Ag Leader Technology Cotton Picker Installation Installation Instructions for John Deere cotton picker models: 9986 & 9996 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) 232-5363 ext. 1. PN: 2006100-7 August 2005 Rev C 1
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 Cotton, 2006100-7 1 1 1 1 Emitter Assembly 3000287 2 4 5 6 Detector Assembly 3000288 2 4 5 6 Header Sensor Standard 2000322-1 1 1 1 1 Arm Assy (18 in rod, S-hook, chain, spring) 2000311-2 1 1 1 1 Template Welded (Cotton duct) 3000715 1 1 1 1 Template Flat Strap (Cotton duct) 3000716 1 1 1 1 Mounting Plate Cotton Sensor 3000721 4 8 10 12 Antenna Mounting Plate (with dual lock) 3000654 1 1 1 1 Cable Kit Cotton, 2 rows () 2001258 1 Cable Kit Cotton, 4 rows () 2001259 1 Cable Kit Cotton, 5 rows () 2001260 1 Cable Kit Cotton, 6 rows () 2001261 1 Ground speed cable 12 ft. 2000407-6 1 1 1 1 Fan speed cable 10 ft. 2000408-2 1 1 1 1 Flow sensor cable 2 sensor 2100005-1 1 Flow sensor cable 4 sensor 2100006-3 1 Flow sensor cable 5 sensor 2100004-1 1 Flow sensor cable 6 sensor 2100013-1 1 Distribution cable 2100007-1 1 1 1 1 Grounding cable 2 row 2100015-1 1 Grounding cable 4 row 2100016-1 1 Grounding cable 5 row 2100017-1 1 Grounding cable 6 row 2100018-1 1 Cab cable 3000914 1 1 1 1 WP plugged tower 3 pin 2000902-3 1 1 1 1 Cable installation kit 2000901-1 1 1 1 1 Alcohol swab pack 2002811 2 2 2 2 Gray plastic cable clamps 2002812 6 6 6 6 Cable tie 15 in. 2002817-15 20 20 20 20 Cable tie 6 in. 2002817-6 40 40 40 40 Adhesive mounting base 2 way 2002821-2 6 6 6 6 2 August 2005 Rev C
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 Parts Kit Cotton, 2 rows () 2001336-4 1 Parts Kit Cotton, All rows () 2001336-5 1 1 1 Header Sensor Inst. Kit Generic 2000330-4 1 1 1 1 S-Hook 2000329-3 1 1 1 1 Cap screw 5/16 x 1 in. 2002001-31100 3 3 3 3 Lock Nut 5/16 in. 2002055-31 3 3 3 3 Flat Washer 5/16 in. 2002071-31 4 4 4 4 Hose clamp 39 in. 2000645-39 1 1 1 1 Drill bit 9/32 in. 2001000-28 1 1 1 1 Drill bit 11/32 in. 2001000-34 1 1 1 1 Drill bit 1/4 in. 2001001-25 1 1 1 1 Hole saw 1-3/8 in. 2001002-138 1 1 1 1 Transfer punch 13/32 in. 2001003-41 1 1 1 1 Square file 5/16 in. 2001006 1 1 1 1 File handle 2001019 1 1 1 1 RTV silicon sealant 2001011 1 1 1 1 Monitor bracket installation kit 2001304-9 1 1 1 1 Drill Bit 13/64 in. 2001000-20 1 1 1 1 Self tapping screw 1/4 x 3/4 in. 2002075-25075 4 4 4 4 Cap screw 1/4 x 3/4 in. 2002001-25075 2 2 2 2 Hex Nut 1/4 in. 2002051-25 2 2 2 2 Split Lock washer 1/4 in. 2002061-25 2 2 2 2 Flat Washer 1/4 in. 2002071-25 4 4 4 4 Hardware kit 37 pieces 2001339-1 1 Hardware kit 75 pieces 2001339-2 1 1 1 Slotted truss head screw 1/4 x 3/4 in. 2002250-25075 37 75 75 75 Split lock washer 1/4 in. 2002061-25 37 75 75 75 Hex nut 1/4 in. 2002051-25 37 75 75 75 Permanent marker 2002813 1 1 1 1 Grommet 3/4 in. I.D. x 1-3/8 in. P.H.D. 2002824-75 1 1 1 1 Ceiling bracket 3000690 1 1 1 1 PN: 2006100-7 August 2005 Rev C 3
Cotton Picker Installation Ag Leader Technology Important Notices You will save time and prevent wrong installation of components by closely following these step-by-step instructions. If you have questions, call Ag Leader Technology at 515-232-5363 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 (CAUTION, IMPORTANT and NOTE) are provided to draw attention to information that is important for the safe/correct installation and operation of this product. CAUTION will alert you to situations that will impact the physical safety of you or others. IMPORTANT will alert you to the potential for damage to the product or loss of data. NOTE will provide you with additional information to simplify a procedure or clarify a process. Keep parts list and installation instructions for use as a reference after completing installation. Section Contents Item Page Installing Monitor 5 Installing Cab, Power & Distribution Cables 7 Installing Fan Speed Cable 10 Installing Ground Speed Cable 12 Installing Header Height Sensor 13 Installing Cotton Flow Sensors 16 Installing Flow Sensor Cable & Static Ground Cable 24 Final Inspection 25 Operational Checkout 26 4 August 2005 Rev C
Ag Leader Technology Cotton Picker Installation Installing Monitor Parts required for procedure: (1) PF3000, PF3000 Pro, or PF Advantage (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. NOTE: Recommended mounting position is on frame rail of ceiling along right window as shown in Figure 1. This places the monitor within easy reach and in a convenient viewing position. Figure 1. Monitor bracket installed PN: 2006100-7 August 2005 Rev C 5
Cotton Picker Installation Ag Leader Technology 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 1. 3. Using bracket as template, mark (4) mounting holes on frame of cab near right window as shown in Figure 1. 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 monitor to U-bracket. 6 August 2005 Rev C
Ag Leader Technology Cotton Picker Installation Installing Cab, Power & Distribution Cables Parts required for procedure: (1) Cab cable (1) Distribution cable (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) Grommet (1) Alcohol swab packet Cable ties Step-by-Step Procedure 1. Connect cab cable to mating connector on bottom of monitor. IMPORTANT: Never use force to mate electrical connectors. If connectors do not mate easily, they are not aligned properly 2. Route cab cable down right side of cab post. Use adhesive backed cable clips as necessary to secure cable to window. Clean window with provided alcohol swab before adhering clips to window. 3. Drill a hole in air conditioning duct below right window using provided #19 drill bit as shown in Figure 3. Attach screw-mounting base with flat head screw. Secure display cable to base with cable tie. Screw-mounting base Figure 3. Cab cable routing PN: 2006100-7 August 2005 Rev C 7
Cotton Picker Installation Ag Leader Technology 4. Route cab cable along right side of cab to back right corner. 5. Connect power lead coming out of round 24 pin connector to power strip mounted on wall as shown in Figure 4. Figure 4. Power cable connected to power strip 6. Route 24-pin connector of cab cable and excess power cable into hollow area in right-rear corner of cab. Cab cable will be accessed from outside cab in a later step. NOTE: Installation inside cab is finished. 7. Remove wall plate on exterior wall of cab. It is located on right side of cab in lower rear corner as shown in Figure 5. 8. Install distribution cable as follows: 8 August 2005 Rev C
Ag Leader Technology Cotton Picker Installation Figure 5. Wall plate removed Cable shield Figure 6. Shield on back corner of cab a. Remove shield that protects cable connections at back wall of cab as shown in Figure 6. b. Drill a 1-3/8 in. hole in open area under shield using provided hole saw. Be careful not to damage existing wiring on either side of cab wall. c. Install 3/4 in. I.D. x 1-3/8 in. P.H.D. grommet around wires of distribution cable. d. Insert distribution cable and grommet into 1-3/8 in. hole in cab so 24-pin connector remains inside cab and multiple connectors are outside cab. e. Mate 24-pin plug of cab cable with 24-pin receptacle of distribution cable. f. Reinstall wall plate and cable shield. PN: 2006100-7 August 2005 Rev C 9
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 7 and 8. Figure 7. Fan exposed on left side of machine 10 August 2005 Rev C
Ag Leader Technology Cotton Picker Installation Figure 8. 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 8. 3. Route fan speed cable to distribution cable 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 mating connector of distribution cable. Coil and secure excess cable with cable ties. PN: 2006100-7 August 2005 Rev C 11
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 as follows: a. Drop belly cover under front axle by removing (2) pins. b. After dropping belly cover, back of trans-axle will be exposed. Near middle of back side of trans-axle is a sensor that will plug into ground speed sensor cable. DO NOT connect to this sensor. c. Ground speed sensor is on top of trans-axle. Sensor cannot be seen. You must reach through and around with one hand to connect cable. 2. Route ground speed cable to distribution cable 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. 3. Connect ground speed cable to mating connector of distribution cable. Coil and secure excess cable with cable ties. 12 August 2005 Rev C
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 cap screw 5/16 x 1 in. (4) Flat washer 5/16 in. (2) Lock nut 5/16 in. Cable ties Step-by-Step Procedure 1. Position header sensor under right side of cab on flange of support member as shown in Figures 9 & 10. Mark (2) outside slots of middle row with permanent marker. Figure 9. Header sensor installed PN: 2006100-7 August 2005 Rev C 13
Cotton Picker Installation Ag Leader Technology Figure 10. Header sensor installed 2. Punch and drill center of each slot marked on support member. Use provided 11/32 in. drill bit. 3. Install header sensor using (2) 5/16 x 1 in. cap screws, washers and lock nuts. 4. Install arm assembly into hole of sensor pivot shaft using a nut and lock washer on each side of shaft. 5. It may be necessary to bend threaded rod to prevent interference with other components. 6. Connect free end of spring to S-hook on arm assembly and pinch hook closed. 7. Install stainless steel hose clamp around main support structure of header. 8. Secure chain of header sensor under stainless steel clamp at desired height. Adjustments can be made by adjusting chain length from S-hook. 14 August 2005 Rev C
Ag Leader Technology Cotton Picker Installation NOTE: The spring is included for extreme situations when the header needs to travel more than the chain and rod will allow. If your application does not require the spring, it is recommended to not use it. The spring can stretch causing the calibration to change, thus the yield monitor can incorrectly stop logging data. IMPORTANT: Ensure chain will be clear of rotating shafts and does not pull the rod at an extreme angle. 9. Route header sensor cable under cab to area near distribution cable. 10. Connect header sensor cable to mating connector of distribution cable. Coil and secure excess cable with cable ties. PN: 2006100-7 August 2005 Rev C 15
Cotton Picker Installation Ag Leader Technology COTTON FLOW SENSOR INSTALLATION FOR 9986/9996 General Information Each duct requires an Emitter and Detector to sense cotton flow as shown in Figure 11. Each Emitter has (5) individual infrared light emitters within each housing to cover width of duct. Likewise, each detector has (5) individual sensors within each housing to line up with emitter across duct. Therefore, it is critical to measure accurately and follow diagrams closely. Remove upper duct from picker before installing mounting plates. This can be done by detaching duct from fixed-mounting tube in front of basket. This will make it easier to work on each duct. To mount sensors, use mounting plate and appropriate template to position bracket and mark needed holes. Brackets will be removed before drilling and cutting holes. Once sensors are installed, ensure telescoping lower duct does not block sensors when head is raised. If this occurs, remove no more than 3 inches from top of lower duct. Detector (back of duct) Emitter (front of duct) Figure 11. Emitter and detector pair 16 August 2005 Rev C
Ag Leader Technology Cotton Picker Installation Installing Flow Sensors on Ducts Parts required for procedure: Quantities may vary depending on number of rows monitored. Emitter/Detector pair (Figure 11) Mounting plates 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 NOTE: The following instructions are for monitoring 2-rows or allrows. See Table 1 for correct measurement for each duct. Installation is otherwise the same for all ducts. For a 2-row monitoring system, install sensors on the following ducts for best performance. See Figure 12 for proper duct/row designations. 4-Row: Rows 1 & 4 5-Row: Rows 1 & 5 6-Row: Rows 2 & 5 Duct numbers Figure 12. Duct designations PN: 2006100-7 August 2005 Rev C 17
Cotton Picker Installation Ag Leader Technology Duct Number Measurement 1, 5, 6 49 inches 2 26-1/2 inches 3, 4 39 inches Table 1. Measurements for each duct Step-by-Step Procedure 1. Remove selected duct from machine. Place back side (side toward basket) of duct on floor. Accurately measure specified measurement (as shown in Table 1 above) from lower end of duct. See Figure 13. Make (2) marks across width of duct to make a straight line. Connect marks with a straight line parallel to lower end of duct. If necessary, refer to figure 14 to ensure you have correct duct before marking. Top Bottom Specified Measurement Figure 13. Illustration of how to measure ducts 18 August 2005 Rev C
Ag Leader Technology Cotton Picker Installation Duct 1,5,6 Duct 2 Duct 3,4 Figure 14. Duct height 2. See Figure 15. Line up top of mounting bracket with line on duct. 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. 3. Hold position of centered mounting bracket as shown in Figure 15 and mark rectangular hole and mounting holes. Figure 15. Bracket held in position for marking holes PN: 2006100-7 August 2005 Rev C 19
Cotton Picker Installation Ag Leader Technology 4. Remove mounting bracket, center punch and drill (6) mounting holes using provided 9/32 in. drill bit as shown in Figure 16. Figure 16. Holes drilled and cut 5. A high-speed air cutting disk, electric cutting disk, saber saw, or jig saw is recommended for cutting rectangular hole. CAUTION: To prevent injuries to yourself or others wear safety goggles or face shield for protection from airborne particles while cutting. 6. When cutting and drilling is complete, file perimeter of rectangular cutout to remove sharp edges. IMPORTANT: There must be absolutely NO burrs, as they will create cotton stringers that may affect yield measurement. 7. 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. 8. With mounting bracket securely fastened to front side of duct, attach hinged template to mounting bracket as shown in Figure 17. Ensure hinged template is fully engaged into hinge, then install (2) nuts to secure template to mounting bracket. 20 August 2005 Rev C
Ag Leader Technology Cotton Picker Installation Figure 17. Hinged template fastened to mounting plate 9. Attach another mounting bracket to template flat strap using (2) nuts as shown in Figure 18. Figure 18. Flat strap template attached to mounting plate PN: 2006100-7 August 2005 Rev C 21
Cotton Picker Installation Ag Leader Technology 10. Slide assembly shown in Figure 18 onto U-shaped strap as seen in Figure 19. Template assembly should be slid on until bracket is tight against duct. Figure 19. Back mounting bracket in position to be marked 11. 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. 12. Drill and cut holes just as was done for bracket on front side of duct. Remove burrs. 13. 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. 14. If necessary, seal gaps between mounting plates and duct with provided RTV silicon. 15. With mounting brackets secured to duct, reinstall duct on machine. 16. 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 20. 22 August 2005 Rev C
Ag Leader Technology Cotton Picker Installation Figure 20. Emitter installed on front side of duct PN: 2006100-7 August 2005 Rev C 23
Cotton Picker Installation Ag Leader Technology Installing Flow Sensor Cable & Static Grounding Cable Parts required for procedure: (1) Flow sensor cable harness (1) Static grounding cable Cable ties Step-by-Step Procedure 1. The flow sensor cable is constructed to connect to each Detector in series beginning with left-most duct. Locate end of cable that has connectors located approximately every 4 feet. Mate last 14-pin connector with mating connector on Detector mounted to left-most duct. (Interpret direction words as if sitting in operator seat.) 2. Connect cable to each Detector from Left to Right across machine. Yield monitor will refer to each sensor set by a number corresponding to each picking unit number. 3. Connect integral cable of emitter to mating 4-pin connector on flow sensor cable at each sensor location. 4. Connect flow sensor cable to mating connector of distribution cable located at right rear corner of cab. 5. Secure flow sensor cable using cable ties. Coil and secure extra cable near distribution cable to avoid interference with moving parts. NOTE: Due to static electricity buildup, plastic ducts must be grounded with provided grounding cable. 6. Remove nut from mounting plate for each detector and attach lug of static grounding cable as shown in Figure 21. 7. Route grounding cable with flow sensor cable 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. 24 August 2005 Rev C
Ag Leader Technology Cotton Picker Installation Static Grounding wire Figure 21. Flow sensor cable and location for static ground wire 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. Lower telescoping duct does not block sensors with header raised. Safety shields have been replaced. PN: 2006100-7 August 2005 Rev C 25
Cotton Picker Installation Ag Leader Technology Operational Checkout Refer to Display Items section in Operation Section for instructions on how to display different items on the screen. Step-by-Step Procedure 1. Start engine. 2. Verify monitor powers up/down properly. a. Turn monitor power switch ON and verify monitor powers up properly. NOTE: The monitor will power up, check a box for each sensor detected and display the harvest screen. If sensors are not properly detected, an alarm will sound. Confirm machine setup is correct by referring to Vehicle Setup in the Operator's Manual. If the problem continues, refer to "Monitor Does Not Find Correct Number of Flow Sensors on Initial Power Up" in the Troubleshooting Section of this manual. b. Turn monitor power switch OFF and verify monitor powers down properly. NOTE: When power switch is turned OFF, monitor will not immediately turn OFF. The screen will display "Now Archiving Data " "Monitor will automatically power down when complete". If monitor does not power up/down as described, re-check cable connections. 3. Display Fan Speed on main operating screen. a. Verify that Fan RPM stays at zero with the Fan OFF. b. Engage fan and verify monitor measures fan RPM. Fan speed should increase and decrease respectively with engine RPM. NOTE: RPM may NOT be accurate, because fan pulses/revolution have not yet been set for your machine. 4. Display "Ground Speed" on the screen. Move the machine slowly to verify the monitor measures MPH at low speeds (below 1 mph). NOTE: MPH may not be accurate until monitor has been calibrated. 5. Engage fan blower with machine at rest and verify monitor reads 0.0 MPH. 6. Display "Head Height" on screen. 26 August 2005 Rev C
Ag Leader Technology Cotton Picker Installation a. Raise and lower header. Verify head height number increases and decreases respectively. b. Adjustment of chain length and bending of threaded arm may be required to get full range from header height sensor. 7. Verify flow sensor signal strength. a. Press the MENU key, DIAG, and Signal Strength. Verify signal strengths are not less than 1000. b. If necessary, adjust sensor position to achieve acceptable signal strength. PN: 2006100-7 August 2005 Rev C 27
Cotton Picker Installation Ag Leader Technology Revision History Date Revision Initials Comments Mar 2002 N/C MB Initial release of instructions Sept 2003 A SAK Added support for PFadvantage Nov 2004 B SLH Reformatted, modified distribution cable installation. Added 9996 support. Aug 2005 C SLH Updated parts list 28 August 2005 Rev C