Table of Content:
1 Introduction
1.1 Foreword
1.2 Symbol Definitions
2 Safety Features
2.1 Cotton Picker Safety Features
3 Safety
3.1 Recognize Safety Information
3.2 Understand Signal Words
3.3 Follow Safety Instructions
3.4 Replace Safety Signs
3.5 Prepare for Emergencies
3.6 Wear Protective Clothing
3.7 Protect Against Noise
3.8 Use Handholds And Steps
3.9 Keep Riders and Children Off Machine
3.10 Operator Ability
3.11 Parking and Leaving the Machine
3.12 Instructional Seat
3.13 Use Seat Belts
3.14 Operate Safely
3.15 Transport Safely
3.16 Use Safety Lights and Devices
3.17 Avoid Electrical Power Lines
3.18 Avoid Backover Accidents
3.19 Avoid Tip-Overs
3.20 Emergency Exit (Right-Hand Cab Window)
3.21 Fire Prevention
3.22 In Case Of Fire
3.23 Fire Extinguishers
3.24 Water-type Fire Extinguisher Location
3.25 Dry Chemical Fire Extinguisher Location
3.26 Auxiliary Water System
3.27 Practice Safe Service and Maintenance
3.28 Operate Basket Dump Cylinder Locks
3.29 Avoid Contact with Moving Parts
3.30 Avoid Entanglement
3.31 Stay Clear Of Rotating Drivelines
3.32 Prevent Machine Runaway
3.33 Install All Guards
3.34 Support Machine Properly
3.35 Use Proper Lifting Equipment
3.36 Avoid Static Electricity Risk When Refueling
3.37 Handle Fuel Safely?Avoid Fires
3.38 Handle Starting Fluid Safely
3.39 Handle Chemical Products Safely
3.40 Decommissioning ? Proper Recycling and Disposal of Fluids and Components
3.41 Handling Batteries Safely
3.42 Work In Ventilated Area
3.43 Avoid Hot Exhaust
3.44 Remove Paint Before Welding or Heating
3.45 Welding Near Electronic Control Units
3.46 Avoid Heating Near Pressurized Fluid Lines
3.47 Avoid High-Pressure Fluids
3.48 Service Drive Belts Safely
3.49 Service Cooling System Safely
3.50 Service Tires Safely
3.51 Tightening Wheel Retaining Bolts/Nuts
3.52 Handle Electronic Components and Brackets Safely
3.53 Use Proper Tools
3.54 Using Compressed Air For Cleaning
3.55 Do Not Open High-Pressure Fuel System
3.56 Wait Before Opening High-Pressure Fuel System
3.57 Service Accumulator Systems Safely
3.58 Protect Against High Pressure Spray
4 Safety Signs
4.1 Do Not Contact Electrical Lines Decal
4.2 Seat Belt Decal
4.3 Park Brake Decal
4.4 In Case of Fire Decal
4.5 Emergency Exit Decal
4.6 Tip Over Hazard Decal
4.7 Do Not Ride Decal
4.8 Bypass Start Decal
4.9 Prevent Fires Decals
4.10 Fire Hazard Decal
4.11 Pressurized Coolant Hazard Decal
4.12 Hydraulic Lift Cylinder Safety Stops Decal
4.13 Power Driven Parts Decal
4.14 Rotating Fan Hazard Decal
4.15 Rotating Driveline Decal
4.16 Row Unit Entanglement Decal
4.17 Do Not Step Decals
4.18 Conveyor Hazard Decal
4.19 Basket Door Cylinder Stop Decal
4.20 Basket Lift Cylinder Lock Decal
4.21 Hot Exhaust Decal
5 Operator’s Station
5.1 General View of Controls and Indicators
5.2 Armrest Console Controls
5.3 Multi-function Lever Palm Rest Adjustment
5.4 Multi-Function Lever Buttons
5.5 Row Units Raise/Lower Button
5.6 Basket Unload Buttons
5.7 Guidance System Engage Button
5.8 Guidance System On-Off Button
5.9 Row Guidance Offset Adjustment Dial
5.10 Fan Switch
5.11 Row Units Switch
5.12 Height Sensing Response Rate Dial
5.13 Height Adjust Buttons
5.14 Moistener System Flush Button
5.15 Moistener System Solution Pressure Adjust Button
5.16 Engine Speed Buttons
5.17 Road/Field Mode Button
5.18 Transmission Range 1 Button
5.19 Transmission Range 2 Button
5.20 Park Brake Button
5.21 Differential Lock Button
5.22 Basket Extension and Ducts Raise/Lower Button
5.23 Compactor Augers Auto/Manual Button
5.24 Operator Interface Controls
5.25 Accessory Power Outlet (12 V DC)
5.26 Armrest Console Quick Reference Instructions
5.27 Corner Post Display and Indicators
5.28 Vehicle Monitor Display
5.29 Fuel Level Gauge
5.30 Engine Coolant Temperature Gauge
5.31 Vehicle Ground Speed Display
5.32 Tachometer Display
5.33 Warning Indicators
5.34 Lighting Control Panel
5.35 Windshield Wiper Switch
5.36 Light Switches
5.37 Cab Interior Light
5.38 Hazard Lights
5.39 Road Lights
5.40 Field Lights
5.41 Work Lights
5.42 Heating and Air Conditioning Control Panel
5.43 Cab Temperature Control System
5.44 Rear Camera System (If equipped)
5.45 Steering Column
5.46 Turn Signals
5.47 Steering Wheel Tilt and Height Adjustment
5.48 Key Switch
5.49 Travel Brake Pedals
5.50 Operator’s Seat Adjustment
5.51 Left-Hand Armrest and Seat Back Adjustment
5.52 Right-Hand Armrest and Control Console Adjustment (Rotating Cam System)
5.53 Right-Hand Armrest and Control Console Adjustment (Slide Adjust System)
5.54 Seat Belts
5.55 Auxiliary Power Outlet Strip and Diagnostic Connector
5.56 Rear View Mirrors
5.57 Emergency Exit
5.58 Row Unit and Drum Identification
6 Break-In Service
6.1 Breaking-in Engine
6.2 After 1 Hour
6.3 After 5 Hours
6.4 After 10 Hours
6.5 After 20 Hours
6.6 After 50 Hours
6.7 After 100 Hours
6.8 After 375 Hours
7 Prestarting Checks
7.1 Check Engine Oil Level
7.2 Drain Primary Fuel Filter Water Separator
7.3 Check Engine Coolant Level
7.4 Check Lubricant Level in Grease Tank
7.5 Check Solution Level in Moistener System Tank
7.6 Check Hydraulic and Hydrostatic Oil Level
7.7 Check Pump Drive Gearbox Oil Level
7.8 Fill Fuel Tank
7.9 Inspect Tires
7.10 Clean Windows, Mirrors, and Lights
7.11 Check Auxiliary Water System
7.12 Check Fire Extinguishers
7.13 Charge Water Fire Extinguisher
8 CommandCenter? Display Screens
8.1 Armrest Display Unit (ADU) Navigation
8.2 Operator Interface Controls
8.3 Diagnostic Trouble Codes at Start-Up
8.4 Service Reminder Screen
8.5 Home Page Screens
8.6 Harvest Information Screen
8.7 Machine Configuration Screen
8.8 Engine Information Screen
8.9 Diagnostics and Calibration Screens
8.10 Active Alarms Screen
8.11 Diagnostic Readings Screens
8.12 Engine and Fan Hour Meters Screen
8.13 Calibration Screens
8.14 Daily Service Mode Screens
8.15 Diagnostic Trouble Codes Information Screens
9 Operating the Machine
9.1 Preparing for Safe Operation
9.2 Starting Engine
9.3 Starting Engine in Cold Weather
9.4 Cold Start Valve (If Equipped)
9.5 Changing Starting Fluid Cans
9.6 Cold Weather Operation
9.7 Warming Engine
9.8 Idling Engine
9.9 Stopping Engine
9.10 Preparing to Drive Machine
9.11 Driving Machine
9.12 Driving Machine on Public Roads
9.13 Stopping Machine
9.14 Parking Machine
9.15 Harvesting
9.16 Operating Compactor Augers
9.17 Unloading Basket
9.18 Disabling Basket Door Automatic Operation
9.19 Reacting to a Plugged Row Unit
9.20 Unplugging a Row Unit
9.21 Operating Row Units in Tether Mode
9.22 Lowering Basket Extension and Ducts
9.23 Raising Basket Extension and Ducts
9.24 Bleeding Basket Extension and Duct Lift Cylinders
9.25 Using Basket Door Cylinder Safety Stops
9.26 Positioning Units for Transport
9.27 Towing Machine (Engine Operational)
9.28 Towing Machine (Engine Non-operational)
10 Transporting the Machine
10.1 Preparing Machine for Truck Transport
11 Operator Presence System
11.1 Operator Presence System
11.2 Operator Presence System Check
12 Row Guidance System
12.1 Row Guidance System Information
12.2 Manual RowSense Guidance System
12.3 AutoTrac RowSense Guidance System Information
12.4 AutoTrac Guidance System Information
12.5 Operating Guidance System
12.6 Gain Adjustment Diagnostics
12.7 Calibrating Guidance System
13 Header Height Control
13.1 Header Height Control Theory Of Operation
13.2 Header Height Control Operation and Adjustment
13.3 Header Height Control Response Rate Adjustment
13.4 Header Height Control Initial Response Rate Settings
13.5 Header Height Control Calibration
14 Moistener System
14.1 Moistener System Component Location
14.2 Moistener System Operation
14.3 Using Moistener Flush System
14.4 Adjusting Solution Pressure
14.5 Reacting to Spindle Buildup
14.6 Cold Weather Operation
14.7 Using John Deere Spindle Cleaner
14.8 Spindle Cleaner Storage
14.9 Filling Moistener System Tank
14.10 Priming Solution Pump
14.11 Adjusting Solution Pump Belt
14.12 Cleaning Solution Strainer
14.13 Cleaning Nozzles
14.14 Clean and Inspect Check Valve
14.15 Moistener Column
14.16 Checking Moistener Column Position
14.17 Adjusting Moistener Column Position
14.18 Checking Moistener Column Height
14.19 Adjusting Moistener Column Height
14.20 Replacing Moistener Column Pads
15 Row Units
15.1 Moving Row Units
15.2 Adjusting Row Unit Tilt
15.3 Adjusting Stalklifters
15.4 Adjusting Plant Guides and Installing Stalklifter Rods
15.5 Adjusting Grid Bars
15.6 Adjusting Pressure Plate Clearance
15.7 Adjusting Pressure Plate Spring Tension
15.8 Checking Doffer Column Adjustments
15.9 Checking Doffer Column Height
15.10 Adjusting Doffer Column Height
15.11 Adjusting Doffer Column Tilt
15.12 Replacing Spindles
15.13 Replacing Picker Bars
15.14 Removing Doffer Column
15.15 Installing Doffer Column
15.16 Draining and Filling Row Unit Gear Cases
15.17 Draining and Replacing Unit Drive Gear Case Oil
15.18 Calibrating Row Units
15.19 Changing Machine Configuration
15.20 Installing Scrapping Plates (Attachment)
16 Air System
16.1 Air Hose Reference Chart
16.2 Nozzle Configuration
16.3 Hose Sleeves and Hose Supports
16.4 Inspecting and Adjusting Cotton Fan Belts
17 Basket
17.1 Using Basket Handrails
17.2 Accessing Interior Of Basket
17.3 Lowering Ducts While Leaving Basket Extension Raised For Cleaning
17.4 Operating Basket Dump Cylinder Locks
17.5 Adjusting Door Chain Tension
17.6 Adjusting Floor Chain Tension
17.7 Basket Full Sensor Location
18 Onboard Lubrication System
18.1 Onboard Lubrication System Component Location
18.2 Assemble Lubricant Transfer Pump
18.3 Filling GreaseTank
18.4 Operating Onboard Lubrication System
18.5 Bleeding Grease Pump
18.6 Manual Lubrication Procedure
18.7 Cleaning or Replacing Onboard Lubrication System Filters
19 Electrical System Service
19.1 Battery Disconnect Switch
19.2 Fuse Identification
19.3 Fuse Identification
19.4 Replacing Fuses
19.5 Replace Bulbs
19.6 Bulb Part Numbers
19.7 Safety Rules for Halogen Bulb Replacement
19.8 Replacing Halogen Cab Headlight and Field Light Bulbs
19.9 Adjusting Halogen Cab Headlights and Field Lights
19.10 Replacing Platform Field Lights
19.11 Safety Rules When Replacing High Intensity Discharge (HID) Xenon Bulbs
19.12 Replacing High Intensity Discharge (Xenon) Light Bulbs (If Equipped)
19.13 Adjusting High Intensity Discharge (Xenon) Lights (If Equipped)
19.14 Work Lights
19.15 Replace Front Warning Light Bulbs
19.16 Replace Rear Reverse, Stop/Tail, and Turn Signal/Hazard LED Lights
19.17 Turn Signal Indicator Bulb Replacement
19.18 Replacing Dome Light Bulbs
20 Engine and Drive Train
20.1 Replacing Engine Fan and Accessory Drive Belt
20.2 Rotary Screen Belt Routing
20.3 Replacing Rotary Screen Drive Belts
20.4 Removing and Cleaning 60 Micron Fuel Strainer
20.5 Replacing Primary and Final Fuel Filter Elements
20.6 Servicing Precleaner
20.7 Removing and Replacing Air Cleaner Elements
20.8 Inspecting Element
20.9 Checking Coolant Level
20.10 Draining and Flushing Cooling System
20.11 Filling Cooling System
20.12 Winterizing Cooling System
20.13 Cleaning Radiator, Cooler Cores, Rotary Screen, and Trash Expeller
20.14 Adjusting Rotary Screen Trash Expeller
20.15 Engine Control Unit (ECU) Diagnostic Codes
20.16 Do Not Modify Fuel System
20.17 Diagnosing Engine Problems
21 Wheels and Tires
21.1 Service Tires Safely
21.2 Discarded Tires
21.3 Checking Tires
21.4 Jacking Up Rear Axle
21.5 Jacking up Front Axle
21.6 Adjusting Mud Scrapers (If Equipped)
21.7 Checking Guide Wheel Toe-In
21.8 Adjusting Guide Wheel Toe-In
22 Batteries
22.1 Handling Batteries Safely
22.2 Preventing Battery Damage
22.3 Servicing Batteries
22.4 Charging Batteries
22.5 Using a Booster Battery
22.6 Removing and Installing Batteries
23 Fuels, Lubricants, and Coolants
23.1 Handle Fuel Safely?Avoid Fires
23.2 Diesel Fuel
23.3 Biodiesel Fuel
23.4 Lubricity of Diesel Fuel
23.5 Oilscan? and CoolScan?
23.6 Alternative and Synthetic Lubricants
23.7 Lubricant Storage
23.8 Extended Diesel Engine Oil Service Intervals ? Non-Emissions Certified and Certified Tier 1 and Stage I
23.9 John Deere Break-In Plus? Engine Oil
23.10 Diesel Engine Oil ? Non-Emissions Certified and Certified Tier 1 and Stage I
23.11 Hydraulic, Hydrostatic, and Transmission Oils
23.12 Final Drive and Powered Rear Axle Lubricant
23.13 Row Unit Gear Case Lubricant
23.14 Picker Bar and Spindle Lubricants
23.15 Multipurpose Extreme Pressure (EP) Grease
23.16 Diesel Engine Coolant (engine with wet sleeve cylinder liners)
23.17 Drain Intervals for Diesel Engine Coolant
23.18 John Deere COOL-GARD? II Coolant Extender
23.19 Supplemental Coolant Additives
23.20 Additional Information About Diesel Engine Coolants and John Deere COOL-GARD? II Coolant Extender
23.21 Testing Diesel Engine Coolant
23.22 Operating in Warm Temperature Climates
24 Lubrication and Maintenance
24.1 Required Emission-Related Information
24.2 Decommissioning ? Proper Recycling and Disposal of Fluids and Components
24.3 Using High-Pressure Washers
24.4 Cleaning Cab Air Filters
24.5 Service Interval Chart
25 Lubrication and Maintenance?Every 6 Hours
25.1 Clean Basket Hood
25.2 Clean Row Units
25.3 Lubricate Row Unit Gear Train
25.4 Inspect Solution Nozzles
25.5 Clean Solution Nozzles
25.6 Clean Rotary Screen Trash Expeller
26 Lubrication and Maintenance?Every 12 Hours
26.1 Clean Duct Hood and Basket
26.2 Clean Behind Cab and Under Basket
26.3 Clean Muffler and Exhaust Pipe Area
26.4 Clean Cotton Fans, Power Module, and Engine Compartment
26.5 Clean Moistener System Solution Strainer
26.6 Clean Radiator, Cooler Cores, Rotary Screen, and Trash Expeller
26.7 Clean Halogen Work Lights
26.8 Clean Cab Air Inlet Screens
26.9 Clean Cab Fresh Air Filter
26.10 Clean Cab Recirculating Air Filter
26.11 Clean Mud From Between Dual Wheels and Frame
26.12 Inspect Tires and Check Inflation Pressure
26.13 Check Compactor Auger Gear Train
26.14 Check Brush Bars and Door Impact Sensors
26.15 Check Basket Door and Floor Conveyor Chain Tension
26.16 Lubricate Unit Lift Rockshaft Bearings
26.17 Lubricate Plastic Cross-Shaft Covers (If Chained to Units)
26.18 Lubricate Guide Axle Kingpin Bearings
26.19 Check Engine Oil Level
26.20 Drain Fuel Filter Water Separator
26.21 Check Coolant Level in Surge Tank
26.22 Check Solution Level in Moistener System Tank
26.23 Check Auxiliary Water System
26.24 Check Fire Extinguishers
26.25 Check Hydraulic and Hydrostatic Oil Level
26.26 Check Pump Drive Gear Case Oil Level
26.27 Check Transmission Oil Level
26.28 Check Row Unit Gear Case Oil Level
26.29 Check Unit Drive Gear Cases for Leaks
27 Lubrication and Maintenance?Every 50 Hours
27.1 Reset Service Reminder on Armrest Display Unit
27.2 Remove and Clean Cab Roof Air Inlet Panel
27.3 Remove and Clean Cab Fresh Air Filter
27.4 Inspect Fuel Strainer
27.5 Lubricate Lower Doffer Bearing
27.6 Lubricate Row Unit Lift Frame Components
28 Lubrication and Maintenance?Every 100 Hours
28.1 Lubricate Row Unit Cross-Shaft Universal Joints
28.2 Lubricate Row Unit Support Frame Rollers
28.3 Lubricate Final Drive Axle Couplers
28.4 Lubricate Final Drive Axle Outer Bearings
28.5 Lubricate Rear Axle Tie Rod Ends and Pivot Pin
28.6 Tighten Wheel Bolts
28.7 Clean and Inspect Moistener System Check Valve
29 Lubrication and Maintenance?Every 250 Hours
29.1 Remove and Clean Cab Recirculating Air Filter
29.2 Change Engine Oil and Filter
29.3 Removing and Cleaning 60 Micron Fuel Strainer
29.4 Replace Primary and Final Fuel Filters
29.5 Clean and Inspect Lubrication System Filters
29.6 Lubricate Row Unit Lift Frame Turnbuckles
30 Lubrication and Maintenance?Every 400 Hours or Annually
30.1 Drain and Replace Row Unit Gear Case Oil
30.2 Drain and Replace Unit Drive Gear Case Oil
30.3 Change Transmission Oil and Filter
30.4 Change Pump Drive Gear Case Oil and Filter
30.5 Change Hydraulic Oil and Filters
30.6 Check Final Drive Oil Level
30.7 Remove Unit Drive Motor, Check Splines, Repack with Grease, and Install Unit Drive Motor
31 Lubrication and Maintenance?Every 2000 Hours
31.1 Change Front Axle Final Drive Oil
31.2 Change Rear Axle Housing Oil
31.3 Change Rear Axle Gear Case Oil
31.4 Change Rear Axle Planetary Final Drive Oil
31.5 Check Engine Valve Tappet Clearance
32 Lubrication and Maintenance?Annually
32.1 Clean Fuel Tank Vent
32.2 Clean Hydraulic Reservoir Breather
32.3 Clean Pump Drive Gear Case Breather
32.4 Clean Transmission Breather
32.5 Clean Rear Axle Breather
32.6 Clean Battery Connections
32.7 Replace Primary and Safety Air Cleaner Elements
32.8 Lubricate Brake Pedal Pivots
32.9 Clean and Refill Doffer Bearing Housings
32.10 Lubricate Row Unit Idler Bearings
32.11 Check Drive Belt Alignment and Tension
32.12 Test Coolant Condition
32.13 Inspect Seat Belt
33 Lubrication and Maintenance?Every 6000 Hours or 6 Years
33.1 Drain, Flush, and Fill Cooling System and Replace Thermostats
34 Troubleshooting
34.1 Air System
34.2 Moistener System
34.3 Basket Control
34.4 Header Height Control
34.5 Row Guidance System
34.6 Lubrication System
34.7 Row Units
34.8 Vari-Row System (VRS) Row Units
34.9 Hydrostatic Drive System
34.10 ProDrive? Transmission
34.11 Steering
34.12 Engine
34.13 Electrical System
34.14 Operator’s Station
34.15 Operator Presence System and Inspection Bypass System
35 Storage
35.1 Preparing Machine for Storage
35.2 Preparing Engine for Storage
35.3 Removing Machine from Storage
36 Specifications
36.1 Machine Specifications
36.2 Machine Dimensions
36.3 Metric Bolt and Screw Torque Values
36.4 Unified Inch Bolt and Screw Torque Values
36.5 High Pressure Face Seal Torque Chart
36.6 Service Recommendations For Flat Face O-Ring Seal Fittings
36.7 Record Product ID and Component Serial Numbers
36.8 Keep Machines Secure
36.9 Keep Proof of Ownership
36.10 Limited Battery Warranty
37 John Deere Service Keeps You on the Job
37.1 John Deere Is At Your Service