Installation Instructions for CaseIH cotton picker models: Instructions for 2-row monitoring only CAUTION: 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: 2005835 January 2010 Rev A 1
Ag Leader Technology Note: Indented items indicate parts included in an assembly listed above Quantity by Model Part Name/Description Part Number CPX610 CPX620 Instruction Kit Cotton, CPX610/620 4101048 1 1 Emitter Assembly 4000924 4 4 Detector Assembly 4000615 4 4 Header Sensor Standard 2000322-1 1 1 Arm Assy (18 in rod, S-hook, chain, spring) 2000311-2 1 1 Antenna Mounting Plate (with dual lock) 3000654 1 1 Hood Adapter Assembly 3000293 2 2 Module Kit Speed 4101049 1 1 Mounting plate 4000244 1 1 Speed Sensor module (Rev 8) 4001005 1 1 Module installation kit 4101005 1 1 Drill bit 13/64 in. 2001000-20 1 1 Drill bit 9/32 in. 2001000-28 1 1 Transfer punch 11/32 in. 2001003-34 1 1 Hex head cap screw 1/4 x 3/4 in. 2002001-25075 5 5 Hex nut 1/4 in. 2002051-25 5 5 Split lock washer 1/4 in. 2002061-25 5 5 External tooth lock washer 1/4 in. 2002063-25 3 3 Self-tapping screw 1/4 x 3/4 in. 2002075-25075 3 3 Hex serrated flange nut 1/4 in. 2002225 5 5 Sheet metal screw #14 x 1/2 in. 2002232-14050 3 3 Cable Kit Cotton, 2 rows (CPX610/620) 4101060 1 1 Display cable 12 ft. 4001608-12 1 1 Power cable 4000277 1 1 Power control relay 4000708-1 1 1 Header height adapter cable 4000236-2 1 1 CAN Bus Harness 4000532 1 1 CAN Bus stub 2 ft. 4000219-2 1 1 Fan speed cable 12 ft. 4000675-12 1 1 Ground speed cable 8 ft. 4000235-8 1 1 Cable installation kit 2000901-21 1 1 Cab wall plate kit 2000644-2 1 1 Cab wall plate 2000128 1 1 Phillips screw - #6 x 1/2 in. 2002031-06050 4 4 Hex nut #6 2002051-06 4 4 Internal tooth lock washer #6 2002062-06 4 4 Self-tapping screw 1/4 x 3/4 in. 2002075-25075 4 4 Grommet 3/4 in. ID x 1-7/16 in. P.H.D. 2002825-75 1 1 2 January 2010 Rev A
Note: Indented items indicate parts included in an assembly listed above Quantity by Model Part Name/Description Part Number CPX610 CPX620 RTV silicon sealant 2001011 1 1 Blade fuse 20 amp 2001012 1 1 Gray plastic cable clamps 2002812 5 5 Cable tie 15 in. 2002817-15 10 10 Cable tie 6 in. 2002817-6 20 20 Adhesive mounting base 2 way 2002821-2 5 5 Parts Kit Cotton, 2 rows (2155/2555, CPX420/610/620) 2001336-2 1 1 Post bracket 3000691 1 1 Anchor bar 2000139 1 1 Header Sensor Inst. Kit Generic 2000330-4 1 1 S-Hook 2000329-3 1 1 Cap screw 5/16 x 1 in. 2002001-31100 3 3 Lock Nut 5/16 in. 2002055-31 3 3 Flat Washer 5/16 in. 2002071-31 4 4 Drill bit 9/32 in. 2001000-28 1 1 Transfer punch 11/32 in. 2001003-34 1 1 Square file 5/16 in. 2001006 1 1 File handle 2001019 1 1 Monitor bracket installation kit 2001304-2 1 1 Drill Bit 13/64 in. 2001000-20 1 1 Cap screw 1/4 x 3/4 in. 2002001-25075 3 3 Cap screw 1/4 x 1 in. 2002001-25100 1 1 Hex Nut 1/4 in. 2002051-25 2 2 Hex lock nut 1/4 in. 2002055-25 2 2 Split Lock washer 1/4 in. 2002061-25 2 2 Flat Washer 1/4 in. 2002071-25 4 4 Self tapping screw 1/4 x 3/4 in. 2002075-25075 4 4 Hardware kit 35 pieces 2001337-1 1 1 Serrated flange nut 1/4 in. 2002249-25 35 35 Slotted truss head screw 1/4 x 1/2 in. 2002250-25050 35 35 Permanent marker 2002813 1 1 PN: 2005835 January 2010 Rev A 3
Ag Leader Technology Important Notices Please carefully follow these step-by-step instructions. If you have questions, contact 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 (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 Cable 8 Installing Power Cable 10 Installing Speed Sensor Module 11 Installing Fan Speed Cable 12 Installing Ground Speed Cable 13 Installing Header Height Sensor 14 Installing Hood Adapters and Flow Sensors 16 Installing CAN Bus Harness 20 Final Inspection 21 Operational Checkout 22 4 January 2010 Rev A
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: 2005835 January 2010 Rev A 5
Ag Leader Technology Installing Display Parts required for procedure: (1) Display (1) Post bracket (1) Anchor bar (reinforces post bracket) (1) U-bracket (1) Marking pen (1) Transfer punch (1) Drill bit 13/64 in. (4) Self-tapping screw 1/4 x 3/4 in. (3) Hex head cap screw 1/4 x 3/4 in. (1) Hex head cap screw 1/4 x 1 in. (4) Flat washer 1/4 in. (2) Split lock washer 1/4 in. (2) Hex nut 1/4 in. (2) Lock nut 1/4 in. NOTE: Recommended mounting position is on right side of cab pillar as shown in Figure 2. This places the monitor within easy reach and in a convenient viewing position. Figure 2. Post bracket installed 6 January 2010 Rev A
Step-by-Step Procedure 1. Assemble anchor bar to right post bracket using (2) 1/4 x 3/4 in. cap screws and (2) 1/4 in. lock nuts. 1/4 in. cap screws and nuts are used on 2-hole end of anchor bar. See Figure 3 for an illustration of how anchor bar assembles to post bracket. 2. Position bracket assembly on right cab post so top of bracket is approximately 3 in. below ceiling. 3. Using post bracket as a template, mark (4) holes on cab post with permanent marker and center punch to maintain proper alignment. 4. Drill holes with 13/64 in. drill bit provided. 5. Attach post bracket to cab post with 1/4 x 3/4 in. self-tapping screws. 6. Attach U-bracket to right post bracket using 1/4 in. cap screws, washers, and nuts as shown in Figure 3. NOTE: Multiple mounting holes and slots allow for versatility in mounting. Ensure gauges on pillar will not be blocked. Figure 3. U-bracket assembled to post bracket 7. Before tightening U-bracket, install monitor to determine best position for ease of viewing. 8. Remove monitor and tighten U-bracket. 9. Re-install monitor. PN: 2005835 January 2010 Rev A 7
Ag Leader Technology Installing Display Cable Parts required for procedure: (1) Display cable (1) Grommet 3/4 in. ID x 1-7/16 in. P.H.D. Cable clips Step-by-Step Procedure 1. Fully open right cab window. The first several steps will be performed while standing outside of cab near opened window. 2. Remove cover from console that is located right of operator seat and beneath operator controls. 3. Locate display cable and power control relay. Connect power control relay to mating 4-position weather pack connector of display cable. See Figure 1 for an illustration. 4. Route 4-position round cannon connectors and ethernet connector (located at one end of display cable) into console and toward back wall. Continue routing cable toward cab wall so connectors are accessible behind removable wall plate in a later step. Remaining connectors (near same end of display cable that is routed into cab corner) should remain accessible from top side of console. 5. Remove black molded plastic shroud from right exterior side of cab as shown in Figure 4 to expose removable wall plate. Plastic cover Figure 4. Molded plastic cover on right side of cab 8 January 2010 Rev A
6. Remove screws from perimeter of metal plate that cables pass through. Pull metal wall plate away from cab wall. 7. Remove adhesive cover from existing round hole above wall plate. 8. Locate 4-position round cannon connectors and ethernet connector of display cable that was routed into corner of cab in step 4 by reaching through large access hole in cab wall. 9. Route 4-position round cannon connectors and ethernet connector of display cable through round hole of cab wall from inside. There is an interior wall that display cable must pass through before pulling through exterior hole. 10. Cut provided 3/4 in. I.D. x 1-7/16 in. P.H.D. grommet and install it around display cable. Insert grommet into hole in cab wall. NOTE: If GPS will be installed, route GPS cable into cab thru same hole that display cable connector is passed through before installing grommet. Connect GPS cable to mating 9-position serial connector of display cable. Provided null-model cable will be required for non-ag Leader branded GPS units. 11. Reinstall wall plate. 12. Do not replace molded plastic shroud at this time. It will be replaced after CAN Bus harness is installed in a later section. 13. Inside cab, route 28-position round connector on opposite end of display cable down to floor within console. Proceed to route connector through gap between console wall and cab wall as shown in Figure 5. Console wall will flex enough to allow connector to pass through. 14. Route display cable forward along floor to cab pillar and then up pillar to display. 15. Connect 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. 16. Coil excess cable in console beside seat. 17. Secure cable as necessary using provided cable clips and ties. PN: 2005835 January 2010 Rev A 9
Ag Leader Technology Display cable Figure 5. Display cable exiting console Installing Power Cable Parts required for procedure: (1) Power cable Cable clips Step-by-Step Procedure 1. Mate tee end of power cable with auxiliary power connector located behind and to the right of operator seat. 2. Route opposite end of power cable with 3-socket tower connector down into console beside operator seat. 3. Mate power cable with power pigtail of display cable (See step 4 of previous section) 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. 10 January 2010 Rev A
Installing Speed Sensor Module Parts required for procedure: (1) Speed Sensor module (1) Punch (1) Drill bit 13/64 in. (2) Sheet metal screw #14 x 1/2 in. Step-by-Step Procedure 1. Position Speed Sensor module above cab wall plate and plastic shroud as shown in Figure 6. Figure 6. Speed module installed 2. Mark locations of center hole in each flange onto cab wall. A light colored marker or scribe is ideal for this procedure. CAUTION: Make sure mounting hole locations will not interfere with anything behind cab wall before drilling. 3. Punch and drill (2) holes using provided punch and 13/64 in. drill bit. 4. Secure Speed Sensor module to cab wall using provided #14 x 1/2 in. sheet metal screws. PN: 2005835 January 2010 Rev A 11
Ag Leader Technology Installing Fan Speed Cable Parts required for procedure: (1) Fan speed cable Cable ties Step-by-Step Procedure 1. Locate fan speed sensor connection on right side of machine as shown in Figure 7. Fan speed cable connection Figure 7. Fan speed connection 2. Disconnect existing connectors and install tee end of fan speed sensor between existing wiring harness and fan speed sensor. 3. Route fan speed cable to Speed Sensor module located on right wall 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 6-pin Shaft Speed connector of Speed Sensor module. Coil and secure excess cable with cable ties. 12 January 2010 Rev A
Installing Ground Speed Cable Parts required for procedure: (1) Ground speed cable Cable ties Step-by Step Procedure 1. Locate ground speed sensor connection at transmission as shown in Figure 8. Ground speed sensor Tee connection Figure 8. Ground speed sensor connection 2. Disconnect existing connectors and install tee end of ground speed sensor between existing wiring harness and ground speed sensor. 3. Route ground speed cable to Speed Sensor module located on right wall 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 mating 2-pin Ground Speed connector of Speed Sensor module. Coil and secure excess cable with cable ties. PN: 2005835 January 2010 Rev A 13
Ag Leader Technology 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) 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. Install arm assembly into hole of sensor pivot shaft using a nut and lock washer on each side of shaft. 2. Position header sensor in center of support beam near right side of cab as shown in Figure 9. Figure 9. Positioning header sensor 3. Mark mounting holes on support beam using header sensor as a template. 4. Center punch and drill mounting holes using provided punch and 11/32 in. drill bit. 5. Install header sensor using (2) 5/16 x 1 in. cap screws, washers and lock nuts. 6. Attach S-hook to existing cap screw on row unit as shown in Figure 10. 14 January 2010 Rev A
Cap screw Figure 10. Cap screw on row unit for attaching S-hook 7. Connect adapter cable to integral cable of header sensor and route to Speed Sensor module on right wall of cab. 8. Connect header sensor cable to mating 8-pin Position Sensor connector of Speed Sensor module. Coil and secure excess cable with cable ties. Figure 11. Finished installation PN: 2005835 January 2010 Rev A 15
Ag Leader Technology Installing Hood Adapters and Flow Sensors Parts required for procedure: (4) Emitter/Detector pair (2) Hood adapter (28) Truss head screw 1/4 in. (28) Flange nut 1/4 in. CAUTION: Flow sensor installation is dependent on machine configuration. Install hood adapters and flow sensors as follows based on machine configuration. 6-Row Wide: Rows 1 & 6 6-Row Narrow: Rows 5 & 6 Super 4-Row: Not Supported NOTE: It is possible to install hood adapters and flow sensors on any of the double-width outside hoods. Although installation on hoods near ladder or catwalk will likely require that a modification be made to the ladder and/or catwalk. Ag Leader does NOT recommend making any modifications to ladder or catwalk on CPX610 or CPX620 machines. Step-by-Step Procedure 1. Remove double-width hoods (as specified above) from machine. 2. See Figure 12. From bottom of hood, measure up 13-3/4 in. on back of hood and 20-1/4 in. on front. 3. Using a square, extend marks around hood as shown in Figure 12. This identifies section of hood to be removed. 16 January 2010 Rev A
Figure 12. Section of hood to remove 4. Use a suitable cutting tool to cut along inside edge of marks. 5. File burrs and rough edges. 6. Insert hood adapter flanges inside hood. Mark (14) locations for mounting holes on hood. 7. Center punch and drill (14) mounting holes as shown in Figure 13 using provided punch and 9/32 in. drill bit. File burrs from around holes. PN: 2005835 January 2010 Rev A 17
Ag Leader Technology Figure 13. Mounting holes drilled in hood 8. Attach hood adapter to hood using provided truss head screws and flange nuts as shown in Figure 14. Install screws from inside so nuts are on outside of hood. Figure 14. Hood adapter secured to hood 18 January 2010 Rev A
9. Reinstall hood assembly onto chute. 10. Repeat Steps 1 through 9 to install 2 nd hood adapter. 11. See Figure 15. Install emitters (sensor with integral cable) on front side of hood adapters and detectors on back side of hood adapters. Hinge up and tighten captive nuts. Detector (Back of Hood) Emitter (Front of Hood) Figure 15. Emitter and Detector pair PN: 2005835 January 2010 Rev A 19
Ag Leader Technology Installing CAN Bus Harness Parts required for procedure: (1) CAN Bus harness 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. See Figure 16. Emitter pigtail Figure 16. CAN Bus connected to detectors 1 & 2 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. 20 January 2010 Rev A
4. Route remainder of CAN Bus harness down to display cable that was installed in a previous section. 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 so that it can be tucked under molded plastic shroud that protects cab wall plate. 9. Replace molded plastic shroud. 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. PN: 2005835 January 2010 Rev A 21
Ag Leader Technology 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. 22 January 2010 Rev A
Revision History Date Revision Initials Changes Dec 2006 N/C SLH - Initial release of instructions Jan 2010 A WDS - Changed display cable PN: 2005835 January 2010 Rev A 23