Cotton Picker Parts List Installation Instructions for John Deere cotton picker model: Two row and all row systems included. IMPORTANT: Ensure the instructions you use for the installation correspond to the machine model. If you receive the incorrect installation instructions, contact Ag Leader Technology Technical Support at (515) 232-5363 ext. 1. September 2003 2006100-4
Cotton Picker Parts List Note: Indented items indicate parts included in an assembly listed above Quantity by Model 9970 Part Name/Description Part No. 2 Rows Monitored 4 Rows Monitored Instruction Kit Cotton(All JD Models) 2006100-1 1 1 1 5 Rows Monitored Arm Assy (18 in rod, S-hook, 16 in. chain, spring) 2000311-2 1 1 1 Header Sensor Standard 2000322-1 1 1 1 Antenna Mounting Plate (with dual lock) 3000324 1 1 1 Template Welded ASM (Cotton chute) 3000715 1 1 1 Template Flat Strap (Cotton chute) 3000716 1 1 1 Mounting Plate Cotton Sensor (w/spacer) 3000721 4 8 10 Shield Cotton Sensor JD Ladder 3000725 1 1 Spacer, Mounting Plate Cotton 3000218 4 8 Cable Kit Cotton, 2 rows (JD 9965/70/76) 2001248 1 Cable Kit Cotton, 4 rows (JD 9965, 70, 76) 2001254 1 Cable Kit Cotton, 5 rows (JD 9965, 70, 76) 2001255 1 Parts Kit Cotton, 2 rows (JD 9960/65/70/76) 2001336-6 1 Parts Kit Cotton, All rows (JD 9960, 65, 70, 76) 2001336-7 1 1 Emitter Assembly Cotton, 5 Position 3000287 2 4 5 Detector Assembly Cotton, 5 Position 3000288 2 4 5 September 2003 2006100-4 8-1
Cotton Picker Parts List Ag Leader Technology Note: Indented items indicate parts included in an assembly listed above Part Name/Description Part No. 2 Rows Monitored Quantity by Model 9970 4 Rows Monitored 5 Rows Monitored Monitor Bracket Inst. Kit 2001304-9 1 1 1 Drill Bit Tin Coated 13/64 2001000-20 1 1 1 Self Tapping Hex Slotted Hd Screw, 2002075-25075 4 4 4 1/4 x3/4 Hex Hd Capscrew, Coarse Thd, Gr 5, ZP 2002001-25075 2 2 2 1/4 x3/4 Hex Nut, Coarse Thd, ZP 1/4 2002051-25 2 2 2 Split Lock washer, ZP 1/4 2002061-25 2 2 2 Flat Washer, Std, ZP 1/4 2002071-25 4 4 4 Cab Wall Bracket Kit (21XX, 9x50,9960-76) 2000644-2 1 1 1 Cab Wall Bracket - Generic 2000128 1 1 1 Phillips Round Head Screw, ZP, 6-32x.50 2002031-06050 4 4 4 Hex Nut, Coarse Thd, ZP #6-32 2002051-06 4 4 4 Internal Tooth Lock washer, ZP #6 2002062-06 4 4 4 Self Tapping Hex Slotted Hd Screw 1/4 x 3/4 2002075-25075 4 4 4 Header Sensor Inst. Kit Generic 2000330-4 1 1 1 S-Hook - #63 bent angled 2000329-3 1 1 1 Hex Hd Capscrew, Coarse Thd, Gr 5, ZP 2002001-31100 3 3 3 9/32 x 1 in. Hex Nylock Nut, Coarse Thd, ZP 9/32 in. 2002055-31 3 3 3 Flat Washer, Standard, ZP 9/32 in. 2002071-31 4 4 4 Post Bracket Monitor (JD Cotton, Case) 3000693 1 1 1 8-2 September 2003 2006100-4
Cotton Picker Installation Important Notices You will save time and prevent wrong installation of components by closely following the step-by-step instructions. If you have questions, call Ag Leader Technology at 515-232-5363 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. Place the Installation instructions and Parts Lists in their sections in the Operator s Manual to prevent their loss or to use as reference after completing installation. Section Contents Item Page Installing PF Series Monitor in Cab 9-2 Connecting Power Cable for 9970 9-5 Installing Distribution Cable for 9970 9-6 Installing Fan Speed Cable 9-7 Installing Ground Speed Cable 9-9 Installing Header Height Sensor 9-10 Installing Flow Sensors 9-13 Installing Flow Sensor Cables 9-42 Installing Static Grounding Cable 9-42 Final Inspection 9-43 Operational Checkout 9-44 IMPORTANT: The installation instructions to install the flow sensors are provided; specific for each picker model. The picker model number is displayed in very large letters and should be the same as the picker model for which you ordered a system, i.e. 9965, 9970, 9976. If you have an incorrect chute installation instruction set please call Ag Leader Technology, Technical Support at 515-232-5363, ext. 1. September 2003 2006100-4 9-1
Cotton Picker Installation Ag Leader Technology Installing Monitor in Cab Parts required for this procedure: Monitor Unit Post Bracket U-Bracket Screw-mount cable-tie base, mounting screw and cable ties. Cab Cable Monitor Bracket Install Kit (screws, bolts, washers and nuts) Step-by-Step Procedure 1. Using the hardware from the monitor install kit, attach the post bracket to the u-bracket as shown in Figure 1. NOTE: If installing a YM2000, PF3000 or PF3000 Pro monitor, mount the u-bracket in the same position as shown in Figure 1. Figure 1. Monitor Bracket Assembly 9-2 September 2003 2006100-4
Cotton Picker Installation 2. Position the post bracket assembly along the right side of cab. Move the assembly forward or backward to obtain the optimum position for your viewing. Figure 2 is the recommended mounting position. Figure 2. Post Bracket Mounting Location (9976 Shown) 3. Using the post bracket as a template, mark three mounting holes on the right upper sidewall of the cab as shown in Figure 2. September 2003 2006100-4 9-3
Cotton Picker Installation Ag Leader Technology 4. Center punch and drill the mounting holes with the provided 13/64 inch drill bit. 5. Attach the post bracket to the cab wall with three 1/4x3/4 inch selftapping screws. 6. Reattach the u-bracket to the post bracket (See Figure 1). 7. Mount the monitor in the bracket. IMPORTANT: Never use force to mate electrical connectors. If the connectors do not push together easily, they are not aligned properly. Using force will only result in damage to the connectors. 8. Connect the cab cable to the monitor. 9. Route the cab cable from monitor to the distribution cable, by going down the center post and then along the cab floor back to the distribution cable. Tie the cab cable to center post with cable ties. 9-4 September 2003 2006100-4
Cotton Picker Installation Connecting Power Cable for 9970 Step-by-Step Procedure Parts required for this procedure: Pigtail off cab cable 1. Route the power pigtail from the cab cable to the front of the console. 2. Place the cable between the window and the console. 3. Remove power cap on the 3-spade power source located at the front of console. 4. Mate power pigtail to connector on console. See Figure 5. 5. Turn the combine ignition switch on the ON position and turn the monitor ON. If the monitor does not power up, turn power switch off and recheck the cable connections. Figure 5. Power pigtail connected. September 2003 2006100-4 9-5
Cotton Picker Installation Ag Leader Technology Installing Distribution Cable for a 9970 Step-by-Step Procedure Parts required for this procedure: Distribution Cable Cab Wall Bracket Kit Drill bit 1. Locate the hole under the floor mat in the right rear corner of the cab. See Figure 6. 2. Fasten the cab wall bracket to the square flange of the round connector of the cab cable using four #6-32 x1/2 inch screws with nuts and lock washers. 3. Hold the bracket flush against the floor of the cab so the square flange if the round connector is facing up and centered in the hole. Mark in the center of one of the corner holes of the bracket. 4. Remove the bracket and make a center punch mark on the pen mark. Use the #7 drill bit to drill a hole for a 1/4 inch self tapping screw. 5. Hold the bracket in its mounting position ensuring it is flush with the floor and install the 1/4 inch self tapping screw. 6. With the bracket held in its mounting position, center punch and drill the three remaining corner holes of the bracket. Install three remaining 1/4-inch self-tapping screws. 7. From outside the cab, connect round 24-pin connector of distribution cable to round 24-pin connector of cab cable. 8. Loop any excess cab cable and secure it with a cable tie. 9-6 September 2003 2006100-4
Cotton Picker Installation Figure 6. Cab Cable and Distribution Installed. Installing Fan Speed Cable Parts required for this procedure: Fan speed cable Cable ties Step-by-Step Procedure 1. Locate Fan Shaft Speed Sensor at the front end of fan blower (just above the lower frame rail about halfway between the front and rear wheels on left side of combine). 2. Install the two-connector end of the fan speed cable, to the jumper between the existing wiring harness and fan shaft speed sensor. 3. Tie fan speed cable to existing cables as shown in Figure 7. September 2003 2006100-4 9-7
Cotton Picker Installation Ag Leader Technology Cable ties Cable connection Figure 7. Fan Speed Cable Connection at Fan Blower Shaft NOTE: In all steps, tie the fan speed cable to the cable along which it is being routed at 12 to 18 inch intervals. Be sure it is tied down well enough to keep it away from moving parts. 4. Follow existing machine wiring to the right side of machine and forward from fan blower. Be sure to tie it securely where it passes near moving parts. 5. When the cable is routed to the right side of the machine, route the cable forward along the existing electric wiring to the cab. 6. About 6 inches above the charge pump begin routing the fan speed cable along the hydrostatic pump control push/pull cable. Follow this cable to the area under the steering column and connect the fan speed cable to the distribution cable. 9-8 September 2003 2006100-4
Cotton Picker Installation Installing Ground Speed Cable Parts required for this procedure: Ground speed cable Cable ties Step-by-Step Procedure 1. Locate ground speed sensor on top of the drive transmission (just behind the center of the front axle). 2. Install the two-connector end of the ground speed cable, to jumper between the existing wiring harness and the ground speed sensor. 3. Route the cable to the right side of the machine as shown in Figure 8. 4. Route the cable with the previously installed fan speed sensor cable until you reach the cab. 5. Route the cable under the cab securing it at 12-18 inch intervals and connect the ground speed cable to the distribution cable. Cable connection Figure 8. Ground Speed Cable Connection at Transmission September 2003 2006100-4 9-9
Cotton Picker Installation Ag Leader Technology Installing Header Height Sensor Parts required for this procedure: Header height sensor assembly (with integral cable) Two 5/16 x 1 inch bolts with lock washers and nuts Arm assembly (threaded rod with S-hook) Anchor spring with S-hook Cable ties Step-by-Step Procedure 1. Position the header sensor under the cab so that: 1a. The sensor is mounted on the right most support member where the brake master cylinder is attached. The middle slot of the header sensor will be positioned on the existing hole of support member. Mark the position of the forward slot on the sensor. 1b. While holding the sensor in place, temporally insert the threaded arm into the shaft to verify there is no interference. 2. Drill a 3/8 inch hole, on the mark made in Step 1a. See Figure 9. Existing Hole Drilled Hole Brake Master Cylinder Figure 9. 3/8 inch hole drilled on support member. 9-10 September 2003 2006100-4
Cotton Picker Installation 3. Install two 5/16 x 1-inch bolts through the drilled holes and side row of holes in the top of sensor frame. See Figure 10. 4. Install the arm assembly in the hole in the sensor pivot shaft with a nut and lock washer on each side of the shaft. 5. Verify arm alignment and tighten bolts to support member. IMPORTANT: Do not apply excessive torque. This can deform the sensor frame and prevent proper operation. Tighten nuts only enough to firmly hold the sensor in place and then check to see the arm pivots smoothly and always returns to the spring centered position. 6. Connect the free end of the spring to the S-hook on arm and pinch the hook closed. Figure 10. Header Sensor attached to support member September 2003 2006100-4 9-11
Cotton Picker Installation Ag Leader Technology 7. Refer to Figure 11 and use an existing hole and bolt to attach the S-hook to the frame or row unit on the header. IMPORTANT: Ensure the chain will be clear of the rotating shafts and does not pull on the rod at an extreme angle. 8. It may be necessary to bend the threaded rod to prevent interference with other components. 9. Route header sensor cable to the area under the cab to the distribution cable. 10. Connect header sensor cable to distribution cable. Figure 11. S-Hook attached to right-hand row unit. 9-12 September 2003 2006100-4
Cotton Picker Installation Cotton Flow Sensor Installation for 9970 IMPORTANT: Flow sensor installation on John Deere pickers is dependent on the type of machine you own. Please carefully read the instructions. Install sensors on the following rows (for a two row monitoring system) based on machine design for best performance. 4-Row: Rows 1 & 4 5-Row: Rows 1 & 5 6-Row: Rows 2 & 5 NOTE: The following instructions are for a system monitoring two rows as well as all rows. Use the table of contents below to find the appropriate instructions for the duct you are mounting to. IMPORTANT: An all row system requires a restraint on the lowering of the ducts. If this restraint is not used, the sensors will hit the back glass of the cab. Ag Leader Technology will not warranty any sensors damaged or be liable for bodily injury or for damage to the cotton picker as a result of not exercising caution when lowering the basket and ducts. If the restraint is not used, the mounting brackets and sensors must be completely removed before lowering the basket. Item Page Installing Cotton Flow Sensors for 9970 9-13 Installing on two rows: Installing on Plastic Duct with Ladder 9970 9-15 Installing on Outside Ducts without Ladder 9970 9-25 Installing on all rows: (continuation from above) Installing Duct Restraint (All Row Systems) 9970 9-32 Installing on Metal Duct behind Cab 9970 9-35 September 2003 2006100-4 9-13
Cotton Picker Installation Ag Leader Technology Sensor Installation Overview 1. Remove specified upper duct from the picker by detaching the duct from the fixed-mounting tube just in front of the basket. This will make it easier to work on each duct. 2. Positioning of the sensors depends on the machine configuration such as metal or plastic ducts, and regular or ladder ducts. Follow the positioning instructions closely to ensure accurate mounting of the sensors to maximize accuracy. 3. Each duct requires an Emitter and Detector pair (See Figure 12) to sense the cotton flow as the cotton is blown to the basket. Each Emitter has five individual infrared light emitters within each housing to cover the width of the duct. Likewise, each detector has five individual sensors within each housing to match up across the duct to sense the light from the emitters. 4. Therefore, it is critical to measure accurately and follow the diagrams closely. 5. To mount the sensors, use the mounting plate and appropriate template to position the bracket and mark the needed holes. The brackets will be removed and the holes drilled and the opening for the sensors cut. 6. Once the sensors are installed make sure the telescoping lower duct does not block the sensors when head is raised. If this is occurring, remove no more that 3 inches off the top of the lower duct. Detector (Back of Chute) Emitter (Front of Chute) Figure 12. Emitter and Detector pair 9-14 September 2003 2006100-4
Cotton Picker Installation Installing on Plastic Duct with Ladder 9970 1. Remove the duct with ladder from the machine. Before removing the ladder from the duct, you will use the mounting bracket as a template to drill a hole through the ladder and duct. This will allow for easy alignment when everything is disassembled. Place the sensor-mounting bracket below the top horizontal bar. See Figure 13. Allow the top edge of the mounting bracket to rest against the pipe. Center the mounting bracket with the ladder. 2. Mark, center punch, and drill (use 9/32-inch bit) the top center hole through the ladder and duct. 3. Remove the ladder hardware from the duct. Hole to drill Bracket edge touching pipe Figure 13. Sensor Position for duct ladder. September 2003 2006100-4 9-15
Cotton Picker Installation Ag Leader Technology Cutting the hole in the ladder 4. An access hole for the sensor and mounting bracket needs to be cut in the back of the ladder. 5. Align the mounting bracket on the back of the ladder by placing the mounting bracket against the ladder, centered on the hole you just drilled. You probably want to do this on the backside of the ladder since the sides of the ladder will not be in your way. (See Figure 14) Orient the mounting bracket so the studs on the mounting bracket are toward the top of the ladder (up). Use a square to assure the bracket is square to the ladder. 6. Mark a line on the outside perimeter of the mounting bracket. 7. For cutting the access opening, it is recommended to use a highspeed air, electric cutting disk or plasma cutter. CAUTION: To prevent injuries to yourself or others wear safety goggles or face shield for protection from airborne particles while cutting. 8. When cutting is complete use a flat file to remove all sharp edges around perimeter of rectangular cutout. Bolt in middle hole of Mounting Bracket Figure 14. Plate on back of ladder with bolt holding it in place to mark the outside perimeter. 9-16 September 2003 2006100-4
Cotton Picker Installation Mounting the sensor brackets to the duct 9. Align the mounting bracket on the duct by pinning the bracket to the duct in the hole you first drilled. Orient the bracket so the studs on the bracket are toward the outlet of the duct (up). Use a square to assure the mounting bracket is square to the duct. 10. Mark the holes and center rectangular cutout. 11. Remove the mounting bracket and drill the six center-punched positions with a 9/32-inch drill bit. 12. For cutting the rectangular openings, it is recommended to use a reciprocating saw on plastic ducts. CAUTION: To prevent injuries to yourself or others wear safety goggles or face shield for protection from airborne particles while cutting. 13. When cutting and drilling is complete, use a flat file to remove all rough edges around perimeter of rectangular cutout. IMPORTANT: There must be absolutely NO burrs, as they will create cotton stringers that may affect yield accuracy. 14. Securely fasten the mounting bracket using six 1/4 x 3/4 inch truss head screws and six lock washers and nuts. You may want to use the template to double check for alignment before tightening the bolts. 15. Once the mounting bracket is securely fastened to the front side of the duct, attach the hinged template to the mounting bracket as seen in Figure 16. Make sure that the hinged bracket is pushed all of the way down into the hinge and using two nuts, securely fasten the template to the mounting bracket. NOTE: The nuts should be on the outside of the hood so it doesn t protrude into the flow of the cotton. If bolts are installed wrong, errors could be caused in yield data. 16. Attach the second mounting bracket to the template flat strap using two more nuts. As shown in Figure 16. September 2003 2006100-4 9-17
Cotton Picker Installation Ag Leader Technology Figure 15. Hinged plate template Exploded View Assembled View Figure 16. Template and sensor mounting bracket. 9-18 September 2003 2006100-4
Cotton Picker Installation Figure 17. Template and U-shaped strap September 2003 2006100-4 9-19
Cotton Picker Installation Ag Leader Technology 17. Slide the assembly seen in Figure 16 onto the U-shaped strap as seen in Figure 17. The template assembly should be slid on until it mates up with the duct. 18. Mark the six holes and center rectangular opening. 19. Remove the mounting bracket, center punch the holes, and drill the six center-punched positions with a 9/32-inch drill bit. 20. For cutting the rectangular openings, it is recommended to use a reciprocating saw on plastic ducts. CAUTION: To prevent injuries to yourself or others wear safety goggles or face shield for protection from airborne particles while cutting. 21. When cutting and drilling is complete use a flat file to remove all rough edges around perimeter of rectangular cutout. IMPORTANT: There must be absolutely NO burrs, as they will create cotton stringers that may affect yield accuracy. 22. Securely fasten the mounting bracket using six 1/4 x 3/4 inch truss head screws and six lock washers and nuts. You may want to use the template to double check for alignment before tightening the bolts. NOTE: The nuts should be on the outside of the hood so it doesn t protrude into the flow of the cotton. If bolts are installed wrong, errors could be caused in yield data. 9-20 September 2003 2006100-4
Cotton Picker Installation 23. Reattach the ladder to the duct by using all the same hardware. 24. Install the sensors and check to see if the sensors can be accessed easily. The emitter (sensor with a cable) should be installed on the front side of the duct and the detector on the backside of the duct. Cable should be run out the side between the ladder and duct. 25. Remove sensors to prevent damage. 26. To prevent damage to the Emitter on the ladder chute, a sensor shield (Figure 18) has been provided for installation. You will need to drill two 9/32-inch holes to mount the ladder sensor shield. Mounting the Sensor Shield 27. In the area on the side of the ladder rail, between the top pipe and ladder rung, measure down 5/8 inch from the bottom edge of the ladder step slot. See Figure 19. 28. Measure over 7/16 inch from the top edge of the ladder. 29. Center punch the location and drill using the 9/32-inch drill bit. 30. Repeat Steps 27-29 for the hole on the other side of the rail. 31. Use a file to clean any burrs. 7/16 inch From top edge of lip 5/8 inch Figure 18. Sensor Shield Figure 19. Layout for Shield hole September 2003 2006100-4 9-21
Cotton Picker Installation Ag Leader Technology 32. You will use the 1/4 x 1-inch bolts as studs to allow the shield to pivot. NOTE: Installing the bolts and shield is difficult due to the width of the shield and the length of the bolts. Follow the steps below carefully for proper installation. See Figure 23. Top hole location for 1/4 x 1 inch bolt Sensor Shield Figure 20. Sensor shield positioned on ladder rail front and side views. 33. Place a 1/4 x 1-inch bolt into one of the holes and screw a nut partially onto the bolt. Using the top hole on the shield, slide the shield (oriented as shown in Figure 20) onto the bolt that is on the outside of the nut you just attached. See Figure 20 and 21. Once the shield is on this stud, tighten the nut against the ladder rail to fix the bolt. 9-22 September 2003 2006100-4
Cotton Picker Installation Sensor Shield 1/4 x 1 inch Bolt Figure 21. Sensor shield and bolt. 34. Do the same for the other side as seen in Figure 22. 35. Screw the nylock nuts on the end of the studs until the shield is at an acceptable tightness. See Figure 23. 36. Use the provided RTV silicone to seal the gaps between the mounting plates and the chute. September 2003 2006100-4 9-23
Cotton Picker Installation Ag Leader Technology Nylock Nuts Figure 22. Sensor shield and bolts on ladder chute Figure 23. Sensor shield installed 9-24 September 2003 2006100-4
Cotton Picker Installation Installing on Outside Ducts without Ladder 9970 1. Before removing the ducts from the machine, measure 43 inches from the bottom of the duct on the front side and place the top of the mounting bracket with sensor in place at this mark. Make certain there is no interference with the mounting location on both sides of the duct. If there are obstructions that can not be moved, adjust the sensor location accordingly. Check this for the ducts in transport mode as well as harvesting mode. The goal is to mount the sensor as high as possible on the duct to prevent interference from the lower telescoping duct. 2. Remove the duct from the machine. With the outlet of the black duct facing the floor, accurately measure 43 inches from the lower end of the duct. See Figure 24. Make two marks across the width of the duct to make a straight line. Using a square, connect the marks with a straight line, parallel to the lower end of the duct. 43 inch measurement Figure 24. 43 inch measurement September 2003 2006100-4 9-25
Cotton Picker Installation Ag Leader Technology 3. Line up the top of a mounting bracket with the line on the duct. Orient the bracket so the studs on the bracket are toward the outlet of the duct (up). Center the mounting bracket side-to-side on the duct by accurately marking a vertical centerline on the duct and positioning the center holes of the mounting bracket over the centerline 4. Using duct tape, fix the position of the centered mounting bracket and mark the rectangular hole and mounting holes. See Figure 25. 5. Remove the mounting bracket and center punch the six mounting holes to be drilled. 6. Drill the six center-punched positions with a 9/32-inch drill bit. 7. For cutting the rectangular openings, it is recommended to use a high-speed air, electric cutting disk or plasma cutter for metal ducts. Saber and jigsaws will work for the plastic ducts. 43 inch measurement Figure 25. Attaching template to mounting bracket 9-26 September 2003 2006100-4
Cotton Picker Installation Figure 26. Positioning mounting bracket on duct CAUTION: To prevent injuries to yourself or others wear safety goggles or face shield for protection from airborne metal particles while cutting. IMPORTANT: It is highly recommended to use the cutting tools stated. However, if a jig saw or a torch is used, you should take extreme caution that the edge of the duct and ladder is not bent and rough as cotton will catch and result in error from stringers. 8. When cutting and drilling is complete use a flat file to remove all sharp edges around perimeter of rectangular cutout and carefully file off sharp burrs around drilled holes. IMPORTANT: There must be absolutely NO burrs, as they will create cotton stringers that may affect yield accuracy. 9. Use six of the 1/4 x 3/4-inch truss head screws and six lock washers and nuts to fasten the mounting bracket holes to the duct. NOTE: The nuts should be on the outside of the hood so it doesn t protrude into the flow of the cotton. If bolts are installed wrong, errors could be caused in yield data. September 2003 2006100-4 9-27
Cotton Picker Installation Ag Leader Technology 10. Once the mounting bracket is securely fastened to the front side of the duct attach the hinged template to the mounting bracket as seen in Figure 27. Make sure that the hinged bracket is pushed all of the way down into the hinge and using two nuts securely fasten the template to the mounting bracket. 11. Attach the second mounting bracket to the template flat strap using two more nuts. As shown in Figure 28. 12. Slide the assembly seen in Figure 28 onto the U-shaped strap as seen in Figure 28. The template assembly should be slid on until it mates up with the duct. Figure 27. Attaching template to mounting bracket. Exploded View Assembled View Figure 28. Attaching template strap to 2 nd mounting bracket. 9-28 September 2003 2006100-4
Cotton Picker Installation Mounting Plate U-shaped Template Figure 29. U-Shaped template and Mounting Bracket 13. After marking the holes and rectangular opening, remove the mounting bracket, center punch the holes, and drill the six centerpunched positions with a 9/32-inch drill bit. 14. For cutting the rectangular openings, it is recommended to use a high-speed air, electric cutting disk or plasma cutter for metal ducts. Saber and jigsaws will work for the plastic ducts. CAUTION: To prevent injuries to yourself or others wear safety goggles or face shield for protection from airborne metal particles while cutting. MPORTANT: It is highly recommended to use the cutting tools stated. However, if a jig saw or a torch is used, you should take extreme caution that the edge of the duct and ladder is not bent and rough as cotton will catch and result in error from stringers. 15. When cutting and drilling is complete use a flat file to remove all sharp edges around perimeter of rectangular cutout and carefully file off sharp burrs around drilled holes. IMPORTANT: There must be absolutely NO burrs, as they will create cotton stringers that may affect yield accuracy. September 2003 2006100-4 9-29
Cotton Picker Installation Ag Leader Technology 16. Securely fasten the mounting bracket using six 1/4 x 3/4 inch truss head screws and six lock washers and nuts. You may want to use the template to double check for alignment before tightening the bolts. Once optimum alignment is achieved, securely tighten the bolts. NOTE: The nuts should be on the outside of the hood so it doesn t protrude into the flow of the cotton. If bolts are installed wrong, errors could be caused in yield data. 17. After the mounting brackets are securely fastened. Mount the ducts back on the machine. 18. Use the provided RTV silicone to seal the gaps between the mounting plates and the chute. 19. Place an emitter (sensor with a cord) in the front mounting bracket (side closest to the cab) and a detector in the back mounting bracket. Hinge up and securely fasten the captive nuts. The Emitter is shown in Figures 30 and 31. Figure 30. Emitter mounted on duct (Close up) 9-30 September 2003 2006100-4
Cotton Picker Installation Figure 31. Emitter Mounted on Duct IMPORTANT: If you are installing a system that will monitor two rows, you have now completed the sensor install. Proceed to the Sensor Cable Installation on Page 9-42 to complete installation. IMPORTANT: If you are installing an all row monitoring system, continue to the next section. September 2003 2006100-4 9-31
Cotton Picker Installation Ag Leader Technology Installing Duct Restraint (All Row Systems) 9970 Recommended doing this before re-installing any of the ducts. IMPORTANT: This section is for all row systems only. The restraint entails simply a bolt being placed along the rail that the main duct frame slides on. The bolt will prevent the ducts from lowering too far but allow the basket to continue down into transport mode. If the ducts are not restrained, there will be interference with the sensors and cab. IMPORTANT: All row systems require a restraint on the lowering of the ducts. If this restraint is not used, the sensors will hit the back glass of the cab. Ag Leader Technology will not warranty any sensors damaged or be liable for bodily injury as a result of not exercising caution and properly using the constraint when lowering the basket and ducts. If the restraint is not used, the mounting brackets and sensors must be completely removed before lowering the basket. The restraint will not guarantee the prevention of interference without further adjustments. NOTE: Before re-installing any of the ducts, it is recommended to install this restraining bolt since the ducts are not in the way. Follow the same procedure for both rails. 1. Raise the ducts into harvesting position and lock into place for safety. 2. Measure up 16-1/4 inch from the center of the existing hole on the tubing up the tube and mark. (See Figure 32.) 3. On the side of the tubing, center punch and drill the 11/32-inch hole in the center of the square tubing. (See Figure 33.) 4. Place the 9/32 x 2-inch bolt in the hole and tighten the 9/32-inch nylock nut on the protruding side. 5. When you complete the sensor install and re-install the ducts, you will need to check and adjust the position of the ducts. 9-32 September 2003 2006100-4
Cotton Picker Installation 16-1/4 inch measurement Chute Adjustment Plate Existing hole location Figure 32. 16-1/4 inch measurement Figure 33. Chute Adjustment Plate September 2003 2006100-4 9-33
Cotton Picker Installation Ag Leader Technology IMPORTANT: The mounting locations instructed below do not guarantee the clearance of the sensors and cab or ducts and basket without further adjustment. 6. Adjust the angle of the ducts (See Figure 33) to obtain the proper setting. The proper setting includes an acceptable clearance between the sensors and back glass as well as an acceptable clearance between the end of the ducts and the basket as it continues down to transport mode. 7. When you have an acceptable adjustment, carefully raise and lower the basket to check for proper adjustment. 8. If you are unable to achieve proper adjustment because the basket will hit the end of the ducts when going from harvest mode to transport mode, you have three options. It is recommended to do one of the first two options because it is likely the operator of the machine will forget to make any special adjustments when going from harvest mode to transport mode. Option 1: Usually it may only be one duct that imposes a problem. It is possible to place washers or spacers between the duct and mounting plate. This will work for the outside ducts, which are prone to cause more interference. Option 2: Trim off a small portion of the end of the duct to allow enough clearance for the basket to be all the way down for transport mode. Option 3: Put your basket in intermediate mode to transport from field to field. Refer to your Pickers Operator's Manual to learn more about this, as some pickers may not have this option. Or make a temporary adjustment to transport the machine. If any adjustments are made, make absolute sure the duct restraining bolt is in place before harvesting for safety purposes. If you are often raising and lowering the basket, a temporary adjustment is not recommended. 9-34 September 2003 2006100-4
Cotton Picker Installation Installing on Metal Ducts Behind Cab 9970 IMPORTANT: This section is for all row systems only. 1. Remove the ducts from behind the cab. 2. Measure up 45-1/4 inches from the bottom edge of the duct on the backside and draw a horizontal line square to the side of the chute. See Figure 34. 45-1/4 inch measurement Figure 34. 45-1/4 inch measurement on chute. September 2003 2006100-4 9-35
Cotton Picker Installation Ag Leader Technology 3. Line up the top of a mounting bracket with the line on the duct. Orient the bracket so the studs on the bracket are toward the outlet of the duct (up). Center the mounting bracket side-to-side on the duct by accurately marking a vertical centerline on the duct and positioning the center holes of the mounting bracket over the centerline. See Figure 35. 4. Using duct tape, fix the position of the centered mounting bracket and mark the rectangular hole and mounting holes. 5. Remove the mounting bracket and center punch the six mounting holes to be drilled. Figure 35. Positioning mounting bracket on duct 9-36 September 2003 2006100-4
Cotton Picker Installation 6. Drill the six center-punched positions with a 9/32-inch drill bit. 7. For cutting the rectangular openings, it is recommended to use a high-speed air, electric cutting disk or plasma cutter for metal ducts. IMPORTANT: It is highly recommended to use the cutting tools stated. However, if a jig saw or a torch is used, you should take extreme caution that the edge of the duct and ladder is not bent and rough as cotton will catch and result in error from stringers. CAUTION: To prevent injuries to yourself or others wear safety goggles or face shield for protection from airborne metal particles while cutting. 8. When cutting and drilling is complete use a flat file to remove all sharp edges around perimeter of rectangular cutout and carefully file off sharp burrs around drilled holes. IMPORTANT: There must be absolutely NO burrs, as they will create cotton stringers that may affect yield accuracy. 9. Use six of the 1/4 x 3/4-inch truss head screws and six lock washers and nuts to fasten the mounting bracket holes to the duct. NOTE: The nuts should be on the outside of the hood so it doesn t protrude into the flow of the cotton. If bolts are installed wrong, errors could be caused in yield data. 10. Once the mounting bracket is securely fastened to the front side of the duct attach the hinged template to the mounting bracket as seen in Figure 36. Make sure that the hinged bracket is pushed all of the way down into the hinge and using two nuts securely fasten the template to the mounting bracket. 11. Attach the second mounting bracket to the template flat strap using two more nuts. As shown in Figure 37. September 2003 2006100-4 9-37
Cotton Picker Installation Ag Leader Technology Figure 36. Attaching template to mounting bracket. Exploded View Assembled View Figure 37. Attaching template strap to 2 nd mounting bracket. 9-38 September 2003 2006100-4
Cotton Picker Installation Figure 38. U-Shaped template and Mounting Bracket 12. Slide the assembly seen in Figure 37 onto the U-shaped strap as seen in Figure 38. The template assembly should be slid on until it mates up with the duct. 13. After marking the holes and rectangular opening, remove the mounting bracket, center punch the holes, and drill the six centerpunched positions with a 9/32-inch drill bit. 14. For cutting the rectangular openings, it is recommended to use a high-speed air, electric cutting disk or plasma cutter for metal ducts. Saber and jigsaws may work in this location since the material being cut is much thicker and will not bend. IMPORTANT: It is highly recommended to use the cutting tools stated. However, if a jig saw or a torch is used, you should take extreme caution that the edge of the duct and ladder is not bent and rough as cotton will catch and result in error from stringers. CAUTION: To prevent injuries to yourself or others wear safety goggles or face shield for protection from airborne metal particles while cutting. September 2003 2006100-4 9-39
Cotton Picker Installation Ag Leader Technology 15. When cutting and drilling is complete use a flat file to remove all sharp edges around perimeter of rectangular cutout and carefully file off sharp burrs around drilled holes. IMPORTANT: There must be absolutely NO burrs, as they will create cotton stringers that may affect yield accuracy. 16. Securely fasten the mounting bracket using six 1/4 x 3/4 inch truss head screws and six lock washers and nuts. You may want to use the template to double check for alignment before tightening the bolts. Once optimum alignment is achieved, securely tighten the bolts. NOTE: The nuts should be on the outside of the hood so it doesn t protrude into the flow of the cotton. If bolts are installed wrong, errors could be caused in yield data. 17. After the mounting brackets are securely fastened. Mount the ducts back on the machine. 18. Use the provided RTV silicone to seal the gaps between the mounting plates and the chute. 19. Place an Emitter (sensor with a cord) in the front mounting bracket (side closest to the cab) and a detector in the back mounting bracket. Hinge up and securely fasten the captive nuts. The Emitter is shown in Figure 39. 9-40 September 2003 2006100-4
Cotton Picker Installation Figure 39. Emitter mounted on duct (Close up) September 2003 2006100-4 9-41
Cotton Picker Installation Ag Leader Technology Installing Flow Sensor Cable Parts required for this procedure: Flow sensor Cable Harness Static Grounding Cable (9970 and 9976 ONLY) Cable Ties Step-by-Step Procedure 1. The flow sensor cable is constructed to connect to each of the Detectors in series beginning with the left-most duct. (See Figure 40) Locate the end of the cable that has connectors located approximately every 4 feet. Mate the last 9-pin connector with the mating connector on the detector mounted to the left-most duct. (The machines left) 2. Connect each of the Detectors from Left to Right on the machine. The yield monitor will refer to each sensor by the same number that corresponds to the number of row picking unit. 3. Connect the cable attached to the emitter to the mating 4-pin connector on the flow sensor cable at each sensor location. 4. Secure the flow sensor cable to the mounting tube that fixes the position of the ducts. 5. Route the flow cable to the distribution cable under the cab securing it at 18-inch intervals, away from any moving parts. Installing Static Grounding Cable NOTE: Due to static electricity buildup, the plastic chutes must be grounded with the provided grounding gable. 1. Refer to Figure 40 and remove the nut and attach the static grounding cable by its lug to each detector. 2. Route the grounding cable with the sensor cable to a location where the grounding cable can be attached to the chassis of the picker. Ensure the lug attached to the chassis had a good connection by removing paint as necessary for metal to metal contact. 9-42 September 2003 2006100-4
Cotton Picker Installation Attach 5/16 inch Grounding Cable Leader here Figure 40. Flow Sensor Cable Final Inspection Installation is now complete. Do a walk around of the machine and complete the following: All cable connections have been made. Excess cable has been tied out of the way, so there is no potential interference. All tools have been removed from the machine. All cap screws and captive nuts are tight on the sensor mounts. When header is raised, ensure that the lower telescoping duct does not block the sensors. September 2003 2006100-4 9-43
Cotton Picker Installation Ag Leader Technology Operational Checkout Step-by-Step Procedure Refer to the Display Items section in the Operation Section for instructions on how to display different items on the screen. 1. Start engine. 2. Verify the monitor powers up/down properly. 2a. Turn the monitor power switch ON and verify the monitor powers up properly. NOTE: The monitor will power up, check a box for each sensor detected and display the harvest screen of four selected items. If sensors cannot be located, confirm the 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. 2b. Turn the monitor power switch OFF and verify the monitor powers down properly. NOTE: When the power switch is turned OFF the monitor will not immediately turn OFF. The screen will display "Now Archiving Data " "Monitor will automatically power down when complete". If the monitor does not power up/down as described, re-check the cable connections. 3. Display Fan Speed on the screen. 3a. Verify that Fan RPM stays at zero with the Fan OFF. 3b. Engage the fan and verify the monitor measures fan RPM. It should increase as the engine speed engine increases all the way too full engine speed, if not re-check cable connections. 9-44 September 2003 2006100-4
Summary of Changes John Deere 9960, 9965, 9970, 9976 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 will NOT be accurate, because the monitor has not yet been calibrated to your machine. 5. Start the fan blower with the machine at rest and verify that the monitor reads 0.0 MPH. 6. Display "Head Height" on the screen. 6a. Lift the head and verify the head height number increases. Lower the head and verify the head height number decreases. (If it increases instead of decreases, or vice versa refer to the Operator's Manual to change the setup on the monitor.) 6b. Adjustment of chain length and bending of threaded arm may be required to get full range of the header height sensor. 7. Check for acceptable sensor signal strength. 7a. Press the MENU key, DIAG, and Signal Strength. Verify the signal strengths are not less than 8000. 7b. Adjust sensor mounting position to achieve acceptable signal strength. Refer to the Setup Section of the Operator s Manual to adjust the monitor to your machine. NOTE: You may have some hardware leftover. Some of the additional hardware may include replacement ladder rails and aluminum shims. (The shims are only needed for mounting behind the cab of a 9976.) If there is a possibility you left out the shim during installations. Double-check the relevant instructions. Additionally, if you have a 2-row system, you will have extra 5/16-inch bolts. *** September 2003 2006100-4 9-45
Summary of Changes Summary of Changes Revision 1 August 2001 Initial release of this document. Revision 2 September 2003 Changes to include the PFadvantage. September 2003 2006100-4