epoxy type glue or a layer of nonmagnetic tape to help prevent the magnets from being dislodged by filed residue. Install the speed sensor L bracket securely to the frame with the screws provided and position it so that one of the large holes aligns with the magnets on the drive shaft. To install the speed sensor cable, first turn one locking nut onto the sensor. Then insert the sensor into the selected large hole on the bracket and turn on the remaining locking nut. Adjust both nuts to set the spacing between the end of the sensor and the magnet between ¼ and ½ (6-13 mm). When the distance is set, turn both lock nuts tight to hold the sensor in place. DO NOT over-tighten. Route the speed sensor cable to the TNgs100 module and connect it to the speed connector on the module. Avoid areas of high heat and areas with moving parts. A 5 ft. (1.5m) 3-pin extension cable is provided if more length is required to reach the module. Install the yellow cable ties provided with the extension cable on each end of the cable to maintain color code. Secure the cable with the cable ties provided. 14

15 Installation (cont) Range Remote Run/Hold Kit Installation In addition to the manual run/hold switch on the console, the system is equipped with a Range Remote Run/Hold Kit. This standard feature will automatically stop the area and distance counting functions when the combine platform is raised. It eliminates the need to manually flip the switch on the console, providing hands-free operation of the system when making turns and moving between fields. The hinged bracket and sensor/magnet assembly install under the cab. A spring connected to a length of chain attaches between the feeder housing and the end of the hinged bracket. The basic idea is that when the platform is lowered, the sensor is moving away from the magnet. When the sensor is moving away from the magnet, the system automatically engages in RUN status, activating distance and area counting. When the platform is raised, the sensor becomes aligned with the magnet automatically, putting the system in HOLD status, and stopping distance and area counting. For detailed assembly procedures of the range run/hold bracket, see the instruction sheet included with the kit. Remote Run/Hold (hinged) Bracket Installation Area Magnet Remote Sensor on End of Bracket Chain Combine s Feeder Housing 15

16 Installation (cont) Range Remote Run/Hold Kit Installation (cont) Install the assembled hinged bracket under the right-hand side of the cab with the screws provided. The long arm of the hinged bracket should be pointing toward the header. The end of the arm should align with a flat area under the cab for the magnet to mount on. Install the remote sensor at the end of the hinged bracketing up at the bottom of the cab. Install the magnet directly above the remote sensor to the underside of the cab. Route the remote sensor cable to the TNgs100 module and connect it to the run/hold connector on the module. Avoid areas od high heat and areas with moving parts. A 5 ft. (1.5m) 2-pin extension cable is provided if extra cable length is required. Secure the cable with the cable ties provided. The chain bracket should be installed slightly in from (toward the pivot point of the feeder housing) or directly below the sensor end of the hinged bracket. DO NOT install it to an area on the feeder housing that extends past the end of the hinged bracket. Raise the header to the height that should activate the automatic HOLD status during operation in the field or transporting between fields. Mark the area on the feeder housing where the chain bracket will be installed (typically 8-24 from the pivot point of the feeder housing). Install the chain bracket with the screws provided. With the header raised to the HOLD height, attach the spring to the sensor end of the hinged bracket, and connect the chain to the spring. Lower the header to its operational height. Check that the hinged bracket is moved past its normal traveling range. NOTE: In hilly conditions, the header may be lowered well beyond the normal operating level as the combine moves over the top of a hill. Make certain to allow for additional extension of the hinged bracket, spring and chain. Range Run/Hold Bracket with Sensor Installed Mount Under the Combine Cab Route the Sensor Cable to the 2-pin Extension Cable connected to the module Mount to the Feeder Housing Chain Bracket Chain Install the Sensor at the End of the Bracket Spring This illustration shows the platform in both the lower and raised positions. The chain length may be adjusted to account for changing field conditions and different operating heights associated with the interchanging of heads on the machine. IMPORTANT: When using this feature, be sure to place the manual run/hold switch on the console in the RUN position. RUN HOLD 16

17 Installation (cont) Grain Flow Sensor Installation Use extra care when opening the package. The system has been packaged to protect the grain flow sensor from damage in shipment. If any part of the system appears to be damaged, contact a Micro-Trak technician immediately for a replacement component and return shipping instructions. CAUTION: DO NOT flex the grain flow sensor forks prior to installing the sensor in the top of the clean grain elevator. Exerting abnormal pressure ion the sensor forks may stress (stretch) the sensor bar, resulting in failure of the sensor. The patented grain flow sensor measures the mass through the top of the clean grain elevator into the flow of the grain. As grain moves past the forks from the clean grain elevators to the bin loading auger, a force is applied to the sensor. As force is applied to the sensor, a frequency is generated and sent to the module. The module processes this frequency, based on the flow calibration value (See Appendix E, Finetuning Flow Sensor Values) and sends it to the console to display yield information. When yield changes in the filed, the flow of grain (mass) through the combine also changes, which in turn changes the force being applied to the flow sensor. This is how the console displays your changing yields, on-the-go. The grain flow sensor mounts in the top of the clean grain elevator of the combine and will fit most makes and models. On the following pages you will fins installation guidelines and recommendations for specific makes and models of combines. If your particular make and model of combine is not listed, contact a Micro-Trak technician for assistance with the grain flow sensor installation. DO NOT attempt installation without assistance from our technical staff. Elevator Adjustment For optimum grain flow sensor accuracy, adjust your combine s clean grain elevator chain so the gap between the paddles and the top of the elevator is within ½ inch to 1½ inches. Although these distances are approximate, you will get the most accurate readings if the distance is as close as possible to ½ inch. Depending on the length of your elevator chain, you may need to add half or full links to the chain to achieve proper chain adjustment. Although every combine is different, generally each full link added to the elevator chain will allow approximately ½ inch additional travel to the chain tightener. DO NOT place all of the new links in the same paddle section. Maintaining even paddle spacing will prevent gaps in grain flow, and promote greater flow sensor accuracy. As always, follow the combine manufacturer s recommendations for proper chain tension and routine adjustments. Clean Grain Elevator Chain Paddle Sprocket Full Link Grain Flow Sensor Sensor Forks ½ inch to 1½ inch Clearance Half Link NOTE: Maintain even spacing between paddles. 17

18 Installation (cont) IH Combines Models 1440, 1460, 1480 On the models listed above, there is a factory installed inspection door located at the top of the clean grain elevator that is used for sensor installation. On all 1400 series combines, the top of the clean grain elevator is located inside the grain bin on the right-hand side. Access to the inspection door is from inside the grain bin on the top of the machine. NOTE: If the mount bracket DOES NOT look or fit the same as the original equipment door, contact a Micro-Trak technician to determine if you have the correct flow sensor installation kit. All 1400 series IH combines use the same inspection door at the to of the clean grain elevator. A mount bracket that duplicates and replaces the original inspection door is included with the kit Series - ALL Models Mount Bracket After completing installation of the mount bracket and flow sensor, route the flow sensor cable to the TNgs100 module. Route the cable away from moving parts and components that generate high heat. Also, route the cable as far away as possible from two-way radio and cellular phone antennas and their associated antenna cables. Plug the cable into the flow connector on the module. Tie back any excess cable and secure it away from moving parts, areas that generate high heat and two-way radio and cellular phone antennas and cables. Cut the BLUE ground wire attached to the flow sensor cable to the length required to reach the frame ground screws used for the module s ground wire. Strip the insulation from the end of the ground wire and crimp on a ring terminal. Attach the ground wire to the ground on the frame (this is the same screw used for the module s ground wire). Make certain that there is good Metal-to-metal contact. This ground helps protect the flow sensor from electrical interference from cellular phones, two-way radios, etc. Routing the cable inside or under metal body parts may provide additional protection from electrical interference. If the combine is equipped with grain tank extensions, make certain that the flow sensor cable is not pinched between the extension and the top of the grain tank. If the extensions fold up and down, make sure that the flow sensor does not became pinched or cut when the extension fold. Simply remove the factory installed inspection door and install the flow sensor mount bracket in its place. Insert the flow sensor onto the mount bracket and secure it with the four bolts on the bottom of the sensor housing. Make sure to position the sensor so that the urethane coating on the front of the sensor forks and deflector plate faces into the flow of grain (NOTE: The flow direction decals on the sensor housing and mount brackets). No extra installation hardware is required. 18

19 Installation (cont) IH Combines (cont) Models 1600 (ALL Models) and 2100 Series (Models WITHOUT Removable Inspection Door) On 1600 series models, models with serial numbers 172,844 and below, model with serial numbers 179,999 and below and models with serial numbers 191, 482 and below there is not an inspection door located at the top of the clean grain elevator to use for sensor installation. However, the grain flow sensor still needs to be installed in that area. Some custom fabrication to the top of the clean grain elevator is required. Access to the top of the elevator is from inside the grain bin on the top of the machine. An access holes heeds to be cut in the elevator and the universal bracket installed over the access hole. Pictured below is an illustration of the template used to mark the cutout area for the access hole. DO NOT use the one on this page. Remove the CASE/IH Access Hole Template located in Appendix B at the back of this manual for use during installation. Side A Case/IH Side D ACCESS HOLE Template FOR ILLUSTRATION USE ONLY Side C Side B 19

20 Installation (cont) IH Combines (cont) Models 1600 (ALL Models) and 2100 Series (Models WITHOUT Removable Inspection Door) (cont) NOTE: Models 1680, 1688 and 2188 Case/IH combines have wider clean grain elevators than other 1600 and 2100 series models (the access hole must be cut in a different location). Positioning Access Hole Template for Case/IH Models 1640, 1660, 1644, 1666, 2144 and 2166 Locate the Case/IH Access Hole Template in Appendix B and remove it by cutting along the solid lines. Place the template on your combine s clean grain elevator as shown below. Position the template so that side A is ½ (12mm) from the top bracket on the elevator. Side D should be positioned approximately 2 1/8 (54mm) from the edge of the elevator wall. (centered between the alignment bolts). Trace around the outside of the template (this will be your cut line). Position Side D Approx. 2 1/8 from the Left End of the Cross Member (Center Between the Alignment Bolts) Alignment Bolts Top Bracket Side D Side A Place Case/IH ACCESS HOLE Template Here Side B Position the Top of the Template ½ Below the Top Bracket Side C 20

21 Installation (cont) IH Combines (cont) Models 1600 (ALL Models) and 2100 Series (Models WITHOUT Removable Inspection Door) (cont) Positioning Access Hole Template for Case/IH Models 1680, 1688, and 2188 Model 1680, 1688 and 2188 combines have wider clean grain elevators that the other 1600 and 2100 series models; this requires a slight modification to the installation procedures. Locate the Case/IH Access Hole Template in Appendix B and remove it by cutting along the solid lies. Place the template on your combine s clean grain elevator as shown. For all 1680, 1688 and 2188 model combines, position the template so that Side A is ½ (13mm) from the top bracket on the elevator. Side D should be positioned approximately 2 7/8 (73mm) from the elevator wall (centered between alignment bolts). Trace around the outside of the template (this will be your cut line). Position Side D Approx. 2 7/8 from the Left End of the Cross Member (Center Between the Alignment Bolts) Alignment Bolts Top Bracket Side D Side A Place Case/IH ACCESS HOLE Template Here Side B Position the Top of the Template ½ Below the Top Bracket Side C 21

22 Installation (cont) IH Combines (cont) Models 1600 (ALL Models) and 2100 Series (Models WITHOUT Removable Inspection Door) (cont) CAUTION: DO NOT use a cutting torch or welder to cut the access hole. Grain or dust present in the elevator could ignite causing damage or personal injury. Cut the opening in the clean grain elevator using a Milwaukee T or T blade. A #30 (.1285 or 3.26MM) drill bit is recommended for the rivet holes. Initially, drill only two rivet holes on opposite corners and rivet the mount in place. Use the mount bracket as a guide to drill the remaining holes (this will help insure proper alignment). Secure the mount in place (only 12 rivets are needed to secure sides A and C). Sides B and D will not be attached; they should fit snugly into the curve of the opening you have made. Grain Flow Sensor Mount Bracket Urethane Coating on the Opposite Side of the Deflector Plate Must Face the Flow of Grain Side A Approximate Cut Lines Direction of Grain Flow Side D Flow Sensor Opening Side B Removable Brackets Rivet Hole Openings (Sides A and C Only) Side C Install the flow sensor onto the mount bracket. The urethane coating on the front of the sensor fork must also be facing into the flow of grain (note the flow direction decals on the sensor housing and mount bracket). Attach the flow sensor to the sensor mount with the four bolts provided. After completing installation of the mount bracket and flow sensor, route the flow sensor cable to the TNgs100 module. Route the cable away from moving parts and components that generate high heat. Also, route the cable as far as possible from two-way radio and cellular phone antennas and their associated antenna cables. Plug the cable into the flow connector on the module. Tie back any excess cable and secure it away from moving parts, areas that generate heat, and two-way radio and cellular phone antennas and cables. Cut the BLUE ground wire attached to the flow sensor cable to the length required to reach the frame ground screw used for the module s ground wire. Strip the insulation from the end of the ground wire and crimp on a ring terminal. Attach the ground wire to the ground screw on the frame (this is the same screw used for the module s ground wire). Make certain that there is good metal-to metal contact. This ground helps protect the flow sensor from electrical interference from cellular phones, two-way radios, etc. Routing the cable inside or under metal body panels may produce additional protection from electrical interference. If the combine is equipped with grain tank extensions, make certain that the flow sensor cable is not pinched between the extension and the top of the grain tank. If the extensions fold up or down, make sure that the flow sensor cable does not become pinched or cut when the extensions fold. 22

23 Installation (cont) Case/IH Combines Models 2100 Series WITH Removable Inspection Door On models with serial numbers 172, 845 and up, models with serial numbers 180,000 and up and models with serial numbers 191,483 and up, there is a factory installed inspection door located at the top of the clean grain elevator that is for sensor installation. A mount bracket that duplicates and replaces the original inspection door is provided with the flow sensor kit. NOTE: If the mount bracket DOES NOT look or fit the same as the original equipment door, contact a Micro-Trak technician to determine if you have the correct flow sensor installation kit Series (with removable inspection door) Mount Bracket Simply remove the factory installed inspection door and install the flow sensor mount bracket in its place. Insert the flow sensor onto the mount bracket and secure it with the four bolts on the bottom of the sensor housing. Make sure to position the sensor so that the urethane coating on the front of the sensor forks and deflector plate faces into the flow of grain. NOTE: The flow direction decals on the sensor housing and mount brackets. No extra installation hardware is required. After completing installation of the mount bracket and flow sensor, route the flow sensor cable to the TNgs100 module. Route the cable away from moving parts and components that generate high heat. Also, route the cable as far away as possible from two-way radio and cellular phone antennas and their associated antenna cables. Plug the cable into the flow connector on the module. Tie back any excess cable and secure it away from moving parts, areas that generate high heat and two-way radio and cellular phone antennas and cables. Cut the BLUE ground wire attached to the flow sensor cable to the length required to reach the frame ground screws used for the module s ground wire. Strip the insulation from the end of the ground wire and crimp on a ring terminal. Attach the ground wire to the ground on the frame (this is the same screw used for the module s ground wire). Make certain that there is good Metal-to-metal contact. This ground helps protect the flow sensor from electrical interference from cellular phones, two-way radios, etc. Routing the cable inside or under metal body parts may provide additional protection from electrical interference. If the combine is equipped with grain tank extensions, make certain that the flow sensor cable is not pinched between the extension and the top of the grain tank. If the extensions fold up and down, make sure that the flow sensor does not became pinched or cut when the extension fold. 23

24 Installation (cont) John Deere Combines Models 6620, 7720, 8820, 9400, 9500, 9600 On the models listed above, there is a factory installed inspection door located at the top of the clean grain elevator that is used for sensor installation. On 6620, 7720 and 8820 models, the top of the clean grain elevator is located on the right-hand side of the machine, next to the grain bin. On 9400, 9500 and 9600 models, the top of the clean bin elevator is located inside the grain bin on the right-hand side. Access to the inspection door is from inside the grain bin on the top of the machine. NOTE: If the mount bracket DOES NOT look or fit the same as the original equipment door, contact a Micro-Trak technician to determine if you have the correct flow sensor installation kit. All model 6620 and 7720 combines and all model 8820 combines with serial number of 464,350 and LOWER use the same style inspection door at the top of the clean grain elevator. All model 8820 combines with a serial number of 464,351 and HIGHER use the same style inspection door, however, it is two inches wider than the inspection door used on the 6620, 7720 and LOW serial number 8820 combines. A mount bracket that duplicates and replaces the original equipment inspection door is provided with the flow sensor kit. Model 6620, 7720 and 8820 (low serial numbers mount bracket) Simply remove the factory installed inspection door and install the flow sensor mount bracket in its place. Insert the flow sensor onto the mount bracket and secure it with the four bolts on the bottom of the sensor housing. Make sure to position the sensor so that the urethane coating on the front of the sensor forks and deflector plate faces into the flow of grain. Model 8820 (high serial numbers mount bracket) NOTE: The flow direction decals on the sensor housing and mount brackets. No extra installation hardware is required. 24

25 Installation (cont) John Deere Combines (cont) Models 6620, 7720, 8820, 9400, 9500, 9600 (cont) All model 9400 and 9500 combines use the same style inspection door at the top of the clean grain elevator. All model 9600 combines use an inspection door that is wider than the inspection door on the 940 s and 950 s. A mount bracket that duplicates and replaces the original equipment inspection door is provided with the flow sensor kit. Model 9400 and 9500 Mount Bracket Simply remove the factory installed inspection door and install the flow sensor mount bracket in its place. Insert the flow sensor onto the mount bracket and secure it with the four bolts on the bottom of the sensor housing. Make sure to position the sensor so that the urethane coating on the front of the sensor forks and deflector plate faces into the flow of grain (NOTE: The flow direction decals on the sensor housing and mount brackets). No extra installation hardware is required. After completing installation of the mount bracket and flow sensor, route the flow sensor cable to the TNgs100 module. Route the cable away from moving parts and components that generate high heat. Also, route the cable as far away as possible from two-way radio and cellular phone antennas and their associated antenna cables. Plug the cable into the flow connector on the module. Tie back any excess cable and secure it away from moving parts, areas that generate high heat and two-way radio and cellular phone antennas and cables. Model 9600 Mount Bracket Cut the BLUE ground wire attached to the flow sensor cable to the length required to reach the frame ground screws used for the module s ground wire. Strip the insulation from the end of the ground wire and crimp on a ring terminal. Attach the ground wire to the ground on the frame (this is the same screw used for the module s ground wire). Make certain that there is good Metal-to-metal contact. This ground helps protect the flow sensor from electrical interference from cellular phones, two-way radios, etc. Routing the cable inside or under metal body parts may provide additional protection from electrical interference. If the combine is equipped with grain tank extensions, make certain that the flow sensor cable is not pinched between the extension and the top of the grain tank. If the extensions fold up and down, make sure that the flow sensor does not became pinched or cut when the extension fold. 25

26 Installation (cont) John Deere Combines (cont) Models 4400, 6600 and 7700 On the models listed above, there is an inspection door located at the top of the clean grain elevator to use for sensor installation. Custom fabrication to the clean grain elevator inspection door is required Access to the top of the clean grain elevator is on the right-hand side of the machine next to the grain bin. Front Edge of Inspection Door An access hole must be cut in the inspection door and the universal mount bracket installed over the access hole. Locate the Deere/Gleaner Access Template in Appendix B and remove it * 1 1/8 by cutting along the solid lines. Remove the inspection door from the top of the clean grain elevator. Place the template on the inspection door as shown below. Position the template so that side A is approximately 1 7/8 (48mm) from the front edge of the inspection door. Side B should be positioned approximately 1 1/8 (29mm) from the side edge of the inspection door (template should be centered on the inspection door; see the following diagram). Trace around the outside of the template (this will be your cut line). Cut the opening in the inspection door using a Milwaukee T or T blade. A #30 (.1285 or 3.26MM) drill bit is recommended for the rivet holes. Position the universal mount bracket over the access hole so that the urethane coating on the deflector plate faces the back edge of the inspection door. The direction of flow decal on the mount bracket should be pointing toward the front edge of the inspection door. Initially, drill only two rivet holes on opposite corners and rivet the mount bracket in place. Use the mount bracket as a guide to drill the remaining holes (this will help ensure proper alignment). Secure the mount in place with remaining rivets provided. Install the flow sensor onto the mount bracket. The urethane coating on the front of the sensor forks must also be facing into the flow of grain (note the flow direction decals on the sensor housing and the mount bracket). Attach the flow sensor to the sensor mount with the four bolts provided. After completing installation of the mount bracket and flow sensor, route the flow sensor cable to the TNgs100 module. Route the cable away from moving parts and components that generate high heat. Also, route the cable as far away as possible from two-way radio and cellular phone antennas and their associated antenna cables. Plug the cable into the flow connector on the module. Tie back any excess cable and secure it away from moving parts, areas that generate high heat and two-way radio and cellular phone antennas and cables. 26 Side A 1 7/8 Place Deere/ Gleaner Access Hole Template Here * Side A Back Edge of Inspection Door Cut the BLUE ground wire attached to the flow sensor cable to the length required to reach the frame ground screws used for the module s ground wire. Strip the insulation from the end of the ground wire and crimp on a ring terminal. Attach the ground wire to the ground on the frame (this is the same screw used for the module s ground wire). Make certain that there is good Metal-to-metal contact. This ground helps protect the flow sensor from electrical interference from cellular phones, two-way radios, etc. Routing the cable inside or under metal body parts may provide additional protection from electrical interference. If the combine is equipped with grain tank extensions, make certain that the flow sensor cable is not pinched between the extension and the top of the grain tank. If the extensions fold up and down, make sure that the flow sensor does not became pinched or cut when the extension fold. Older Model John Deere Combines Custom-fit flow sensor installation kits are not currently available for older model John Deere combines. However, with some custom fabrication of the inspection door, the flow sensor can successfully be installed using the Universal Flow Sensor Installation Kit available from Micro-Trak (call for Availability). The Sensor should be centered across the flow of the discharge side of the top of the clean grain elevator. Position the sensor so that the forks extend into the flow of grain as close to the elevator paddles as possible, without touching them (approximately ½ to 1 clearance). NOTE: Allowing the elevator paddles to come into contact with the sensor forks will cause irreparable damage to the sensor.

27 Installation (cont) Gleaner Combines Models L2, M2, N5, N6, N7, R40, R50, R60, R70, R42, R52, R62 and R72 On the models listed above, there is a panel located at the top of the clean grain elevator to use for sensor installation. However, since the flow of the grain varies from model to model, the grain flow sensor needs to be installed slightly differently for each model. Custom fabrication to the clean grain elevator panel is required. Access to the top of the elevator is from inside the grain bin on the top of the machine. An access hole needs to be cut in the clean grain elevator panel and the universal mount bracket installed over the access hole. Pictured below is an illustration of the template used to mark the cutout area for the access hole. DO NOT use the one on this page. Remove the Deere/Gleaner Access Hole Template located in Appendix B at the back of this manual for use during installation. Side B Side A Deere/Gleaner ACCESS HOLE Template FOR ILLUSTRATION USE ONLY Positioning Access Hole Template for Gleaner Models L2 and M2 Locate the Deere/Gleaner Access Hole Template in Appendix B and remove it by cutting along the solid lines. Place the template on your combine s clean grain elevator panel as shown below. Position the template so that side A is 6½ (165mm) from the front edge of the panel. Side B should be positioned approximately 2 5/8 (67mm) from the edge of the panel (see the following diagram). Trace around the outside of the template (this will be your cut line). Front Edge of Panel Side A Place Deere/ Gleaner Access Hole Template Here Grain Flow Back Edge of Panel 2 5/8 * Side B * 6½ 27

28 Installation (cont) Gleaner Combines (cont) Models L2, M2, N5, N6, N7, R40, R50, R60, R70, R42, R52, R62 and R72 (cont) Positioning Access Hole Template for Gleaner Models N5, N6, N7, R60 and R70 Locate the Deere/Gleaner Access Hole Template in Appendix B and remove it by cutting along the solid lines. Place the template on your combine s clean grain elevator panel as shown below. Position the template so that side A is 8¼ (210mm) from the front edge of the panel. Side B should be positioned approximately 3¾ (95mm) from the edge of the panel (see the following diagram). Trace around the outside of the template (this will be your cut line). Grain Flow Front Edge of Panel Side A Place Deere/ Gleaner Access Hole Template Here Back Edge of Panel * 3 ¾ * Side B * 8¼ Positioning Access Hole Template for Gleaner Models R40, R50, R42, R52, R62 and R72 Locate the Deere/Gleaner Access Hole Template in Appendix B and remove it by cutting along the solid lines. Remove the latch from your combine s clean grain elevator panel. Place the template on the panel as shown below. Position the template so that side A is 9 (229mm) from the front edge of the panel. Side B should be positioned approximately 3 3/8 (85mm) from the edge of the panel (see the following diagram). Trace around the outside of the template (this will be your cut line). Top View * Secure Panel w/self-tapping Screws Front Edge of Panel Side A Place Deere/ Gleaner Access Hole Template Here Grain Flow Back Edge of Panel * 3 3/8 * Side B 9 28

29 Installation (cont) Gleaner Combines (cont) Models L2, M2, N5, N6, N7, R40, R50, R60, R70, R42, R52, R62 and R72 (cont) CAUTION: DO NOT use a cutting torch or welder to cut the access hole. Grain or dust present in the elevator could ignite causing damage or personal injury. Cut the opening in the clean grain elevator using a Milwaukee T or T blade. A #30 (.1285 or 3.26MM) drill bit is recommended for the rivet holes. Position the mount bracket over the access hole so that the urethane coating on the deflector plate face the back edge of the inspection door. the direction of flow decal on the mount bracket should be pointing toward the front edge of the inspection door. NOTE: The mount bracket attaches to the clean grain elevator panel with rivets. Rivets MUST be installed up from the bottom through the panel and then through the mount bracket. With the smooth head of the rivet on the bottom, the panel will still easily slide on and off on the top of the clean grain elevator. Initially, drill only two rivet holes on opposite corners and rivet the mount in place. Use the mount bracket as a guide to drill the remaining holes (this will help insure proper alignment). Secure the mount in place with the remaining rivets provided. Install the flow sensor onto the mount bracket. The urethane coating on the front of the sensor fork must also be facing into the flow of grain (note the flow direction decals on the sensor housing and mount bracket). Attach the flow sensor to the sensor mount with the four bolts provided. After completing installation of the mount bracket and flow sensor, route the flow sensor cable to the TNgs100 module. Route the cable away from moving parts and components that generate high heat. Also, route the cable as far as possible from two-way radio and cellular phone antennas and their associated antenna cables. Plug the cable into the flow connector on the module. Tie back any excess cable and secure it away from moving parts, areas that generate heat, and two-way radio and cellular phone antennas and cables. Cut the BLUE ground wire attached to the flow sensor cable to the length required to reach the frame ground screw used for the module s ground wire. Strip the insulation from the end of the ground wire and crimp on a ring terminal. Attach the ground wire to the ground screw on the frame (this is the same screw used for the module s ground wire). Make certain that there is good metal-to metal contact. This ground helps protect the flow sensor from electrical interference from cellular phones, two-way radios, etc. Routing the cable inside or under metal body panels may produce additional protection from electrical interference. If the combine is equipped with grain tank extensions, make certain that the flow sensor cable is not pinched between the extension and the top of the grain tank. If the extensions fold up or down, make sure that the flow sensor cable does not become pinched or cut when the extensions fold. 29

30 Installation (cont) Ford New Holland Combines (cont) Models TR75, TR85, TR86, TR95, TR96, TR97, TR98 On the models listed above, there is a factory installed inspection door that is used for sensor installation at the top of the clean grain elevator. A mount bracket that duplicates and replaces the original equipment inspection door is provided with the flow sensor kit. TR95, 96, 97 and 98 Mount Bracket NOTE: If the mount bracket DOES NOT look or fit the same as the original equipment door, contact a Micro-Trak technician to determine if you have the correct flow sensor installation kit. Simply remove the factory installed inspection door and install the flow sensor mount bracket in its place. Insert the flow sensor onto the mount bracket and secure it with the four bolts on the bottom of the sensor housing. Make sure to position the sensor so that the urethane coating on the front of the sensor forks and deflector plate faces into the flow of grain (NOTE: The flow direction decals on the sensor housing and mount brackets). No extra installation hardware is required. After completing installation of the mount bracket and flow sensor, route the flow sensor cable to the TNgs100 module. Route the cable away from moving parts and components that generate high heat. Also, route the cable as far away as possible from two-way radio and cellular phone antennas and their associated antenna cables. Plug the cable into the flow connector on the module. Tie back any excess cable and secure it away from moving parts, areas that generate high heat and two-way radio and cellular phone antennas and cables. Cut the BLUE ground wire attached to the flow sensor cable to the length required to reach the frame ground screws used for the module s ground wire. Strip the insulation from the end of the ground wire and crimp on a ring terminal. Attach the ground wire to the ground on the frame (this is the same screw used for the module s ground wire). Make certain that there is good Metal-to-metal contact. This ground helps protect the flow sensor from electrical interference from cellular phones, two-way radios, etc. Routing the cable inside or under metal body parts may provide additional protection from electrical interference. TR75, 85 and 86 Mount Bracket If the combine is equipped with grain tank extensions, make certain that the flow sensor cable is not pinched between the extension and the top of the grain tank. If the extensions fold up and down, make sure that the flow sensor does not became pinched or cut when the extension fold. Combines not Listed For combines not listed, a Universal Flow Sensor Installation Kit is available from Micro-Trak (call for availability). The flow sensor can successfully be installed with some custom fabrication of the inspection door. The sensor should be centered across the flow of the discharge side of the top of the clean grain elevator. Position the sensor so that the forks extends into the flow of grain as close to the elevator paddles as possible, without touching them (approximately ½ to 1 clearance). NOTE: Allowing the elevator paddles to come into contact with the sensor forks will cause irreparable damage to the sensor. 30

31 Installation (cont) Cable Connection at the Grain Flow Sensor The cable attached to the grain flow sensor may be unplugged at the sensor for cable replacement or if the sensor needs to be removed from the machine for storage or service. The cable enters the sensor housing through an access panel located on the top or side of the sensor housing. DO NOT CUT THE SENSOR CABLE TO DETACH IT FROM THE SENSOR. If your grain flow sensor housing (top or side) is not equipped with an access panel where the sensor cable attaches, contact Micro-Trak about receiving an updated sensor housing. Disconnecting Cable Locate the access panel with cable entering the sensor housing, and turn the tabs on the plastic fasteners one quarter turn to unlock them. Pull the access panel straight away from the sensor housing to allow clearance for the fasteners. Locate the clear 4-pin connector behind the access panel, and unplug it. DO NOT REMOVE THE ACCESS PANEL FROM THE CABLE. The access panel should remain attached to the grain flow sensor cable. The grain flow sensor cable may now be replaced or rerouted, and the grain flow sensor may now be removed for storage, service, etc. Connecting Cable Plug the two clear 4-pin connectors together, and tuck the connection next to the electronic module (black box) located inside the access area. Make sure that there is adequate clearance in the access area for the access panel to be installed. Position the access panel over the access area. For top-mounted access panels, note the direction of grain flow decal for proper orientation of the access panel. For sidemounted access panes, no special orientation is required. Align the fasteners with the holes in the sensor housing, and press the access panel into place. DO NOT FORCE. The access panel should make complete contact with the sensor housing. While firmly holding the access panel in place, turn the tabbed stud on the fasteners so the tab is positioned as shown below. to lock the fasteners in place, simply push the tabbed stud inward. The stud should snap into place, securing the access panel to the housing. Fasteners Access Panel 31

32 Installation (cont) DMC Moisture Sensor Kit Installation NOTE: For more detailed instructions on DMC Moisture Sensor Kit Installation, please refer to the DMC Combine Calc-U-Dri II Owner s Manual or contact DMC at (515) Use extra care when opening package. The system has been packaged to protect the sensor from damage in shipment. The moisture sensor is installed on the bottom side of the clean grain tube located at the top of the combine s clean grain elevator. It registers the moisture content of the grain as it passes along side the moisture sensor blade that extends into the auger. NOTE: A special mount bracket (P/N 12858) must be used for moisture sensor installation on Gleaner combines. The clean grain auger should be removed and disassembled prior to attempting moisture sensor installation. When installing the sensor, position the moisture sensor installation template on the bottom off the auger housing so that the top of the template is approximately 6 (152mm) from the discharge end of the auger housing. Use the adhesive on the back of the template to hold it in place. A sample template page with step-by-step installation procedures for the moisture sensor follows. After you have inserted the sensor into the auger tube, secure it in place with the hose clamp provided, Use a selftapping screws to attach the ground strap to the auger tuber. Position the strap at a 90 angle from the sensor. Make sure that the sensor is oriented properly in the tube. Note the direction of grain flow. Confirm that the direction of grain flow matches the decal on the side of the sensor. Route the moisture sensor cable from the hopper to the TNgs100 module (keep the cable away from areas of intense heat). When routing the cable, it is i9mportant to attach it securely so that the grain being drawn out of the hopper does not pull on the cable causing loose or broken connections; cable ties are provided to secure the sensor cable in place. Connect the moisture sensor cable to the moisture sensor connector on the module. Coil up any excess cable and secure it away from moving parts and ares that generate high heat. If the combine is equipped with grain tank extensions, make certain that the moisture sensor cable is not pinched between the extensions and the top of the grain tank. If the extensions fold up and down, make sure the moisture sensor cable does not become pinched or cut when the extension fold. If you already have a DMC moisture sensor, order a 6-pin connector kit (see Appendix A, Replacement Parts List). Contact a Micro-Trak technician for details on the installation of the connector. Clean Grain Auger Tube with Moisture Sensor Installed Attach a Hose Clamp to Hold the Sensor Securely in Place Clean Grain Auger Tube with Moisture Sensor and Gleaner Mount Bracket Installed Attach a Hose Clamp to Hold the Sensor Securely in Place Flow Flow Attach the Ground Strap to the Auger Tube Route to the 6-Pin Connector on the TNgs100 Attach the Ground Strap to the Auger Tube Route to the 6-Pin Connector on the TNgs100 32

33 Installation (cont) Moisture Sensor Installation Template NOTE: The clean grain auger must be removed and disassembled prior to attempting moisture sensor installation. 1. Position the template on the bottom of the auger housing so that the top of the template is approximately 6 (152mm) from the discharge end of the auger housing. Use the adhesive on the back of the template to hold it in place. 2. Mark the rectangle on the auger housing and remove the template. 3. Carefully cut out the marked area from the auger housing. The moisture sensor block must fit tightly in the hole. DO NOT TORCH CUT THE HOLE! 4. Slide the auger into the housing in the normal operating position and mark the flighting that sweeps over the sensor hole that was cut just cut. 5. Remove the auger from the housing, locate the marks on the flighting and weld the flighting to the auger shaft ½ (13mm) above the top mark and below the bottom mark. 6. Remove all of the flighting approximately 6½ (165mm), clear to the shaft between the welds. (TOP) NOTE: To double the thickness of the flighting on each side of the sensor opening, cut the flighting you have just removed in half and weld it to the flighting on each side of the sensor opening. This step is optional. 7. Smooth out any rough edges on the flighting and on the auger shaft and reassemble the clean grain auger. 8. Check to make certain that the flighting does not make contact with the moisture sensor blade by inserting the Sensor Clearance Gauge (provided) into the sensor hole and rotating the auger in the housing. 9. If the flighting comes in contact with the Sensor Clearance Gauge, disassemble the clean grain auger and remove more flighting. Reassemble and check the clearance again. Repeat if necessary. FOR ILLUSTRATION ONLY! NOTE: Refer to the Grain-Trak Installation/Operator s Manual for detailed instructions and diagrams of the moisture sensor installation. (BOTTOM) 33

34 All Calibration Purpose To operate properly, the console must be provided with specific information about the sensors being used and the equipment to be monitored and/or controlled. This section explains each calibration step in detail, shows you how to enter calibration values, and chooses among options for the system. Grain-Trak has two calibration modes, ALL and Abr. The ALL calibration mode must be used when the console is being calibrated for the first time or when you wish to view and/or change every calibration value. Once the system has been completely calibrated (ALL calibration), Abr calibration mode is a useful shortcut that allows you to view and/or change only those values that are most frequently changed, (See Chapter 3, Abbreviated Calibration, for use of this mode). Before beginning actual calibration, read over each step s description carefully to see what information you will need. Making the necessary measurements ahead of time will prevent needless interruptions during calibration. The Calibration Help Sheets found on pages XX through XX may be used to record important calibration information. Not ever step will be shown as you calibrate your system. Depending on the variables you select, only the necessary steps will ne displayed. For example, if you select WET in Step six (volume display), Step 10 (shrink moisture) will be skipped automatically. Shown below is an explanation of the various symbols displayed during the ALL calibration mode. yield wet (if no droplet, yield dry) moisture symbol warning indicator abbreviated description of calibration step area where numerical values are displayed or options are selected distance symbol row symbol active calibration step number calibration symbol wheel circumference symbol speed symbol (MPH/KMPH) area where counter mode is indicated (Load, Field or Total) or file number is displayed memory card symbol Push the left switch down to store a calibration value (or option) in memory and advance to the next calibration step. Press the right switch up or push the right switch down to select an option or adjust a value during each calibration step. 34

35 All Calibration (cont) Grain-Trak Display Console To select the ALL calibration mode, follow these steps in numbered order Grain-Trak Display Console 1. Turn ignition switch on. 2. Push the left switch down and hold. 3. Press the right switch up and release. Continue to hold the left switch down. 4. Release the left switch to enter the"all" calibration mode. The console will automatically advance to the first step of "ALL" calibration. NOTE: During "ALL" calibration of the system, you can return to the first step or skip ahead to Step 17 by using the following switch combinations. This procedure can ONLY be used during steps one through 16. TO RETURN TO BEGINNING OF CALIBRATION TO ADVANCE TO END OF CALIBRATION 1. Push the left switch down and HOLD. 2. Press the right switch up and RELEASE. 1. Push the left switch down and HOLD. 2. Push the right switch down and RELEASE. 3. Release the left switch. 3. Release the left switch. 35

36 All Calibration (cont) Entering Calibration Values Press the +/- switch up or push the +/- switch down to enter and adjust numerical values, to alternate between two options or to cycle through as series of options. When the desired number or symbol is displayed, push the left switch down to the KEY symbol to lock it in and move to the next step. Switch Function lock-in and advance + - adjust value or select option NOTE: Displays show factory calibration values. Adjust as necessary. Description of ALL Calibration Steps Calibration variables are presented in the following order: 1. Contrast Controls the darkness of the characters shown on the console's display. Lowering the contrast value will reduce unwanted background in the display. Choose a setting from 1 (lightest) to 16 (darkest). (darker) (advance) (lighter) 2. System Units Allows you to select the units of measurement you want to use for displaying information. Select "AE" for American English or "SI" for metric. Select AE (American English) or SI (Standard Metric) (SI) (advance) (AE) A measurement conversion table is found on the following page. 36

37 All Calibration (cont) Conversion Tables American English (AE): Speed - miles per hour Area - acres Distance - feet Volume - bushels Metric (SI): Speed - kilometers per hour Area - hectares Distance - meters Volume - kilograms Calibration steps requiring length or width measurements are entered in inches. The circumference value for speed calibration is entered in inches. Calibration steps requiring length or width measurements are entered in millimeters. The circumference value for speed calibration is entered in millimeters. Measurement Conversion Table English to Metric Linear Measurement Land Measurement Weight Measurement 1 inch = 25.4 millimeters 1 foot = millimeters or.305 meters 1 yard =.914 meters 1 mile = kilometers 1 acre =.405 hectares 1 square mile = 2.59 square kilometers or 259 hectares (1 square mile = 640 acres) 1 pound =.4536 kilograms Metric to English Linear Measurement Land Measurement Weight Measurement 1 millimeter =.039 inches 1 meter = feet or inches 1 kilometer =.621 miles 1 hectare = acres 1 square kilometer =.386 square miles or acres (1 square kilometer = 100 hectares) 1 kilogram = 2.2 pounds 37

38 All Calibration (cont) Entering Calibration Values (cont) 3. Wheel Circumference The wheel circumference value is related to the type of speed sensor that is installed and used by Grain- Trak to calculate your ground speed. Standard Magnetic Speed Sensor With a magnetic sensor, the wheel circumference value is arrived at indirectly by entering a rough value, driving a pre-measured distance and then fine-tuning the displayed distance to match the test distance. Because of differences in wheel-to-driveshaft ratios, a calibration value for these types of installations cannot be determined by measuring a wheel. For this reason, simply use any number between 20" to 30" (510mm to 760mm) for a driveshaft with one magnet and 10" to 15" (255mm to 380mm) for a driveshaft with two magnets. Once the rough value has been entered, finish calibrating the system. Trak-Star Ultrasonic Speed Sensor If you are using a Trak-Star Ultrasonic Speed Sensor or a similar approved unit, enter the calibration number that is included with the unit. Instructions for fine-tuning the wheel circumference value are in Appendix D. The wheel circumference value must be between 0.00 and inches for American English system units and.1 and 5000mm for metric units. (increase) (advance) (decrease) 4. Row Width Note: The wheel circumference symbol will flash during this step. This step is used to designate the distance between rows or the overall header width. If a row crop header is being used, enter the distance between rows. If a platform header is being used, you may divide it into equivalent rows covered or enter the overall width. The row width value can be between.0 and 2578 inches for AE system units or.0 to millimeters for SI systems units. Enter the distance between rows or the effective working width of the header. Use the appropriate system units (inches or millimeters). (increase) (advance) (decrease) 38 Note: The row symbol will flash during this step.

39 All Calibration (cont) Entering Calibration Values (cont) 5. Number of Rows The system will monitor between one and twelve rows. If row spacing (distance between rows) was entered in Step 4, select the equivalent number of rows covered. If the overall header width was entered in Step 4, select one row. The system will display the number of rows and the total row width in inches or millimeters. Select the number of rows your header covers. If the effective working width was entered in Step 4, select one row. (increase) (advance) (decrease) 6. Volume Display Grain-Trak can display yield data as WET volume or calculated DRY volume. Select WET or DRY to indicate whether yield information will be displayed in wet volume or dry volume. If WET is selected, Steps 10 and 11 are skipped automatically. Select WET to display wet yield volume. Select DRY to display calculated dry yield volume. (wet) (advance) (dry) 7. Moisture Sensor Select YES or NO to indicate whether or not a moisture sensor is installed with the system. If YES is selected, Step 11 will be skipped automatically. If NO is selected, Step 12 will be skipped automatically. Select YES if a moisture sensor is installed. Select NO if a moisture sensor is not installed. (yes) (advance) (no) 39

40 All Calibration (cont) Entering Calibration Values (cont) 8. Crop Type Select the type of crop you are harvesting. Programmed choices include: corn, soybeans, wheat, oats, alternate crop #1 and alternate crop #2. The last two settings may be used to identify a crop other than those listed. The console displays the standard density (weight per volume) for the crop selected. Select the crop you are harvesting: corn, soybeans (SbnS), wheat (Wht), oats (OAtS), crop 1 or crop 2. (advance) (toggle between available crop choices) 9. Crop Density (Weight) Used to set the standard density (weight per volume) for the crop type selected in Step 8. Adjust the displayed density to match the standard density used to calculate volume (e.g. bushels) for the crop type selected. You may not get the displayed density to exactly match the standard density. Adjust the displayed density as closely as possible to the standard density. DO NOT enter the actual test weight of the crop being harvested. Example: Most elevators will use pounds as the standard weight for calculating a bushel of corn, regardless of what the actual test weight of the corn really is. Typical Standard Densities corn = pounds per bushel soybeans = pounds per bushel wheat = pounds per bushel oats = pounds per bushel Enter the standard density (weight) used to calculate volume for the crop type selected in Step 8. See Description of Calibration for details. (increase) (advance) (decrease) 40

41 All Calibration (cont) Entering Calibration Values (cont) 10. Shrink Moisture Grain-Trak uses the information entered in this step for calculating DRY yield volume. This step is skipped automatically if WET was selected in Step six (Volume Display). If DRY was selected, enter the moisture level the system should use to calculate dry volume. The shrink moisture value ranges from.1 to If you are drying the grain for storage, enter the moisture level that the grain will be dried to. If you are hauling grain to an elevator for storage or sale, enter the moisture level to which the elevator will dry the grain. Enter the moisture level the system should use to calculate dry volume. This step is skipped automatically if WET volume was selected. (increase) (advance) (decrease) 11. Default Moisture This step is skipped automatically if a moisture sensor is installed or if no moisture sensor is installed and WET was selected in Step 6 (Volume Display). If no moisture sensor is installed and DRY was selected, use a moisture tester to determine the actual moisture of the crop being harvested and enter that value here. Grain-Trak will use this value with the shrink moisture value to calculate DRY yield volume. As actual moisture levels change, this value should also be adjusted. If no moisture sensor is installed, enter the actual moisture of the crop. This step is skipped automatically if a moisture sensor is installed or if no moisture sensor is installed and WET volume was selected. (increase) (advance) (decrease) 41

42 All Calibration (cont) Entering Calibration Values (cont) 12. Moisture Sensor Offset This step is skipped automatically if no moisture sensor is installed. If a moisture sensor is installed, use this step to fine-tune the readings from the moisture sensor (use a hand-held tester or take a sample to the elevator for testing). See Appendix E for the procedure used to fine-tune the moisture sensor calibration value. NOTE: You may not get the displayed moisture to exactly match the actual moisture. Adjust the displayed moisture as closely as possible to the actual moisture. Write down the moisture sensor offset value and keep it in a safe place. If calibration values are ever accidentally changed, you can simply re-enter this number. This procedure should be repeated periodically during harvest as a check to maintain accuracy. Adjust the offset value so that the displayed moisture matches the actual moisture. This step is skipped automatically if no moisture sensor is installed. See Description of Calibration and Appendix E (Fine-Tuning Moisture Sensor Calibration Value) for details. Until a load is stored, this value should be set to 0.0. (increase) (advance) (decrease) This screen indicates that the load moisture value was not stored for calibration. To store the load moisture value for calibration, select the counter zeroing mode for load. With the load data showing, push the right-hand switch down and HOLD until the display returns to normal operating mode, then release the switch. NOTE: The displayed moisture may not exactly match the actual moisture. Adjust the displayed moisture as closely as possible to the actual moisture. Indicates no load moisture value stored. 42

43 All Calibration (cont) Entering Calibration Values (cont) 13.Flow Sensor Calibration Each flow sensor has a calibration value that represents the number of grams per sensor pulse passing by the sensor. The calibration value will vary depending on the type of crop being harvested, the size (capacity) of the combine the sensor is installed on and the size of the flow sensor that is installed. As a starting point, enter To finetune this calibration value, see Appendix F. (increase) (advance) (decrease) This screen indicates that the load pounds were not stored for calibration. To store the load pounds for calibration, select the counter zeroing mode for load. With the load data showing, push the righthand switch down and HOLD until the display returns to normal operating mode, then release the switch. NOTE: The displayed load pounds may not exactly match the actual load pounds. Adjust the displayed load pounds as closely as possible to the actual load pounds. Indicates no load weight value stored. 43

44 All Calibration (cont) Entering Calibration Values (cont) Null Frequency The flow sensor uses a load cell (strain gauge) to measure mass flow. Flow passing by the load cell exerts a pressure on the load cell, which generates a frequency (flow signal). This frequency is then translated into the yield readings shown on the Grain-Trak console. Even at zero flow, the load cell is still generating a frequency or flow signal. This frequency is called the null, or zero flow frequency. To prevent the system from counting yield when there is no flow past the sensor, you must set the zero flow point for the system. By doing this, you are simply telling the system that the frequency it sees when there is no flow past the sensor represents zero flow (no yield). Calibration steps 14 and 15 are used to set the null frequency of the grain flow sensor. 14. Nulling Mode Step 14 allows you to choose between the two nulling modes, auto and manual. Auto Null When AUTO is selected, based on fixed conditions known by the system, Grain-Trak will automatically read and store the zero flow point (null frequency) of the flow sensor during normal operation. Manual Null When MANUAL is selected, Grain-Trak will read and store the zero flow point (null frequency) of the flow sensor ONLY when YES is selected for Flow Sensor Null (Step 15 in calibration). It is recommended that you select AUTO null so that if the null frequency should change slightly during operation, the system will automatically read and store the new null frequency. If this is the first calibration of the system, if there is no flow present at the sensor, if installation of the sensor has been altered since initial calibration, or if the load cell has been repaired or replaced since initial calibration you should select YES to Step 15 to manually set the null frequency even when AUTO is selected. If you select Auto Null in step 14: Grain-Trak will automatically read and store the null frequency even if the null frequency shifts during operation. If you select Manual Null in step 14: Grain-Trak will read and store the null frequency ONLY IF you select YES in calibration step 15. Select AUTO to have the system automatically set the zero flow point (null frequency) or MANUAL to disable the auto feature. (manual) (advance) (auto) 44

45 All Calibration (cont) Entering Calibration Values (cont) 15. Flow Sensor Null Perform this step on level ground the first time the system is calibrated. The flow sensor must be installed and plugged into the system. For maximum accuracy, the speed and RPM of the combine should be as close as possible to the average speed and RPM of the combine during normal operation. There must not be any flow passing by the sensor (no pressure on the load cell) during the nulling process. If there is flow present at the sensor while nulling, the flow will be read and displayed as zero flow. This may result in the console displaying negative flow (-FLO) when there is actually no flow past the sensor. This step is used to tell the system to read and store the zero flow point (null frequency) of the flow sensor. The display will show the current frequency of the flow sensor load cell. To set the zero flow point of the flow sensor at this time, select YES. If you are recalibrating the system and there is flow present at the flow sensor, select NO to skip past the nulling procedure. Select YES for step 15 if: you are calibrating the system for the first time there is no flow present at the sensor installation of the sensor has been altered since initial calibration the load cell has been repaired or replaced since initial calibration. Select YES to set the zero flow point (null frequency) of the flow sensor at this time. See Description of Calibration for details. (yes) (advance) (no) Note: The triangle symbol will flash during this step. If you respond YES to Step 15, the system will display the message "nullin" for approximately five seconds and then continue on to the next step. 45

46 All Calibration (cont) Entering Calibration Values (cont) 16. Remote Run/Hold Polarity Use this step to tell the system how the remote sensor should work based on the current position of the header. If the header is raised and in its traveling position, select HOLD. If the header is lowered and in the operating position, select RUN. If no remote sensor is installed, select RUN. Select the current status of the Remote Run/Hold Sensor. If the header is fully raised, select HOLD. If the header is fully lowered, select RUN. (advance) If you are not using Data-Trak, the system will exit ALL Calibration upon advancing past Step File Number If a memory card is installed, this step is used to assign a file number to which data will be stored on the card. Enter the file number that the data should be stored to on the memory card. If you are not recording to the card, enter "----" and the system will exit calibration. Enter the file number that the data should be stored to on the card. This value can be between 1 and If you are not going to write data to a card at this time, enter "----" and the system will exit calibration. (increase) (advance) (decrease) 46

47 All Calibration (cont) Entering Calibration Values (cont) 18. Write Interval If a memory card is installed, this step tells the system how often to write information to the card.. The chart below will help you to determine the appropriate interval. Enter the interval (in seconds) that the system should use when writing data to the card. (increase) (advance) (decrease) After selecting the "KEY" position to advance past Step 18 (Write Interval), the system will automatically exit the calibration mode and return to normal operation mode. Detailed information regarding the operation of the system follows in Chapter 4. MEMORY CARD RECORDING TABLE Recording Interval (in seconds) Number of Recordings Per Hour Recording Interval MPH (distance traveled in feet 1 between saves/writes to card) Card Size (megabyte) Maximum Hours of Recording Card Size (megabyte) Maximum Hours of Recording

48 All Calibration (cont) Calibration Help Sheet Use this help sheet to record calibration information needed to correctly set up the system. The help sheet outlines each calibration step, the factory setting for each step and a line for recording your specific calibration setting. Calibration Step 1. Contrast 2. System Units 3. Wheel Circumference 4. Row Width 5. Number of Rows 6. Volume Display Factory Calibration Setting 8 AE DRY Your Calibration Setting 7. Moisture Sensor 8. Crop Type CORN SBNS YES WHT OATS CROP 1 & 2 9. Crop Density Shrink Moisture Default Moisture Moisture Sensor Offset Flow Sensor Calibration Nulling Mode 15. Flow Sensor Null 16. Remote Run/Hold Polarity 17. File Number 18. Write Interval AUTO NO HOLD (head up) RUN (head down) NOTE: Step 11 (Default Moisture) is skipped if a moisture sensor is installed, or if no moisture sensor is installed and WET volume is selected in Step 6 (Volume Display). Step 10 is skipped if WET volume is selected in Step 6. Step 12 is skipped if no moisture sensor is installed. Steps 17 & 18 are skipped if not Data-Trak is installed. Step 18 is skipped is file number =. 48

49 All Calibration (cont) Calibration Help Sheet (cont) Calibration Step 1. Contrast 2. System Units 3. Wheel Circumference 4. Row Width 5. Number of Rows 6. Volume Display Factory Calibration Setting 8 AE DRY Your Calibration Setting 7. Moisture Sensor 8. Crop Type CORN SBNS YES WHT OATS CROP 1 & 2 9. Crop Density Shrink Moisture Default Moisture Moisture Sensor Offset Flow Sensor Calibration Nulling Mode 15. Flow Sensor Null 16. Remote Run/Hold Polarity 17. File Number 18. Write Interval AUTO NO HOLD (head up) RUN (head down) NOTE: Step 11 (Default Moisture) is skipped if a moisture sensor is installed, or if no moisture sensor is installed and WET volume is selected in Step 6 (Volume Display). Step 10 is skipped if WET volume is selected in Step 6. Step 12 is skipped if no moisture sensor is installed. Steps 17 & 18 are skipped if not Data-Trak is installed. Step 18 is skipped is file number =. 49

50 All Calibration (cont) Calibration Help Sheet (cont) Calibration Step 1. Contrast 2. System Units 3. Wheel Circumference 4. Row Width 5. Number of Rows 6. Volume Display Factory Calibration Setting 8 AE DRY Your Calibration Setting 7. Moisture Sensor 8. Crop Type CORN SBNS YES WHT OATS CROP 1 & 2 9. Crop Density Shrink Moisture Default Moisture Moisture Sensor Offset Flow Sensor Calibration Nulling Mode 15. Flow Sensor Null 16. Remote Run/Hold Polarity 17. File Number 18. Write Interval AUTO NO HOLD (head up) RUN (head down) NOTE: Step 11 (Default Moisture) is skipped if a moisture sensor is installed, or if no moisture sensor is installed and WET volume is selected in Step 6 (Volume Display). Step 10 is skipped if WET volume is selected in Step 6. Step 12 is skipped if no moisture sensor is installed. Steps 17 & 18 are skipped if not Data-Trak is installed. Step 18 is skipped is file number =. 50

51 All Calibration (cont) Calibration Help Sheet (cont) Calibration Step 1. Contrast 2. System Units 3. Wheel Circumference 4. Row Width 5. Number of Rows 6. Volume Display Factory Calibration Setting 8 AE DRY Your Calibration Setting 7. Moisture Sensor 8. Crop Type CORN SBNS YES WHT OATS CROP 1 & 2 9. Crop Density Shrink Moisture Default Moisture Moisture Sensor Offset Flow Sensor Calibration Nulling Mode 15. Flow Sensor Null 16. Remote Run/Hold Polarity 17. File Number 18. Write Interval AUTO NO HOLD (head up) RUN (head down) NOTE: Step 11 (Default Moisture) is skipped if a moisture sensor is installed, or if no moisture sensor is installed and WET volume is selected in Step 6 (Volume Display). Step 10 is skipped if WET volume is selected in Step 6. Step 12 is skipped if no moisture sensor is installed. Steps 17 & 18 are skipped if not Data-Trak is installed. Step 18 is skipped is file number =. 51

52 Abbreviated (Abr) Calibration Selecting Base Abr Calibration Mode Once the system has been completely calibrated, it may be necessary at a later date to change some of the settings. Any setting can be changed by reentering the ALL calibration mode. However, for faster access, the Abbreviated calibration mode takes you directly to those steps which typically may require periodic adjustment. There are three modes within the "Abr" calibration mode: Base, Moisture and Card. This chapter describes how to select the three "Abr" calibration modes, provides a brief description of each step, and gives adjustment instructions. The "Abr" calibration steps are numbered as they appear in ALL calibration. To select the Base "Abr" calibration mode, follow these steps in numbered order: Grain-Trak Display Console 1. Turn the ignition switch ON. 2. Push the left switch DOWN and hold. 3. Press the right switch UP two times and release. Continue to hold the left switch down. You will be in the Base mode. 4. Release the left switch to enter the Base "Abr" calibration mode. The console will automatically advance to the first step of Base "Abr" calibration. Entering Calibration Values Press the "+/-" switch up or push the "+/-" switch down to enter and adjust numerical values, to alternate between two options or to cycle through a series of options. When the desired number or symbol is displayed, push the left switch down to the KEY symbol to lock it in and move to the next step. Switch Function lock-in and advance adjust value or select option NOTE: Displays show factory calibration values. Adjust as necessary. NOTE: Screens are shown for illustration only. 52

53 Abbreviated (Abr) Calibration (cont) Base Abr Calibration Steps 3. Wheel Circumference The wheel circumference value is partly determined by the type of speed sensor that is installed. (increase) (advance) (decrease) Note: The wheel circumference symbol will flash during this step. Standard Magnetic Speed Sensor With a standard magnetic speed sensor, you will determine the wheel circumference value by entering a rough value, driving a pre-measured distance and then fine-tuning the displayed distance to match the test distance. Due to differences in wheel-to-driveshaft ratios, you cannot determine the wheel circumference value by measuring a wheel. Rather, use any number between 20 inches to 30 inches (510 mm to 760 mm) for a driveshaft ratio with one magnet, or 10 inches to 15 inches for a driveshaft with two magnets. After you have entered this rough value, finish calibrating the system. Trak-Star Ultrasonic Speed Sensor If you are using a Trak-Star ultrasonic speed sensor, or a similar approved unit, enter the calibration number included with the unit. NOTE: The wheel circumference value must be between 0.00 and 199 inches, or.1 and 5000 millimeters. 4. Row Width Enter the distance between rows or the effective working width of the header. Use the appropriate system units. (increase) (advance) (decrease) Note: The row symbol will flash during this step. This step designates the distance between rows, or the overall header width. If a row crop header is being used, enter the distance between rows. If a platform header is being used, you may divide it into equivalent rows covered, or enter the overall width. The row width value can be between.0 and 2578 inches, or.0 to millimeters. NOTE: Screens are shown for illustration only. 53

54 Abbreviated (Abr) Calibration (cont) Base Abr Calibration Steps (cont) 5. Number of Rows (increase) (advance) (decrease) The system will monitor between one and 12 rows. If row spacing (distance between rows) was entered in step four, select the equivalent number of rows covered. If the overall header width was entered in step four, select one row. The system will display the number of rows and the total row width in either inches or millimeters. 8. Crop Type (advance) (toggle between the available crop choices) Select the type of crop you are harvesting. Programmed choices include corn, soybeans, wheat, oats, alternate crop #1 and alternate crop # 2. The last two settings listed may be used to identify a crop other than those listed. The console displays the standard density (weight per volume) for the crop selected. NOTE: Screens are shown for illustration only. 54

55 Abbreviated (Abr) Calibration (cont) Base Abr Calibration Steps (cont) 9. Crop Density (Weight) (increase) (advance) (decrease) This step is used to set the standard density (lb or kg per unit volume) for the crop type selected in step eight. Adjust the displayed density to match the standard density used to calculate volume for the crop type selected. You may not get the displayed density to exactly match the standard density, so adjust the displayed density as closely as possible to the standard density. DO NOT enter the actual test weight of the crop being harvested. Most elevators will use pounds as the standard weight for calculating a bushel of corn, regardless of the corn's actual test weight. Typical standard densities Corn = pounds per bushel Soybeans = pounds per bushel Wheat = pounds per bushel Oats = pounds per bushel 10. Shrink Moisture Enter the moisture level the system should use to calculate dry volume. This step is skipped automatically if WET volume was selected. (increase) (advance) (decrease) Grain-Trak uses the information entered in this step for calculating DRY yield volume. This step is skipped automatically if WET was selected in step 6 (volume display). If DRY was selected, enter the moisture level the system should use to calculate dry volume. The shrink moisture value may range from.1 to If you are drying the grain for storage, enter the moisture level to which the grain will be dried. If you are hauling grain to an elevator for storage or sale, enter the moisture level to which the elevator will dry the grain. NOTE: Screens are shown for illustration only. 55

56 Abbreviated (Abr) Calibration (cont) Base Abr Calibration Steps (cont) 13. Flow Sensor Calibration (increase) (advance) (decrease) As a starting point, enter This screen indicates that the load pounds were not stored for calibration. To store the load pounds for calibration, select the counter zeroing mode for load. With the load data showing, push the righthand switch down and HOLD until the display returns to normal operating mode, then release the switch. NOTE: The displayed load pounds may not exactly match the actual load pounds. Adjust the displayed load pounds as closely as possible to the actual load pounds. Indicates no flow calibration value stored. Nulling the Grain Flow Sensor The grain flow sensor uses a load cell (strain gauge ) to measure mass flow. Flow passing by the sensor exerts a pressure on the load cell which generates a frequency (flow signal). As flow (pressure) increases, so does the frequency. Even when there is no flow past the sensor (no pressure on the load cell) the load cell is generating a frequency or flow signal. This zero flow frequency is known as the null frequency. To prevent the system from counting yield when there is no flow passing by the sensor you must null the flow sensor (set the zero flow point). When you null the flow sensor, you are simply telling the system that the frequency (flow signal) it is currently seeing represents zero flow (no yield). Steps 14 and 15 are used to set the null frequency of the grain flow sensor. 14. Nulling Mode (manual) (advance) (auto) Select AUTO to have the system automatically set the zero flow point (null frequency) of the flow sensor, or MANUAL to disable the auto feature. NOTE: Screens are shown for illustration only. 56

57 Abbreviated (Abr) Calibration (cont) Base Abr Calibration Steps (cont) 15. Flow Sensor Null Select YES to set the zero flow point (null frequency) of the flow sensor at this time. (yes) (advance) (no) Note: The triangle symbol will flash during this step. This step is used to tell the system to read and store the zero flow point (null frequency) of the flow sensor. The display will show the current frequency of the flow sensor load cell. To set the zero flow point of the flow sensor at this time, select YES. NOTE: The flow sensor must be installed and plugged into the system, and the combine must be running at RPMs similar to actual harvesting speeds. Everything must be engaged. There must be no flow passing by the sensor (no pressure on the load cell) during the nulling process. If there is flow present at the sensor while nulling, the flow will be read and displayed as zero flow. This may cause the console to display negative flow (-FLO) when there is actually no flow present at the sensor. If you select YES, the system will display the message "nullin" for approximately five seconds and then continue on to the next step. After selecting the "KEY" position to advance past Step 15 (Flow Sensor Null), the system will automatically exit calibration mode and return to normal operation mode. Detailed information regarding the operation of the system follows in Chapter 4. NOTE: Screens are shown for illustration only. 57

58 Abbreviated (Abr) Calibration (cont) Selecting Moisture Abr Calibration Mode To select the Moisture "Abr" calibration mode, follow these steps in numbered order: Grain-Trak Display Console 1. Turn the ignition switch ON. 2. Push the left switch DOWN and hold. 3. Press the right switch UP three times and release. Continue to hold the left switch down. You will be in the Moisture mode. 4. Release the left switch to enter the moisture "Abr" calibration mode. The console will automatically advance to the first step of Moisture "Abr" calibration. Entering Calibration Values Press the "+/-" switch up or push the "+/-" switch down to enter and adjust numerical values, to alternate between two options or to cycle through a series of options. When the desired number or symbol is displayed, push the left switch down to the KEY symbol to lock it in and move to the next step. Switch Function lock-in and advance adjust value or select option NOTE: Displays show factory calibration values. Adjust as necessary. NOTE: Screens are shown for illustration only. 58

59 Abbreviated (Abr) Calibration (cont) Moisture Abr Calibration 6. Volume Display Grain-Trak can display yield data as WET volume or calculated DRY volume. Select WET or DRY to indicate whether yield information will be displayed in wet volume or dry volume. (wet) (advance) (dry) 7. Moisture Sensor Select YES or NO to indicate whether or not a moisture sensor is installed with the system. (yes) (advance) (no) Select YES if a moisture sensor is installed. Select NO if a moisture sensor is not installed. NOTE: Step 11 is next if NO moisture sensor is installed. NOTE: Screens are shown for illustration only. 59

60 Abbreviated (Abr) Calibration (cont) Moisture Abr Calibration (cont) 12. Moisture Sensor Offset This step is skipped automatically if no moisture sensor is installed. If a moisture sensor is installed, use this step to fine-tune the readings from the moisture sensor. See Appendix E for the procedure used to fine-tune the moisture sensor calibration value. Write the moisture sensor offset value down and keep it in a safe place. If calibration values are ever accidentally changed, you can simply re-enter this number. This procedure should be repeated periodically during harvest as a check to maintain accuracy. Use a hand-held moisture tester to test the grain, or take a sample to the elevator for testing. Adjust the offset value so that the displayed moisture matches the actual moisture. This step is skipped automatically if no moisture sensor is installed. See Appendix E (Fine-Tuning Moisture Sensor Calibration Value) for details and instructions. (increase) (advance) (decrease) NOTE: You may not get the displayed moisture to exactly match the actual moisture. Adjust the displayed moisture as closely as possible to the actual moisture. This screen indicates that the load moisture value was not stored for calibration. To store the load moisture value for calibration, select the counter zeroing mode for load. With the load data showing, push the right-hand switch down and HOLD until the display returns to normal operating mode, then release the switch. NOTE: The displayed moisture may not exactly match the actual moisture. Adjust the displayed moisture as closely as possible to the actual moisture. Indicates no load moisture value stored. After selecting the "KEY" position to advance past Step 12 (Moisture Sensor Offset), the system will automatically exit calibration mode and return to normal operation mode. Detailed information regarding the operation of the system follows in Chapter 4. NOTE: Screens are shown for illustration only. 60

61 Abbreviated (Abr) Calibration (cont) Selecting Card Abr Calibration Mode NOTE: Card "Abr" Calibration Mode is only available when a Data-Trak is being used. To select the Card "Abr" calibration mode, follow these steps in numbered order: Grain-Trak Display Console Turn the ignition switch ON. Push the left switch DOWN and hold. 3. Press the right switch UP four times and release. Continue to hold the left switch down. You will be in the Card mode. 4. Release the left switch to enter the Card "Abr" mode. The console will automatically advance to the first step of Card "Abr" calibration. Entering Calibration Values Press the "+/-" switch up or push the "+/-" switch down to enter and adjust numerical values, to alternate between two options or to cycle through a series of options. When the desired number or symbol is displayed, push the left switch down to the KEY symbol to lock it in and move to the next step. Switch Function lock-in and advance adjust value or select option NOTE: Displays show factory calibration values. Adjust as necessary. NOTE: Screens are shown for illustration only. 61

62 Abbreviated (Abr) Calibration (cont) Card Abr Calibration Display Screens Calibration variables are presented in the following order: 17. File Number If a memory card is installed, this step is used to assign a file number to which data will be stored on the card. Enter the file number that the data should be stored to on the memory card. If you are not recording to the card, enter "----" and the system will exit calibration. Enter the file number that the data should be stored under on the card. This value can be between 1 and If you are not recording to a card, enter "----" and the system will exit calibration. (increase) (advance) (decrease) 18. Write Interval If a memory card is installed, this step tells the system how ofter to write information to the card. The chart on the following page will help you to determine the appropriate interval. Enter the interval (in seconds) that the system should use when writing data to the card. (increase) (advance) (decrease) After selecting the "KEY" position to advance past Step 18 (Write Interval), the system will automatically exit the calibration mode and return to normal operation mode. Detailed information regarding the operation of the system follows in Chapter 4. NOTE: Screens are shown for illustration only. 62

63 Abbreviated (Abr) Calibration (cont) Memory Card Recording Table MEMORY CARD RECORDING TABLE Recording Interval (in seconds) Number of Recordings Per Hour Recording Interval MPH (distance traveled in feet 1 between saves/writes to card) Card Size (megabyte) Maximum Hours of Recording Card Size (megabyte) Maximum Hours of Recording

64 Operation Operation Display During operation, the display console will appear similar to the one shown below. yield per area (droplet indicates WET volume) (no droplet indicates DRY volume) Active Counters 1. total yield (droplet indicates WET volume) (no droplet indicates DRY volume) 2. total area grain moisture level ground speed rows covered Counter Mode Indicator - active counters are currently displaying load information Description of Displayed Information Yield Per Area The console continuously displays yield per area (wet or dry - chosen during calibration) on-the-go. As actual yields change through the field, the console will display the yield at the combine's current location (remember that there is a lag time from when the grain enters the header until it reaches the flow sensor at the top of the clean grain elevator). If the console shows a water droplet in the bushel basket, the system is displaying WET yield per area. If there is not a droplet in the bushel basket, the system is displaying DRY yield per area. Grain Moisture Level The console continuously displays moisture on-the-go. As actual moisture changes through the field, the console will display the moisture at the combine's current location (remember that there is a lag time from when the grain enters the header until it reaches the moisture sensor in the combine grain tank). Ground Speed Note: Display shows AE system units The console continuously displays your current ground speed. The speed readout is not affected by the RUN/HOLD status of the system. 64

65 Operation (cont) Description of Displayed Information (cont) Average Yield per Area and Average Moisture You may also view the average yield per area (wet or dry - selectable during calibration) and averag e moisture, on-the-go. To view the averages for Yield per Area and Moisture, press the left-hand console switch UP and HOLD. The display will show the average Yield per Area and Average Moisture for as long as the left-hand switch is held in the UP position. When the switch is released, the console will resume displaying instantaneous information. When average is selected, the displayed information corresponds to the counter mode selected. The counter mode indicator is located in the lower right-hand corner of the display (average for a load, field or total). See Counter Modes for details. If the system is in HOLD status, average information can still be viewed. Active Counters The console continuously displays information in the two active counters. These counters will display one of three of the following sets of information. Sample console displays are shown for each counter set. Counter Set 1 Counter Set 2 Counter 3 1. Total Yield 1. Yield per Hour 1. Total Yield (wet or dry) (wet or dry) (wet or dry) 2. Total Area 2. Area per hour 2. Distance You may cycle the display among the three sets of active counters at any time, on-the-go or while stopped. To cycle among the active counter sets, press the right-hand console switch UP and RELEASE. Each time the right-hand switch is pressed UP, the display will advance to the next counter set. If counter set 3 is on the display when you press the right-hand switch UP, the display will advance to counter set 1. Total Yield and Total Area information displayed in the active counters corresponds to the counter mode selected. The counter mode indicator is located in the lower right-hand corner of the display (counter information for a load, field or total). See Counter Modes for details. 65

66 Operation (cont) Description of Displayed Information (cont) Counter Modes Grain-Trak can be set up to record yield and area information on three separate counters: LOAD, FIELD and TOTAL. The LOAD counter mode can be used to record yield and area totals for each combine hopper of grain harvested or for each truck or wagon of grain harvested. The FIELD counter mode can be used to record yield and area totals for each field or part of a field harvested. The TOTAL counter mode can be used to record yield and area totals for an entire farm or harvest season. See Resetting Totals for details on resetting individual counters. You may cycle the display among the three counter modes at any time, on-the-go or while stopped. Press the right-hand console switch DOWN and RELEASE. Each time the righthand switch is pressed DOWN, the display will cycle to the next counter mode. If LOAD information is being displayed when you press the right-hand switch DOWN, the counter mode will advance to display FIELD information. When average information is selected for viewing, the displayed information corresponds to the counter mode selected. If the FIELD counter mode is selected, the display will show the average Yield per Area and Average Moisture based on the yield and area totals in the FIELD counters. The same applies to the LOAD and TOTAL counter modes. Run/Hold Operation HOLD status may be activated on Grain-Trak to prevent area and distance from counting while turning on the ends of the field or while driving between fields. The left-hand console switch may be used to manually activate HOLD status. To manually select HOLD, press the left-hand console switch DOWN and RELEASE. The console will display a "HOLd" message in the Yield per Area readout on the display. To manually select RUN status, simply press the left switch down again and release. When the standard range remote run/hold kit is properly installed, the system automatically puts itself in HOLD status and stops area and distance counting when the combine's header is raised. A "HOLd" message is displayed in the Yield per Area readout. When the header is lowered, RUN status is automatically activated. If the console continues to display "HOLd" when the header is lowered to the RUN position, check that the range run/hold kit is operating properly as the header is raised and lowered and that HOLD was not manually selected with the console run/hold switch. See calibration Step 16 for details. 66

67 Operation (cont) Description of Displayed Information (cont) WET or DRY Yield Information Grain-Trak can display yield information as WET yield volume or calculated DRY yield volume (see calibration Step 6 for details). When displaying WET yield volume, a droplet will be shown in the bushel basket symbol ( ). When calculated DRY yield volume is being displayed, there will not be droplet in the bushel basket ( ). See Description of Calibration for details. Changing Working Width Grain-Trak allows you to change the effective working width on the console, on-the-go, as your actual harvesting width changes, so that totals for area and calculations for yield per area are correct. Pressing the middle console switch to the right or left and releasing will increase or decrease the effective working width of the console by the Row Width increment that was entered during calibration. If you calibrated a 30 inch row width and eight rows, each flip of the middle console switch to the right or the left would increase or decrease the effective working width by 30 inches. Note: The first press of the middle switch activates the row change mode, but does not change the number of rows. If you were harvesting only half of an eight-row header swath, you would flip the center console switch to the left five times to subtract four rows (120 inches) from the effective working width. When using this function, the console will show the new number of rows and the effective working width for approximately three seconds, and then return to normal operation display. If the total width of the header was entered as one row, this function does not apply. Null Status Null Status will be displayed as follows: decrease increase Immediately after power-up, and if one hour has passed since the most recent null, =N will be displayed until the next null procedure is performed. If Auto-Null was selected in calibration, then 20 seconds after stopping or 20 seconds after putting the combine head in the HOLD position, =N will flash until: 1. Auto-Null is successfully completed ( =N will disappear) or 2. The console detects speed AND the combine head has been lowered to the RUN position for 12 seconds ( =N will disappear only if the most recent null occurred within the past hour). If Auto-Null was successful, the calipers symbol ( ) will be displayed for two seconds. For each successful Auto-Null that takes place before speed is detected AND before the head is lowered to the RUN position, =N will be displayed for about one-half second and will be displayed for two seconds. 67

68 Operation (cont) Description of Displayed Information (cont) GPS and Mapping Display Grain-Trak also supports the use of GPS (Global Positioning Systems) and mapping. The Data-Trak Memory Card Reader provides the interface between Grain-Trak and GPS and mapping. When recording to Data-Trak using GPS, the Grain-Trak console will display some basic GPS information. The sample console display to the right shows the additional GPS information shown on the Grain-Trak console. The readout in the lower right-hand corner of the display will automatically cycle between the counter mode indicator and the file number (next to the diskette symbol) that data is being stored to on the memory card. The readout in the bottom center position of the display will show the heading (compass degrees) of the combine. The readout in the lower left-hand corner of the display will automatically cycle between the number of satellites the GPS receiver is currently seeing and the overall quality of the signal being received from the satellites. Review the Data-Trak Installation and Operator's Manual for more details. "S04," not "504" heading file number or counter indicator DGPS System Interface for Mapping With the addition of a Data-Trak Memory Card Drive, the Grain-Trak system may be used with latitude and longitude input from a differentially corrected Global Positioning System (DGPS) receiver for mapping. For a fully functional Grain-Trak display, the DGPS receiver should output information in NMEA version 2.01 format, strings GGA, GSA, VTG and ZDA in RS-232 format, N-1 (4800 baud, 8 data bits, no parity, 1 stop bit.) The receiver must output the GGA data string for the harvest record; if some of the other strings are not available, some of the Grain-Trak display features will not function but the position data for mapping will be recorded. Harvest Report Interface With the addition of a Data-Trak Memory Card Drive, (with or without a DGPS receiver installed), yield, moisture and area data can be stored to the card and later printed in a spread sheet format (not a map). If a DGPS receiver is installed, you can also display and print a yield trail map. Refer to the Micro-Trak Card Reader software or your mapping software for details. 68

69 Zeroing Counters Purpose You will use the Counter Zeroing Mode: When the display shows the OFL message When you wish to make independent measurements on a daily, per field or per load basis When fine-tuning the speed sensor When fine-tuning the flow sensor and moisture sensor. OFL Message The Grain-Trak display's counters have specific ranges, and once their limits have been reached, you must manually reset the counters to zero before normal operation can continue. When a counter's limit has been reached, "OFL" will appear in the counter's display area. The system's counter limits are as follows: A. Top Counter TOTAL YIELD (Load, Field, Total) (0-1,999,999 volume units) System Units AE (0-1,999,999 volume units) System Units SI Bottom Counter TOTAL AREA (Load, Field, Total) (0-199,999 acres) System Units AE (0-199,999 hectares) System Units SI B. Distance (0-199,999 feet) System Units AE (0-199,999 meters) System Units SI A A or B Independent Measurements For monitoring productivity, it may be useful to measure the yield and area of an individual load or field, or the total covered per day. This is easily done with Grain-Trak's triple yield and area counters. These counters are designated as TOTAL, FIELD and LOAD and may be reset independently of one another. There are several variables to consider when clearing the system's stored values. Depending on your specific combining practices, you may want to clear the LOAD counters after each hopper full of grain you combine. The FIELD counters may be cleared after you finish combining a specific area of a field or an entire field. The TOTAL counters may be cleared after you have finished combining a farm or after you have finished combining for the season. If you clear LOAD, you will only clear the values for the LOAD counters. Average yield per area and moisture for the LOAD counters are also reset to zero. NOTE: To clear the LOAD counters on-the-go without entering the Counter Zeroing Mode or storing calibration LOAD data in non-volatile memory, simply hold the right switch DOWN for approximately three seconds. If you clear FIELD, you will clear the FIELD and LOAD counters. Average yield per area and moisture for each of these counters are also reset to zero. If you clear TOTAL, you will clear the TOTAL, FIELD and LOAD counters. Average yield per area and moisture for all counters are also reset to zero. 69

70 Zeroing Counters Selecting the Counter Zeroing Mode To access the Counter Zeroing Mode, follow these steps in numbered order: Grain-Trak Display Console 1. Turn the ignition switch ON. 2. Push the left switch DOWN and HOLD. Zeroing mode indicator 3. Push the right switch DOWN and RELEASE. Continue to hold the left swich down. 4. Release the left switch. The console will automatically advance to the first counter. Use of switches in the Counter Zeroing Mode Left Switch Right Switch accepts the displayed total and advances to the next counter zeros the displayed total *restores total NOTE: To restore a total that was mistakenly cleared, you must press the right hand switch up immediately. A total cannot be restored once you have advanced to the next counter. 70

71 Zeroing Counters Console Zeroing Display Screens 1. Load Counters If you clear LOAD, you will only clear the values for the LOAD counters. Average Yield per Area and Moisture for the load are also reset to zero. To store LOAD for calibration: With the LOAD data showing, push the righthand switch down and HOLD until the display returns to normal operating mode, then release the switch. (advance) (restore) (0) 2. Field Counters If you clear FIELD, you will clear the FIELD and LOAD counters. Average Yield per Area and Moisture for field and load are also reset to zero. (restore) (advance) (0) 3. Total Counters If you clear TOTAL, you will clear the TOTAL, FIELD and LOAD counters. Average Yield per Area and Moisture for all counters are also reset to zero. (restore) (advance) (0) 4. Distance (restore) (advance) (0) After selecting the "KEY" position to advance past the Distance counter, the console will automatically exit the Zeroing Mode and return to the normal operational mode. NOTE: Screens are shown for illustration only. 71

72 Troubleshooting Care and Maintenance Proper care and maintenance of the system will help prevent down-time due to problems. Store the console in a cool, dry location if it will not be used for an extended period of time, such as during the winter. The console features non-volatile memory, so totals and calibration numbers are retained when the console is disconnected from power. As with any electronic equipment, use care when cleaning the console so that water or other liquids do not enter the case. Any time the system is not being used, make sure that the grain flow sensor is free from obstruction or debris that could exert pressure on the sensor forks. Consult your dealer or distributor or a Micro-Trak service technician for further care and maintenance recommendations for the grain flow sensor. General All Grain-Trak components are tested prior to packaging, so unless there has been damage in shipment, you can be confident that everything will be operational when you receive it. However, if you encounter a problem that appears to be related to equipment failure, NEVER open any of the components. Opening a component voids the system's warranty. Contact Micro-Trak Systems for assistance. We will correct any defect. Most problems are the result of simple mistakes. Before contacting a service technician, carefully check your installation and review the operating instructions. A detailed list of possible problems and their solutions follows: Console Appears Dead Check for 12 volts at the power source. Check the fuse in the power cable. If the fuse is blown, check all the cables for pinched or cut areas and for any bare wires. Check for 12 volts at the console connector. If there are 12 volts at the console connector, the console may be defective. Contact a Micro-Trak technician for assistance. Console Is Erratic in Operation Check all cables for damage or bad connections. Check that all cables are routed as far away as possible from ignition wires, air conditioning clutches and similar equipment. If a two-way radio or cellular phone is installed, check that all Grain-Trak cables are routed as far away as possible from the radio and cellular equipment, their power cables and antennas. Displayed Measurements Do Not Make Sense Check that the correct System Units (Step 2 in calibration), have been selected. 72

73 Troubleshooting (cont) General (cont) Speed Is Erratic Or Reads Zero Check to make sure a wheel circumference value (Step 3 in calibration), has been entered. Use the appropriate system units. Check all cables for damage or bad connections. Check the speed sensor installation for proper mounting, alignment with magnets and spacing from magnets. If you are using a Trak-Star Ultrasonic Speed Sensor or a radar, review their respective Installation and Operator's manuals for troubleshooting procedures. Disconnect the speed cable from the TNgs100 module. Using a clip lead or other jumper wire (a paper clip bent in a "U" or a small needle-nose pliers), rapidly short together the two outside pins (pins A and C) of the speed connector on the module. If the console registers speed, the console and module are okay but the speed harness or speed sensor may be defective. If the console does not register speed, the module and/or console may be defective. Contact a Micro-Trak technician for assistance. A D B C D C B A D C B A A B C D A C B B A C B A F E D C B A I/O RUN/HOLD SPEED (yellow) FLOW (green) MOISTURE SYSTEMS, INC. TNgs100 GRAIN SENSOR INPUT A Component COMPUTER PROGRAM 1993 OPENING CASE VOIDS WARRANTY MFG. IN MANKATO, MN U.S.A. Speed Reading Is Inaccurate Perform Fine-Tuning Wheel Circumference Value. See Appendix D. Distance Count Is Inaccurate Perform Fine-Tuning Wheel Circumference Value. See Appendix D. Area Does Not Count Make sure that the system is in RUN, not HOLD. Make sure that the remote run/hold sensor is mounted properly. Make sure that the Row Width and Number of Rows (Steps 4 and 5 in calibration), have been entered correctly. Use the appropriate system units. Check that a wheel circumference value has been entered (Step 3 in calibration). Use the appropriate system units. Perform Fine-Tuning Wheel Circumference Value. See Appendix D. 73

74 Troubleshooting (cont) General (cont) Area Count Is Inaccurate Check that the Row Width and Number of Rows (Steps 4 and 5 in calibration), have been entered correctly. Use the appropriate system units. Check and make sure that the operational width on the console matches the actual width being harvested. Perform Fine-Tuning the Wheel Circumference Value. See Appendix D. Yield Per Area Reads Negative Flow Check that there is no grain flow or obstructions at the grain flow sensor. Reset the null frequency (zero flow condition) of the grain flow sensor (Step 14 in calibration). No Readout of Yield or Yield Per Area Check the flow sensor cable for damage or bad connections. Disconnect the flow cable from the TNgs100 module. Enter calibration and advance to the flow sensor null step (Step 15 in calibration). Using a clip lead or other jumper wire (a paper clip bent in a "U" or a needle-nose pliers), rapidly short together the two outside pins (pins A and C) of the flow connector on the module. If the console displays a frequency, the console and module are okay but the flow harness or flow sensor may be defective. If the console does not display a frequency, the module and/or console may be defective. Contact a Micro-Trak technician for assistance. A D B C D C B A D C B A A B C D A C B B A C B A F E D C B A I/O RUN/HOLD SPEED (yellow) FLOW (green) MOISTURE SYSTEMS, INC. TNgs100 GRAIN SENSOR INPUT A Component COMPUTER PROGRAM 1993 OPENING CASE VOIDS WARRANTY MFG. IN MANKATO, MN U.S.A. 74

75 Troubleshooting (cont) General (cont) Yield Count Is Inaccurate or Erratic Perform Fine-Tuning Flow Sensor Calibration Value. See Appendix E. If DRY volume was selected for displaying yield data, check that the Crop Density and Shrink Moisture values (Steps 9 and 10 in calibration) match the standard density and shrink moisture values used by your elevator. Also check that the displayed moisture matches the actual moisture. Review Moisture Sensor Offset (Step 12 in calibration). Check grain flow sensor for loose or missing fasteners/bolts/nuts. NOTE: If the bolts holding the finger/strain gauge assembly are loose or missing, serious damage to the combine could result. Unable to Write Data to the PCMCIA Card Check that the PCMCIA Card's Write Protect Switch is in the OFF position. If the switch is in the ON position, the system will not allow you to write data to the PCMCIA card. Check that the PCMCIA card has been properly formatted for both your Grain-Trak and Data-Trak systems. Check Data-Trak's LED for error messages, and refer to the Data-Trak manual. Console Error Messages This message indicates that Data-Trak may not be communicating with the GPS receiver, or that the information Data-Trak is receiving from the GPS receiver may be invalid. If Data-Trak is installed and this message appears, check that the RS232 cable is properly connected. If there are no cable problems, the GPS receiver may be damaged. Contact a Micro-Trak technician for assistance. This message may take a few seconds to disappear after power-up. This message at power up indicates that there is no communication with the TNgs100 module. Check the 4-pin I/O cable connected to the module. 75

76 Troubleshooting (cont) Console Error Messages (cont) This message indicates that voltage has dropped below a specific threshold (10.75 v), causing the moisture sensor to operate unpredictably. "Pbd" ("power bad") and the percent moisture will flash intermittently; the hazard symbol (triangle) will also flash. The screen will continue to display this message until the problem is eliminated. Using a voltmeter, test for 12 DC volts at the power source. This message indicates that there is a mismatch in calibration between the console and the module. This will occur if either the console or module has been replaced in the system. Enter calibration and verify the calibration settings if a component has been replaced. This message indicates that the flow frequency input to the module is below ~4 Hz. The console displays this condition as OFLO for instantaneous yield while the condition exists and for 10 seconds after it is corrected. This message indicates that either the console, module or Data-Trak (if used) is not being supplied with enough power (voltage must be greater that 11.0 volts). Check the voltage at the power connections (4-pin connectors, pins A and B) at the console and the module. Verify that 12 volts are available at the connection to the combine's power supply. Verify that the cables or connectors are not damaged. 76

77 Troubleshooting (cont) Console Error Messages (cont) This message indicates that the TNgs100 module has lost communication with the console. Check the 4-pin I/O cable connected to the module. The following errors are non-user-correctable: 1. Console, module, Data-Trak and card reader RAM and ROM errors. 2. Console, module and Data-Trak EEPROM errors. The word Error will appear in the volume display for about one out of every three seconds, along with a two-character error code in the area display. Volume and area information will be displayed as usual for the other two seconds. All other display areas will be unaffected. 77

78 Appendices 78

79 Appendix A Replacement Parts List The following replacement parts are available from your dealer or directly from Micro-Trak Systems. When ordering parts, please list the model number of the console, a description of the parts that you want to order and their respective part numbers. PART NUMBER DESCRIPTION one-bay expansion system kit suction cup console mount kit suction cup " x 1" Dual Lock TM fastener kit (four sets) speed sensor bracket " black nylon cable tie console adjustment knob hardware bag magnet with foam tape backing console mount well nut pin square 5 ft. (1.5m) extension cable pin square 10 ft. (3m) extension cable pin square 15 ft. (4.6m) extension cable pin square 20 ft. (6.1m) extension cable pin square connector replacement kit pin 5 ft. (1.5m) extension cable pin 10 ft. (3m) extension cable pin 15 ft. (4.6m) extension cable pin 20 ft. (6.1m) extension cable pin connector replacement kit pin 5 ft. (1.5m) extension cable pin 10 ft. (3m) extension cable pin 15 ft. (4.6m) extension cable pin 20 ft. (6.1m) extension cable pin connector replacement kit pin connector replacement kit Range Remote Run/Hold Kit Magnet Kit Power Cable Kit Speed Sensor Kit Grain-Trak TNy4400 console Grain-Trak TNgs100 module Grain-Trak Installation/Operator's Manual * Parts and specifications are subject to change without notice. 79

80 Appendix B Installation Templates Side D Side A Case/IH Access Hole Side B Template Side C Cut along solid black lines. Side A Case/IH Side D Access Hole Side B Template 80 Side C

81 Appendix B (cont) Installation Templates (cont) Cut along solid black lines. Side A Deere/Gleaner Side B Access Hole Template Side A Deere/Gleaner Side B Access Hole Template Side A Deere/Gleaner Side B Access Hole Template 81

82 Appendix C Conversion Table English to Metric When You Know Multiple By To Find LINEAR MEASUREMENT inches 25.4 millimeters feet meters yards meters miles 1.61 kilometers LAND MEASUREMENT square inches square millimeters square feet square meters square yards square meters acres.405 hectares square miles 2.59 square kilometers LIQUID MEASUREMENT fluid ounces milliliters pint liters quart liters gallons liters VOLUME cubic feet cubic meters cubic yards cubic meters DRY MEASUREMENT quart liters peck liters bushel liters FUEL CONSUMPTION 10 miles per gallon = 4.25 kilometers per liter Metric to English When You Know Multiple By To Find LINEAR MEASUREMENT millimeters.039 inches meters 3.28 feet meters 1.09 yards kilometers.62 miles LAND MEASUREMENT square millimeters square inches square meters square feet square meters square yards hectares 2.47 acres square kilometers square miles LIQUID MEASUREMENT milliliters fluid ounces liters pint liters quart liters 2.64 gallons VOLUME cubic meters cubic feet cubic meters cubic yards DRY MEASUREMENT liters quart liters peck liters bushels FUEL CONSUMPTION 10 kilometers per liter = 23.5 miles per gallon Conversion Abbreviations Symbols Symbols Symbols in. = inches pt. = pint km = kilometers ft. = feet qt. = quart mm2 = square millimeters yd. = yards gal. = gallon m2 = square meters ml. = miles ft3 = cubic feet ha = hectares in2 = square inches yd3 = cubic yards km2 square kilometers ft2 = square feet pk. = peck ml = milliliters yd2 = square yards bu. = bushel l = liters ml2 = square miles mm = milliliters dal = dekaliters (10 liters) fl oz. = fluid ounces m = meters m3 = cubic meters 82

83 Appendix D Fine-Tuning Wheel Circumference Value This procedure is used to correct the rough distance value that was entered during calibration of the system. Since this value determines the accuracy of many system measurements, each step should be performed as precisely as possible. PREPARATION Read Zeroing Counters and familiarize yourself with the procedure for clearing the distance counter. The system should be fully installed and calibrated. Select a straight tract od ground that is similar to your actual field conditions and as level as possible. Measure a distance of 1000 ft. or 500 meters. Clearly mark the beginning and the end points. For maximum accuracy, make sure that the equipment is set up just as it will be used in the field. ADJUSTMENT PROCEDURES - DISTANCE CALIBRATION 1. Turn the ignition on. The display console should be lit. Align the front of the combine at the starting point of the measured distance ft. or 500 meters 2. Toggle the right switch on the console to + until the distance counter is displayed. The distance counter has an up arrow next to it. 3. Enter the Zeroing Mode, Advance to the distance counter (Step 4) and reset the distance counter total to zero. Exit the Reset Mode. 4. If a remote run/hold sensor is installed, make sure the equipment and the console are in the RUN position. 5. Drive the measured distance. The display console will register a speed and distance will accrue on the display. When the front of the combine is exactly in line with the end point, place the run/hold switch in the HOLD position and stop the combine. 6. Enter the ALL calibration mode. Advance to Wheel Circumference (Step 3 in Calibration). Compare the displayed distance to the actual distance driven. distance measurement wheel circumference value adjust If the measurements do not agree, use the +/- switch to adjust the distance value. As you adjust the value in the distance counter, the wheel circumference value will also change. When the number shown in the distance counter matches the actual distance driven, you have arrived at the correct calibration value. NOTE: You may not be able to adjust the displayed distance to exactly match the actual distance driven. Adjust the displayed distance as close as possible to the actual distance. Write down the new wheel circumference number and keep it in a safe place. If the calibration values are ever accidently changed, you can simply re-enter this number. To achieve the greatest accuracy, repeat this procedure a second time. (+) (-) 83

84 Appendix E Fine-Tuning Moisture Sensor Calibration Value This procedure is used to fine-tune the rough calibration value that was entered during initial calibration of the system, to re-calibrate the moisture sensor for a change in crop or to simply confirm calibration periodically during harvest. Because the accuracy of the moisture sensor calibration value will determine the accuracy of the yields measurement, each step should be performed as precisely as possible. NOTE: For best results, always calibrate the moisture sensor and grain flow sensor at the same time using the same calibration load. Stay in calibration until both moisture offset and flow cal have been adjusted. PREPARATION Read Zeroing Counters and familiarize yourself with the procedure for clearing the distance counter. The system should be fully installed and calibrated. For maximum accuracy, make sure that the equipment is set up just as it will be used in the field. ADJUSTMENT PROCEDURES - Moisture Sensor CALIBRATION 1. Turn the ignition on. The display console should be lit. Make sure that the combine s grain tank is completely empty. 2. Enter the Counter Zeroing Mode, and reset the LOAD counter values to zero. Exit the Counter Zeroing Mode. NOTE: For maximum accuracy, the speed and RPM of the combine during this procedure should be as close as possible to the average speed and RPM of the combine during normal operation. 3. Begin harvesting. Harvest at least one combine load of grain. 4. Test a sample of the grain for its moisture content at an elevator, or use a hand-held moisture tester. NOTE: DO NOT reset the LOAD counter between loads if more than one combine load is used for this procedure. 5. After harvesting the desired load quantity to be used for calibration purposes, you must store the LOAD moisture. To store the load moisture, enter the Counter Zeroing Mode. With the LOAD totals shown (Step 1), hold the +/- switch to the minus ( - ) until the values for load bushels and acres reset to zero. After about three (3) seconds, the console will briefly display Init in the upper left readout and automatically return to normal operating mode. NOTE: You MUST continue to hold the minus ( - ) switch until the console returns to normal operating mode for the LOAD moisture to be stored in calibration. If the switch is released before returning to operating mode, press the +/- switch up to restore the LOAD totals, and then repeat the procedure for storing LOAD moisture. Once the LOAD moisture has been successfully stored to calibration, normal operation may continue. Zeroing the LOAD counter will not affect the LOAD moisture stored in calibration. 6. Enter ALL calibration and advance to Moisture Sensor Offset (Step 12). Compare the moisture constant from the elevator or hand-held moisture test to the moisture content displayed on the console. See diagram below. load moisture value load moisture offset value adjust (-) If the actual moisture does not agree with the displayed moisture, use the +/- switch on the console to adjust the displayed moisture to match the actual moisture. As you adjust the displayed moisture, the moisture sensor offset value will also change. When the displayed moisture matches the actual moisture, you have arrived at the correct moisture offset value. NOTE: You may not get the displayed moisture to exactly match the actual moisture. Adjust the displayed moisture as closely as possible to the actual moisture. Write the new moisture sensor offset number down and keep it in a safe place. If calibration values are ever accidentally changed, you can simply re-enter this number. To achieve greatest accuracy, repeat this procedure a second time. This procedure should be repeated periodically during harvest as a check to maintain accuracy. When an adjustment has been made to the moisture sensor offset value, the LOAD moisture will be erased from calibration upon exiting calibration. Viewing moisture sensor offset (Step 12) will show dashed lines ( --- ) instead of moisture. (+) 84

85 Appendix F Fine-Tuning Grain Flow Sensor Calibration Value This procedure is used to fine-tune the rough calibration value that was entered during initial calibration of the system, to re-calibrate the flow sensor for a change in crop or to simply confirm calibration periodically during harvest. Because the accuracy of the flow sensor calibration value will determine the accuracy of the yields measurement, each step should be performed as precisely as possible. NOTE: For best results, always calibrate the moisture sensor and grain flow sensor at the same time using the same calibration load. Stay in calibration until both moisture offset and flow cal have been adjusted. PREPARATION Read Zeroing Counters and familiarize yourself with the procedure for clearing the distance counter. The system should be fully installed and calibrated. For maximum accuracy, make sure that the equipment is set up just as it will be used in the field. If the switch is released before returning to operating mode, press the +/- switch up to restore the LOAD totals, and then repeat the procedure for storing LOAD pounds. Once the LOAD pounds has been successfully stored to calibration, normal operation may continue. Zeroing the LOAD counter will not affect the LOAD pounds stored in calibration. 6. Enter ALL calibration and advance to Flow Sensor Calibration (Step 13). See diagram below. NOTE: The console will measure and display WET weight. Make sure the scaled weight used for this procedure is WET weight. pounds (wet) ADJUSTMENT PROCEDURES - Moisture Sensor CALIBRATION 1. Turn the ignition on. The display console should be lit. Make sure that the combine s grain tank is completely empty. 2. Enter the Counter Zeroing Mode, and reset the LOAD counter values to zero. Exit the Counter Zeroing Mode. NOTE: For maximum accuracy, the speed and RPM of the combine during this procedure should be as close as possible to the average speed and RPM of the combine during normal operation. 3. Begin harvesting. Harvest at least one combine load of grain. The larger the quantity of grain that is used to finetune the calibration value, the more precise the adjustment will be. 4. Completely unload the combine s grain tank into a weigh wagon. If a weigh wagon in not available, unload the grain into a truck or wagon to haul to an elevator for weighing. NOTE: DO NOT reset the LOAD counter between loads if more than one combine load is used for this procedure. 5. After harvesting the desired load quantity to be used for calibration purposes, you must store the LOAD pounds. To store the load pounds, enter the Counter Zeroing Mode. With the LOAD totals shown (Step 1), hold the +/- switch to the minus ( - ) until the values for load bushels and acres reset to zero. After about three (3) seconds, the console will briefly display Init in the upper left readout and automatically return to normal operating mode. NOTE: You MUST continue to hold the minus ( - ) switch until the console returns to normal operating mode for the LOAD pounds to be stored in calibration. 85 flow sensor calibration value adjust If the actual scaled weight does not agree with the displayed moisture, use the +/- switch on the console to adjust the displayed weight to match the actual scales weight. As you adjust the displayed weight, the flow sensor calibration value will also change. When the displayed weight matches the actual scaled weight, you have arrived at the correct moisture offset value. NOTE: You may not get the displayed weight to exactly match the actual scaled weight. Adjust the displayed weight as closely as possible to the actual scaled weight. Write the new flow sensor calibration number down and keep it in a safe place. If calibration values are ever accidentally changed, you can simply re-enter this number. To achieve greatest accuracy, repeat this procedure a second time. This procedure should be repeated periodically during harvest as a check to maintain accuracy. When an adjustment has been made to the grain sensor flow sensor calibration value, the LOAD weight will be erased from calibration upon exiting calibration. Viewing flow sensor calibration (Step 13) will show dashed lines ( ---- ) instead of pounds. (+) (-)

86 Appendix G Grain Flow Sensor Load Cell Replacement Procedure Load Cell Replacement - Style 1 Sensors (NOT Ford/New Holland Installations) Style I Cover Assembly cross-beam of fork assembly (flat side) spacer cover screws sensor cover new load cell 15. Secure the new load cell bar to the fork assembly with the two hex head screws removed in Step Remove the fork assembly/load cell from the vise. 17. Place on of the rubber spacers on the cover assembly, aligning holes in the rubber spacer over the mounting bolts. 18. Place the new o-rings on the mounting bolts. Lightly lubricate the o-rings. 19. Lightly lubricate both sides of the load cell bar on the mounting end of the bar. 20. Place the load cell bar on top of the rubber spacer on the cover assembly. Place the other rubber spacer on top of the load cell bar, lining up holes in the spacer over the mounting bolts and the half sheer nub of the load cell bar. 21. Place a small amount of lubricate on top of the second rubber space. 22. Place the spacer cover over the rubber spacer, lining up holes in the spacer cover over the mounting bolts. 23. Place new #10 locking hex head nuts on each mounting bolt, and tighten nut to 40 in-lbs (4.5 Nm). 24. Reconnect the interface cable between the load cell and the sensor cover. 25. Push the sensor cover straight down into the sensor housing, and replace the four hex head bolts that were removed in Step 4. Note the direction of the flow decal. 26. Reconnect the four-pin connector of the sensor cover to the access panel connector. 27. Place the access panel on the sensor housing and push the plastic fasteners down to lock. 28. Secure the grain flow sensor to the mount bracket using the four hex head screws that were removed in Step Fine-tune the grain flow grain sensor according to the instruction found in Appendix F, page 85. vise urethane coating on sensor forks Style I Load Cell Replacement sensor cover rubber spacer spacer cover rubber spacer half sheer nub mounting bolt load cell bar o-ring spacer cover - end view 1. Locate the access panel with the cable entering the sensor housing, and turn the plastic fastener one quarter turn to unlock. Refer to page XX (Cable Connection at the Grain Flow Sensor) for details. 2. Pull the access panel away from the r sensor housing, and unplug the four-pin connector. DO NOT remover the access panel from the cable. 3. Remove the grain flow sensor from the mount bracket by removing the four hex head screws. KEEP THE SCREWS. 4. Remove the four hex head bolts connecting the cover assembly to the sensor housing, and pull the cover assembly straight up to remove. KEEP THE BOLTS. 5. Disconnect the interface cable between the load cell and the sensor cover. 6. Remove and discard the two locking hex nuts holding the load cell to the sensor cover. 7. Remove the spacer cover from the mounting bolts. 8. Remove and discard the rubber spacer from under the spacer cover. See the diagram on page XX. 9. Pull the old load cell straight up and off the mounting bolts. 10. Remove and discard the remaining rubber spacer. 11. Remove and discard the old o-rings from the mounting bolts. 12. Insert the cross-beam of the fork assembly, urethane-coated side up, into a vise. See the diagram to the below. 13. Detach the load cell from the fork assembly by removing the two hex head screws. KEEP THE SCREWS. 14. Place the new load cell on the fork assembly in the same position as the old one. 86

87 Appendix G (cont) Grain Flow Sensor Load Cell Replacement Procedure (cont) Load Cell Replacement - Style 1 Sensors (Ford/New Holland Installations) 1. Remove the grain flow sensor from the mount bracket be removing the four hex head screws. KEEP THE SCREWS. 2. Locate the access panel with the cable entering the sensor housing, and turn the plastic fastener tabs one quarter turn to unlock. Refer the page xx (Cable Connection at the Grain Flow Sensor) for details. 3. Pull the access panel away from the sensor housing, and unplug the 4-pin connector. DO NOT remove the access panel from the cable. 4. Remove the two hex head mounting bolts holding the load cell to the sensor housing, and pull load cell far enough out of the sensor housing so that you can disconnect the interface cable between the load cell and the sensor housing. 5. Disconnect the interface cable between the load cell and the sensor cover. 6. Completely remove the load cell from the sensor housing. 7. Insert the cross-beam of the fork assembly, urethanecoated side up, into a vise. See diagram below. Style 2 Cover Assembly spacer cover new load cell screws vise urethane coating on sensor forks 8. Detach the load cell from the fork assembly by removing the two hex head screws. KEEP THE SCREWS. 9. Place the new load cell on the fork assembly in the same position as the old one. 10. Secure the new load cell bar with the two hex head screws removed in Step Remove the fork assembly/load cell from the vise. 12. Remove and discard the old o-rings from the mounting bolts removed in Step Insert the mounting bolts into the spacer cover, and place new o-rings on the mounting bolts. 14. Remove and discard the old rubber spacers. 15. Insert the load cell far enough into the sensor housing so that you can reconnect the interface cable between the load cell and the sensor housing. 16. Completely insert the load cell into the sensor housing. 17. Lightly lubricate both sides of the load cell bar on the mounting end of the bar. 18. Place new rubber spacers in the same position as the ones removed in Step 18. Be sure the half sheer nub of the load cell is lined up with the offset in the top rubber spacer. 19. Line up holes of sensor housing, rubber spacers and load cell. 20. Place mounting bolts/spacer cover assembly into the lined-up holes. 21. Alternately tighten the mounting bolts to keep the spacer cover from binding. 22. Tighten the mounting bolts to 40 in-lbs (4.5Nm). 23. Reconnect the 4-pin connector of the sensor housing to the access panel connector. Set Screw Adjustment 24. For Style 2 sensors, view from the bottom of the sensor, and loosen the lock nut on the set screw. Using an allen wrench, tighten the set screw until light contact is made with the back of the cross-beam of the fork assembly (view through the inspection hole). DO NOT apply pressure to the load cell by overtightening. Damage may result. Once contact is mode, loosen the set screw eleven complete revolutions. Using an allen wrench, hold the set screw from turing, and tighten the locking nut securely. 25. Place the access panel on the sensor housing and push the plastic fasteners down to lock. 26. Place the sensor housing back into the mount bracket and secure with the screws removed in Step Fine tune the Grain Flow Sensor according to the instructions found in Appendix F page 85. Style 2 Load Cell Replacement o-ring half sheer nub rubber spacer spacer cover mounting bolt rubber spacer load cell bar 87

88 Appendix H Grain-Trak Display Console The Grain-Trak console will display several different symbols throughout the calibration and operation steps. Shown below are various symbols that will appear as you operate and calibrate your system. Depending on the variables you sect while calibrating or operating the system, different symbols will appear. volume wet (if no droplet, volume dry) moisture warning symbol for error messages or null calibration Counter Zeroing Mode distance area per hour number of rows volume per acre calibration wheel circumference volume per hour speed (MPH/KPH) direction of travel counter (load, field, total) or file number calibration step, number of satellites or signal quality (for GPS) < - writing to card DIF - differential OFF - differential lost advance to next screen decrease row width increase row width 88

89 Appendix I Record Formats HEADER AND DELIMITER (All record types) Record Start UI 5AAH Record Type UC 0: Normal, 1: Calibration, 2: Sigma File ID Number UI MT Console, 0-9,999 Record Length UC Record Length (Includes 5 header bytes) Record End UI 0121H (Delimiter ar end or record) WRITE RECORD TYPES: Normal Modes, 57 bytes including header and delimiter GPS Data: Latitude SL +/ minutes, Negative = South Longitude SL +/ minutes, Negative = South Altitude SL +/- 214, meters GPS Date UI bits 0-4, 5-8, 9-15: day, month, years after 1990 GPS Time UL seconds after midnight, GMT 0-86, 399 GPS Speed UL , 496, kn/hr Heading UI degrees PDOP UC HDOP UC VDOP UC DiffSat UL bit 0, diff on; bits 1-30, sats in view; bit 312, GPS fix Harvest Data: Mass SF Mass: Kgx100 0-$7F FF FF (IEEE 754 standard format) MXM SF Mass times moisture: Kgx100 0-$7F FF FF (IEEE 754 standard format) Area SF Area: square meters Kgx100 0-$7F FF FF (IEEE 754 standard format) Speed UI mm/sec, Subtract 8, 192 offset from raw data ( ) NumRows UC 0-12 rows Width UI mm Run/Hold UC bit 0, 1: network R/H, system R/H (0 = RUN, 1 = HOLD) bits 2-6 = GeoMarker switch status (bit 2 = switch 1, --, bit 6 = Switch 5) 0 = OFF, 1 = ON Sigma Modes, 21 bytes including header and delimiter: Mass SF Mass: Kgx100 0-$7F FF FF (IEEE 754 standard format) MXM SF Mass times moisture: Kgx100 0-$7F FF FF (IEEE 754 standard format) Area SF Area: square meters Kgx100 0-$7F FF FF (IEEE 754 standard format) Reset Flags UC bit 0, 1, 2, 3: distance, total, field, load Calibration Modes, 23 bytes including header and delimiter: NumRows UC 0-12 rows Width UI mm Crop Type UI (1) CORN, (2) SBNS, (3) WHEAT, (4) OATS, (5) CROP1, (6) CROP 2 Crop Weight UL 0.0=19,999,999 (kg/volume) times 100 (units of volume are not specified since they may be user defined) Shrink UC (% times 10) FlowCal UL 999,999 hundredths of grams/pulse (grams/pulse times 100) Spare _C reserved SX: Signed UX: Unsigned xc: (1 byte) Character XI: (2 byte) Character XL: (4 byte) Long XF: (4 byte) Float 89

90 NOTES 90

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92 M a n u f a c t u r e d i n t h e U.S.A. b y: 111 East LeRay Avenue / P.O. Box 99 / Eagle Lake, MN U.S. and Canada: (800) Phone: (507) Fax: (507) trakmail@micro-trak.com Micro-Trak Systems, Inc. Printed in the U.S.A Micro-Trak Systems, Inc. P/N Rev C