2-row and All-row systems included.

Transcription

1 Ag Leader Technology Cotton Picker Installation Installation Instructions for John Deere cotton picker models: 2-row and All-row systems included. IMPORTANT: Ensure the model numbers shown above correspond to the machine model. If you receive the incorrect installation instructions, contact Ag Leader Technology Technical Support at (515) ext. 1. PN: January 2010 Rev B 1

2 Cotton Picker Installation Ag Leader Technology Note: Indented items indicate parts included in an assembly listed above Quantity by Rows Monitored 2 Rows 4 Rows 5 Rows 6 Rows Part Name/Description Part Number Monitored Monitored Monitored Monitored Instruction Kit CAN, Cotton, Emitter Assembly Detector Assembly Header Sensor Reversed Arm Assy (18 in rod, S-hook, chain, spring) Template Welded (Cotton duct) Template Flat Strap (Cotton duct) Mounting Plate Cotton Sensor Antenna Mounting Plate (with dual lock) Module Kit Speed Mounting plate Speed Sensor module (Rev 8) Module installation kit Drill bit 13/64 in Drill bit 9/32 in Transfer punch 11/32 in Hex head cap screw 1/4 x 3/4 in Hex nut 1/4 in Split lock washer 1/4 in External tooth lock washer 1/4 in Self-tapping screw 1/4 x 3/4 in Hex serrated flange nut 1/4 in Sheet metal screw #14 x 1/2 in Cable Kit Cotton, 2 rows () Cable Kit Cotton, 4 rows () Cable Kit Cotton, 5 rows () Cable Kit Cotton, 6 rows () Display cable 12 ft Power cable Power control relay Header height adapter cable CAN Bus harness 2 sensor CAN Bus harness 4 sensor CAN Bus harness 5 sensor CAN Bus harness 6 sensor January 2010 Rev B

3 Ag Leader Technology Cotton Picker Installation Note: Indented items indicate parts included in an assembly listed above Quantity by Rows Monitored 2 Rows 4 Rows 5 Rows 6 Rows Part Name/Description Part Number Monitored Monitored Monitored Monitored Grounding cable 2 row Grounding cable 4 row Grounding cable 5 row Grounding cable 6 row CAN Bus stub 1 ft Fan speed cable 10 ft Ground speed cable 10 ft Cable installation kit Alcohol swab pack Gray plastic cable clamps Cable tie 15 in Cable tie 6 in Adhesive mounting base 2 way Parts Kit Cotton, 2 rows () Parts Kit Cotton, All rows () Header Sensor Inst. Kit Generic S-Hook Cap screw 5/16 x 1 in Lock Nut 5/16 in Flat Washer 5/16 in Hose clamp 39 in Drill bit 9/32 in Drill bit 11/32 in Drill bit 1/4 in Hole saw 1-3/8 in Transfer punch 13/32 in Square file 5/16 in File handle RTV silicon sealant Monitor bracket installation kit Drill Bit 13/64 in Self tapping screw 1/4 x 3/4 in Cap screw 1/4 x 3/4 in Hex Nut 1/4 in Split Lock washer 1/4 in Flat Washer 1/4 in Hardware kit 37 pieces Hardware kit 75 pieces Slotted truss head screw 1/4 x 3/4 in Split lock washer 1/4 in Hex nut 1/4 in Permanent marker Grommet 3/4 in. I.D. x 1-3/8 in. P.H.D Monitor bracket PN: January 2010 Rev B 3

4 Cotton Picker Installation Ag Leader Technology Important Notices Please carefully follow these step-by-step instructions. If you have questions, contact Ag Leader Technology at x 1. Direction words (LEFT and RIGHT) are commonly used when describing an installation procedure. Interpret direction words as if sitting in operator seat. Signal words (DANGER, WARNING, CAUTION and NOTE) are provided to draw attention to information that is important for the safe/correct installation and operation of this product. Indicates an imminently hazardous situation that, if not avoided, will result in death or serious injury. Indicates a potentially hazardous situation that, if not avoided, could result in death or serious injury. Indicates a potentially hazardous situation that, if not avoided, may result in minor or moderate injury. CAUTION Indicates practices that may result in property damage, but do not involve personal injury. NOTE The preferred signal word to address practices not involving property damage, or personal injury. Section Contents Item Page System Layout 5 Installing Display 6 Installing Display & Power Cables 8 Installing Speed Sensor Module 11 Installing Fan Speed Cable 12 Installing Ground Speed Cable 14 Installing Header Height Sensor 15 Installing Cotton Flow Sensors 17 Installing CAN Bus Harness & Static Ground Cable 25 Final Inspection 26 Operational Checkout 27 4 January 2010 Rev B

5 Ag Leader Technology Cotton Picker Installation System Layout This section illustrates the general layout of the cotton yield monitoring system. The purpose of the illustration is to aid in the installation procedure. Use this section for reference as needed when installing the system components. Figure 1. System Layout PN: January 2010 Rev B 5

6 Cotton Picker Installation Ag Leader Technology Installing Display Parts required for procedure: (1) Display (1) Ceiling bracket (1) U-bracket (1) Marking pen or scribe (1) Punch (1) Drill bit 13/64 in. (4) Self-tapping screw 1/4 x 3/4 in. (2) Hex head cap screw 1/4 x 3/4 in. (2) Split lock washer 1/4 in. (2) Hex nut 1/4 in. Step-by-Step Procedure 1. Attach U-bracket to ceiling bracket using 1/4 in. hardware from monitor installation kit as shown in Figure 2. Figure 2. U-bracket assembled to ceiling bracket 2. Position bracket assembly along right side of cab. Move assembly forward or backward to obtain optimum position for viewing as shown in Figure 3. 6 January 2010 Rev B

7 Ag Leader Technology Cotton Picker Installation Figure 3. Monitor bracket installed 3. Using bracket as template, mark (4) mounting holes on frame of cab near right window. 4. Center punch and drill mounting holes with provided 13/64 in. drill bit. 5. Attach bracket to cab ceiling with (4) 1/4 x 3/4 in. self-tapping screws. 6. Reattach U-bracket to ceiling bracket. NOTE: The display brackets have several mounting slots for flexibility in mounting. Determine which combination is most desirable before tightening cap screws. 7. Mount display to U-bracket. PN: January 2010 Rev B 7

8 Cotton Picker Installation Ag Leader Technology Installing Display & Power Cables Parts required for procedure: (1) Display cable (1) Power cable (1) Power control relay (2) Adhesive backed cable clips (1) Drill bit #19 (1) Screw mounting base and flat head screw (1) Hole saw 1-3/8 in. (1) Drill bit 1/4 in. (1) Grommet (1) Alcohol swab packet Cable ties Step-by-Step Procedure 1. Connect smaller round connector of display cable to mating connector on back of display. CAUTION: Never use force to mate electrical connectors. If connectors do not mate easily, they are not aligned properly 2. Route display cable down right side of cab post. Tuck cable neatly behind plastic cover of cab pillar where possible to keep cable secure. 3. Drill a hole in air conditioning duct below right window using provided #19 drill bit as shown in Figure 4. Attach screw-mounting base with flat head screw. Secure display cable to base with cable tie. Power Strip Screw mounting base Figure 4. In-cab installation 8 January 2010 Rev B

9 Ag Leader Technology Cotton Picker Installation 4. Connect power control relay (see Figure 1) to mating 4-position shroud connector of display cable. 5. Connect 3-socket tower connector of power cable to mating 3-pin shroud connector of display cable. Plug opposite end of power cable into power strip located on right wall of cab as shown in Figure 4. NOTE: The power cable provides full-time power and switched power to the display. By default, the display will power up and down with the ignition switch. This feature can be disabled by removing the fuse from the switched power wire. If the fuse is removed, the operator must turn the display on and off manually. 6. Route display cable into access hole in right rear corner of cab. NOTE: At this point, installation inside the cab is complete. 7. Remove access panels from right wall of cab and from rear wall of cab as shown in Figure 5. Access Panels Figure 5. Access panels to remove 8. With access panel removed from rear wall of cab, drill a 1-3/8 in. hole through cab wall using provided hole saw as shown in Figure 6. CAUTION: Be careful to avoid wires on interior side of cab wall when drilling hole. PN: January 2010 Rev B 9

10 Cotton Picker Installation Ag Leader Technology 1-3/8 hole Figure /8 in. hole drilled through cab wall 9. Pass ethernet connector of display cable through hole in cab wall first, then 4- position round cannon connectors (CAN A and CAN B) through hole in cab wall and install provided grommet around wires as shown in Figure 7. CAN Bus harness will be mated with connector in a following section. NOTE: If GPS will be used, route GPS cable before installing grommet. Display cable Figure 7. Grommet installed over display cable and GPS cable 10. Replace access panel that was removed from right wall of cab. Do not replace access panel that protects cables at rear wall of cab. It will be reinstalled in a following section. 10 January 2010 Rev B

11 Ag Leader Technology Cotton Picker Installation Installing Speed Sensor Module Parts required for procedure: (1) Speed Sensor module (1) Punch (1) Drill 9/32 in. (2) Hex head bolt 1/4 x 3/4 in. (2) Flat washer 1/4 in. (2) Hex nut 1/4 in. Step-by-Step Procedure 1. Position Speed Sensor module on side of metal cable shield as shown in Figure 8. Position near lower end to ensure Speed Module Stub is long enough to reach display cable. Speed Sensor module Figure 8. Speed Sensor module installed 2. Mark locations for middle holes in each flange of Speed Sensor module onto side of box. 3. Punch and drill (2) holes using provided punch and 9/32 in. drill. 4. Secure Speed Sensor module using provided 1/4 in. bolts, flat washers and hex nuts. PN: January 2010 Rev B 11

12 Cotton Picker Installation Ag Leader Technology Installing Fan Speed cable Parts required for procedure: (1) Fan speed cable Cable ties Step-by-Step Procedure 1. Remove shield behind left front wheel to access fan area. Fan speed sensor will be very close to side of machine. See Figures 9 and 10. Fan speed sensor Figure 9. Fan exposed on left side of machine 12 January 2010 Rev B

13 Ag Leader Technology Cotton Picker Installation Fan speed sensor Figure 10. Fan speed sensor with cable connected 2. Install tee end of fan speed cable between existing wiring harness and fan speed sensor as shown in Figure Route fan speed cable to Speed Sensor module located at right rear corner of cab. Route cable along existing wires, hoses, or tubes. Secure with cable ties to keep clear of moving parts. 4. Connect fan speed cable to 6-pin Shaft Speed connector of Speed Sensor module. Coil and secure excess cable with cable ties. PN: January 2010 Rev B 13

14 Cotton Picker Installation Ag Leader Technology Installing Ground Speed cable Parts required for procedure: (1) Ground speed cable Cable ties Step-by Step Procedure 1. Locate ground speed sensor on top of transmission as shown in Figure 11. If possible, access sensor from front of machine. If ducts prohibit access from front, lower access panel behind transmission to gain access. Do not crawl under head w/o proper safety stops installed. In the event of hydraulic failure, serious injury or death may result. Sensor Front of machine Figure 11. Top view of transmission 2. Install tee end of ground speed cable between existing wiring harness and sensor. 3. Route ground speed cable to Speed Sensor module located at right rear corner of cab. Route cable along existing wires, hoses, or tubes. Secure with cable ties to keep clear of moving parts. 4. Connect ground speed cable to 2-pin Ground Speed connector of Speed Sensor module. Coil and secure excess cable with cable ties. 14 January 2010 Rev B

15 Ag Leader Technology Cotton Picker Installation Installing Header Height Sensor Parts required for procedure: (1) Header height sensor with integral cable (1) Arm assembly (18 in. rod, S-hook, chain, spring) (1) S-hook (1) Hose clamp 39 in. (1) Punch (1) Drill bit 11/32 in. (2) Hex head bolt 5/16 x 1 in. (4) Flat washer 5/16 in. (2) Lock nut 5/16 in. Cable ties Step-by-Step Procedure 1. Install arm assembly into hole of sensor pivot shaft using a nut and lock washer on each side of shaft. NOTE: The header sensor installation may vary from one machine to another due to differences in picker configurations. Please use your judgment to determine the best mounting location. Refer to Figure 12 as an example of an installation that worked well in one situation. Figure 12. Header sensor installed PN: January 2010 Rev B 15

16 Cotton Picker Installation Ag Leader Technology 2. Position header sensor under cab in a location that is most appropriate for machine configuration. Use the following criteria to assist in determining mounting location: a. Mounting location must be clear of moving parts. This includes location for threaded arm assembly and chain assembly. b. Threaded arm must be able to travel through a wide range of motion when header is raised and lowered in order to optimize performance. c. Header must not crush header sensor when row units are fully raised. d. Header sensor anchor point must not interfere with side-to-side adjustment of row units. 3. With header sensor mounting location determined, use provided 11/32 in. drill to drill mounting holes. It is possible that existing holes in frame will suffice and no new holes will be required. 4. Install header sensor using (2) 5/16 x 1 in. bolts, flat washers and lock nuts. 5. Determine anchor point location for arm assembly using same criteria listed in step 2. A stainless steel hose clamp has been provided to aid in creating a versatile anchor point. 6. Secure chain of header sensor under stainless steel clamp at desired height. Adjustments can be made by adjusting chain length from S-hook. 7. Take note of small clearance between header sensor chain and rotating shaft shown in Figure 12. Arm assembly may be bent if necessary to eliminate potential for interference. 8. Connect header sensor adapter cable to integral cable of header sensor. 9. Route header sensor cable to right rear corner of cab where Speed Sensor module is located. 10. Connect header sensor to 8-pin Position Sensor connector of Speed Sensor module. 11. Coil and secure excess cable with cable ties as necessary. NOTE: Before proceeding, verify sensor will not interfere with raising or side-to-side movement of row units. Modify installation if necessary. 16 January 2010 Rev B

17 Ag Leader Technology Cotton Picker Installation Installing Flow Sensors on Ducts Parts required for procedure (quantities vary depending on number of rows monitored): Emitter/Detector pair (Figure 13) Mounting plate Template welded Template flat strap Slotted truss head screws 1/4 x 3/4 in. Split lock washers 1/4 in. Hex nuts 1/4 in. RTV silicon sealant Step-by-Step Procedure NOTE: Each duct requires an Emitter and Detector to sense cotton flow as shown in Figure 13. Each Emitter has (5) individual infrared light emitters within each housing. Likewise, each detector has (5) individual sensors to correspond with each emitter. Detector (Back of Hood) Emitter (Front of Hood) Figure 13. Emitter and detector pair For a 2-row monitoring system, install sensors on the following ducts for best performance. See Figure 14 for proper duct/row designations. 4-Row: Rows 1 & 4 5-Row: Rows 1 & 5 6-Row: Rows 2 & 5 PN: January 2010 Rev B 17

18 Cotton Picker Installation Ag Leader Technology Duct numbers Figure 14. Duct designations 1. Remove selected duct from machine. Place back side of duct on floor. 2. Measure specified distance from bottom of duct as called out in Figure 15. Make (2) marks across width of duct and then draw a straight line across duct to connect marks. See Figure 16 for an illustration. NOTE: Precise measurements are critical for installation. Figure 15. Measurements for each duct 18 January 2010 Rev B

19 Ag Leader Technology Cotton Picker Installation Top Bottom Specified Measurement Figure 16. Illustration of how to measure ducts Duct 1,5,6 Duct 2 Duct 3,4 Figure 17. Duct height PN: January 2010 Rev B 19

20 Cotton Picker Installation Ag Leader Technology 3. Line up top of mounting bracket with line on duct as shown in Figure 18. Orient bracket so studs on bracket are toward outlet of duct (up). Center mounting bracket side-to-side on duct by accurately marking a vertical centerline on duct and positioning center holes of mounting bracket over centerline. 4. Hold position of centered mounting bracket and mark rectangular hole and (6) mounting holes. Figure 18. Bracket held in position for marking holes 5. Remove mounting bracket, center punch and drill (6) mounting holes using provided punch and 9/32 in. drill bit. 6. Cut rectangular hole using a cutting disk or saw. Figure 19 illustrates how the duct should look when drilling and cutting is complete. CAUTION: To prevent injuries to yourself or others wear safety goggles or face shield for protection from airborne particles while cutting. 7. When cutting and drilling is complete, file perimeter of rectangular cutout to remove sharp edges. NOTE: Filing is not complete until all burrs have been removed. Burrs may catch stringers and cause yield errors. 20 January 2010 Rev B

21 Ag Leader Technology Cotton Picker Installation Figure 19. Holes drilled and cut 8. Install (6) 1/4 x 3/4 in. truss head screws with lock washers and nuts to secure mounting bracket to duct. Install screws from inside so nuts are on outside of duct. 9. With mounting bracket securely fastened to front side of duct, attach hinged template to mounting bracket as shown in Figure 20. Ensure hinged template is fully engaged into hinge, then install (2) nuts to secure template to mounting bracket. Figure 20. Hinged template fastened to mounting plate PN: January 2010 Rev B 21

22 Cotton Picker Installation Ag Leader Technology 10. Attach another mounting bracket to template flat strap using (2) nuts as shown in Figure 21. Figure 21. Flat strap template attached to mounting plate 11. Slide assembly shown in Figure 21 onto U-shaped strap as seen in Figure 22. Template assembly should be slid on until bracket is tight against duct. 22 January 2010 Rev B

23 Ag Leader Technology Cotton Picker Installation Figure 22. Back mounting bracket in position to be marked 12. With back bracket in position, mark locations for (6) mounting holes and rectangular cutout just as was done for bracket on front side of duct. Remove template. NOTE: Due to irregularly shaped ducts, the locations marked for the back bracket may not be centered side to side on duct. That is normal. It is more important that the sensors be lined up properly using the provided alignment template than being centered side to side on the duct. 13. Drill and cut holes just as was done for bracket on front side of duct. Remove burrs. 14. Secure mounting bracket using (6) 1/4 x 3/4 in. truss head screws with lock washers and nuts. Install screws from inside so nuts are on outside of duct. It is a good idea to use template to double check alignment before tightening fasteners. With optimum alignment achieved, securely tighten fasteners. 15. If necessary, seal gaps between mounting plates and duct with provided RTV silicon. This is most easily done before ducts are reinstalled on machine. 16. With mounting brackets secured to duct, reinstall duct on machine. 17. Install emitter (sensor with integral cable) in front mounting bracket and detector in back mounting bracket. Hinge up and tighten captive nuts. Emitter is shown in Figure 23. PN: January 2010 Rev B 23

24 Cotton Picker Installation Ag Leader Technology Figure 23. Emitter installed on front side of duct 24 January 2010 Rev B

25 Ag Leader Technology Cotton Picker Installation Installing CAN Bus Harness & Grounding cable Parts required for procedure: (1) CAN Bus harness (1) Static grounding cable (necessary for plastic ducts) Cable ties Step-by-Step Procedure CAUTION: The CAN Bus harness must be secured with cable ties to prevent damage from cotton and other debris. When securing CAN Bus to machine, make sure it will move appropriately when ducts are raised or lowered when switching to and from transport mode. CAN Bus harness may be damaged if care is not taken when securing it. 1. Locate end of CAN Bus harness that is labeled Sensor 1. Connect Sensor 1 connector of CAN Bus harness with mating connector of left-most detector installed on machine. 2. Connect emitter pigtail (located on front side of duct) to mating connector on CAN Bus harness. 3. Proceed to connect CAN Bus harness to corresponding sensor sets from left to right across machine until all sensor sets have been connected. 4. Route remainder of CAN Bus harness down to display cable that was installed in a previous section (See Figure 7 on page 10). 5. Plug CAN Bus into display cable. Black female connector of display cable mates with black male connector of Y-Splice on CAN Bus. 6. Plug black female connector of speed module stub into remaining male connector (light color) of Y-Splice on CAN Bus. 7. Plug gray female connector of speed module stub into 4-pin CAN Bus connector of Speed Sensor module. 8. Coil and secure excess CAN Bus harness near display cable. 9. Replace rear panel of metal compartment that protects cables. NOTE: To limit static electricity buildup, sensor mounting plates on plastic ducts must be grounded with provided grounding cable. 10. Remove nut from mounting plate for each detector and attach lug of static ground cable as shown in Figure 24. PN: January 2010 Rev B 25

26 Cotton Picker Installation Ag Leader Technology 11. Route grounding cable with CAN Bus harness to a location where grounding cable can be attached to picker chassis. Ensure lug attached to chassis has a good connection by removing paint as necessary for metal-to-metal contact. Emitter Pigtail CAN Bus Harness Ground Wire Figure 24. CAN Bus harness and ground wire connected to Sensor 1 Final Inspection Installation is complete. Walk around machine to verify the following: All cable connections have been made. Excess cable has been tied out of way to avoid interference. All tools have been removed from machine. All cap screws and captive nuts are tight on sensor mounts. Safety shields have been replaced. 26 January 2010 Rev B

27 Ag Leader Technology Cotton Picker Installation Operational Checkout An operational checkout cannot be performed until a harvest configuration has been created and activated. Refer to Quick Reference Sheet (see instruction kit) or Operator s Manual for instructions. Step-by-Step Procedure 1. Press and release power button. 2. Create and activate a harvest configuration. a. Refer to Quick Reference Sheet and/or Operator s Manual. 3. Verify CAN modules are powered and communicating. a. Each module has an LED indicator. It should flash green. 4. From RUN screen, touch SYSTEM button in top right corner of screen. Touch CAN tab. All modules should be displayed in the list. You should see (1) Speed Sensor module and as many Flow Sensor modules as are installed on the machine. If all modules are not in list, cycle power to display. A machine monitoring (2) rows should have a list that looks like this: 208 FLOW SENSOR 209 FLOW SENSOR 239 SPEED MODULE 5. Touch Diagnostics tab within SYSTEM screen. a. Verify FAN SPEED (RPM) signal. 1. Fan speed should register zero with fan off. 2. Engage fan. Display should register an RPM value. At full throttle, fan speed should be greater than 2500 RPM. b. Verify GROUND SPEED (MPH) signal. 1. Ground speed should register zero with picker at rest. 2. Move picker slowly. Display should register MPH value at low speeds (below 1 MPH). NOTE: If using wheels as primary speed sensor, ground speed reading on display may not agree with picker readout until system has been calibrated. c. Verify HEADER HEIGHT (%) signal 1. Raise and lower header. Header height % should increase and decrease respectively. PN: January 2010 Rev B 27

28 Cotton Picker Installation Ag Leader Technology Revision History Date Revision Initials Changes Dec 2006 N/C SLH - Initial release Sep 2007 A SLH - Changed header sensor installation section Jan 2010 B WDS - Changed display cable 28 January 2010 Rev B