Note: Indented items indicate parts included in Quantity by Model an assembly listed above Early Models Late Models Part Name/Description Part Number 9400/ 9500/ 9600/ 9400 9500 9600 9410 9510 9610 Instruction Kit JD 9x00/9x10 4101007 1 1 1 1 1 1 Flow Sensor Early 9x00 4000231 1 1 1 Flow Sensor Late 9x00, 9x10 4000200 1 1 1 Deflector Assembly Early 94/9500 4000226 1 1 Deflector Assembly Late 94/9500, 94/9510 2000758-1 1 1 Deflector Assembly Early 9600 4000228 1 Deflector Assembly Late 9600, 9610 2000758-2 1 Flow Sensor Template 2000795 1 1 1 1 Flow Sensor Template 2000796 1 1 Lower Adjuster Early 9x00 2000255-1 1 1 1 Lower Adjuster Late 9x00 2000255-2 1 1 1 Header Sensor Standard 2000322-1 1 1 1 1 1 1 Arm Assembly 18 rod, S hook 2000311-1 1 1 1 1 1 1 Cab Wall Plate 9x00 2000400 1 1 1 1 1 1 Anchor Bracket Kit header sensor 2001306-1 1 1 Module Kit 4101004 1 1 1 1 1 1 Moisture Sensor module 4001538 1 1 1 1 1 1 Speed Sensor module 4001005 1 1 1 1 1 1 Module mounting plate 4000244 2 2 2 2 2 2 EMU control cable 3ft. 4001539-3 1 1 1 1 1 1 Moisture sensor adaptor cable 4001605-1 1 1 1 1 1 1 Module installation kit 4101005 1 1 1 1 1 1 Drill bit 13/64 in. 2001000-20 1 1 1 1 1 1 Drill bit 9/32 in. 2001000-28 1 1 1 1 1 1 Transfer punch 11/32 in. 2001003-34 1 1 1 1 1 1 Hex head cap screw 1/4 in. x 3/4 in. 2002001-25075 5 5 5 5 5 5 Hex nut 1/4 in. 2002051-25 5 5 5 5 5 5 Split lock washer 1/4 in. 2002061-25 5 5 5 5 5 5 External tooth lock washer 1/4 in. 2002063-25 3 3 3 3 3 3 Self tapping screw 1/4 in. x 3/4 in. 2002075-25075 3 3 3 3 3 3 Hex serrated flange nut 1/4 in. 2002225 5 5 5 5 5 5 Sheet metal screw #14 x 1/2 in. 2002232-14050 3 3 3 3 3 3 PN: 2005801 December 2009 Rev D 1
Ag Leader Technology Note: Indented items indicate parts included in Quantity by Model an assembly listed above Early Models Late Models Part Name/Description Part Number 9400/ 9500/ 9600/ 9400 9500 9600 9410 9510 9610 Cable Kit 4101006 1 1 1 1 1 1 System power cable 4000242-1 1 1 1 1 1 1 Power jumper 4000243-1 1 1 1 1 1 1 EMU power cable 2000909-2 1 1 1 1 1 1 Elevator speed cable 4000234-20 1 1 1 1 1 1 Ground speed cable 4000235-18 1 1 1 1 1 1 CAN Bus harness 4000326-4 1 1 1 1 1 1 Speed module stub 4000219-1 1 1 1 1 1 1 Moisture module stub 4000220-1 1 1 1 1 1 1 WP Plugged tower 3 pin 2000902-3 1 1 1 1 1 1 Cable installation kit generic 2000901-1 1 1 1 1 1 1 Cable ties 6 2002817-6 50 50 50 50 50 50 Cable ties 15 2002817-15 10 10 10 10 10 10 Adhesive cable clamps gray plastic 2002812 6 6 6 6 6 6 Adhesive mounting base 2 way 2002821-2 6 6 6 6 6 6 Alcohol swab pack 2002811 2 2 2 2 2 2 Parts Kit 9400/9500/9410/9510 2001312-35 1 1 1 1 Parts Kit 9600/9610 2001312-36 1 1 Header sensor installation kit 94/9500 2000330-2 1 1 1 1 Header sensor installation kit 9600 2000330-3 1 1 Extension spring 2000328 1 1 1 1 S-hook 2000329-3 1 1 1 1 Hex hd capscrew, ZP 5/16 x 1 2002001-31100 1 1 1 1 Hex nylock nut, ZP 5/16 2002055-31 1 1 1 1 Split lockwasher, ZP 5/16 2002061-31 2 2 2 2 2 2 Flat washer, ZP 5/16 2002071-31 14 14 14 14 14 14 Hex hd capscrew, ZP 8mm x 60mm 2002101-08060 2 2 2 2 2 2 Flow sensor installation kit 94/9500 2001300-17 1 1 1 1 Flow sensor installation kit 9600 2001300-18 1 1 Rubber impact plate 4 x 5.5 2000544-2 1 1 1 1 Impact plate, UHMW 6 x 5.5 3000644 1 1 Hex hd capscrew, ZP 5/16 x 3/4" 2002001-31075 2 2 6 2 2 6 Hex serrated flange nut, ZP 5/16 2002057-31 2 2 6 2 2 6 Flat washer, ZP 5/16 2002071-31 0 0 4 0 0 4 Socket hd screw, ZP 1/4" x 1/2" 2002074-25050 4 4 4 4 4 4 Cable tie 6 2002817-6 6 6 6 6 6 6 Grommet 3/4 in. ID x 1-7/16 in. P.H.D. 2002825-75 1 1 1 1 1 1 2 December 2009 Rev D
Note: Indented items indicate parts included in Quantity by Model an assembly listed above Early Models Late Models Part Name/Description Part No. 9400/ 9500/ 9600/ 9400 9500 9600 9410 9510 9610 Lower adjuster installation kit 94/9500 2001301-1 1 1 1 1 Lower adjuster installation kit 9600 2001301-2 1 1 Nametag Do Not Adjust! 2000132 1 1 1 1 1 1 Spacer 94/9500 2000259-1 1 1 1 1 Spacer 9600 2000259-2 1 1 Adjuster drill template 9x00 2000511 1 1 1 1 1 1 Drill bit 13/32 2001000-41 1 1 1 1 1 1 Transfer punch 13/32 2001003-41 1 1 1 1 1 1 Square file 5/16 2001006 1 1 1 1 1 1 Bearing 30mm 2001009-30 1 1 1 1 1 1 Offset link CA550 2001015 1 1 1 1 1 1 File handle 2001019 1 1 1 1 1 1 Alcohol swab pack 2002811 1 1 1 1 1 1 Monitor bracket installation kit 9x00 2001304-1 1 1 1 1 1 1 Hex hd capscrew, ZP 1/4 x 5/8 in. 2002001-25062 2 2 2 2 2 2 Hex nut, ZP 1/4 in. 2002051-25 2 2 2 2 2 2 Split lockwasher, ZP 1/4 in. 2002061-25 2 2 2 2 2 2 Flat washer, ZP #10 2002071-10 2 2 2 2 2 2 Hex hd capscrew, ZP 5mm x 20mm 2002101-05020 2 2 2 2 2 2 Post bracket monitor 3000689 1 1 1 1 1 1 Elevator Mount System (EMS) std RH 4100400 Elevator Mount System (EMS) OEM style 4100406 1 1 1 1 1 1 EMU JD 9x00/9x10 4000250 1 1 1 1 1 1 Decal JD 9x00/9x10 elevator 2000717 1 1 1 1 1 1 EMS Installation Kit 2001322-6 1 1 1 1 1 1 Fuse 1.25 x.25 in. 5 amp 2000061-5 3 3 3 3 3 3 Screwdriver proximity switch 2001038 1 1 1 1 1 1 Carriage bolt 1/4 x 5/8 in. 2002021-25062 6 6 6 6 6 6 Self-tapping screw #8 x 3/8 in. 2002075-08038 5 5 5 5 5 5 Hex serrated flange nut 1/4 in. 2002225 6 6 6 6 6 6 Moisture Sensor 3 ft 4001215 1 1 1 1 1 1 Combine Model Early Models (1989 & 1990) before Serial Number: 9400 640100 640099 9500 640200 640199 9600 640300 640299 Late Models (1991 & newer) after Serial Number: PN: 2005801 December 2009 Rev D 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 Common Components 5 Installing Display 7 Installing Display Cable 9 Installing Speed Sensor Module 11 Installing Power Jumper & Power Cable 13 Installing Elevator Speed Cable 15 Installing Ground Speed Cable 17 Installing Header Height Sensor 19 Installing Lower Adjuster 21 Installing Flow Sensor 25 Installing Elevator Mount Unit (EMU) OEM style 29 Installing a transferred EMU from another combine 34 Installing Moisture Sensor Module 37 Installing Moisture Sensor 39 Installing CAN Bus, Module Stubs & EMU Power 40 Final Inspection 41 Operational Checkout 42 4 December 2009 Rev D
Common Components 1. Terminator (Brown seal) 2. Plug (Blue seal) 3. Y-Splice Figure 1. CAN Bus connectors 1. Speed Sensor module 2. Moisture Sensor module Figure 2. Modules PN: 2005801 December 2009 Rev D 5
Ag Leader Technology Figure 3. System Layout 1. Display 2. Display cable 3. Power control relay 4. Speed Sensor module 5. Speed module stub 6. CAN Bus harness 7. Moisture module stub 8. Moisture Sensor module 9. Moisture sensor cable 10. Elevator Mount Unit 11. Flow sensor 6 December 2009 Rev D
Installing Display Parts required for procedure: (1) Display (1) Post bracket (1) U-bracket (2) Hex head cap screw 5mm x 20mm (2) Hex head cap screw 1/4 x 5/8 in. (2) Split lock washer 1/4 in. (2) Hex nut 1/4 in. (2) Flat washer #10 NOTE: Recommended mounting position is on right cab post as shown in Figure 4. This places display within easy reach and in a convenient viewing position. Figure 4. Display brackets installed on cab pillar PN: 2005801 December 2009 Rev D 7
Ag Leader Technology Step-by-Step Procedure 1. Remove top (2) Phillips head screws that hold plastic molding to left side of right-front cab post. Place screws in armrest console. 2. Using (2) 5mm x 20mm cap screws and flat washers provided, mount post bracket to left side of cab post as shown in Figure 4. NOTE: Tighten cap screws enough to hold bracket firmly, but be careful not to strip threads in cab post. 3. Attach U-bracket to post bracket using provided 1/4 in. hardware. Do not tighten. NOTE: Multiple mounting holes and slots allow for versatility in mounting. 4. Install display to determine best position for ease of viewing. 5. Remove display and tighten U-bracket to post bracket. 6. Re-install display. 8 December 2009 Rev D
Installing Display Cable Parts required for procedure: (1) Display cable (PN: 4001608-12 included in display kit) (3) Stick-on snap-open/closed cable clips (1) Cab wall connector plate (7 in. x 9-1/2 in. with 6 connector holes) (1) Power control relay (PN: 4000708-1 is included in display kit) (1) Grommet - 3/4 in. ID x 1-7/16 in. P.H.D. Cable ties Step-by-Step Procedure 1. Connect small round connector of display cable to mating connector on back of display. CAUTION: Never use force to mate electrical connectors. If connectors do not mate easily, they are not aligned properly. 2. Route display cable to floor. Secure it along edge of window as needed with adhesive backed cable clips. NOTE: Clean window with alcohol swab to ensure proper adhesion of clips to window. 3. Route individual connectors of display cable through opening in right-rear corner of cab (cable will be accessed through exterior wall plate in later step). 4. Plug power control relay (Figure 3, #3) into mating connector of display cable. NOTE: Installation inside cab is complete. 5. Raise shield on right side of combine to expose cab wall plate located on side of cab above front tire. 6. Disconnect all (5) electrical connectors from connector plate. 7. Place disconnected cables out of way so connector plate is fully accessible. 8. Remove (6) screws from around outside edge of wall plate and pull it away from cab wall. 9. Remove remaining (3) screws from wall plate while holding nuts on back of plate to release connector clamps from wall plate. 10. Remove rubber plug from original wall plate and install in new wall plate. PN: 2005801 December 2009 Rev D 9
Ag Leader Technology 11. Locate individual connectors of display cable through opening in cab wall. The display cable will be installed into upper-right hole of wall plate in next step. Leave power control relay, 9-pin GPS, and 2-pin power-out pigtails of display cable accessible from inside cab. 12. Install new wall plate in place of original plate as follows: a. Use original clamps to re-attach bottom (4) connectors to wall plate. NOTE: Ensure the proper 37-pin connector is in the lower left hole. Look at pin patterns on mating connector if there is any question. b. Route individual connectors of display cable into upper-right hole of wall plate labeled Yield Monitor. Split grommet and install it around display cable. Reinsert grommet into hole. c. Use top connector clamp to secure top left connector (Armrest to lefthand main) to wall plate. d. Do not attach plate to cab wall. Plate will be secured to wall in next section. NOTE: If a GPS cable will be routed into cab, route it now. GPS cable will plug into 9-pin pigtail connector of display cable. Refer to GPS installation instructions for specific details. It may be necessary to drill a hole through wall plate and install a grommet if one does not exist. 10 December 2009 Rev D
Installing Speed Sensor Module Parts required for procedure: (1) Speed Sensor module (1) Module mounting plate (1) Marking pen or scribe (1) Punch (1) Drill bit 9/32 in. (2) Hex head cap screw 1/4 in. (2) External tooth lock washer 1/4 in. (2) Split lock washer 1/4 in. (2) Hex nut 1/4 in. (2) Serrated flange nut 1/4 in. Extra fasteners are provided Step-by-Step Procedure 1. Position a module mounting plate above wall plate as shown in Figure 5. Figure 5. Module mounting plate installed 2. Mark locations for middle top and bottom holes on cab wall using a scribe. CAUTION: Ensure location of holes will not interfere with anything behind cab wall before continuing to next step. 3. Gently punch and drill holes using provided punch and 9/32 in. drill bit. 4. Secure module mounting plate to cab wall using provided 1/4 in. cap screws with external tooth lock washers from inside. Install split lock washers and hex nuts on outside as shown in Figure 5. 5. Mount Speed Sensor module to mounting plate using provided 1/4 in. serrated flange nuts as shown in Figure 6. PN: 2005801 December 2009 Rev D 11
Ag Leader Technology Figure 6. Speed Sensor module installed 6. Re-attach cab wall plate with screws retained during removal. 7. Re-attach original (5) cables to connectors in wall plate. NOTE: Ensure retaining rings on all connectors are turned far enough clockwise to snap into locked positions, so cables cannot come loose in field. Do not use pliers to tighten. 12 December 2009 Rev D
Installing Power Jumper & Power Cable Parts required for procedure: (1) Power cable (1) Power jumper (12 in. long, red wires, 24-pin connector at each end) Cable ties Step-by-Step Procedure 1. Lift hydraulic cylinder safety stop and fully lower feeder house. 2. Disconnect 24-pin cable connection under front-left corner of cab as shown in Figure 7. 3. Install power jumper inline with existing connectors. Existing connectors Power jumper Power cable Figure 7. Power jumper and power cable installed 4. Loop wires of power jumper and use large cable tie to secure to left front cab support. 5. Plug 2-pin connector of power cable into mating connector of power jumper as shown in Figure 7. 6. Install ground terminal of power cable to stud where horn is mounted. 7. Run power cable in front of center and right supports for lower plastic trim of cab. PN: 2005801 December 2009 Rev D 13
Ag Leader Technology 8. Secure power cable to center support so fuse holder hangs down near bottom of cab trim, but does not hang below it. 9. Route cable behind gear shift lever, over cab ground strap and through space between cab floor and right-hand cab support. 10. Secure power cable to top of right step support. 11. Connect power cable to display cable. It may be necessary to remove plug from display cable before power cable can be plugged in. 14 December 2009 Rev D
Installing Elevator Speed Cable Parts required for procedure: (1) Elevator speed cable Cable ties Step-by Step Procedure 1. Locate clean grain auger low shaft speed sensor at left end of clean grain auger (just above lower frame rail about halfway between front and rear wheels on left side of combine) as shown in Figure 8. 2. Install tee end of elevator speed cable between existing wiring harness and low shaft speed sensor. Do not confuse ground speed and elevator speed cables. 3. Route cable as follows: Figure 8. Elevator speed tee connection NOTE: Tie elevator speed cable to combine at 12 to 24 in. intervals to keep it clear of moving parts. a. Follow existing harness upward from shaft speed sensor. b. Follow straw walker low shaft speed sensor cable forward. c. From straw walker shaft sensor cable, jump to hydrostatic pump control cable as shown in Figure 9. PN: 2005801 December 2009 Rev D 15
Ag Leader Technology Figure 9. Elevator speed cable routing d. Follow hydrostatic control cable forward until it crosses brake fluid reservoir bracket. e. Follow bracket toward cab. Tie cable to both ends of bracket as shown in Figure 10. Figure 10. Elevator speed cable routing f. Place a long, thin rod between the cab and grain tank from right side of combine. Push rod through to left side of combine. g. Tape end of elevator speed cable to rod and pull cable through to right side of combine. Remove tape and connect elevator speed cable to 6-pin Shaft Speed connector of Speed Sensor module NOTE: It is not possible to connect cables to Speed Sensor module incorrectly. 16 December 2009 Rev D
Installing Ground Speed Cable Parts required for procedure: (1) Ground speed cable Cable ties Step-by-Step Procedure 1. Start engine and raise feeder house to its highest position. Turn off engine. To prevent serious injury or death to you or others, set parking brake and lower hydraulic cylinder safety stop on left header lift cylinder. 2. Locate ground speed sensor on the top of 3-speed ground drive transmission (just in front and near center of front combine axle). 3. Install tee end of ground speed cable between existing wiring harness and ground speed sensor as shown in Figure 11. NOTE: Tie ground speed cable to combine at 12 to 24 in. intervals to keep it clear of moving parts. Figure 11. Ground speed tee connection at transmission 4. Feed cable over axle to right side of combine in front of cleaning fans. NOTE: Later model combines have a screen in this area which may have to be temporarily removed. Ensure ground speed cable is not pinched or rubbing on a sharp edge when screen is replaced. PN: 2005801 December 2009 Rev D 17
Ag Leader Technology 5. Secure cable to brake line on right side of transmission (your left as you face transmission from front). NOTE: Keep ground speed cable away from nearby brake drum and hydraulic line. 6. Secure cable to lower right frame rail ahead of and behind fan bearing bracket as shown in Figure 12. Figure 12. Ground speed cable secured to frame on right side 7. Route ground speed cable along existing harness that connects to fan speed sensor. Follow cable back, up, and forward until it reaches area near Speed Sensor module. 8. Connect ground speed cable to 2-pin Ground Speed connector of Speed Sensor module. NOTE: It is not possible to connect cables to Speed Sensor module incorrectly. 18 December 2009 Rev D
Installing Header Height Sensor Parts required for procedure: (1) Header height sensor (1) Arm assembly (1) Extension spring with S-hook and bolt (9400-9500) (1) Extension spring with anchor bracket and bolt (9600) (2) Hex head cap screw 8mm x 60mm (14) Flat washers 5/16 in. (2) Lock washers 5/16 in. Cable ties Step-by-Step Procedure 1. Remove front and rear screws in bank of hydraulic tubing clamps under right hand side of cab. NOTE: For 9400, 9410, 9500, 9510 models it may be necessary to loosen all hydraulic tubing clamps and adjust position of hydraulic tubes toward right side of combine to get clearance for header sensor. 2. Position header sensor so cable routes back, and open end of housing is facing down. Place (1) 8mm x 60mm screw with lock washer and flat washer through top front slot of sensor. 3. Place (6) flat washers over screw on top of sensor and start screw into threaded hole from which front clamp screw was removed. See Figure 13 for proper orientation. Figure 13. Header height sensor installed (9400, 9410, 9500, 9510) 4. In similar manner, install other 8mm x 60mm screw in top rear slot of header sensor and start it into hole at back of hydraulic clamps. PN: 2005801 December 2009 Rev D 19
Ag Leader Technology 5. Align header sensor parallel with side of combine and tighten both screws. 6. Install arm assembly in hole of sensor pivot shaft using a nut and lock washer on each side of shaft. 7. Position S-hook approximately 4 in. from front end of threaded rod and lock it in position with nuts on each side. 8. On 9400, 9500, 9410 and 9510 models, install anchor hook for extension spring in hole in shield bracket on side of feeder house, using a 5/16 in. cap screw and lock nut. 9. On 9600 and 9610 models, attach anchor bracket with extension spring to shield bracket using a 5/16 in. cap screw and nut as shown in Figure 14 (wider feeder house requires this bracket be used to position spring in line with arm of header sensor). NOTE: A shield on right side of feeder house may interfere with anchor bracket. If so, notch out a clearance hole in shield. Figure 14. Header height sensor installed (9600, 9610) 10. Route cable back to cab wall plate area just under cab support. Secure cable to cab support using large cable tie. 11. Connect header height cable to 8-pin Position Sensor connector of Speed Sensor module. NOTE: It is not possible to connect cables to Speed Sensor module incorrectly. 20 December 2009 Rev D
12. With pliers, bend loops on S-hooks fully closed so extension spring can not come loose. 13. Raise feeder house and verify header sensor does not interfere with feeder house when fully raised. 14. Hold sensor pivot shaft with wrench across flats and bend threaded arm upward slightly so it just holds spring tight with feeder house raised. Installing Elevator Adjuster CAUTION: A slide adjuster must be installed at lower end of clean grain elevator, so top shaft of elevator can remain in a fixed position. Without this lower slide adjuster, weight calibration will change every time top shaft is adjusted. CAUTION: If elevator chain and top sprocket have several years of use, it is recommended to install new parts. Changing these parts later will affect the calibration of the monitor. Parts required for procedure: (1) Elevator adjuster assembly and 35mm bearing (1) Metal drill template (1) Offset link for elevator chain (1) Transfer punch 13/32 in. (1) Drill bit 13/32 in. (1) Square file 5/16 in. Step-by-Step Procedure NOTE: For 1997 models and newer combines, do not install lower elevator adjuster. The combine is already equipped with a similar lower adjuster from the factory. 1. Loosen drive belt for clean grain elevator by pulling out on belt and moving hairpin in spring guide rod to keep spring tension released. 2. Turn clean grain elevator by hand until connector links are accessible at bottom of elevator. NOTE: You must turn the elevator by moving the drive belt. There is too much friction to allow you to turn it with the chain paddles. 3. Remove bearing and bearing flanges at lower end of elevator. PN: 2005801 December 2009 Rev D 21
Ag Leader Technology 4. Install metal template, as shown in Figure 15, using (3) screws that were used to retain bearing flanges. 5. Center punch elevator boot at each corner of drill template using provided 13/32 in. transfer punch. NOTE: Check position of chain paddles before drilling to avoid drilling into them. Figure 15. Drill template installed on clean grain elevator 6. Drill all (4) holes using provided 13/32 in. drill bit. Leave drill template installed. 7. File all (4) holes square to match drill template using provided file. 8. Remove drill template. 9. Install bearing and bearing flanges loosely onto adjuster plate using original (3) screws. 10. Remove spacer that is outside sprocket on clean grain auger shaft. Replace it with longer spacer provided. CAUTION: Failure to install longer spacer will allow chain paddles to rub on side of elevator, causing excessive wear. 11. Mount slide plate loosely to elevator boot using provided 10mm carriage bolts. Ensure adjuster slides freely over entire length of slots. 22 December 2009 Rev D
NOTE: On some combines, a slight interference between the center divider plate of the clean grain elevator and the bushing welded to the auger shaft may prevent full upward travel of the slide plate. Figure 16 illustrates this interference with the arrow in the upper left corner. NOTE: If this interference exists, a small notch must be cut out of the center divider to allow full travel of the slide plate. To do this, first drop the shaft to its lowest position. Remove the blade from a hacksaw and re-install it with the blade between the shaft and the divider plate. Then saw upward from the bottom of the divider. Turn the hacksaw blade 90 degrees to saw sideways to meet the first cut. NOTE: Since the amount of material which must be removed is small (about 1/4 in. square), it is also possible to remove it with a file. Figure 16. Interference at center divider of clean grain elevator 12. After full travel of the slide plate is verified, adjust the top shaft of the clean grain elevator to its full upward position using the following procedure: a. Loosen lock nut on original chain slack adjuster and adjust it upward until increased resistance can be felt. b. Check position of slide adjuster. If it is up tight against its mounting bolts, add an offset link to elevator chain. c. Adjust upward until increased resistance can be felt and slide adjuster can still be moved. PN: 2005801 December 2009 Rev D 23
Ag Leader Technology NOTE: Perform a final check of the position of the top adjuster by observing the position of the bearing side plate at the top of the clean grain elevator. In the full upward position, the top of the slide plate is even with the tip of the side plate of the clean grain elevator. 13. After proper adjustment of top shaft, tighten all bolts on lower adjuster with lower auger shaft suspended by elevator chain. 14. Replace plastic cover over end of clean grain auger shaft on later model combines equipped with this cover. When fully installed, lower adjuster should look like Figure 17. Figure 17. Finished installation of lower adjuster 15. Re-tension elevator drive belt by moving hairpin in spring guide rod. 16. Install decal which says Do not Adjust, Use Lower Adjuster on front of clean grain elevator housing by top adjuster (clean housing of dirt and oil so decal will adhere properly). 24 December 2009 Rev D
Installing Flow Sensor Parts required for procedure: (1) Flow sensor (1) Rubber impact plate (1) Punch (1) Drill bit 11/32 in. (6) Hex hd cap screw 5/16 x 3/4 in. (less required for 9400/9500/9410/9510) (4) Flat washer 5/16 in. (less required for 9400/9500/9410/9510) (6) Hex serrated flange nut 5/16 in. (less required for 9400/9500/9410/9510) (2) Socket head screw 1/4 in. NOTE: The flow sensor installation process differs slightly between early and late models. The break between early and late models occurred in 1991. Refer to serial number reference chart on page 3 to determine early or late distinction. Step-by-Step Procedure 1. Loosen all (4) and completely remove (2) of (4) nuts that secure access panel at top of clean gain elevator. Remove panel. 2. Remove flange nuts (13mm socket size) from 8 mm studs on deflector plate that is mounted inside top of elevator. Remove deflector from elevator through top opening of elevator. Install nuts back onto studs and set deflector plate aside. 3. Remove flange nuts from 10mm bolts that attach cover plate to OEM flow sensor mounting hole. Install bolts back into cover and set aside. At this point, top of elevator will look like Figure 18. Figure 18. Ready to install flow sensor PN: 2005801 December 2009 Rev D 25
Ag Leader Technology NOTE: If combine is not equipped with factory holes, complete steps 4 through 6. If combine has factory holes as shown in Figure 18, skip to step 7. 4. Attach cutout template to elevator such that (2) holes on template fit over (2) studs that secured access panel. Secure bottom of template with duct tape. See Figure 19 for clarification. CAUTION: This procedure differs slightly between early and late models. For late models, use set of holes near top edge to align template with studs. For early models, use lower set of holes to align template with studs. Figure 19. Cutout template secured to elevator (9500 shown) 5. Outline large rectangular opening on elevator head with a marker. Center punch corners and drill with a 1/2 in. drill bit. 6. Cut opening for flow sensor with a suitable cutting device. Remove any burrs. 7. With handle on flow sensor up, install flow sensor (without rubber impact plate) into opening by hooking bottom end of flow sensor inside bottom edge of opening. Ensure flow sensor is resting on bottom edge of opening and is lying straight on top of elevator. 26 December 2009 Rev D
NOTE: For 9400/9500/9410/9510 models, top (2) holes of flow sensor should align with existing holes in elevator head eliminating need for drilling. Skip to step 9. 8. For 9600 & 9610 models only, perform following steps: a. Use flow sensor as template to mark and center punch (2) holes near top of flow sensor onto elevator head. b. Remove flow sensor from elevator and drill 11/32 in. (9mm) diameter holes at these locations. c. Install (4) 5/16 x 3/4 in. cap screws with flat washers into holes that were used to mount original elevator deflector. Install cap screws with washers from inside with flange nuts on outside. NOTE: The (2) holes on each side of flow sensor opening do not need to be plugged. The flow sensor housing will cover these holes. d. Re-install flow sensor into opening as described in step 7. 9. Secure flow sensor with (2) 5/16 x 3/4 in. cap screws and flange nuts, with heads of bolts inside elevator. See Figure 20 for finished installation. Figure 20. Flow sensor installed 10. Secure rubber-coated impact plate to flow sensor from inside elevator housing using (2) 1/4 x 1/2 in. socket head cap screws as shown in Figure 21. CAUTION: Ensure curved end of impact plate is up and pointing toward elevator paddles. PN: 2005801 December 2009 Rev D 27
Ag Leader Technology NOTE: Tighten socket head screws to 180 inch-pounds (15 footpounds), or as tight as possible without stripping the hex. Figure 21. Impact plate installed 11. Install deflector assembly into opening at top of elevator with plate extending toward flow sensor. Hold deflector assembly down firmly against elevator, and slide it as far away from flow sensor as mounting studs will allow. Fasten deflector plate to elevator using (4) 10mm flange nuts as shown in Figure 22. Figure 22. Flow sensor and deflector installed 28 December 2009 Rev D
Installing Elevator Mount Unit (EMU) Parts required for procedure: (1) Elevator Mount Unit (EMU) (6) Carriage bolt 1/4 x 5/8 in. (6) Hex serrated flange nut 1/4 in. Additional parts required for combines without factory cut holes: (1) Template Upper Hole (1) Template Lower Hole (1) Marking pen (1) Drill bit 9/32 in. (1) Square file NOTE: Installation of EMU is broken up into (2) sections. The 1 st section details how to install an OEM style EMU specifically designed for these models. The 2 nd section details how to install a standard style EMU from a different model combine. If transferring an EMU from another combine, skip to next section on page 34. CAUTION: If a JD factory installed elevator mount unit has been removed, an open circuit must be completed in order to get an elevator speed signal. Wires 622 and 623 located in plug on right side of combine where elevator mount unit was plugged in must be jumped together. A jumper plug kit is available through JD (PN: AH211729). Step-by-Step Procedure (OEM style) 1. Raise side shield on right side of combine to access clean grain elevator. NOTE: Combines prior to 1997 without factory holes require a template kit (pn: 2001341) to mark and cut holes. The hole pattern will match factory holes on 1997 and newer machines. Steps 2 thru 6 detail this process. For 1997 & newer combines with factory holes, skip to step 7. 2. Mark holes and cutouts on clean grain elevator using provided templates. a. Smaller cutout template is used for marking bottom hole. Push flange of template against middle ridge and rest bottom edge of template on lower boot flange. Mark cutout area and holes with marker. b. Larger cutout template is used for marking top hole. Push flange of template against middle ridge and rest bottom edge of template on lower boot. Mark cutout area and holes with marker. See Figure 23 for clarification of this procedure. PN: 2005801 December 2009 Rev D 29
Ag Leader Technology Figure 23. Cutout template placement 3. Center punch and drill 9/32 in. holes in (8) mounting locations marked. 4. Using a suitable cutting tool, cut inlet and outlet holes. Cut just inside of marked lines to prevent grain from leaking around holes. 5. Remove sharp edges around holes that may cause paddle wear or prevent a clean mounting of EMU using metal file. 6. Square up (8) 9/32 in. holes using provided square file. This is necessary so carriage bolts can be used to attach EMU to elevator. NOTE: Next step only applies to 1997 and newer machines that have factory holes on clean grain elevator. 7. Remove cover plates from elevator as shown in Figure 24. Do not throw cover plates away. They can be reused if EMU is removed. Elevator should look like Figure 25 with cover plates removed. 30 December 2009 Rev D
Figure 24. Factory-installed cover plates Figure 25. Inlet and outlet holes PN: 2005801 December 2009 Rev D 31
Ag Leader Technology 8. Disassemble EMU by removing electrical cover and elevator adapter plate from main housing. 9. Attach elevator plate using 1/4 in. carriage bolts and flange nuts as shown in Figure 26. Use top (2) holes of inlet and all (4) holes of outlet. Figure 26. Elevator adapter plate installed 10. Install main housing to elevator adapter plate as shown in Figure 27. Make sure main housing is tightly pushed against elevator plate in all locations and tighten (9) serrated flange nuts to hold plate and housing together. 32 December 2009 Rev D
Figure 27. Main housing installed NOTE: The EMU electrical cover will be installed in a later section. Proceed to section entitled Installing Moisture Module on page 37. PN: 2005801 December 2009 Rev D 33
Ag Leader Technology Step-by Step Procedure (Standard EMU) NOTE: Skip this section unless you are transferring a standard style EMU from another combine. 1. Remove spacer block from EMU. 2. Position spacer block on side of elevator just below main elevator support. Push spacer block up against bottom edge of support. Channel through center of spacer block will provide clearance for center-divider flange on elevator. Position spacer block as far forward toward front of machine as center divider will allow. 3. For machines with factory holes, remove upper cover on side of elevator and place spacer block over opening exactly as instructions describe above. In this position, inlet hole for EMU will extend upward from existing hole. Ag Leader can provide a cover plate to re-establish factory hole if EMU is removed. CAUTION: Orientation of spacer block is very important for proper installation of EMU to prevent damaging elevator paddles and clean grain elevator. 4. Mark outline of holes in spacer block on clean grain elevator and (5) holes that will be used to attach spacer block to elevator. 5. Extend opening of inlet hole to 8 inches so outline on elevator matches cavity on back of spacer block. See Figure 28. CAUTION: Extending dimensions of inlet hole is critical for operation of EMU. If dimensions are not extended, moisture will be inaccurate due to insufficient grain passing by sensor. Figure 28. Holes marked on elevator 34 December 2009 Rev D
6. Drill 1/2 in. holes in all corners of inlet and outlet holes. Drill (5) 9/32 in. holes for mounting elevator mount unit. NOTE: If paddles are in the way, loosen tension on clean grain elevator belt and rotate paddles. 7. Cut inlet and outlet holes using an appropriate cutting tool. Stay inside marked lines. 8. Use a file to remove burrs or rough edges after cutting. 9. Install (5) 1/4 x 1-3/4 in. pan head screws with external tooth lock washers through mounting holes from inside. Attach jam nuts to screws as shown in Figure 29. Figure 29. EMU mounting bolts installed 10. Mount spacer block to (5) bolts as shown in Figure 30. PN: 2005801 December 2009 Rev D 35
Ag Leader Technology Figure 30. Spacer block mounted to elevator 11. Attach elevator mount unit with (5) 1/4 in. lock nuts as shown in Figure 31. Figure 31. EMU mounted to spacer block 12. Install (4) self-tapping screws into plastic spacer block to finish installation of EMU to spacer block. NOTE: The EMU electrical cover will be installed in the next section. 13. A new belt-drive decal has been provided to replace the decal that got covered up by EMU. Apply decal on elevator above EMU. 14. Tighten elevator drive belt if it was loosened in an earlier step. 36 December 2009 Rev D
Installing Moisture Sensor Module Parts required for procedure: (1) Moisture Sensor module (1) EMU control cable (1) Marking pen (1) Punch (1) Drill bit 9/32 in. (2) Hex head cap screw 1/4 x 3/4 in. (2) Split lock washer 1/4 in. (2) Hex nut 1/4 in. Extra fasteners are provided Step-by-Step Procedure 1. Position Moisture Sensor module on bracket in front of clean grain elevator as shown in Figure 32. Moisture sensor module Figure 32. Moisture Sensor module installed NOTE: When determining mounting location, ensure cabling will reach between Moisture Sensor module and EMU. 2. Mark locations of (1) hole in each flange of Moisture Sensor module onto combine bracket. Outside holes will be easiest to drill due to angle of bracket. PN: 2005801 December 2009 Rev D 37
Ag Leader Technology 3. Punch and drill (2) holes using provided center punch and 9/32 in. drill bit. 4. Secure Moisture Sensor module to bracket using provided 1/4 in. cap screws, lock washers and hex nuts. 5. Connect 8-position deutsch plug of EMU control cable with mating CONTROL receptacle of moisture module. 6. Connect weather pack connectors of EMU control cable to EMU components. 3-position shroud mates with proximity switch and 2-position tower mates with motor as shown in Figure 33. NOTE: The new moisture module contains built in circuitry for controlling the EMU. It is no longer necessary to connect an external relay to the moisture module cabling. Prox. Switch Motor Figure 33. EMU control cable connected to EMU NOTE: If EMU was previously used with a YM2000 or PF series yield monitor, it is equipped with a manual cleanout button on electrical cover that will not be used. Remove cleanout button and install rubber plug that has been provided in all upgrade kits. 7. Reinstall electrical cover onto EMU. A slot on side of electrical cover allows module cabling to pass through. 38 December 2009 Rev D
Installing Moisture Sensor Parts required for procedure: (1) Moisture sensor with integral cable Cable ties Step-by-Step Procedure 1. Locate moisture sensor as shown in Figure 34. Provided sensor is a new revision as of August 2009. Functionally it is identical to its predecessor, but there are a couple of noteworthy differences. a. Sensor cover is integrated into moisture sensor assembly for ease of installation. b. Ground strap has been eliminated. Electrical connection between moisture sensor and EMU is achieved through the mounting stud/wing-nut/sensor housing interface. Figure 34. Moisture sensor 2. Install moisture sensor into EMU housing by engaging tab on bottom of moisture sensor cover with tab on side of housing. Tilt sensor upward to insert sensor blade into grain cavity and secure cover with a wing nut. 3. Route moisture sensor cable to moisture module. Connect 8-position deutsch plug of moisture sensor cable with mating SENSE receptacle of moisture module. 4. Secure excess cable with zip ties to keep it clear of moving parts. PN: 2005801 December 2009 Rev D 39
Ag Leader Technology Installing CAN Bus, Module Stubs and EMU Power Parts required for procedure: (1) CAN Bus harness (1) Moisture module stub (1) Speed module stub (1) EMU battery power cable Cable ties Step-by-Step Procedure NOTE: Begin routing CAN Bus at Moisture Sensor module and work toward flow sensor and display cable as detailed in following steps. 1. Plug gray female connector of moisture module stub into mating gray male connector of Moisture Sensor module. 2. Plug black female connector of moisture module stub into Y-Splice of main CAN Bus harness. NOTE: The CAN Bus harness resembles a Y configuration. (2) cables are connected with a Y-Splice on one end and corrugated together for several feet. Moisture module stub plugs into Y-Splice on double corrugated end. 3. Route CAN Bus to body of combine and forward to display cable. Follow existing cables, hoses or tubes when possible. 4. Plug shorter CAN Bus (labeled: To Speed Module) into display cable. Black female connector of display cable mates with black male connector of Y-Splice on CAN Bus. 5. Plug black female connector of speed module stub into remaining white male connector of Y-Splice on CAN Bus. 6. Plug gray female connector of speed module stub into 4-pin CAN Bus connector of Speed Sensor module. 7. Route longer CAN Bus (labeled: To Flow Sensor) up into grain tank through window on front wall of grain tank as shown in Figure 35. 8. Connect CAN Bus to flow sensor. Flow sensor will plug into white connector of Y-Splice installed on CAN Bus. 9. Begin securing CAN Bus to grain tank wall. Start at flow sensor and work toward window. Excess cable can be coiled near display cable. 40 December 2009 Rev D
Figure 35. CAN Bus through window in grain tank 10. Route EMU power cable to batteries as detailed in following steps: a. Connect 2-socket tower connector of power cable to fused 2-pin shroud connector of Moisture Sensor module. b. Route power cable to batteries following an existing wiring harness if possible. The batteries are located behind and left of engine compartment. c. Connect lugs of the power cable to terminals of battery. Make sure red fused wire of power cable goes to positive terminal of battery and black wire goes to negative terminal. d. Check for 12-volt power across terminals. Final Inspection Installation is complete. Walk around combine 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 combine All fasteners are tight PN: 2005801 December 2009 Rev D 41
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. b. Flow sensor LED is located on load cell. Most flow sensors have a hole in housing that enables viewing LED without removing sensor. c. The following modules should be listed as CAN devices within the display: 239 SPEED MODULE 240 FLOW SENSOR 244 MOISTURE MODULE 4. Verify the following analog input signals (a, b & c can be verified at the RUN screen, but (d) must be verified through the DIAGNOSTIC screen): a. ELEVATOR SPEED (RPM) signal. 1. Elevator speed should register zero with separator off. 2. Engage separator and header. Display should register RPM value. At full throttle, elevator speed is approximately 425 RPM +/- 50. b. GROUND SPEED (MPH) signal. 1. Ground speed should register zero with combine at rest. 2. Move combine 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 combine readout until system has been calibrated. c. HEADER HEIGHT (%) signal 1. Raise and lower header. Header height % should increase and decrease respectively. d. TEMPERATURE (C) signal. 1. Temperature in Celsius should be displayed as a value other than zero. Accuracy is not important, as it will be calibrated later. 42 December 2009 Rev D
Revision History Date Revision Initials Changes May 2004 N/C SLH - Initial release Jun 2004 A SLH - Removed RTV from flow sensor installation Jul 2004 B SLH - Modified Operational Checkout Mar 2007 C SLH - Updated Parts List Dec 2009 D WDS - Changed display cable - Changed moisture module - Changed moisture sensor PN: 2005801 December 2009 Rev D 43