Cotton Picker Installation Installation Instruction for John Deere cotton picker models: 9900-9950 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. Note: These machine models do not have a fan speed sensor, which is needed for the Ag Leader yield monitor. The sensor part number through your John Deere dealer is Part Number AH116104. Other parts may also be used depending on the model of your machine which includes the sprocket or wheel and a bracket to hold the sensor.
Cotton Picker Parts List Note: Indented items indicate parts included in an assembly listed above Quantity by Model 9900-9950 4 Chutes Part Name/Description Part No. Monitored Instruction Kit Cotton(All JD Models) 2006100-1 1 Arm Assy (18 in rod, S-hook, 16 in. chain, spring) 2000311-2 1 Header Sensor Standard 2000322-1 1 Antenna Mounting Plate (with dual lock) 3000324 1 Template Welded ASM (Cotton chute) 3000715 1 Template Flat Strap (Cotton chute) 3000716 1 Mounting Plate Cotton Sensor (w/spacer) 3000721 8 Shield Cotton Sensor JD Ladder 3000725 1 Cable Kit Cotton, 4 rows (JD9960) 2001241 1 Parts Kit Cotton, All rows (JD 9960, 65, 70, 76) 2001336-7 1 Emitter Assembly Cotton, 5 Position 3000287 4 Detector Assembly Cotton, 5 Position 3000288 4 8-1
Cotton Picker Parts List Ag Leader Technology Note: Indented items indicate parts included in an assembly listed above Quantity by Model 9900-9950 4 Chute Part Name/Description Part No. Monitored Monitor Bracket Inst. Kit 2001304-9 1 Drill Bit Tin Coated 13/64 2001000-20 1 Self Tapping Hex Slotted Hd Screw, 2002075-25075 4 1/4 x3/4 Hex Hd Capscrew, Coarse Thd, Gr 5, ZP 2002001-25075 2 1/4 x3/4 Hex Nut, Coarse Thd, ZP 1/4 2002051-25 2 Split Lock washer, ZP 1/4 2002061-25 2 Flat Washer, Std, ZP 1/4 2002071-25 4 Cab Wall Bracket Kit (21XX, 9x50,9960-76) 2000644-2 1 Cab Wall Bracket - Generic 2000128 1 Phillips Round Head Screw, ZP, 6-32x.50 2002031-06050 4 Hex Nut, Coarse Thd, ZP #6-32 2002051-06 4 Internal Tooth Lock washer, ZP #6 2002062-06 4 Self Tapping Hex Slotted Hd Screw 1/4 x 3/4 2002075-25075 4 Header Sensor Inst. Kit Generic 2000330-4 1 S-Hook - #63 bent angled 2000329-3 1 Hex Hd Capscrew, Coarse Thd, Gr 5, ZP 2002001-31100 3 9/32 x 1 in. Hex Nylock Nut, Coarse Thd, ZP 9/32 in. 2002055-31 3 Flat Washer, Standard, ZP 9/32 in. 2002071-31 4 Post Bracket Monitor (JD Cotton, Case) 3000693 1 8-2
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 to Switched Power for 9960 9-5 Installing Distribution Cable for 9960, 9965 9-5 Installing Power Cable for 9960 9-7 Installing Fan Speed Cable 9-8 Installing Ground Speed Cable 9-10 Installing Header Height Sensor 9-11 Installing Flow Sensors 9-14 Installing Flow Sensor Cables 9-33 Final Inspection 9-34 Operational Checkout 9-35 IMPORTANT: The installation instructions to install the flow sensors are for the JD 9900-9950 models. These instructions are purposely written in general terms, as there are many variations of chutes for these picker models. If you have the incorrect flow sensor installation instruction set or questions please call Ag Leader Technology, Technical Support at 515-232-5363, ext. 1. 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
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. 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
Cotton Picker Installation Connecting to Switched Power Step-by-Step Procedure Parts required for this procedure: Pigtail off cab cable 1. The pigtail originating from the 24-pin connector of the cab cable needs to the connected to switched power. 2. The key switch on the control console to the right of the driver s seat is where switched power can be found. 3. The female spade connector of the pigtail will connect to an unused male spade connector on the key switch. 4. In order to route the pigtail through the control console; several screws need to be removed and an access panel facing the seat can be moved. 5. The pigtail can be routed from the back left of the control console in towards the right cab wall and then forward to the key switch. Installing Distribution Cable 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 5. 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. 9-5
Cotton Picker Installation Ag Leader Technology 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. Figure 5. Cab Cable and Distribution Installed. 9-6
Cotton Picker Installation Installing Power Cable to Battery Parts required for this procedure: Power cable (cable with a yellow inline fuse holder) Cable ties Step-by-Step Procedure 1. Connect wire without the yellow fuse holder to the negative terminal by installing the ring terminal on the battery terminal clamp bolt. 2. Connect the wire with the yellow fuse holder to the positive terminal by installing the ring terminal on the battery terminal clamp bolt. 3. Route the power cable to the area under the cab by passing it under the bracket between the engine compartment and the battery compartment. Bend the middle tab of the bracket, which separates the two main wiring harnesses up so the battery cable can pass through. To Battery Connection Ground Speed Connection To Fan Speed Connection Figure 6. Cable routing 9-7
Cotton Picker Installation Ag Leader Technology 4. Route the battery cable along the existing wire harness and fan/ground speed sensor cables under the cab. 5. Connect the power cable to the distribution cable. 6. Turn the monitor ON. If it does not power up, immediately shut it off and make sure you have the power cable wires connected to the correct terminal on the battery. NOTE: Be sure to route the cable and tie it down so that pinching or rubbing against sharp edges cannot damage it. Installing Fan Speed Sensor and Cable Parts required for this procedure: Fan speed cable Cable ties Fan speed sensor and sprocket Step-by-Step Procedure NOTE: These machine models (9900-9950) do not have a fan speed sensor, which is needed for the Ag Leader yield monitor. The sensor part number through your John Deere dealer is Part Number AH116104. Other parts from the newer models may also be used depending on the model of your machine which include the sprocket or wheel and a bracket to hold the sensor. Double check the machines fan configuration and shaft diameter before purchasing the parts. The sprocket that is used does not need to have the same number of teeth as the newer models. The number of teeth of the sprocket can be changed in the monitor. 1. Become familiar with how the sensor is configured on a newer machine and purchase the proper parts to install a fan speed sensor. See Figure7 to see the location of a fan speed sensor on a newer model machine. 2. Once the sensor is installed, 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. 9-8
Cotton Picker Installation 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. 9-9
Cotton Picker Installation Ag Leader Technology Installing Ground Speed Cable NOTE: Many older machines DO NOT have a ground speed sensor. You can operate with out ground speed by using GPS. 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 9-10
Cotton Picker Installation 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 NOTE: Machine models may vary from the instructions below. The sensor should be mounted to get good range of motion as the header is raised and lowered and not to be in the way or damaged when the header is fully raised. 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. 9-11
Cotton Picker Installation Ag Leader Technology 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 9-12
Cotton Picker Installation 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. 9-13
Cotton Picker Installation Ag Leader Technology Cotton Flow Sensor Installation for 9900-9950 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 which has 4 sensors for 4 chutes) based on machine design for best performance. 2-Row: Rows 1 and 2 4-Row: Rows 1 & 4 If there is a different configuration, contact Ag Leader Technology Technical Support at (515) 232-5363 ext. 1. The sensors, together, should monitor complete rows if possible. Care must be taken when selecting chutes since the front or back picking drums of two different rows are often joined by the same chute. For example, a 9950 must monitor the two chutes behind the cab and each chute on the left and right side. This is the only configuration available without monitoring all six chutes. 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. Item Page Installing Cotton Flow Sensors on Ducts General 9-14 Installing on Metal Duct with Ladder 9-20 Installing on Outside Ducts without Ladder 9-26 9-14
Cotton Picker Installation Sensor Installation Overview 1. 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. Therefore, it is critical to measure accurately. 2. 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. 3. 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. Some general criteria that should be used when installing on various chutes: Sensor faces must be parallel for proper alignment Sensors must not be on a curved portion of the chute such that there is cotton directly hitting the sensor. This will subject the lens covers to excessive wear. The sensors should be mounted on a portion of the chute that will not conflict with other components, in both transport mode and harvest mode. The sensor should be mounted as high as possible to prevent interference from the telescoping of the chutes as the header is raised and lowered. Use the example provided to calculate the correct amount of spacers needed for each sensor to allow for unparallel chute walls. Always mount the emitter with the correct amount of spacers first, then align the detector to the emitter. A template is provided to assist in sensor alignment. If at all possible try and mount on a chute that the hinged template will fit around. If the hinged template will not work, measure as accurately as possible to align the sensors. See figures 22, 23, 24. 9-15
Cotton Picker Installation Ag Leader Technology Detector (Back of Chute) Emitter (Front of Chute) Figure 12. Emitter and Detector pair Calculating the shim thickness to compensate for unparallel chute walls First to compensate for unparallel chutes you need to calculate the amount of shims that is needed for each sensor mounting plate. As seen in the Figure 13, several measurements are needed that will be used in the equation below to calculate the thickness of spacers that will be needed. It does not matter where the sensor will be mounted when taking these measurements, all that matters is the length (L) is from the bottom to the top measurement. The slope or angle of the chute will be the same from the top to bottom. Refer to Figure 13 to take the top measurement and subtract it from the bottom measurement. Multiply the remainder times 3. Divide the product by the length. The last box on the right is the total thickness of spacers needed under the bottom of the mounting plate for each sensor. Note there is already a 0.12 inch spacer welded to the mounting plate. Therefore you want to subtract 0.12 inch from the value you calculate in the right box. Top Bottom = X 3 = /L = inches For example: Refer to Figure 14, you determine that you have a top measurement of 10 inches, a bottom measurement of 6 inches and a length of 48 inches. In this example you would have to have spacers up to 1/4 inch on each sensor. (0.25 0.12 = approximately 1/8 [0.125] inch needed) NOTE: It does not matter where the sensor will be mounted when taking these measurements, all that matters is the length (L) is from the bottom to the top measurement. The slope or angle of the chute will be the same from the top to bottom. 10 6 = 4 X 3 = 12 /48 = 0.25 or 1/4 inch As seen in Figure 15, the spacers can be strips of aluminum or metal or washers stacked to achieve the desired thickness. 9-16
Cotton Picker Installation Top Measurement Length Measurement Bottom Measurement Figure 13.Chute measurement layout 9-17
Cotton Picker Installation Ag Leader Technology Figure 14. Example of chute layout Figure 15. Mounting plate attached with shims 9-18
Cotton Picker Installation Illustrating the importance of aligning the detector from the emitter. The detector should always be aligned from the emitter. The figures below illustrate this. Since the detectors are aligned from the emitters, the emitters must be mounted first. The emitters should be mounted on the front of the chute. The straight line from one sensor to the other represents a light beam. Figure 16: Illustrates correct alignment. Figure 17: Illustrates the detector aligned from the emitter. The detector is mis-aligned but will still correctly work. Figure 18: Illustrates the emitter aligned from the detector. If the emitter is not very accurately mounted, a small amount of unparallelism can result great misalignment. Figure 16. Correct alignment of sensors, Detector aligned from Emitter Figure 17. Misaligned Detector from Emitter Figure 18. Misaligned Emitter from Detector 9-19
Cotton Picker Installation Ag Leader Technology Installing on Metal Duct with Ladder Use where applies NOTE: The instructions below may or may not be used depending on the configuration and model of your machine. The general concept of the installation can be derived. Before removing the ducts from your machine, decide where you want to mount the sensors. Keep in mind you want the sensors as high as possible to avoid conflict with the telescoping portion of the chute. At the same time, be careful there are no interferences with any other components. 1. Make a mark on the front side of the chute where you want to mount the sensor. Make the mark where the top of the sensor mounting plate will be positioned. See Figure 21 for the bracket and its orientation. 2. In order to use the hinged template on the metal ladder duct, you must remove a small portion of the sidewalls of the ladder. Make a mark on each sidewall from the mark you made in the previous step. Using a square, connect the marks with a straight line, parallel to the lower end of the duct. 3. From this mark measure down towards the bottom of the duct 5 inches as shown in Figure 20. Using a square extend these marks along the outside of the ladder rail. Using a cutting tool, cut along your marks to remove the 5-inch section of each ladder rail shown in Figure 20. Cut the sidewalls all the way to the surface of the ladder that is attached to the duct so there are no sidewalls remaining in this 5-inch section. 4. Center one of the replacement ladder rails in one of the holes you just cut as seen in Figure 21. Center the cut section with the replacement rail and mark and center punch the four holes for the replacement rail. Do this on each side of the ladder. Using a 9/32- inch drill bit, drill all four holes on each side of the ladder. Once holes are drilled, set replacement rails aside. You will bolt them in at the end of this installation. 9-20
Cotton Picker Installation Mark at top of sensor mounting plate 5 inch measurement Figure 19. Mark at top of sensor mounting plate Figure 20. 5 inch measurement on ladder 5. Line up the top of a mounting bracket on the duct with the line and top rail cuts on the ladder (See Figure 21). 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. Figure 21. Orienting the bracket 9-21
Cotton Picker Installation Ag Leader Technology 6. Using duct tape, fix the position of the centered mounting bracket for marking the cutout hole and mounting holes. 7. Mark the center rectangular cutout and center punch the six mounting holes to be drilled. 8. Remove the mounting bracket and drill the six center-punched holes with a 9/32-inch drill bit. 9. For cutting the rectangular opening, it is recommended to use a high-speed air, electric cutting disk or plasma cutter. Saber and jigsaws are not recommended. They do not result in a clean cut. 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. 10. When cutting and drilling is complete use a flat file to remove all sharp edges around the perimeter of the 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. 11. Use six of the 1/4 x 3/4-inch truss head screws and six nuts to fasten the mounting bracket 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. 9-22
Cotton Picker Installation Figure 22. Attaching hinged template 12. Once the mounting bracket is securely fastened to the front side of the duct, attach the hinged template to the mounting bracket as seen Figure 22. Make sure the hinged template is pushed all of the way down into the hinge and using two nuts securely fasten the template to the mounting bracket. 13. Attach the second mounting bracket to the template flat strap using two more nuts as shown in Figure 23. Exploded View Assembled View Figure 23. Attaching template strap to 2 nd mounting bracket 9-21
Cotton Picker Installation Ag Leader Technology 14. Slide the assembly seen in Figure 23 onto the U-shaped strap as seen in Figure 24. The template assembly should be slide on until it mates up with the duct. 15. 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. 16. 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. 17. 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. 9-22
Cotton Picker Installation Figure 24. Holes ready to be marked 18. Attach the mounting bracket using six 1/4 x 3/4-inch truss head screws. You may want to double check for alignment using the templates before securely fastening all screws. NOTE: Ladder rails may need to be modified or substituted with your own plates, as these rail replacements are for late model machines. 19. Put the replacement ladder rails in place. Fasten the ladder rails using three 1/4 x 3/4-inch truss head screws and three lock washers and nuts. Do not place a bolt in the hole as indicated in the Figure 25. You will install a shield later that will utilize these holes. Repeat this to fasten the second ladder rail. Refer to Figure 25 to see the overall final installation with ladder rails and emitter in place. Do not place bolt in this hole. Both sides. Figure 25. Emitter installed in ladder 9-23
Cotton Picker Installation Ag Leader Technology Installing the sensor shield NOTE: This shield is designed for late model machines, some modifications or deviations from these instructions may be needed. 20. Use the 1/4 x 1-inch bolts as studs for the shield to pivot on. Follow the steps below carefully as it can be a little tricky installing the bolts and shield due to the width of the shield and the length of the bolts. See Figure 29. 21. Place a 1/4 x 1 inch bolt into the holes of the replacement rails that you left empty earlier (See Figure 25 & 26) and screw a nut partially onto the bolt. 22. Slide the bottom hole of the shield (oriented as shown in Figure 27) onto the bolt that is on the outside of the nut you just screwed on. Once the shield is on this stud, tighten the nut against the ladder rail to fix the bolt. 23. Repeat Step 21 and 22 for the other side of the rail as seen in Figure 28. 24. Screw the nylock nuts on the end of the studs until the shield is at an acceptable tightness. See Figure 29. 25. After the mounting brackets and replacement rails are securely fastened, place the sensors into the hinges to check for interference. Hinge up and fasten the captive nuts. The emitter (sensor with cable) should be mounted on the front side of the ducts (closest to the cab). 26. Remove the sensors (to prevent damage) and re-install the duct back on the machine. 27. Use the provided RTV silicone to seal the gaps between the mounting plates and the chute. Figure 26. Sensor Shield installed (Side View) 9-24
Cotton Picker Installation Figure 27. Sensor shield and bolt Figure 28. Sensor shield and bolts on ladder chute Nylock Nuts Figure 29. Sensor Shield installed 9-25
Cotton Picker Installation Ag Leader Technology Installing on Outside Ducts without Ladder Note: The instructions below may or may not be used depending on the configuration and model of your machine. The general concept of the installation can be derived. Before removing the ducts from your machine, decide where you want to mount the sensors. Keep in mind you want the sensors as high as possible to avoid conflict with the telescoping portion of the chute. At the same time, be careful there are no interferences with any other components 1. Make a mark on the front side of the chute where you want to mount the sensor. Make the mark where the top of the sensor mounting plate will be positioned. See Figure 30 for the bracket and its orientation. 2. Remove the duct from the machine. With the outlet of the black duct facing the floor, accurately 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. 9-26
Cotton Picker Installation 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 30. 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. 43 inch measurement Figure 30. Attaching template to mounting bracket 9-27
Cotton Picker Installation Ag Leader Technology Figure 31. 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. Refer to the example at the beginning of this section to calculate the proper amount of spacers needed. 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. Including the proper amount of spacers on the bottom side. 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. 9-28
Cotton Picker Installation 10. Once the mounting bracket is securely fastened to the front side of the duct with the proper amount of spacers attach the hinged template to the mounting bracket as seen in Figure 32. 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 33. 12. Slide the assembly seen in Figure 33 onto the U-shaped strap as seen in Figure 33. The template assembly should be slid on until it mates up with the duct. Figure 32. Attaching template to mounting bracket. Exploded View Assembled View Figure 33. Attaching template strap to 2 nd mounting bracket. 9-29
Cotton Picker Installation Ag Leader Technology Mounting Plate U-shaped Template Figure 34. 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. 9-30
Cotton Picker Installation 16. Securely fasten the mounting bracket using six 1/4 x 3/4 inch truss head screws and six lock washers and nuts. Make certain to include the proper amount of shims on the bottom side of the chute. 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 35 and 36. Figure 35. Emitter mounted on duct (Close up) 9-31
Cotton Picker Installation John Deere 9900-9940 Ag Leader Technology Figure 36. Emitter Mounted on Duct 9-32
Cotton Picker Installation John Deere 9900-9940 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 37) 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. 9-33
Cotton Picker Installation Ag Leader Technology Figure 37. 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. 9-34
Cotton Picker Installation John Deere 9900-9940 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. 9-35
Cotton Picker Installation Ag Leader Technology 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. *** 9-36
Summary of Changes John Deere 9900-9940 Summary of Changes Revision 1 August 2001 Initial release of these instructions. Revision 2 September 2003 Changes to include the PFadvantage.