CONVERSION MANUAL: JD 600F TO NH TRxx

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1 CONVERSION MANUAL: JD 600F TO NH TRxx b HEADSIGHT.COM

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3 About Headsight Headsight Contact Info Headsight, Inc B Road Bremen, IN Phone: Fax: Web: Technical Assistance Phone: About this Manual How to use this manual The instructions in this manual are in the order that they should be completed for new installations. Complete all applicable instructions in each section before proceeding. Note that some sections are labeled to indicate they only apply to certain machines or applications. An index is available in the front of the manual to help find technical information for previously installed systems. This icon designates information of which you should take note. This icon indicates a special tool needed for a given task. This icon designates an important instruction. Disclaimers Headsight, Horizon, Pinpoint, Insight, Foresight, Feathersight Truesense and Truesight are trademarks of Headsight, Inc. All other trademarks are property of their respective owners. Suggestions If you have any suggestions to improve this manual please call or info@headsight. com. Headsight s products are protected by one or more of the following US Patents , , , , and other patents pending. Copyright Headsight, Inc i

4 Table of Contents About Headsight i About this Manual i Installation 1 Control Unit 2 Main Harness 3 Hydra-Flex Cab Conversion Installation 5 Cab Controller 5 Cab Adapter Harness 5 Header Adapter Harness Mounting 6 Calibration 7 Sensor Calibration 7 Settings 8 Adjusting Float Pressure 8 Operation 9 Control Unit Layout 9 Enabling Height Control 10 Adjusting Header Height 11 Adjusting Height Sensitivity 11 Adjusting Tilt Sensitivity 11 Advanced Information 12 Theory of Operation 12 Sensors 12 Control Unit: Front Panel Controls 12 Height Operation 12 Wiring 13 Main Harness 13 Cab Adapter Harness 14 Header Adapter Harness 15 Height and Tilt Connector Identification Guide- Headsight Harness 16 Schematics 17 Main Harness 17 Feeder Harness 18 Header Adapter Schematic 19 Cab Adapter Harness Schematic 20 Diagnostics 21 Troubleshooting by Symptom 21 Troubleshooting Common Combine Problems 25 Reel/Flex Pressure Diagnostics 26 Troubleshooting Sensors and Harnesses 28 Parts 29 STATEMENT OF LIMITED WARRANTY 30 ii

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6 Installation Installation Before working under header always: 1. Perform all combine and header manufacturer safety precautions for servicing header. 2. Insert stop to prevent movement of header. 3. Turn off combine and remove key from ignition. 4. Set combine parking brake. 5. Disconnect all drive shafts from the header. 1

7 This Headsight height control system is designed for New Holland TR series combines. This allows these combines to operate the Pressure and Reel controls of a JD 600F platform. To operate height control (HHC), a HB4-NHTR-31N kit is necessary. Routing cable properly is essential to durability of electrical controls. Take the time to fully understand the requirements, and carefully route and tie all cables in safe locations away from heat, wear, or pinch points. Installation Control Unit 1. On earlier combines, mount the control unit and bracket to the bottom of the gauge console in the approximate location shown with the two self tapping screws provided. 2. On late model TR s, mount control unit just to the right of the control corner post, either on the control console or on the ceiling. 3. Make sure to leave clearance for the harness to plug into the rear of the control unit. 2

8 Installation Main Harness The only cross-over between the HHC and the Hydraflex control systems is the wiring on the feeder, and the connection to 12V power. For efficiency, both may be run at the same time. 1. Connect Y811 to the back of the control unit, and route the harness back under the header indicator lights assembly. 2. Making sure the fuse holder and power connection stays inside the cab, find or create an access point and route the rest of the harness out of the right side of cab. Possible access points include routing out the side cab window, routing through an existing access hole, or drilling an access hole in the cab Also route HT9809-FH Feeder Extension at the same time 3. Remove the hydraulic valve body access panel. 4. Route the cables down to under the cab, using the cutout area as shown to get the cable past the hydraulic tank. Pull the cables all the way through until they lie neatly between cab wall and combine body 3

9 5. Route the main harness and FH extension harness under the cab and down with the OEM wiring/hoses to the right front of the feederhouse. Make sure to leave slack for feederhouse motion Route along OEM harness Installation 6. Connect the two 3 pin flat molded connectors to the OEM harness. If your machine does not have lateral float, only connect the Y602 height plug and tape the other 7. Secure to the OEM cabling with zip ties, making sure all wiring is secured safely away from danger. 8. Route Y312 (31 pin header connector) and Y231 on the extension harness over the front of the feederhouse to the left side. Secure it to the OEM hoses Loosen the hose shield and put the cable inside, if desired Secure Y231 near Y Connect Y604 Lights (3p round) to the OEM Header Lights plug on the combine. Older NH combines may use a flat molded connector for lights instead of the round connector. DO NOT connect this OEM lights plug to the Headsight Y602 height or Y603 tilt plug. Contact Headsight or have your dealer make an adapter. 4

10 Installation Hydra-Flex Cab Conversion Installation Cab Controller 1. Use the included suction mount to attach the Cab Controller to the right cab window above the console. Place in an easy to see and reach location 2. Connect Y225 on the Adapter Cab Harness into the controller. Cab Adapter Harness 1. Route the molded 4 pin plug Y connectors into the Fuse compartment of the console. You may need to drill or notch a larger access point Route Y620/Y621 terminals on the main harness into the area as well 2. Find the 4 pin plug shown. It may or may not have a mating plug connected to it, depending on the combine model or year If needed, disconnect the OEM plugs 3. The TR combine kit comes with separate short power adapter. Do not use; the Cab Adapter harness already includes this function. 4. Connect the Red coded plug to the OEM plug with the red, 3 purple, and 2 tan wires The red wire in the OEM plug should line up with the red wire in the adapter 5. If needed, connect the Yellow coded plug to the other OEM connection (should have only 2 wires.) 6. Connect Y620 to the main harness to the bullet terminal on the Cab adapter harness. 7. Connect both Ground rings (Y621) to a clean ground bolt. 8. Connect Y231 on the cab adapter to Y334 on the FH extension harness. 9. Carefully check and tie up all cables so they are neat and out of the way, will not catch on any moving parts, and have adequate slack to allow header movement. 5

11 Header Adapter Harness Mounting 1. Mount the HT2250 bracket and the Header adapter harness (short harness) to the rear of the head near the left of the feederhouse. If possible, use existing holes Note: Bracket design may vary Installation 2. Remove the C clip holding the OEM header electrical connector in the JD single-point plate. 3. Remove the connector from the plate, and press fit into Y202. Ziptie the HT2259 clip to keep them together. 4. Connect Y312 and Y231 on the combine to the header plugs. 6

12 Calibration Before working under header always: Calibration 1. Perform all combine and header manufacturer safety precautions for servicing header. 2. Insert stop to prevent movement of header. 3. Turn off combine and remove key from ignition. 4. Set combine parking brake. 5. Disconnect all drive shafts from the header. Sensor Calibration You will not need to calibrate the sensors for new installations because they are pre-calibrated at the factory. You may recalibrate the sensors if you are unsatisfied with the operating range of the system. You should perform calibration if any of the components of the system are used, or once annually. This step will require 2 people. Its purpose is to level the sensors so the control system sees the same ground height for each. 1. Attach all harness and sensor wiring. 2. Power the header control system. Start the motor, raise the head and install safety stop. Leave motor running Set the MODE switch to OFF Turn the OEM Header Height switch OFF Lateral Tilt 3. For flex heads, adjust the cutterbar sensors to V with the head flat on the ground. The Auto [Cal] light should just turn on at this low position. To adjust the sensors, either Loosen the nuts or screws which hold the sensor (the hall effect sensor or potentiometer, not the entire sensor assembly) & twist the sensor to a new position Adjust the linkage rod between the skid plate and the sensor Height 4. All sensors must be adjusted to an equal voltage/ indicator position for the AHHC to perform properly. 7

13 Settings Adjusting Float Pressure The pressure changes fairly slowly. Hold the Increase or decrease button for 5-10 seconds to see if pressure changes. 1. To increase the pressure, press and hold the Increase Pressure button. 2. To decrease the pressure, press and hold the Decrease Pressure button. 3. The LED pressure indicator shows the approximate pressure in the float system. The green bar shows the normal operating range of the header in flex mode. Running near the bottom of the green area means MORE ground pressure (less hydraulic pressure holding up the cutterbar) Use this area for dry, hard conditions Running near the top of the green area means LESS ground pressure (more hydraulic pressure holding up the cutterbar) Use this area for wet, soft conditions LED Pressure Indicator Increase Decrease Settings Raising the pressure all the way up should lock up the cutterbar for rigid mode 4. The Hydraflex heads are designed to run low. Set the Height point to about 15-25% of the height range, and use the pressure adjustment to keep the head from dragging up. 5. The LED pressure indicator can also show the deck plate position on a corn head if the header is equipped with a Headsight conversion and deck plate sensor. 8

14 Operation Control Unit Layout 1 2 Operation Head Height knob: Adjusts Head Height; MODE must be set to HGT or HGT & TILT 2. Height Sensitivity knob: Adjusts Height Sensitivity, MODE must be set to HGT or HGT & TILT 3. Tilt Sensitivity knob: Adjusts Tilt Sensitivity; MODE must be set to HGT & TILT For a technical explanation of the Height, Sensitivity, and Tilt functions, see Advanced Information 4. Auto [Cal] Light: The Auto [Cal] light performs two functions During sensor calibration, it acts as a low point indicator to help set all sensors uniformly During operation, it will light when the auto height control system is activated 5. MODE switch: The MODE switch selects operating mode, allowing the user to turn off auto height control or operate height control without lateral tilt 9

15 Enabling Height Control 1. Turn OEM Auto Header Height switch ON. 2. Turn MODE switch on Headsight control unit to HGT or HGT & TILT. Due to the internal design of the OEM NH-TR system, the OEM auto header switch may not always turn off auto header control. When using the Headsight system, the MODE switch replaces the OEM switch to turn ON/OFF the height control system. The OEM Auto Header Switch must be left ON. Make sure to turn OFF the MODE switch any time you do not want the header to auto lower or raise. 3. Press header lower button. The Auto [Cal] light on the control unit should be lit 4. To disable, press header raise. The Auto [Cal] Light on the control unit should be off Operation 10

16 Adjusting Header Height 1. Turn the head height knob on the control unit with header control engaged. Clockwise = higher Counter-clockwise = lower 2. Find and mark the minimum acceptable height as noted below; do not operate below this point. Because the Headsight control unit is designed to work with many OEM sensors, it may be possible for the operator to choose a height that is too low for operation meaning that the sensors would never send a raise signal. Operation 3. To test if the height you have chosen is too low, engage the system, then press and release the lower button on the hydro handle. If the header bounces back up to its original position, The chosen height is fine If the header stays in the new position, The height chosen is too low. Do not operate header control at or below this height Adjusting Height Sensitivity 1. Increase height sensitivity (turn CW) for more responsive performance. 2. Decrease height sensitivity (turn CCW) to reduce hunting. You MUST set your accumulator and drop rate before adjusting the sensitivity knob Adjusting Tilt Sensitivity 1. Increase tilt sensitivity (turn CW) for more responsive performance. 2. Decrease tilt sensitivity (turn CCW) to reduce hunting. You may need to adjust the hydraulic flow rate before adjusting the sensitivity knob The head should take at least 5 seconds to tilt fully from one side to the other Takes more time on wider heads 11

17 Advanced Information Theory of Operation A review of the following points will help the service technician to understand the complete system which will help diagnosing specific problems. Sensors Further information on sensors is available in the Header manual. Each sensor returns a variable voltage to the control unit depending on its height high height = high voltage (approximately 4 volts) low height = low voltage (approximately 1 volt) Each sensor has 3 wires (colors of OEM sensor wires vary) red = 5V power black = ground white = signal returned to the control unit (varies between approximately 1.0 and 4.0 volts) Control Unit: Front Panel Controls The control unit contains both the height control analysis circuitry, and the interface to work with the manual controls of the harvester. For a more detailed look at the interface, see Operation, Control Unit The control unit will not activate the outputs unless the OEM Auto Header Height switch is on, and the manual header lower switch has been pressed Height Operation Head Height The control unit compares the sensor closest to the ground to the desired height chosen with the height knob If any sensor has a lower voltage (is nearer the ground) than the height setpoint voltage, the box energizes the raise output This means that any one sensor can raise the head If all sensors have a higher voltage (are farther from the ground) than the height setpoint voltage plus the deadband chosen by the sensitivity knob, the control unit energizes the lower output This means that all sensors must agree to lower the head Sensitivity The sensitivity knobs on the control unit adjust the size of the deadband The deadband is a small area where the system will neither raise nor lower (or tilt) This helps prevent the header from hunting Tilt The left and right sensor signals are compared and a tilt output is enabled as needed The tilt sensitivity knob sets the deadband Raise Point Lower Point Deadband Advanced Info 12

18 Wiring Main Harness Y620 F1 Y811 Y534 Y621 Y604 Y603 Y312 Y602 Advanced Info Connector Description Connects to Y pin Deutsch Header Y534 2 pin Weatherpack Switch kit Y602 Molded 3 pin F-M-M OEM Height Y603 Molded 3 pin M-F-F OEM Tilt Y604 3 pin Deutsch OEM Lights Y620 Bullet Terminal 12V Power Adapter Y621 1/4 Ring Ground Y pin Amp CPC Controller F1 10 Amp Fuse 13

19 Cab Adapter Harness Y225 Power Yellow Code Red Code Y150 GND 12V Y231 Connector Description Connects to Y150 Diode Module HT9223D Module Y pin Deutsch Hydraflex Controller Y231 4 pin Amp Feederhouse Extension Harness 12V Female Bullet HHC Main Harness GND 3/8 Ring Ground Power Molded 4 pin FF-MM x2 Combine Power and Reel Plug Advanced Info 14

20 Header Adapter Harness Y311 Y310 Y232 Y202 Y248 Advanced Info Y pin Deutsch Header connector header single-point Y pin Deutsch Header connector combine side Y232 4 pin Amp Adapter Feeder harness Y310 6 pin Weatherpack Header Recognition Module Y248 3 pin Weatherpack Draper Speed Harness (600FD only) 15

21 Height and Tilt Connector Identification Guide- Headsight Harness Y Y603 Key Description 1 Raise Output 2 Auto Activated 12V Enable 3 Lower Input 4 Unused 5 Tilt Left (CCW) Output 6 Tilt Right (CW) Output Advanced Info 16

22 Schematics Main Harness NOTES: Y620 POWER 12V BATTERY P V SWITCHED RED 16g Y621 GROUND GROUND P1 023 CHASSIS GND BLK 16g Y811 CONTROLLER CHASSIS GND P11 12V POWER P CHASSIS GND BLK 16g V POWER RED 16g SENSOR GND P01 SENSOR +5V P02 LEFT SENSOR P05 L C SENSOR P06 RT C SENSOR P09 RIGHT SENSOR P10 LOWER SOL P03 12V ENABLE P13 RAISE SOL P07 TILT RIGHT P12 TILT LEFT P16 Y816 FUSE A 12V SWITCHED B 12V POWER Y604 LIGHTS CHASSIS GND LEFT HZD LT RIGHT HZD LT A B C 022 CHASSIS GND BLK 16g 031 LEFT HZD LT YEL 16g 032 RIGHT HZD LT Dk GRN 16g Y312 HEADER P30 GROUND P22 LEFT HZD LT P28 RIGHT HZD LT Y534 SELECT REEL FORE REEL AFT A B 134 REEL FORE WHT 16g 134 REEL FORE WHT 16g 135 REEL AFT BRN 16g P10 FLEX PRESS P20 HEAD F/A P26 TRANSPORT P29 12V POWER 100 SENSOR GND Lt BLUE P25 SENSOR GND P06 SENSOR GND 050 SENSOR PWR PINK 081 LEFT SENSOR WHT 082 L C SENSOR WHT 086 RT C SENSOR WHT 087 RIGHT SENSOR WHT P23 SENSOR V+ P05 SENSOR V+ P01 LEFT HGT P03 L C HGT P04 RT C HGT P02 RT HGT 181 LOWER SOL Lt GRN V ENABLE PUR 180 RAISE SOL BRN Y602 HEIGHT A LOWER SOL B 12V ENABLE C RAISE SOL LOWER ENABLE RAISE A B C 3p MOLDED 2M, 1F 183 TILT RIGHT Dk BLUE 182 TILT LEFT ORG Y603 TILT A TILT RIGHT B TILT LEFT T-RT T-LT A 3p MOLDED 1M, 2F B C NO TERM C HT9119 NHTR MAIN 7 Advanced Info 17

23 Feeder Harness Advanced Info Y334 CAB BULKHEAD REEL SELECT P01 FLEX SELECT P02 PRESSURE P03 NOTES: TR COMBINES w/600f, FD. 078 REEL SELECT PUR 079 FLEX SELECT ORG 091 FLEX PRESSURE GRY Y231 HEADER P01 REEL SELECT P02 FLEX SELECT P03 PRESSURE HT9806-FH 2 18

24 Header Adapter Schematic NOTES: Y311 COMBINE LEFT HGT P01 L C HGT P03 RT C HGT P04 RIGHT HGT P02 SENSOR V+ P05 SENSOR GND P06 REEL SPEED P07 REEL VERT P09 FEEL F/A P08 CHASSIS GND P30 LFT HZD LT P22 RIGHT HZD LT P28 STUBBLE LTS P24 SENSOR V+ P12 HEADER TYPE P27 SENSOR GND P13 Y232 FEEDER REEL SELECT P01 FLEX SELECT P02 FLEX PRESSURE P03 Y248 BELT SPEED DRAPER + A DRAPER - B BELT SPEED C 081 LEFT SENSOR WHT 082 L C SENSOR WHT 084 RT C SENSOR WHT 087 RIGHT SENSOR WHT 050 SENSOR V+ PINK 100 SENSOR GND Lt BLU 098 REEL SPEED GRY 112 REEL HGT YEL 113 REEL F/A YEL 022 CHASSIS GND BLK 031 LEFT HZD LT YEL 032 RIGHT HZD LT Dk GRN 033 STUBBLE LTS BRN 058 AUX SNR V+ PINK 070 HEADER TYPE YEL 108 AUX SNR GND Lt BLU 078 REEL SELECT Dk BLU 079 FLEX SELECT ORG 091 FLEX PRESSURE GRY 130 DRAPER + WHT 131 DRAPER - BRN 124 BELT SPEED GRY Y310 HEADER TYPE A SENSOR V+ E HEADER TYPE F SIGNAL GND HEADER TYPE SELECTION TYPE PINK YELLOW BLUE CORN A B F GRAIN A E F DRAPER A B E PICKUP F E A Advanced Info Y202 HEADER P07 LEFT HGT SNS P03 L C HGT SNS P25 RT C HGT SNS P09 RIGHT HGT SNS P20 SENSOR V+ P10 SIGNAL GND P08 REEL SPEED P30 REEL VERT P31 REEL F/A P12 CHASSIS GND P13 LEFT HZD LT P14 RIGHT HZD LT P15 STUBBLE LTS P21 REEL SELECT P19 FLEX SELECT P05 FLEX PRESSURE P26 DRAPER + P27 DRAPER - P29 SHAFT SPEED HT9806-H 6 19

25 Cab Adapter Harness Schematic PUR B RED 16g A RED Y622 RED CODE 12V POWER MASTER A B 12V POWER RED MASTER PUR Y610 12V POWER A 12V POWER LT BLUE TAN C D REEL RAISE C REEL LOWER D REEL - TAN/bk REEL + Lt BLU/bk VALVE + Lt BLU VALVE - TAN MASTER PUR 144 FLEX + TAN 145 FLEX - BRN 078 REEL SELECT Dk BLU Y225 LIGHTBAR PRESSURE FLEX SELECT FLEX + FLEX - GROUND 12V POWER P01 P02 P03 P04 P05 P FLEX PRESSURE GRY 079 FLEX SELECT ORG 144 FLEX + TAN 145 FLEX - BRN 020 CHASSIS GND BLK 16G V POWER RED 16G Y230 GROUND P01 GROUND NOTES: USED FOR ALL NH-TR COMBINES w/600f, FD. MUST INCLUDE DP1 DIODE PACK r2 ADDED DIODE PACK DESIGN JHK Y623 YELLOW CODE A 12V POWER TAN LT BLUE B MASTER C REEL RAISE FACE VIEW D REEL LOWER Y150 DP-1 P06 REEL - P04 REEL + P01 VALVE + P09 VALVE - P10 MASTER Y149 HT9223-D P10 P03 P02 P01 P04 P05 P06 P03 FLEX + P07 FLEX - P05 REEL SELECT P08 NC P09 P08 P07 P11 P12 DIODE PACK, REFERENCE ONLY 078 REEL SELECT Dk BLU Y231 HEADER ADPT P01 REEL SELECT P03 FLEX PRESSURE P02 FLEX SELECT HT9809-CAB 3 Advanced Info 20

26 Diagnostics Troubleshooting by Symptom Nearly every problem with the header control system on CIH combines may be resolved by one of the following simple steps: Make sure each sensor meets basic requirements discussed in Advanced Info section Properly calibrate Insight box Properly calibrate combine Enable appropriate HHC functions Properly set combine electronics and/or hydraulics Symptom Problem Solution Header is too jumpy Unopened or discharged Open accumulator valve 1-2 accumulator turns Test accumulator as per OEM specs Head too sluggish Flow rates too fast Height Sensitivity too high Wide open or partially charged Accumulator Flow rates too slow See Combine Settings See Settings Open accumulator valve 1-2 turns Test accumulator as per OEM specs See Combine Settings Diagnostics No automatic operation: Height or Tilt Active LED not lit Wiring not connected No 12V on Enable wire No 12V power See Installation See Common Combine Problems Test power/ground in fuse panel connection. See Common Combine problems 21

27 Symptom Problem Solution MODE switch not in tilt Height control works but tilt does not Turn MODE switch to HGT & TILT Tilt Sensitivity too low OEM 3 pin flat Tilt connector not connected Sensor defective Check each sensor to see if it will raise the head. Headsight system defective Disconnect 3 pin Tilt connection. (See Wiring ) Measure Tilt Right terminal (see Wiring ) while compressing the left sensor only. Turn up Tilt Sensitivity Connect OEM connector to Headsight harness Repair sensor or wiring If not 10-12V on appropriate tilt wire: Check wiring for broken or rubbed spots Replace Control Unit Measure Tilt Left terminal (see Wiring ) while compressing the right sensor only. Head will not Raise Head drops all the way to ground Should be 10-12V on appropriate tilt wire. Defective combine wiring Wiring not connected Height position set too low Repair combine wiring from Tilt connector to valves See Installation/ Settings sections of manual Adjust Height Position knob All sensors failed Test for 5V at sensors No head / sensors connected Polarity reversed to hall effect sensors OEM Raise Indicator ON Raise wire broken: Check for 12V on Raise terminal of 3 pin Height plug See Troubleshooting: Sensors and Harness Connect at least one sensor to system Make sure pin C is +5V Check solenoid 12V: Repair wire on combine No 12V: check/replace Headsight wiring or controller Diagnostics 22

28 Symptom Problem Solution Head will not Lower Wiring not connected See Installation, Settings sections of manual Head raises all the way to top Height position set too High Adjust Height Position knob on light bar Cutterbar locked up (Flex only) Unbolt/Release pressure on cutterbar CNH flex heads only: reverser See Flex Headers in manual. not installed Sensor/Sensing rod stuck up Repair mechanical linkage/ return spring on cutterbar Cannot operate head high or low enough Any sensor mis-adjusted or failed Disconnect sensors until head will lower OEM Lower Indicator ON Lower wire broken: Check for 12V on Lower terminal of 3 pin Height plug Mis-adjusted sensor(s) Height position set too High Adjust sensor Replace sensor Repair wiring on head Check solenoid 12V: Repair wire on combine No 12V: Check/replace Headsight wiring or controller Check each sensor for proper adjustment. See Calibration Adjust Height Position knob Diagnostics Header dives to ground and Lower Rate set too High See Combine Specific Settings recovers entering crop Accumulator too far open or Adjust/check accumulator discharged Head rocks back and forth Tilt Sensitivity too high Decrease Tilt sensitivity Tilt Speed too high Flow controls needed in tilt circuit. Header tips wrong way (Once head is moved off level, it continues all the way in either direction) Left and Right sensor harnesses reversed Connect sensor harnesses to correct plugs on Y adapter. 23

29 Symptom Problem Solution Head tips all the way one Left and Right sensor harnesses See Flex Headers in manual direction reversed CNH flex heads only: reverser not installed Improperly adjusted sensors Adjust sensors to be about V when sitting flat on the ground Sensor harness improperly wired Poor connection See Diagnostics: Sensor and Harness, note about reversed wires in connectors. Check harness and connectors for cut/torn wire or loose terminals Head will not tip one way Defective Controller Disconnect header plug, and enable AHHC. One of outer sensors misadjusted or failed Check each sensor to see if it will raise head Headsight system defective Disconnect 3 pin Tilt connection. Measure Tilt Right terminal (see diagram above) while compressing the left sensor only. Make sure terminals are properly latched, not pushed back, in connector body If head still tilts, Contact Headsight Adjust sensor Replace sensor Repair wiring on head If not 10-12V on appropriate tilt wire: Check wiring for broken or rubbed spots Replace Control Unit Measure Tilt Left terminal (see Wiring ) while compressing the right sensor only. Should be 10-12V on appropriate tilt wire. Defective combine wiring Repair combine wiring from Tilt connector to valves Diagnostics Head runs slightly out of level Sensors mis-adjusted Adjust sensors for equal voltage when head is level. 24

30 Troubleshooting Common Combine Problems Error Code Problem Solution Head Jumps and Jerks whole harvester No 12V available on 4 pin molded plug in fuse panel No Enable Signal (No 12V available on OEM 3 pin height connector) Manual raise switch does not disengage auto height Unopened or discharged accumulator Flow rates too fast Start combine engine Check OEM fuses OEM AHC system not activated Defective OEM AHC system OEM AHC latching system defective Press header raise Test Enable pin on OEM 3 pin Height plug (see Wiring ) Open Accumulator valve 1-2 turns Test Accumulator as per OEM specs. See Combine Settings Replace blown fuse Repair OEM wiring in cab Turn OEM Auto Header Height switch ON Press Header Lower switch Check for blown fuse Test latch on/off relays Test wiring If 12V, Repair combine latching relay system or find OEM wire shorted to 12V Diagnostics Manual Lower switch does not engage auto height AHC system not Enabled OEM AHC latching Relay system defective (See No Enable signal above) Defective Headsight harness Defective control unit Turn ON OEM AHC switch Turn MODE switch to HGT or HGT & TILT If not 12V, repair combine latching relay system or find OEM wire broken Test wiring to controller for continuity Replace Controller 25

31 Reel/Flex Pressure Diagnostics Symptom Problem Solution Reel does not Raise or Lower Wiring not connected properly Verify that Y232 is connected at header to feeder Verify Y202, Y311 are connected Diode Module Not installed Make sure the Molded Tee is installed correctly in the fuse compartment HT9223 module is installed on Y150 Diverter valve on head not firing Check for 12V at Reel Diverter valve. Verify that Pin 1 of Y232 has 12V when either Reel raise or lower is pressed Verify that Pin 21 of Y202 has 12V when either Reel raise or lower is pressed. Test header harness Hydraulic problem on head Check hoses for correct connection pattern Contact JD service Flex Controller does not light up Power not connected. Make sure the Molded Tee is installed correctly in the fuse compartment. See Installation/ Cab Adapter Harness. Plug not seated Make sure Y225 fully seated in Hydraflex control No 12V to Y225 Check pin 6 (red wire) Flex pressure does not Increase. (Pressure can increase by pressing Reel Raise and Flex Increase simultaneously) Defective control Master Valve not firing Call Headsight. Make sure the Molded Tee is installed correctly in the fuse compartment. See Installation/ Cab Adapter Harness. Make sure the HT9223 module is installed on Y150 Diagnostics 26

32 Symptom Problem Solution Flex pressure does not Increase or decrease. (Cutterbar does not physically move if button held for > 1 minute. Wiring not connected properly Diode Module not installed Plug not seated Diverter valve on head not firing Verify that Y232 is connected at header Verify Y202, Y311 are connected Make sure the Molded Tee is installed correctly in the fuse compartment. See Installation/ Cab Adapter Harness. Make sure the HT9223 module is installed on Y150 Make sure Y225 fully seated in Hydraflex control Check for 12V at Hydraflex Diverter valve. Verify that Pin 2 of Y232 has 12V when either Hydraflex Increase or Decrease is pressed Verify that Pin 19 of Y202 has 12V when either Hydraflex Increase or Decrease is pressed. Flex pressure bar graph does not Increase or decrease. Hydraulic problem on head Defective control Defective pressure sensor (common) Test header harness Check hoses for correct connection pattern Contact JD service Call Headsight. Test/Replace sensor on header See JD Service Diagnostics (Cutterbar does physically move if button held for > 1 minute. Wiring on header defective (common) Defective wiring in Headsight system Defective display Test/Replace wiring on header See JD Service Trace/repair wire from Y202, pin 5 to Y225, pin 1. See attached Schematics. Call Headsight 27

33 Troubleshooting Sensors and Harnesses To properly test the wiring and sensors on the header, follow the steps below in order. Use a Volt Meter as needed. The sensor connector pattern is as follows: Pin A is Ground (Black or Lt Blue) Pin B is Signal (White) Pin C is 5V (Green or Pink) A very common problem during install is to reverse the wires at the connector after removing the plug to route the cables. Make sure that the wires/voltages are as shown. If A & C are reversed, the voltages will swing backwards. The following requirements must be met before testing: Key on, combine engine running Header connected Error Code Problem Solution Measure C to Frame Ground Bad Harness Wiring Disconnect Sensor Plug (Measure voltage on harness plug at sensor) Voltage should be 5V Measure C to A Voltage should be 5V Jump C to B in harness plug Voltage should be 5V If not, check harness for continuity or short on 5V wire Check Combine 5V source If not check harness for continuity on ground wire Check combine sensor ground source If not check signal wire for broken harness or bad connection If you have a Headsight Sensor tester, use it to test the sensor. For all other: (For Insight systems, see Diagnostics/Display Sensor Voltages. For all others, use Combine Diagnostics*) All of the above are correct Verify sensor is connected to extension harness Sensor voltage should be V Harness & combine connections pass test. If sensor cannot be adjusted to achieve a voltage within the range, replace sensor. Diagnostics (For Insight systems, see Diagnostics/Display Sensor Voltages. For all others, use Combine Specific Diagnostics) 28

34 Parts ITEM QTY. PART NUMBER DESCRIPTION 1 1 HT9118 Control Unit 2 1 HT9112 Top Mounting Bracket for (1) 3 1 HT9119 Main Harness 4 1 HT9127 Header Harness 5 1 HT2250 Header Connector Mount 6 1 HT9809-CAB Cab Adapter Harness 7 1 HT9809-FH Feeder Extension Harness Parts 29

35 STATEMENT OF LIMITED WARRANTY For Headsight Products Headsight Inc. (Headsight) warrants its new products to be free from defects in material and workmanship for a period of twelve (12) consecutive months following the date of purchase by the retail purchaser. Headsight Inc. (Headsight) warrants its new corn sensors assemblies for a period of thirty-six (36) months. Headsight warrants genuine Headsight replacement parts and components to be free from defects in material and workmanship for a period of six (6) consecutive months following the date of purchase or the remainder of the original equipment warranty period, whichever is longer. Headsight s obligation under these warranties shall be limited to repairing or replacing, free of charge to the original purchaser, any part that, in Headsight s judgment, shows evidence of such defect. Limitations to Warranty This warranty does not cover: Warranty claims directly resulting from improper installation of the product. Any product damaged by accident, abuse, misuse, or negligence after shipment from Headsight. Any unauthorized product alteration or modification. Any unauthorized repairs made with parts other than genuine Headsight parts. Any repairs performed by anyone other than Headsight or an authorized Headsight dealer unless specifically authorized by Headsight. Warranty Procedure Troubleshooting should be done between farmer/dealer and Headsight through our technical Labor reimbursement will occur only pre-arranged through Headsight technical assistance and be scheduled to a flat rate basis or reasonable time allowance in Headsight s judgment. There is no mileage reimbursement. Diagnostic time will not be reimbursed except in pre-arranged circumstances. Warranty claims should be on typical dealer service work order with a number and name to be attached for any future correspondence. All warranty work must be performed, and claims submitted, within thirty (30) days of the occurrence of the claim and within the warranty period. All parts removed during warranty repair must be returned to Headsight with Headsight s Return Form within thirty (30) days of the occurrence of the claim and within the warranty period. Headsight, Inc. reserves the right to either inspect the product at the original retail purchaser s location or require it to be returned to Headsight, Inc. for inspection. Limitation of Liability Headsight makes no express warranties other than those, which are specifically described herein. Any description of the goods sold hereunder, including any reference to buyer s specifications and any descriptions in circulars and other written material published by Headsight is for the sole purpose of identifying such goods and shall not create an express warranty that the goods shall conform to such description. THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES EXPRESSED OR IMPLIED. There are no implied warranties of merchantability or fitness of a particular purpose. This warranty states Headsight s entire and exclusive liability and buyer s exclusive remedy or any claim for damages in connection with the sale of furnishing of Headsight products, their design, suitability for use, installation or operation, or for any claimed defects herein. HEADSIGHT WILL IN NO EVENT BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES WHATSOEVER, NOR FOR ANY SUM IN EXCESS OF THE PRICE RE- CEIVED FOR THE GOODS FOR WHICH LIABILITY IS CLAIMED. No representative of Headsight nor any dealer associated with Headsight has the authority to change the items of this warranty in any manner whatsoever, and no assistance to purchaser by Headsight in the repair of operation of any Headsight product shall constitute a waiver of the conditions of this warranty, nor shall such assistance extend or revive it. Headsight reserves the right to make improvements in design or changes in specifications at any time, without incurring any obligation to owners of units previously sold. Warranty: 1/

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