JD CORN TO JD D-A-M. Conversion Manual b HEADSIGHT.COM

Transcription

1 JD CORN TO JD D-A-M Conversion Manual 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 Interface Box Mounting 2 Light Bar 3 Calibration 5 Combine Activation (Insight Only) 5 Standard Activation: 91-Up DAM 5 Activation: DAM 6 Activation: MY88 and Prior 7 Initialize Insight 8 Calibrate Insight 8 Sensor Calibration 8 Combine Contour-Master Calibration 9 Settings 10 Combine Settings 10 Automatic Drop Rate 10 Hydraulic Accumulator 10 Insight Settings 11 Tilt Sensitivity 11 Operation 12 Enabling Height Control 12 9x00 and 9x10 series Series 12 Adjusting Header Height 13 Adjusting Height Sensitivity 13 Overview 14 Insight Navigation 14 How to Navigate 14 Meaning of Status Light 14 Screen Contrast Adjustment 14 Resetting Insight to Defaults 15 Updating Insight Software with USB Drive 15 Advanced Information 16 Changing Tilt Orifices 16 Theory of Operation 17 Basic Requirements 17 Reading Voltages 18 Before You Start 18 On the Insight Box : Sensor Voltages 18 On the Insight Box : Output Voltages 18 Wiring and Diagrams 19 Header Adapter Harness 19 ii

5 Header Adapter Schematic 20 Light Bar Schematic 21 Diagnostics 22 Troubleshooting by Symptom 22 Common Combine Problems 26 Troubleshooting by Insight Error Codes 27 Parts 34 STATEMENT OF LIMITED WARRANTY 36 iii

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 Make sure the cable routing is done so no wiring can bind or pinch. Tie up all loose cabling. Properly installed wiring is the most critical aspect of a trouble-free installation. For harness details, see Wiring. Interface Box Mounting Installation 1. Install Insight box at rear of header within reach of feederhouse electrical connection on combine and mark mounting hole locations. 2. Secure box to header. Drill mounting holes using ¼" drill bit Use provided tie straps or ¼" bolts Box must be within reach of the header electrical connector 3. Attach connector mounting plate to header within reach of combine electrical connector. Drill mounting holes using ¼" drill bit Use provided ¼" bolts Box must be within reach of the header electrical connector 4. Connect Y pin header connector to the header. 5. Attach black ground wire to header frame. Required for all combines model 1990 and earlier 6. Connect Y101, 24 pin rectangular plug to the bottom of the Insight box. 7. Mate remaining connectors to combine and header. 16pin OEM Header connector (from combine) 9 pin Light bar 2

8 Installation Light Bar 1. Mount the light bar within easy reach of the operator. 2. Route the light bar wiring down and over under the floor mat to the left side of cab. 3. Route the wiring out the cab door and down under ladder platform. 4. Alternately, route the wire out the right rear corner of the cab through the electrical access panel. Make sure to seal access hole in panel. Route across under cab. 5. xx20 series combines have a cab access plate in the front right corner under floor mat. Remove and notch plate, route wire out hole. 3

9 6. Route the light bar wiring up the left hand side of the feederhouse. Make sure you leave sufficient slack to connect to the header connector plate. Secure away from moving parts. Installation 4

10 Calibration Calibration 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. Combine Activation (Insight Only) To power the Insight Box for setup and calibration, different combines require different procedures. Please follow the correct procedure for your year combine. Standard Activation: 91-Up DAM This procedure also applies to earlier combines that have had header stubble lights wiring added to the OEM header connection. 1. Make sure all connectors and harnessing is installed. 2. Turn the Dial-A-Matic switch OFF to prevent DAM activation. 3. Start the engine. 4. Turn on the field lights ( 91 up) This allows the Insight box to receive power without requiring the header and separator to be engaged 5. The LCD display should now be active on the Insight box. 5

11 Activation: DAM 1. Install the power bypass harness PFI-JD10-P on the feeder. Disassemble the shell on the back of the OEM combine header plug Unscrew Calibration Turn Insert the loose socket through the back shell and into cavity 15 on the OEM Header plug Cavity 15 is where the Brown wire is shown in the picture Route the Power wire up the feeder, around the pivot, and forward under the cab Connect the 2 pin plug to the plug shown next to the horn under the cab 2. Make sure all other connectors and harnesses are properly installed. 3. Power the Insight box. Turn the Dial-A-Matic switch OFF Start the engine The LCD display should now be active on the Insight box 4. The power bypass harness can remain connected during operation. Connecting the combine to a newer head with Stubble lights will mean the lights will be on whenever the combine key is on this should not be a problem. 6

12 Activation: MY88 and Prior 1. Clean, label, and disconnect the electric valve solenoids above the left front tire. Calibration 2. Install the adapter harness on the OEM header connection. Pre-83 AHC DAM On AHC models, connect the ground wire to a clean bolt on the feederhouse. 4. Make sure all other harnesses & connectors are properly installed. 5. To Power the Insight: Turn the D-A-M switch ON Start the engine Manually lower the head until head is 12-18" off ground Adjust the chain switch until switch activates Insight LCD display should light up Proceed with Setup and Calibration 6. After completing all calibration steps, reconnect the valve solenoid plugs. 7

13 Initialize Insight These steps must be performed the first time the Insight box is powered up and each time it is reset. They do not need to be redone each time the Insight box is calibrated. Read the Insight Overview section of the appendix for basic information about how to use the Insight box. 1. Choose Language. 2. On the Insight box: Choose John Deere Choose 9x00/10 & xx20 DAM 3. Choose Header Type. Choose Standard You can reaccess this at any time under >>Setup>>Header Type 4. Choose the number of height sensors. For Standard heads, enter the number of ground sensors To reaccess this you must choose >>Setup>># of Sensors Calibration Calibrate Insight When you initialize Insight, you will be led directly to this calibration routine. If you wish to recalibrate at any other time choose >>Perform Calibration on the Insight main menu. Sensor Calibration 1. Park the combine on a level and smooth surface, preferably a cement driveway or shop floor. 2. Follow on-screen instructions. Raise Header - Press Enter Raise the head high enough that no sensors touch the ground: Press Enter Fully Lower Header - Press Enter Lower the head all the way down onto the skids. Make sure that both ends of the header are flat on the ground. Press Enter 3. If an error appears on the Insight box, see Advanced Information, Adjusting Sensors or Diagnostics. 8

14 Combine Contour-Master Calibration Calibration This calibration should be done each time a combine equipped with Contour-Master has been used on another header with a minimum of once per season. This calibration allows the combine to learn how to level the head. 1. Complete the sensor calibration procedure above. 2. Start the engine and attach the header. 3. Engage the header clutch. 4. Turn off the Contour-Master switch on the armrest. 5. Lower header to the ground (on a level surface) for 2 seconds. 6. Press header raise button. 7. Turn on the Contour-Master switch after the sensors have left the ground (while continuing to raise the header.) 8. If the header does not run level, retry the calibration. 9

15 Settings Combine Settings Properly setting the combine is essential to having responsive header control. You should become very familiar with the steps in this section. Set the automatic drop rate as high as you like without causing head hunting. If the head hunts, decrease the automatic drop rate. For 20 series combines see owners manual for location of drop rate valve and accumulator series are shown. Settings Automatic Drop Rate 1. Use the automatic drop rate valve adjustment knob on the main valve block. Turn in all the way then out ½ turn for initial guess. If the speed is to fast: Hunting will occur If the speed is to slow: The system will not be responsive enough. 2. Common range is 8-12 seconds from header full up to full down in automatic mode. A B A: Automatic Drop Rate Valve B: Manual Drop Rate Valve The maximum automatic drop rate is limited by the manual drop rate. Hydraulic Accumulator 1. Close the accumulator valve all the way. 2. Open the accumulator valve 1 full turn from the closed position. Opening the accumulator to far will give a sloppy response Not opening the accumulator far enough will give a jerky response 10

16 Insight Settings Settings Tilt Sensitivity 1. To change this setting go to >>Settings>>Tilt Sensitivity in the Insight box Default setting is 50. If the head is to jumpy from side to side Decrease sensitivity If you would like the head to be more responsive Increase sensitivity Typical settings are Press Enter to save value 2. If you cannot stop the head rocking side to side with the above settings, see Advanced information/ Changing Tilt Orifices. 11

17 Operation Enabling Height Control 9x00 and 9x10 series 1. Turn Dial-a-Matic switch ON. 2. Engage header clutch. Operation 3. Press header lower button. 4. On all 9x00 and 9x10 John Deere combines, the manual raise switch should ALWAYS override/shutoff auto height control. If not, test / replace the D-A-M control board in the combine Series 1. Adjust the chain length on AHC switch under the cab to turn on header control above the height at which the header first contacts the ground. 2. Turn Auto/Dial-a-Matic switch ON. 3. Lower header until height control engages. 12

18 Adjusting Header Height If a Light Bar is not connected, preset raise and lower points are used, allowing basic operation at one midrange height. Operation 1. Turn the height position knob on the light bar with header control engaged. Clockwise = higher Counter-clockwise = lower 2. Because the Headsight box is designed to work with many OEM sensors, it may be possible for the operator to choose a height that is too low for proper operation, meaning the sensors would never send a raise signal. To test if the height you have chosen is too low, engage the system, then tap 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 on the light bar 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. Set the drop rate and accumulator before adjusting sensitivity knob 13

19 Overview Insight Navigation How to Navigate When in a menu (selection arrow appears to left side) Enter: chooses the selected menu choice Esc: backs up one menu level Up: moves up within the menu choices displayed Down: moves down within the menu choices displayed When in a screen which allows setting of parameters Enter: backs up to last menu level AFTER saving Esc: backs up to last menu level without saving Up: increases the value Down: decreases the value Meaning of Status Light Solid Green: System is operating No errors detected Solid Red: System is NOT operating No height or tilt signals are sent to combine You have changed settings which require calibration of Insight, are currently in a menu which will force a calibration if you make any changes, or are in calibration mode Solid Green with Flashing red: System is operating An error has been detected Repair problem then clear errors Flashing Red: System is operating A sensor has been ignored See note in Troubleshooting by Error - ER16 Repair system - Recalibrate Insight Overview Screen Contrast Adjustment To increase contrast: Press and hold Esc + Press Up to increase contrast (while holding Esc) To decrease contrast: Press and hold Esc + Press Down to decrease contrast (while holding Esc) 14

20 Resetting Insight to Defaults To reset all settings hold + for 5 seconds: Press and hold ESC then Press and hold Enter while holding ESC Hold both for 5 seconds Updating Insight Software with USB Drive Updating software may cause the Foresight option to be disabled. If you have purchased Foresight, contact Headsight before updating software. Overview 1. You will need: USB drive Means of loading USB Stick (computer with USB) 2. Load USB drive with new software files Place insightf.hex in the root directory of USB drive (ex. E:\insightf.hex) Do not change file names 3. If you do not have the new files you may Download updated software from Order pre-loaded USB drive from Headsight, Inc. 4. Remove cap from USB on front of Insight controller 5. Insert USB drive card into USB slot on front of Insight 6. Power Insight Turn on key switch 7. Wait for software to download Yellow light will blink while download is in progress Green light will turn on solid when download is complete 8. Verify update is successful Go to >>About Insight>>Software Version and read software version number 9. Remove USB drive 10. Install cap on USB on front of Insight controller 11. Remove power from Insight Turn off key 15

21 Advanced Information Changing Tilt Orifices The purpose of changing the orifices is to decrease/increase the maximum speed that the Contour-Master can tilt. The factory configuration will be satisfactory for most conditions. However, wide headers may need to adjust the orifices. Only change orifices if the system cannot be set properly by using the sensitivity adjustment on the contour-master card. 1. The target tilt speed is 5 8 seconds from full right to full left for most machines. 2. Using 1/8 Allen wrench, remove original orifice from valve block in tilt cylinder supply lines. Keep orifice in secure location for later use if needed 3. If tilt speed is too fast: Install an orifice that is smaller than the original orifice removed 4. If tilt speed is too slow: Install an orifice that is larger than the original orifice removed, or remove orifice completely.26" Z60904 (Original on 50/60 series).31" H (Original on 00/10 series).46" H Advanced Info 16

22 Theory of Operation A review of the following points will help the service technician to understand the complete system which will help when diagnosing specific problems. 1. Each sensor returns a variable voltage depending on its height. High height = high voltage (approximately 4 volts) Low height = low voltage (approximately 1 volt) 2. Each sensor has 3 wires: 5V power Ground Signal returned to the combine Varies between approximately 1.0 and 4.0 volts 3. The voltages the combine sees are exactly like what it would see with an OEM system. All existing combine controls and settings may be used. Basic Requirements Each sensor must meet basic requirements for the Insight to accept the calibration. If any sensor does not meet the requirements below you must correct it and then recalibrate. See the header manual for sensor adjustment instructions. Advanced Info 1. Signal must always be between 0.3 and 4.7 volts. 2. Signal must change more than 1.0 volts from raised to lowered position for each sensor. 3. John Deere corn sensors are in-adjustable, except by shimming the entire sensor assembly. If the sensor exceeds the allowable voltage range above, the sensor must be rebuilt or replaced. 17

23 Reading Voltages Before You Start The Insight box can display both the input voltages it receives from each sensor and the output voltages it is sending to the combine. Sensor voltage = Insight box input voltage Insight box output voltage = Combine sensor input Insight box scales voltages received to what combine needs to function On the Insight Box : Sensor Voltages 1. From main menu, go to >>Diagnostics>>Disp Sensor Voltages. This shows real-time voltage coming from each sensor Sensor Voltages L LC CTR RC R For more information about sensor history and status see >>Diagnostics>>Detailed Diagnostics>>(parameter of interest.) Left Sens =0.00V Max=0.00V SetH=5.00V Min=0.00V SetL=0.00V Enabled=N Reversed=N Sensor = signal from sensor in volts Max = the maximum voltage sent to Insight box from sensor since last calibrated Min = the minimum voltage sent to Insight box from sensor since last calibrated Enabled = is this sensor enabled to control height? Yes or No SetH = the header raised voltage set-point recorded during calibration SetL = the header lowered voltage set-point recorded during calibration Reversed = is the polarity of this sensor reversed? Yes or No Advanced Info On the Insight Box : Output Voltages 3. From main menu, go to >> Diagnostics>>Detailed Diagnostics>> (parameter of Interest). This shows signal being sent to the combine 4. Raise/Lower Outputs ON or OFF (12V signal) 5. Left or Right Height Out = X.XVolts: 1V with head fully lowered 4V with head raised Dial-A-Matic OUTPUT Raise=OFF Lower=ON Left Height OUTPUT =2.0V 18

24 Wiring and Diagrams Header Adapter Harness Y202 or Y204 Y221 Y223 Y101 Advanced Info Connector Description Connects to Y202/Y pin Deutsch Header connector header single-point or Multipoint Y pin DT Insight Control box Y pin Amp CPC OEM combine header connector Y223 9 pin Amp CPC Light Bar 19

25 Header Adapter Schematic Y101 INSIGHT P18 HGT SET P21 AUX INPUT P19 HGT SENS SET P11 CENTER HGT OUT P24 LOWER P23 RAISE P10 LEFT HGT OUT P12 RIGHT HGT OUT P6 GROUND 001 SIGNAL GND BLK P17 GROUND V POWER RED P4 12V POWER 050 SENSOR PWR PNK 100 SENSOR GND Lt BLU 081 LEFT SENSOR WHT 084 CENTER SENSOR WHT 087 RIGHT SENSOR WHT P2 HGT SNS V+ P3 HGT SNS GND P7 LEFT HGT P8 CENTER HGT P9 RIGHT HGT Advanced Info Y223 LIGHT BAR SENSOR V+ FLEX SELECT HGT SET REEL SELECT FLEX PRESSURE GROUND HGT SENS SET HGT SIGNAL Y221 COMBINE LOWER RAISE LEFT HGT SIG RIGHT HGT SIG GROUND DAS ENABLE DAM ENABLE SWITCHED 12V STUBBLE LTS CHASSIS GND LFT HZD LT RIGHT HZD LT REEL SPEED Y248 BELT SPEED DRAPER + DRAPER - BELT SPEED NOTES: P1 P2 P3 P4 P5 P6 P7 P08 P03 P05 P07 P09 P10 P16 P11 P04 P15 P12 P13 P14 P08 A B C 050 SENSOR PWR PNK 079 FLEX SELECT ORG 120 HGT SET PUR 078 REEL SELECT Dk BLU 091 FLEX PRESSURE GRY 001 SIGNAL GND BLK 121 HGT SENS SET YEL 125 HGT SIGNAL WHT 048 LOWER SIGNAL BRN 049 RAISE SIGNAL Lt GRN 041 LEFT HGT SIG TAN 045 RIGHT HGT SIG TAN 001 SIGNAL GND BLK 001 SIGNAL GND BLK V POWER RED 1N5404 1N V POWER RED 033 STUBBLE LTS BRN 022 CHASSIS GND BLK 031 LEFT HZD LT YEL 032 RT HZD LT Dk GRN 098 REEL SPEED GRY 130 DRAPER + WHT 131 DRAPER - BRN 124 BELT SPEED GRY Y230 GROUND GROUND Y202 HEADER P19 FLEX SELECT P21 REEL SELECT P5 FLEX PRESSURE SENSOR V+ P20 SENSOR GND P10 LEFT HGT SNS P07 CTR HGT SNS P03 RIGHT HGT SNS P09 P04 12V POWER P15 STUBBLE LTS P12 CHASSIS GND P13 LEFT HZD LT P14 RGT HZD LT P08 REEL SPEED P26 DRAPER + P27 DRAPER - P29 SHAFT SPEED P FLEX PRESSURE GRY 023 CHASSIS GND BLK QP0-JD10-31Q 5 20

26 Light Bar Schematic NOTES: Y224 LIGHT BAR 5V PWR HGT SET GROUND SENS SET HGT SIG P1 P3 P6 P7 P8 5V POWER ORG HGT SET GRN GROUND BLK SENS SET RED HGT SIGNAL WHT Advanced Info HT

27 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 Error detected Find and repair error Head will not Lower Head raises all the way to top Wiring not connected, or calibration not completed. See Installation/ Calibration/ Settings sections of manual Sensor(s) locked up Height position set too High Height sensor failed/misadjusted Free Sensor Set Setpoint lower >>Diagnostics>>Display Sensor Voltages Sensors ~ 1-4V as sensing arm travels through stroke (see Theory of Operation) Header is too jumpy Calibration not properly completed Combine improperly set Accumulator not adjusted properly If voltage not correct: Adjust sensor Replace sensor Repair wiring on head Redo Insight calibration Decrease Raise/Drop Rate Decrease sensitivity Open valve 1 turn Check charge pressure Diagnostics Auto Drop rate < 8 seconds with adjustment fully closed Repair Auto drop rate valve assembly 22

28 Symptom Problem Solution Header responds too slowly Calibration not properly Recalibrate Insight box completed Combine improperly set See Combine Settings Section Increase Raise/Drop Rate Multiple sensors failed/error at once Accumulator not adjusted properly No 5V power or ground to head Bad Harness on header Increase sensitivity Open valve 1 turn Check charge pressure Disconnect 31p header connector and measure from pins 10 to 20 on the Adapter Harness. Should be 5V. If not, repair Header Adapter harness Reconnect 31p header plug. Measure across outer wires at any sensor plug for 5V. Cannot operate head low enough Calibration not properly completed Cannot operate head high enough Snoots not adjusted properly Calibration not properly completed If no 5V is available at any one sensor, find broken or shorted wire in header harness. Perform header cal on flat level surface. Lower head fully when requested. Make sure you have 4-6 under gathering chain skids when snoot tips touch. Perform header cal on flat level surface Diagnostics Header dives to ground and recovers entering crop Snoots not adjusted properly Height desired exceeds sensor range Accumulator too far open or discharged Combine improperly set Make sure you have 4-6 under gathering chain skids when snoot tips touch. Use RTC Adjust/check accumulator Decrease Auto Drop Rate Lower valve sticky (Rare) Repair combine Lower valve 23

29 No Automatic operation Symptom Problem Solution Header does not move in AHC mode. Wiring not connected, or calibration not completed. Header control not enabled See Installation/ Calibration/ Settings sections of manual See Operation section Lower switch not pressed Wire shorted on head Insight box not outputting Raise or Lower commands See >>Diagnostics>>Detailed Diag.>>Raise/Lower Outputs Combine Problem See Operation section See All sensors failed Wrong combine selected. See >>Setup>>Combine Select Select JD 9x00/10, 20 DAM Software issue, reboot Insight Contact your JD Service Center Raise OR Lower does not work Improper Calibration Redo Insight Calibration Height position knob too high or low Light bar or connection issue See >>Diagnostics>>Detailed Diag.>>Height Setting IN Should change between 1-4V as Height position knob is rotated. Combine problem Adjust height setpoint Repair Light Bar or wiring too Insight See Common Combine Problems Height works but not Tilt Lateral Tilt disabled Enable Lateral Tilt Increase Tilt Sensitivity. Sensors on head missing or defective >>Head 2>>Tilt Sensitivity Increase Tilt sensitivity >>Diagnostics>>Height/ Tilt>>sensor of interest. L & R ~ 1-4V as sensor travels through stroke (see Theory of Operation) If not: Adjust sensors Replace sensor(s) Repair wiring on head Head rocks back and forth Tilt Sensitivity too high >>Setup>>Tilt Sensitivity Decrease Tilt sensitivity Diagnostics Wrong orifices installed Refer to Changing Tilt Orifices section of manual 24

30 Symptom Problem Solution Left and Right sensors reversed Header tips wrong way (Once head is moved off level, it continues all the way in either direction) Bad adapter harness. -reverse wires 7 & 9 in Y221 Head tips all the way one direction Improperly adjusted sensors Adjust the lateral tilt sensors to both be about 1-1.2V when sitting flat on the ground Sensor not connected, or calibration not completed. Poor connection Sensor or wiring fault Combine Problem See Installation/ Calibration/ Settings sections of manual Check harness and connectors for cut/torn wire or loose terminals Make sure terminals are properly latched, not pushed back, in connector body Troubleshoot header sensors & wiring Contact your JD Service Center. Header runs slightly out of level Header not calibrated correctly Perform Header Cal on flat surface Perform JD ContourMaster CAL Header float not working correctly Make sure the float range of the cutterbar is the same across the width of the head Improperly adjusted sensors Adjust the sensors to both be about 1-1.2V when sitting flat on the ground Recalibrate Insight and combine. Diagnostics 25

31 Common Combine Problems Symptom Problem Solution No Power to Insight box (Initial Stubble Lights are OFF Turn on Stubble Lights setup/activation) (1991 and up) Stubble lights wire to header not functioning. (1991 and up) Test power at combine header connector pin 15 for 12V 89-90, No pin 15, power adapter not installed No Ground Test combine header connector Pin 10 for continuity to ground DAM switch or Feeder Clutch not ON Repair Stubble lights wiring on combine Install Power adapter Repair combine ground wire Pre- 90: Make sure adapter ground wire is attached to head. See Operation Section No power to Insight box (Field Operation) Power supply from combine less than 10V to Insight See No 12V power to Header in Common Combine Problems No Ground Test combine header connector Pin 10 for continuity to ground Damaged wires on OEM harness (typically on feederhouse) Bad D-A-M relay in armrest or bad D-A-M switch. To test, have operator in seat and engage header clutch (D-A-M switch can be in position 1, 2, or 3) xx00-xx20 series combines: Feederhouse position chain is not properly adjusted to pull rocker free of switch under cab or switch is not working Insight box is not outputting the correct raise lower commands Repair combine ground wire Pre- 90: Make sure adapter ground wire is attached to head. Find and fix damaged wires No 12V power available on pin 4 of header plug to power Insight box when D-A-M switch is on and feederhouse clutch is engaged If there is still no 12V available on the header plug, replace relay in the armrest and if necessary replace D-A-M switch Raise, lower, or both raise and lower will not work Manual raise switch does not disengage auto height control Bad wiring on Feederhouse or defective relays on D-A-M board On all 9x00 and 9x10 JD combines, the manual raise switch should ALWAYS override/ shutoff auto height control No 12V available on pin 4 of header plug to power Insight box Check combine operators manual for instructions on adjusting feederhouse position chain, and if necessary, replace switch See >>Diagnostics>>Detailed Diagnostics>>Raise/Lower Outputs Contact JD dealer for service Repair combine wiring (on feederhouse) or replace D-A-M card in combine Diagnostics Manual lower switch does not engage auto height control, DAM switch ON, Feeder clutch ON. See solution for problem: No 12V available on pin 4 of header plug 26

32 Troubleshooting by Insight Error Codes Error Code Problem Solution ER11 Left sensor signal less than 0.3V Left sensor temporarily disconnected. Repair wiring or bad connector Calibrate Insight Box Calibrate Combine ER12 Left sensor signal greater than 4.7V ER13 Left sensor swing less than 0.6V ER16 Left sensor expected but not detected Wiring open Wiring problem Left sensor mechanical range is restricted Left sensor not properly connected Check sensor harness for pinched/broken wiring See sensor test instructions Ground wire to sensor is open Signal short to power Calibrate Insight Box Calibrate Combine See sensor test instructions Verify sensor is not obstructed in swing Verify sensor can collapse fully with header lowered Adjust down stop to allow greater range See sensor test instructions Verify harness is connected to sensor 1 Verify harness is connected properly to control box harness Verify that signal wire (Pin B white wire of sensor cable) is connected to PIN7 of connector Y101 (Insight box) Diagnostics Not enough swing during cal Incorrect number of sensors selected in setup Make sure sensor meets requirements in - Advanced Information - Basic Requirements section of this manual Go to >>Initial Setup>>Number Sensors and choose the correct number of sensors See sensor troubleshooting instructions Control box /wiring failure Contact Headsight 27

33 Error Code Problem Solution ER17 Left sensor detected but not expected Incorrect number of sensors selected in setup Go to >>Setup>>System Select and choose the correct number of sensors ER21 Left Center sensor signal less than 0.3V ER22 Left Center sensor signal greater than 4.7V ER23 Left Center sensor swing less than 0.6V Harness wiring error Control box /wiring failure Left Center sensor temporarily disconnected. Wiring open Wiring problem Left Center sensor mechanical range is restricted Verify that no wires contact PIN7 of connector Y101 Contact Headsight Repair wiring or bad connector Calibrate Insight Box Calibrate Combine Check sensor harness for pinched/broken wiring See sensor test instructions Ground wire to sensor is open Signal short to power Calibrate Insight Box Calibrate Combine See sensor test instructions Verify sensor is not obstructed in swing Verify sensor can collapse fully with header lowered Adjust down stop to allow greater range See sensor test instructions Diagnostics 28

34 Error Code Problem Solution ER26 Left Center sensor expected but not detected Left Center sensor not properly connected Verify harness is connected to left center sensor Verify harness is connected properly to control box harness Verify that signal wire (Pin B white wire of sensor cable) is connected to PIN13 of connector Y101 (Insight box) Not enough swing during cal Make sure sensor meets requirements in - Advanced Information - Basic Requirements section of this manual Incorrect number of sensors selected in setup Go to >>Initial Setup>>Number Sensors and choose the correct number of sensors See sensor troubleshooting instructions Control box /wiring failure Contact Headsight ER27 Left Center sensor detected but not expected Incorrect number of sensors selected in setup Go to >>Setup>>System Select and choose the correct number of sensors Harness wiring error Verify that no wires contact PIN13 of connector Y101 Control box /wiring failure Contact Headsight ER31 Center sensor signal less than 0.3V Center sensor temporarily disconnected. Repair wiring or bad connector Calibrate Insight Box Calibrate Combine Diagnostics ER32 Center sensor signal greater than 4.7V Wiring open Wiring problem Check sensor harness for pinched/broken wiring See sensor test instructions Ground wire to sensor is open Signal short to power Calibrate Insight Box Calibrate Combine See sensor test instructions 29

35 Error Code Problem Solution ER33 Center sensor swing less than 0.6V Center sensor mechanical range is restricted Verify sensor is not obstructed in swing Verify sensor can collapse fully with header lowered Adjust down stop to allow greater range See sensor test instructions ER36 Center sensor expected but not detected Center sensor not properly connected Verify harness is connected to center sensor Verify harness is connected properly to control box harness Verify that signal wire (Pin B white wire of sensor cable) is connected to PIN8 of connector Y101 (Insight box) Not enough swing during cal Make sure sensor meets requirements in - Advanced Information - Basic Requirements section of this manual Incorrect number of sensors selected in setup Go to >>Initial Setup>>Number Sensors and choose the correct number of sensors See sensor troubleshooting instructions Control box /wiring failure Contact Headsight ER37 Center sensor detected but not expected Incorrect number of sensors selected in setup Go to >>Setup>>System Select and choose the correct number of sensors ER41 Right Center sensor signal less than 0.3V Harness wiring error Control box /wiring failure Right Center sensor temporarily disconnected. Wiring open Verify that no wires contact PIN8 of connector Y101 Contact Headsight Repair wiring or bad connector Calibrate Insight Box Calibrate Combine Check sensor harness for pinched/broken wiring Diagnostics See sensor test instructions 30

36 Error Code Problem Solution ER42 Right Center sensor signal greater than 4.7V Wiring problem Ground wire to sensor is open Signal short to power Calibrate Insight Box Calibrate Combine See sensor test instructions ER43 Right Center sensor swing less than 0.6V Right Center sensor mechanical range is restricted Verify sensor is not obstructed in swing Verify sensor can collapse fully with header lowered Adjust down stop to allow greater range See sensor test instructions ER46 Right Center sensor expected but not detected Right Center sensor not properly connected Verify harness is connected to right center sensor Verify harness is connected properly to control box harness Verify that signal wire (Pin B white wire of sensor cable) is connected to PIN14 of connector Y101 (Insight box) Not enough swing during cal Make sure sensor meets requirements in - Advanced Information - Basic Requirements section of this manual Incorrect number of sensors selected in setup Go to >>Initial Setup>>Number Sensors and choose the correct number of sensors See sensor troubleshooting instructions Diagnostics ER47 Right Center sensor detected but not expected Control box /wiring failure Incorrect number of sensors selected in setup Harness wiring error Contact Headsight Go to >>Setup>>System Select and choose the correct number of sensors Verify that no wires contact PIN14 of connector Y101 Control box /wiring failure Contact Headsight 31

37 Error Code Problem Solution ER51 Right sensor signal less than 0.3V Left sensor temporarily disconnected. Repair wiring or bad connector Calibrate Insight Box Calibrate Combine ER52 Right sensor signal greater than 4.7V ER53 Right sensor swing less than 0.6V ER56 Right sensor expected but not detected Wiring open Wiring problem Right sensor mechanical range is restricted Right sensor not properly connected Not enough swing during cal Check sensor harness for pinched/broken wiring See sensor test instructions Ground wire to sensor is open Signal short to power Calibrate Insight Box Calibrate Combine See sensor test instructions Verify sensor is not obstructed in swing Verify sensor can collapse fully with header lowered Adjust down stop to allow greater range See sensor test instructions Verify harness is connected to right sensor Verify harness is connected properly to control box harness Verify that signal wire (Pin B white wire of sensor cable) is connected to PIN9 of connector Y101 (Insight box) Make sure sensor meets requirements in - Advanced Information - Basic Requirements section of this manual Incorrect number of sensors selected in setup Go to >>Initial Setup>>Number Sensors and choose the correct number of sensors See sensor troubleshooting instructions Diagnostics Control box /wiring failure Contact Headsight 32

38 Error Code Problem Solution ER57 Right sensor detected but not expected Incorrect number of sensors selected in setup Go to >>Setup>>System Select and choose the correct number of sensors ER61 Sensor 6 (aux sensor) signal less than 0.3V ER62 Sensor 6 (aux sensor) signal greater than 4.7V ER92 Tilt Sensitivity greater than 4.0V Harness wiring error Control box /wiring failure Wiring open Wiring problem Wiring problem Verify that no wires contact PIN9 of connector Y101 Contact Headsight Check sensor harness for pinched/broken wiring See sensor test instructions Ground wire to sensor is open See sensor test instructions Turn the Tilt sensitivity knob in the cab to Maximum CW. Read under >>Diagnostics>>Detailed Diag.>>Tilt Sens In, on the Insight box Reading between 4.0 and 4.5. Call Headsight for instructions Reading > 4.5V, Combine problem- Check wiring on combine Diagnostics 33

39 Parts ITEM QTY. PART NUMBER DESCRIPTION 1 1 QP0-JD10-31J Adapter Header Harness 2 1 Insight Interface Unit 3 1 HT999LB Cab Light Bar 4 AR PFI-JD10-P Power Adapter (not shown) Parts 34

40 35 This Page Is Intentionally Left Blank

41 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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