Parts List of Combine Kit Note: Indented items indicate parts included Quantity by Model in an assembly listed above Early Models* 9 9 9 4 5 6 0 0 0 Part Name/Description Part No. 0 0 0 Instruction Kit JD Early 9X00, 9X10 2005100-15 1 1 1 Flow Sensor 4000224 1 1 1 Deflector 4000226 1 1 Deflector 4000228 1 Cables Kit (94/95X0-2001200, 96X0-2001201) 200120X 1 1 1 Box - 4-1/4 x 12 x 12 1 1 1 Cable Installation Kit 2000901-1 1 1 1 Bag White Block Reclosable - 2 mil - 9" x 12" 2001906-9x12 1 1 1 Cable Tie 6" 2002817-6 50 50 50 Cable Tie 15" 2002817-15 10 10 10 Grey Plastic Cable Clamps 2002812 6 6 6 Adhesive Mounting Base 2 Way 2002821-2 6 6 6 Alcohol Swab Pack 2002811 2 2 2 Cab Cable (10 ft long) 2000402-1 1 1 1 Grain Flow Sensor Cable (11 ft long) 2000406-1 1 1 Grain Flow Sensor Cable (12 ft long) 2000406-2 1 Distribution Cable (8 in long) 2000403-1 1 1 1 Power Jumper Cable 13 in. 2000404 1 1 1 Power Cable (8 ft, 4 in long) 2000405 1 1 1 Ground Speed Cable (16 ft long) 2000407-1 1 1 Ground Speed Cable (17 ft, 6 in long) 2000407-2 1 Elevator Speed Cable (19 ft, 6 in long) 2000408-1 1 1 1 Anchor Spring & Bracket Assembly 96X0 2001306-1 1 Anchor Chain Bracket 2000310 1 S-Hook - #63 bent 2000329-3 1 Extension Spring 2000328 1 Hex Hd Capscrew, Coarse Thd, Gr 8, ZP 5/16 x 2 2002003-31200 1 Hex Nylock Nut, Coarse Thd, ZP 5/16 2002055-31 1 Cab Wall Plate 2000400 1 1 1 Connector Clamp for Wall Plate 2000401 1 1 1 Combine Model Early models before Serial # Late Models after Serial # 9400 640101 640100 9500 640201 640200 9600 640301 640300 May 2004 2005100-15 8-1
Parts List of Combine Kit Ag Leader Technology Note: Indented items indicate parts included Quantity by Model In an assembly listed above Early Models* 9 9 9 4 5 6 0 0 0 Part Name/Description Part No. 0 0 0 Header Sensor Kit 1 1 1 Box - 4 x 6 x 8 1 1 1 Header Height Sensor Standard 2000322-1 1 1 1 Header Sensor Installation Kit 94/95X0 2000330-2 1 1 Bag White Block Reclosable - 2 mil - 4 x 6 2001906-4x6 1 1 Hex Hd Capscrews, Gr 8.8, ZP 8mm x 60mm 2002101-08060 2 2 Flat Washer, Standard, ZP 5/16 2002071-31 14 14 Split Lockwasher, ZP 5/16 2002061-31 2 2 Extension Spring 2000328 1 1 S-Hook - #63 bent angled 2000329-3 1 1 Hex Hd Screws, Coarse Thd, Gr 5, ZP 5/16 x 1 2002001-31100 1 1 Hex Nylock Nut, Coarse Thd, ZP 5/16 2002055-31 1 1 Header Sensor Installation Kit 96X0 2000330-3 1 1 1 Bag White Block Reclosable - 2 mil - 4 x 6 2001906-4x6 1 1 1 Hex Hd Capscrews, Gr 8.8, ZP 8mm x 60mm 2002101-08060 2 2 2 Flat Washer, Standard, ZP 5/16 2002071-31 14 14 14 Split Lockwasher, ZP 5/16 2002061-31 2 2 2 Threaded Arm Assembly 2000311-1 1 1 1 Rod - 1/4-20 x 36" 2000306 1 1 1 Split Lockwasher, ZP 1/4 2002061-25 3 3 3 Hex Nut, Coarse Thd, ZP 1/4 2002051-25 4 4 4 S-Hook - #63 2000329-1 1 1 1 Combine Model Early models before Serial # Late Models after Serial # 9400 640101 640100 9500 640201 640200 9600 640301 640300 8-2 May 2004 2005100-15
Parts List of Combine Kit Note: Indented items indicate parts included Quantity by Model In an assembly listed above Early Models* 9 9 9 4 5 6 0 0 0 Part Name/Description Part No. 0 0 0 Installation and Parts Kit 1 1 1 Box - 6 x 6 x 12 1 1 1 Post Bracket 3000689 1 1 1 Monitor Bracket Installation Kit 2001304-1 1 1 1 Hex Screw, Gr 8.8, ZP 5mm x 20mm 2002001-25062 2 2 2 Flat Washer, Standard, ZP 10mm 2002171-10 2 2 2 Hex Hd Screw, Coarse Thd, Gr 5, ZP 1/4 x 5/8 2002001-25062 2 2 2 Split Lockwasher, ZP 1/4 2002061-25 2 2 2 Hex Nut, Course Thd, ZP 1/4 2002051-25 2 2 2 Flow Sensor Installation Kit 2001300-17 (94/9500) 2001300-26 (9600) 1 1 1 Hex Hd Screw, Coarse Thd, Gr 5, ZP 5/16"x3/4" 2002001-31075 2 2 2 Hex Serrated Flange Nut, Coarse Thd, ZP 5/16" 2002057-31 2 2 2 Socket Head Screw, Coarse Thd, ZP, 1/4" x 1/2" 2002074-25050 4 4 4 Impact Plate, UHMW 4"x5.5" 3000683 1 1 1 (94/9500) 3000644 (9600) Cable Tie - 6" Black 2002817-6 6 6 6 Lower Adjuster Installation Kit (1-94/95X0, 2-96X0) 2001301-X 1 1 1 Drill Template - 9X00 Adjuster 2000511 1 1 1 Transfer Punch 13/32 2001003-41 1 1 1 Drill Bit Tin Coated 13/32 2001000-41 1 1 1 File Square 5/16 2001006 1 1 1 Offset Link Conveyor Chain 2001015 1 1 1 Nametag - "Do Not Adjust, Use Lower Adjuster" 2000132 1 1 1 Alcohol Swab Pack 2002811 1 1 1 Sprocket Spacer - 2.03" long 2000259-1 1 1 Sprocket Spacer - 3.03" long 2000259-2 1 Bearing - 30mm 2001009-30 1 1 1 File Handle 2001019 1 1 1 Lower Elevator Adjuster, Early 2000255-1 1 1 1 Lower Elevator Adjuster, Late 2000255-2 Combine Model Early models before Serial # Late Models after Serial # 9400 640101 640100 9500 640201 640200 9600 640301 640300 May 2004 2005100-15 8-3
Parts List of Combine Kit Ag Leader Technology Note: Indented items indicate parts included Quantity by Model In an assembly listed above Early Models* 9 9 9 4 5 6 0 0 0 Part Name/Description Part No. 0 0 0 Moisture Sensor (15 ft Cable for E.M.S) 2000411-1 1 1 1 Elevator Mount Moisture Sensor Kit (Grain 2001321-1 1 1 1 Elevator) Elevator Mount Unit RH Green 2000696-1 1 1 1 Battery Power Cable 16 ft Moisture Sensor 2000909-2 1 1 1 E.M.S. Installation Kit Deere 2001322-2 1 1 1 E.M.S. Instruction Kit 2001323-1 1 1 1 Box single walled 18x18x8 Moisture Sensor Kit (Auger) 1-94/95X0,2-96X0 2001319-X 1 1 1 Box - 4 x 6 x 12 1 1 1 Moisture Sensor (15 ft cable) 2000411-1 1 1 Moisture Sensor (16 ft cable) 2000411-2 1 Cutout Template 2000663 1 1 1 Hose Clamps (39 inches long) 2000645-39 2 2 2 Moisture Sensor Installation Kit 2000900-1 1 1 1 Bag White Block Reclosable - 2 mil - 5" x 8" 2001906-5x8 1 1 1 Clearance Gauge Moisture Sensor 2000656 1 1 1 Drill Bit Tin Coated - #19 2001000-19 1 1 1 Self Tapping Hex Screw, Coarse Thd, Gr 5, #1 2002075-10038 2 2 2 Combine Model Early models before Serial # Late Models after Serial # 9400 640101 640100 9500 640201 640200 9600 640301 640300 8-4 May 2004 2005100-15
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 List in their sections of the Operator s Manual to prevent their loss or to use as reference after completing installation. Section Contents Item Page Installing Monitor in Cab 9-2 Installing Cab Wall Connector Plate 9-4 Installing Power Cable 9-7 Installing Elevator Speed Cable 9-8 Installing Ground Speed Cable 9-11 Installing Header Height Sensor 9-14 Installing Elevator Adjuster 9-17 Installing Grain Flow Sensor 9-21 Installing Moisture Sensor 9-24 Final Inspection 9-30 Operational Checkout For PF Series Monitor 9-31 Operational Checkout for YM 2000 9-32 *** May 2004 2005100-15 9-1
Installation Ag Leader Technology Installing Monitor in Cab The following parts are required to install the monitor in the cab of the combine: Monitor Unit Monitor Mounting Brackets (Post bracket and U-bracket) Cab Cable (large diameter cable with rectangular 25 pin connector matching the connector on the bottom of the monitor. Stick-on Snap-open Closed Cable Clips. Alcohol Swabs (supplied) or Window Cleaner and Paper Towels (not supplied). NOTE: The recommended monitor mounting position is on the right hand front cab corner post, as shown in Figure 1. This places the monitor within easy reach and in a convenient viewing position. Figure 1. Post Bracket Mounted on Right Front Cab Post with U-Bracket 9-2 May 2004 2005100-15
Installation Step-by-Step Procedure 1. Remove top (2) Phillips head screws which hold the plastic molding to the left side of the right-front cab post. Place these screws in the armrest console. 2. Using the (2) 5mm x 20mm capscrews and flat washers provided, mount the post bracket to the left side of the cab post. NOTE: Tighten the capscrews enough to hold the bracket firmly, but be careful not to strip the threads in the cab post. 3. Mount the monitor in the u-bracket and hold it up to the post bracket to determine which holes you want to use for mounting the monitor. 4. Using the ¼ in. bolts and nuts provided, attach the u-bracket to the post bracket. Attach the cab cable to the monitor. IMPORTANT: Never use force to mate electrical connectors. If the connectors do not push together easily, they are not aligned properly. Use of force on connectors will result in connector damage. 5. Push the other end of the cab cable through the opening in the rear cab wall which is to the right of and below the operator s seat (you will reach this connector from the outside in a later step). 6. Install adhesive backed snap-open/snap closed cable clips onto the cab cable and attach them to the right-hand cab window to hold the cab cable out of the way. NOTE: Clean the window with an alcohol swab at each location where a clip is attached so they adhere properly. May 2004 2005100-15 9-3
Installation Ag Leader Technology Installing Cab Wall Connector Plate The following parts are required for installation: Connector Plate (7 x 9-1/2- in. with 6 connector holes) Connector clamp (4 x 2 in. with U-shaped cutouts in both ends) Distribution cable (bundle of 8 in. long black wires with seven connectors) Step-by-Step Procedure 1. Disconnect the five electrical connectors from the connector plate on the outside of the right hand cab wall (above right front tire). 2. Place the disconnected cables out of the way so that the connector plate is fully accessible. NOTE: There are two 37-pin connectors (the upper left and lower left). Place the cable so that it will be easy to remember which one is which when it is time to re-connect them. 3. Remove six screws around the outside of the cab plate and pull the cab plate away from the cab wall. 4. While holding the nuts on the back side, remove the remaining three screws to release the connector clamps from the cab plate. 5. Remove the rubber plug from the original cab plate and install it in the new cab plate. 6. Locate the end of the cab cable inside the cab plate opening and position the cable to take up the extra length of cable. 7. Install the new cab plate in place of the original as follows: 7a. Use two of the original clamps to re-attach the bottom four connectors to the cab plate. NOTE: Ensure the proper 37-pin connector is in the lower left hole. Look at the pin patterns on the mating connector if there is any question. 9-4 May 2004 2005100-15
Installation 7b. Place the connector that is on the end of the monitor s cab wire in the upper-right hole in the cab plate. Use the new connector clamp to clamp it and the original top left connector (Armrest to left-hand main) to the cab plate. 7c. Mount the cab plate to the cab wall. When finished, cab plate installation should look like Figure 2. NOTE: Don t forget to replace the metal cable clamp that is under one of the bottom plate mounting screws. Yield Monitor Connector Figure 2. Cab Wall Connector Plate 8. Re-attach the original five cables to the connectors on the cab plate. 9. Install the monitor distribution cable on the upper-right 24-pin connector. May 2004 2005100-15 9-5
Installation Ag Leader Technology NOTE: Ensure the retaining rings on all connectors are turned far enough clockwise to snap into the locked positions, so that the cable cannot come loose in the field. They are sometimes difficult to turn by hand, but they should be turned only by hand, since they can be broken if pliers are used. Distribution Cable Figure 3. Distribution Cable attached to Cab Cable 9-6 May 2004 2005100-15
Installation Installing Power Cable Parts required for installation: Power cable (the cable with an in-line fuse holder) Power jumper (12 in. long, red wires, 24-pin connector at each end) Cable ties Step-by-Step Procedure 1. Lift the hydraulic cylinder safety stop and fully lower the feeder house. 2. Locate the existing 24-pin connector which is under the front left-corner of the cab and disconnect the two halves of this connector. 3. Install the power jumper between the two halves of the existing connector. Ground Terminal installed Power Jumper Cable Power Cable Connector Figure 4. Installed Power Cable underneath Cab 4. Loop the wires of the power jumper use a large cable tie to tie it to the left front cab support, to keep the wires away from the hydraulic lines. 5. Connect the end of the power wire with the fuse and 2 pin connector to the power jumper. 6. Install the ground terminal of the power wire onto the stud on the underside of the cab floor which the horn is mounted. May 2004 2005100-15 9-7
Installation Ag Leader Technology 7. Run the power in front of the center and right-hand supports for the lower plastic face of the cab. 8. Use a cable tie to securely tie the power cable to the center support so that the fuse holder hangs down near the bottom of the cab face, but does not hang below it. 9. Route the cable behind the gear shift lever, over the cab ground strap and through the space between the cab floor and the right-hand cab support. 10. Use a large cable tie to securely tie the power cable to the top of the right side step support. 11. Connect the power cable to the distribution cable. Installing Elevator Speed Cable Parts required for this installation are: Elevator speed cable (identified by tag at the end with two connectors) Cable ties A rod, board or pipe small enough to fit between the cab wall and the grain tank, and long enough to go from one side of the cab to the other. Step-by-Step Procedure 1. Locate the clean grain auger low shaft speed sensor at the left end of the clean grain auger (just above the lower frame rail about halfway between the front and rear wheels on the left side of the combine). 2. Install the end of the elevator speed cable which has two connectors between the existing wiring harness and the low shaft speed sensor (ensure you have the elevator speed cable, NOT the ground speed cable). 3. Use a cable tie to hold cables in position as shown in Figure 5. 9-8 May 2004 2005100-15
Installation Elevator Speed Cable Figure 5. Elevator Speed Cable Connection at Clean Grain Auger 4. Route the cable as follows: NOTE: In all steps, tie the elevator speed cable to the cable along which it is being routed at 12 to 18 in. intervals. Be sure it is tied down well enough to keep it away from moving parts and hydraulic lines. 4a. Follow the existing combine wiring upward from the clean grain auger sensor. 4b. When you reach the cable that goes forward to the straw walker low shaft speed sensor, follow that cable forward. 4c. From the straw walker sensor cable, jump to the hydrostatic pump control cable as shown in Figure 6. May 2004 2005100-15 9-9
Installation Ag Leader Technology 4d. Follow the hydrostatic control cable forward to the point where it crosses the bracket that holds the brake fluid reservoir. 4e. Follow this bracket toward the cab and tie the elevator speed cable at both ends of this bracket as shown in Figure 7. 4f. Place a long, thin rod, board or pipe between the cab and grain elevator tank walls from the right side of the combine. Push the rod through to the left side of the combine. 4g. Tape the end of the elevator speed cable to the rod and pull the cable through to the right side of the combine. Remove the tape and connect the cable to the distribution cable on the cab wall plate. NOTE: It is not possible to connect the cables to the distribution cable incorrectly, since there is only one of each type of connector on the distribution cable. Elevator Speed Cable Figure 6. Routing Elevator Speed Cable 9-10 May 2004 2005100-15
Installation Elevator Speed Cable Figure 7. Routing Elevator Speed Cable Installing Ground Speed Cable Parts required for installation are: Ground speed cable (identified by tag at the end with two connectors) Cable ties Step-by-Step Procedure 1. Start the engine and raise the feeder house to its highest position. Stop the engine. CAUTION: To prevent serious injury or death to you or others, set the parking brake and lower the hydraulic cylinder safety stop on the left header lift cylinder. 2. Locate the ground sensor on the top of the 3-speed ground drive transmission (just in front of the center of the front combine axle). 3. Install the end of the ground speed cable which has two connectors between the existing wiring harness and the ground speed sensor, as shown in Figure 8. May 2004 2005100-15 9-11
Installation Ag Leader Technology Ground Speed Cable Figure 8. Ground Speed Cable Connection at Transmission 2. Feed the cable over the axle to the right side of the combine in front of the cleaning fans. NOTE: Later model combines have a screen in this area which may have to be temporarily removed. Ensure that the ground speed cable is not pinched or rubbing on a sharp edge when the screen is replaced. 5. Use a cable tie to attach the ground speed cable to the brake line on the right side of the transmission (your left side as you are looking back at the transmission. NOTE: Place the cable tie in a position that keeps the ground speed cable away from the brake drum and the hydraulic line that is in that area. 6. Behind the right front wheel, tie the cable to the lower right frame rail, both ahead of and behind the fan bearing bracket, as shown in Figure 9. 9-12 May 2004 2005100-15
Installation Figure 9. Ground Speed Cable tied to Right-Hand Frame Rail 7. Route the ground speed cable along the existing cable that connects to the fan speed sensor. Follow this cable back, upward, and then forward until it reaches the area near the cab wall plate. Be sure to tie the ground speed cable to the existing cable at least every 12 to 18 in. to keep it away from moving parts. 8. Connect ground speed cable to the distribution cable. May 2004 2005100-15 9-13
Installation Ag Leader Technology Installing Header Height Sensor Parts required for installation: Header height sensor assembly (with integral cable) Arm assembly (threaded rod with S-hook) Extension spring with S-hook and bolt (9400-9500) Extension spring with anchor bracket and bolt (9600) 8mm x 60mm screws (2 used) with lock washers (2 used) and flat washers 14 used) Cable ties Step-by-Step Procedure 1. Remove front and rear screws in the bank of hydraulic tubing clamps under the right hand side of the cab. NOTE: For 9400, 9410, 9500, 9510, combines, you may have to loosen all of the hydraulic tubing clamps and adjust the position of the hydraulic tubes towards the right side of combine. This may be required to get enough clearance to mount the header sensor. 2. With the header sensor oriented so that the electrical cable is to the back, and the open end of U-bracket is pointing to the ground, place one of the 8mm x 60mm screws, one lock washer and one flat washer under screw head, through the top front slot in the header height sensor. 3. Place six flat washers over the screw on top of the header height sensor and start the screw into the threaded hole from which the front clamp screw was removed. 4. Similarly, install one 8mm x 60mm screw in the top rear slot in the header sensor and start it into the hole at the back of the hydraulic clamps. 5. Align header sensor parallel with the side of the combine and tighten both screws. 6. Install the arm assembly in the hole in the sensor pivot shaft, using a nut and lock washer on each side of the shaft. 9-14 May 2004 2005100-15
Installation Header Sensor Cable Extension Spring attached to Shield Bracket Figure 10. Header Height Sensor with Feeder House Partially Lowered (9400, 9410, 9500, 9510) 7. Position the S-hook about 4 in. from the end of the threaded arm and lock it in position with the nuts on each side of it. 8. On the 9400, 9500,9410, and 9510, install the anchor hook for the extension spring in the hole in the shield bracket on the side of the feeder house, using the 5/16 in. screw and Nylock nut provided. 9. On the 9600 and 9610, attach the bracket with extension spring to the shield bracket using the 5/16 in. screw and nut provided (this bracket is required to position the spring in line with the arm of the header sensor with the wider feeder house) NOTE: A shield on the right hand side of the feeder house may obstruct mounting the anchor bracket. If so, notch out a clearance hole in the shield. 10. Route cable back to the cab wall plate area just under the cab support. Connect the cable to the distribution cable. Use a large cable tie to hold the cable against the cab support. May 2004 2005100-15 9-15
Installation Ag Leader Technology Anchor Bracket Figure 11. Header Height Sensor with Feeder House Partially Lowered (9600, 9610) 11. With pliers, bend the loops on the S-hooks fully closed so the extension spring can not come loose from the S-hooks. 12. Raise the feeder house and verify the feeder house does not hit the bottom of the header sensor when the feeder house is fully raised. 13. Hold the sensor pivot shaft with a wrench across its flats and bend the threaded arm upward slightly so that it just holds the spring tight with the feeder house raised. 9-16 May 2004 2005100-15
Installation Installing Elevator Adjuster IMPORTANT: A slide adjuster must be installed at the lower end of the clean grain elevator, so the top shaft of the elevator can remain in a fixed position. If you don t install this lower slide adjuster, every time you adjust the top shaft to tighten the chain your grain weight calibration will change. IMPORTANT: If your elevator chain and top drive sprocket have several years of use, it is a good idea to install new parts. If these parts are changed at a later date, it will affect the calibration of the monitor. Parts required for installation: Elevator adjuster assembly and 35mm bearing (same as existing bearing) Metal drill template 13/32 in. transfer punch, 13/32 in. drill bit and 5/16 in. square file (all provided) Half-link for elevator chain Step-by-Step Procedure NOTE: For 1997 models and newer combines, do not install the lower elevator adjuster because the combine is already equipped with a similar lower adjuster as shown in Figure 14. 1. Loosen the drive belt for the clean grain elevator by pulling out on the belt and moving the hairpin in the spring guide rod to keep the spring tension released. 2. Turn the clean grain elevator by hand until the halve links are accessible at the bottom of the 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 the bearing and bearing flanges at the lower end of the elevator. 4. Install the metal template, as shown in Figure 12, using the three screws that were used to retain the bearing flanges. May 2004 2005100-15 9-17
Installation Ag Leader Technology Figure 12. Drill Template Installed on Clean Grain Elevator 5. Using the 13/32 in. transfer punch, center-punch the elevator housing at each of the four corner holes of the drill template. NOTE: Check the position of the chain paddles before drilling to avoid drilling into them. 6. Using the 13/32 in. drill bit, drill through the elevator housing at each end of the corner holes. 7. Using the square file, file the corners of the holes out to match the square holes in the drill template. 8. Remove drill template. 9. Using the original three screws, install the bearing and bearing flanges loosely onto the adjuster slide plate. 10. Remove the spacer that is outside the sprocket on the clean grain auger shaft, replace it with the longer spacer provided. 9-18 May 2004 2005100-15
Installation IMPORTANT: Failure to install the longer spacer will allow the chain paddles to rub on the side of the elevator, causing excessive friction and wear. 11. Using the 10mm carriage bolts provided with the adjuster, mount the slide plate loosely to the clean grain elevator housing. Make sure that the adjuster slides freely over the entire length of the slots. 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 13. 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 13. Interference at Center Divider of Clean Grain Elevator May 2004 2005100-15 9-19
Installation Ag Leader Technology 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: NOTE: This is important. Failure to do this will reduce the accuracy of the monitor. 12a. Loosen the locknut on the original chain slack adjuster and adjust it upward until increased resistance can be felt. 12b. Check the position of the slide adjuster. If it is pulled up tight against its mounting bolts, add a half-link to the elevator chain, and again adjust upward until increased resistance can be felt and slide adjuster can still be moved. 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 the top shaft, tighten all the bolts on the lower adjuster with the lower auger shaft suspended by the elevator chain. 14. Be sure to replace the plastic cover over the end of the clean grain auger shaft on later model combines equipped with this cover. When full installed, the lower adjuster should look like Figure 14. 15. Re-tension the elevator drive belt by moving the hairpin in the spring guide rod. 16. Install the decal which says Do not Adjust, Use Lower Adjuster on the front of the clean grain elevator housing by the top adjuster (clean the housing of dirt and oil so that the decal will adhere properly). 9-20 May 2004 2005100-15
Installation Figure 14. Lower Adjuster on Clean Grain Elevator Installing Grain Flow Sensor Parts required for this procedure: Grain Flow Sensor Flow Sensor Cable (identical 9-pin connectors on both ends) Electric Drill and 11/32 in. drill bit Suitable Metal Cutting Device Small cable ties Step-by-Step Procedure 1. Remove the four nuts which retain the cover at the top of the clean gain elevator and remove top cover. 2. Remove the flange nuts (13mm socket size) from the 8 mm studs on the deflector plate that is mounted inside the top of the elevator. Then remove the deflector from the elevator through the top opening of the elevator. Install the nuts back onto the studs and set the deflector plate aside. May 2004 2005100-15 9-21
Installation Ag Leader Technology 3. Refer to Figure 15 and attach the template. Secure the bottom of the template with duct tape. Use the set of holes closest to the opening to be cut when placing over the threaded studs. NOTE: Be sure NOT to use the upper set of holes when placing the template. Failure to use the correct set of holes will place the flow sensor in the wrong position. 4. Mark the opening. 5. Cut the opening for the flow sensor with a suitable cutting device. Remove any burrs. Threaded Studs DO NOT USE THIS SET OF HOLES Hole set to use to determine template placement Figure 15. Template attached to clean grain elevator. (9500 shown) 6. With the handle on the flow sensor up, install the flow sensor (without the impact plate) in the opening, by hooking the bottom end of the flow sensor inside the bottom of the opening. Ensure the flow sensor is resting on the bottom edge of the opening and is lying straight on the top of the elevator. 9-22 May 2004 2005100-15
Installation 7. With the handle on the flow sensor up, install the flow sensor (without the impact plate) in the opening, by hooking the bottom end of the flow sensor inside the bottom of the opening. Ensure the flow sensor is resting on the bottom edge of the opening and is lying straight on the top of the elevator. 8. On 9600-9610 combines, use the flow sensor as a template, to mark and center punch two holes to be drilled in the elevator housing aligned with the two open holes at the top of the flow sensor housing. Remove the flow sensor from the elevator and drill 11/32 inch (or 9mm) diameter holes at these locations. Remove any sharp burrs remaining after drilling. 9. On 9600-9610 combines, use the (4) 5/16 inch x ¾ inch bolts provided, with one flat washer and flange nut per bolt, to plug the (4) holes that were used to mount the elevator deflector. Place the head of the bolt, with one washer, inside the elevator and install a flange nut on the outside of the elevator. 10. Place the flow sensor housing on the elevator and attach with two 5/16 x 3/4 inch bolts and flange nuts, with the heads of the bolts inside the elevator. See Figure 16. 11. Use two provided 1/4 x 1/2 inch socket head cap screws, attach the impact plate to the load cell inside the elevator housing. See Figure 17. NOTE: Be sure to mount the impact plate with the curved end up and with the curve pointing toward the top elevator sprocket. NOTE: Tighten the socket head screws to 180 inch-pounds (15 footpounds) torque, or as tight as you can get them by hand without stripping the hex wrench. 12. Place the deflector plate assembly over the opening at the top of the elevator with the deflector plate extending toward the flow sensor. Holding the deflector assembly firmly down against the elevator, slide it as far away from the flow sensor as you can, and attach the deflector plate to the elevator using the 10mm flange nuts. See Figure 18. May 2004 2005100-15 9-23
Installation Ag Leader Technology Figure 16. Flow Sensor installed Figure 17. Impact plate installed 9-24 May 2004 2005100-15
Installation Figure 18. Deflector plate installed. 13. Inspect the fit of the new flow sensor housing to the elevator housing. If there are large enough cracks between the flow sensor and the elevator housings to allow grain to flow back into the elevator through these cracks, seal them with silicone sealant or equivalent. 14. Connect either end of the flow sensor cable to the flow sensor. 15. Use a cable tie to attach the flow sensor cable to the right side light wiring. 16. Route the cable along the light wiring by bending the metal clips outward, placing the flow sensor cable under them and bending the cable clips back into place. 17. Follow the light wiring to the lower right corner of the grain tank window. 18. Open the grain tank window and run the cable outside the grain tank by bending it over the lower right corner as shown in Figure 19. May 2004 2005100-15 9-25
Installation Ag Leader Technology Figure 19. Grain Flow Sensor Cable Exiting Grain Tank 19. Close the grain tank window. 20. Connect the other end of the flow sensor cable to the distribution cable at the cab wall plate. 9-26 May 2004 2005100-15
Installation Installing Moisture Sensor IMPORTANT: If you have an elevator mount kit for installing the moisture sensor on the side of the clean grain elevator, ignore the following installation instructions. Installation instructions for the elevator mount kit are included in the box containing the elevator mount kit. If you do not have an elevator mount kit, you must install the moisture sensor on the bottom side of the loading auger inside the grain tank. This requires removing 6-1/2 in. of auger flighting from the center of this auger. NOTE: In field conditions where the combine head is continually picking up moist soil and/or green weeds or crop, a buildup of material may develop on the inside of the loading auger tube. In very severe cases, this may cause excessive wear on the auger flighting where the flighting has been removed for the moisture sensor. If the inside of the auger tube has a film of buildup that is thick enough that it rubs against the auger flighting, remove the moisture sensor and clean the tube in the area where the flighting is cut and check the flighting for wear. Parts required for this procedure: Moisture Sensor Moisture Sensor cutout template and clearance gauge Marking pen Long (32 in. or 39 in.) stainless steel clamps Cable ties Electric drill and drill bits Saber saw with metal cutting blade Hacksaw or torch for cutting auger flighting Handheld grinder May 2004 2005100-15 9-27
Installation Ag Leader Technology Step-by-Step Procedure 1. Remove the loading auger and tube from the grain tank with the top auger bearing holding the auger in its operational position relative to the tube. 2. On the bottom side of the auger tube, make a mark 12 in. from the discharge end of the tube. Then place the cutout template on the auger so that it is centered on this mark and mark the sensor opening (5-11/16 x 1-11/16 in.), as shown in Figure 17. 3. Drill one or more starting holes for the saber saw blade and cut the sensor opening, as shown in Figure 18. 4. Cut the hole in the tube as accurately as possible. It is good to avoid excess clearance around the plastic sensor housing since any such clearance will collect fine material that can affect the accuracy of the sensor. NOTE: Do not cut this hole with a torch. 5. After cutting the opening, check to see that the raised portion of the plastic part of the sensor housing fits into the opening. If it does not, use a file to enlarge the opening until the sensor just fits. Figure 17. Marking sensor opening using template 9-28 May 2004 2005100-15
Installation Figure 18. Cutting sensor opening 6. Rotate the auger inside the tube to align the outside edge of the auger with one end of the sensor opening and mark the auger, as shown in Figure 19. 7. Rotate the auger to align the flighting with the other end of the sensor opening and again mark the auger. NOTE: The auger must be in its normal operating position relative to the tube when you make these marks. 8. Remove the auger from the tube and mark the auger flighting 3/8 in. outside each of the original marks (3/8 in. lengthwise on the auger, not 3/8 in, along the spiral outside diameter of the flighting). Mark the flighting for cutting at these positions, which should be about 6-1/2 in. apart lengthwise on the auger. NOTE: Before cutting the flighting, weld it to the auger shaft just outside of each cut mark. Doing so keeps the flighting from expanding after being cut. 9. Using a hacksaw or torch, remove the 6-1/2 in. length of flighting all the way down to the auger shaft, as shown in Figure 20. Use a grinder or file to smooth off the cut edges of the flighting. May 2004 2005100-15 9-29
Installation Ag Leader Technology Figure 19. Marking Auger NOTE: The outside edge of the flighting is heat treated, requiring grinding a notch before the flighting can be cut with a hacksaw. 10. Re-install the auger into the tube and install the top bearing to hold the auger in its operating position. Hold the sensor clearance gauge in the sensor opening as shown in Figure 18 and rotate the auger to make sure that it clears the gauge. NOTE: If the flighting hits the gauge, additional flighting must be removed to ensure that the moisture sensor will not be damaged. 11. Place the moisture sensor in the opening of the tube and clamp it to the tube with one of the long clamps provided, as shown in Figure 22. NOTE: Be sure to install the sensor with the direction of grain flow arrow pointing towards the top end of the auger (the sensor cable will be toward the bottom end of the auger). 9-30 May 2004 2005100-15
Installation Figure 20. Auger with 6-1/2 in. of flighting removed Figure 21. Sensor Clearance Gauge in Sensor Opening May 2004 2005100-15 9-31
Installation Deere 9400-9600 PF3000 Ag Leader Technology 12. Drill a hole for a sheet metal screw about 90 degrees from the sensor opening and attach the ground strap, as shown in Figure 22. 13. Remove the moisture sensor from the auger tube and re-install the auger and tube in the combine. 14. Reinstall the moisture sensor onto the auger tube after it is back in the combine, and route its cable along the grain flow sensor cable to reach the distribution cable (the one which splits the large 24-pin connector out into six smaller connections). 15. Tie the cable securely to keep it away from sharp edges and to prevent it from being pulled down as grain is unloaded from the grain tank. NOTE: To tie the cable to the auger tube, either: Join two or more long wire ties end-to-end to allow them to reach around the tube OR Use the extra steel clamp provided (but be careful not to cut the cable by clamping it too hard). 16. Remove the sealed cover on the unused 14-pin connector on the distribution cable. Plug the moisture sensor cable into this connector, and loop and tie any excess cable away from moving parts. 9-32 May 2004 2005100-15
Installation Ground Strap Long Clamp Figure 22. Moisture Sensor Installed on Auger Tube Final Inspection Installation is now complete. Do a walk around of the combine and complete the following: All cable connections have been made. Excess cable has been tied out of the way, so there is no interference. All tools have been removed from the combine. All cap screws and carriage bolts are tight. May 2004 2005100-15 9-33
Installation Ag Leader Technology Operational Checkout for PF Series Monitor 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. Turn the monitor power switch ON and verify that the monitor turns on properly. A field and load should be displayed at the top. 3. Display Elevator Speed on the screen. 3a. Verify that elevator RPM stays at zero with the separator and header OFF. 3b. Engage the separator and verify the monitor measures elevator RPM. It should be between 400 450 RPM at full engine speed. NOTE: On some combine models, the header must be engaged to get an elevator speed signal. If you do not get an elevator RPM reading, engage the header drive. 4. Display Ground Speed on the screen. Move the combine slowly to verify the monitor measures MPH at low speeds (below 1 mph). NOTE: MPH will NOT agree with the combine s monitor, because the PF3000 has not yet been calibrated to your combine. 5. Start the separator with the combine at rest and verify that the monitor reads 0.0 MPH. 6. Display Head Height on the screen. 7. Lift the head and verify the head height number increases. Lower the head and verify the head height number decreases. 8. Display Temp on screen and verify that there is a temperature reading. The temperature may be off slightly because it has not been calibrated. Refer to the Setup Section of the Operator s Manual to adjust the monitor to your combine. 9-34 May 2004 2005100-15
Installation Operational Checkout for YM 2000 Step-by-Step Procedure Refer to General Description in the Setup Section of the Operator s manual for a description of the key. 1. Start Engine. 2. Flip the monitor power switch ON and verify that the monitor turns on properly. (a) The top display should show F1 L1 (b) The lower-left display should show SOYBEANS. (c) The lower-right display should show 0.0 AV/B/A. 3. Push the FLOW key twice to display Elevator RPM. (a) Verify that elevator RPM stays at 0 with the separator and header OFF. (b) Engage the separator and verify that the monitor measures elevator RPM. It should be between 400 and 450 RPM at full engine speed. NOTE: On some combine models, the header must be engaged to get an elevator speed signal. If you do not get an elevator RPM reading, engage the header drive. 4. Move the combine slowly to verify that the monitor measures MPH at low speeds (below 1mph). NOTE: MPH will not agree with the combine s monitor, because the yield monitor has not been calibrated to your combine. 5. Start the separator with the combine at rest and verify that the monitor reads 0.0 MPH. 6. Place the feeder house at about mid-height. 7. Place the AREA COUNT switch in the UP position. 8. Select STOP HEIGHT on the top display. May 2004 2005100-15 9-35
Installation Ag Leader Technology 9. If the red AREA COUNT light is ON, increase the stop height displayed on the top line (using the UP ARROW key for the top display) until the light goes out. 10. If the AREA COUNT light is OFF, decrease the stop height displayed until the light comes on. 11. Verify that the AREA COUNT light goes out as the head is dropped slightly below the original position and comes on as the head is slightly above the original position. NOTE: Use small up and down head movements for this check. If you use large motions, it may appear that the head moves too far before the light changes, because there can be up to a 1 second delay in the monitor. 12. Check for proper connection of the moisture sensor as follows (a) Turn On the Yield Monitor 2000. (b) Set MOIST = AUTO under the MOIST key. (c) Press the MOIST key five times to display temperature, which should show a number within a few degrees of the actual ambient temperature. (d) If you know the temperature in the area of the moisture sensor accurately, you can adjust the temperature readout with the lower-left UP or DOWN ARROW keys. (e) If you do not get a reasonable temperature reading (it will indicate 20 DEG F if the sensor is not connected), recheck the connections. Call Ag Leader Technology at 515-232-5363 if you have a problem and cannot find it. NOTE: You cannot get a moisture reading until there is grain flowing through the combine. Also, you will only see the AVG% display when there is no grain flow. *** 9-36 May 2004 2005100-15
Installation Summary of Changes Revision 1 May 2004 Initial Release May 2004 2005100-15 9-37