JD 600F TO CIH 14-25XX

Transcription

1 JD 600F TO CIH 14-25XX Conversion Manual h 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 Insight, Header Adapter Mounting 2 Hydra-Flex Cab Conversion Installation 3 Cab Controller Cab Adapter Harness: Cab Adapter Harness: 5 Feeder House Harness: 6 Draper Speed Kit, 600FD only 6 Calibration 7 Initialize Insight 7 Calibrate Insight 8 Sensor Calibration 8 Combine Ground Calibration (21-25xx Only) 8 CaseIH Series Full-Cal (Perform Only If Needed) 9 CaseIH 21-25xx Series, Tricking Ground Cal 10 Settings 11 Insight Settings 11 Tilt Sensitivity 11 Combine Settings 11 CaseIH 14xx 1688 series controls 12 CaseIH controls 13 Operation Series 15 CIH Series 15 Overview 16 Insight Navigation 16 How to Navigate 16 Meaning of Status Light 16 Screen Contrast Adjustment 16 Resetting Insight to Defaults 17 Updating Insight Software with USB Drive 17 Advanced Information 18 Field Tracker: Adjusting Feeder Position Switch 18 Theory of Operation 19 Basic Requirements 19 Reading Voltages 20 Before You Start 20 On the Insight Box : Sensor Voltages 20 On the Insight Box : Output Voltages 20 On the Insight Box : Tilt Sensitivity 21 Wiring and Diagrams 22 ii

5 Header Interface Harness 22 Feederhouse Harness 23 Cab Interface Harness: 21xx-25xx 24 Cab Interface Harness: 14-16xx 25 Header Adapter Schematic 26 Feederhouse Harness 27 Cab Adapter Schematic: 21-25xx 28 Cab Adapter Schematic: 14-16xx 29 Diagnostics 30 Troubleshooting by Symptom 30 Common Combine Problems 34 Reel/Hydraflex Diagnostics 36 Troubleshooting by Insight Error Codes 38 Parts 45 STATEMENT OF LIMITED WARRANTY 46 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 Complete the installation portion of the header manual before continuing. Insight, Header Adapter Mounting 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 Installation 3. Remove the C clip holding the OEM header electrical connector in the JD single-point plate. 4. Remove the connector from the plate, and press fit into Y202. Ziptie the HT2259 clip to keep them together. 5. Mate 3 (Y301) and 5 (Y302) pin connectors to combine. 6. Connect the hazard lights plug (Y304) to the combine. 7. A 1 pin connection (Y306) is provided for stubble lights on the header. If you wish to use stubble lights, Find a source location on combine for field lights Route included single brown wire from the combine field lights to Feeder and connect to Y306 Y301 2

8 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. For the 21-25xx, connect Y225 on the Adapter Cab Harness into the controller Cab Adapter Harness: Please see the included wiring diagram in Advanced Info for a visual guide to wire connection. 1. Open the access panel to the right of the cab and clean the cab wiring access plate area thoroughly. 2. Unplug connector CIH labels CONN xx combines: rectangular 24 pin 23-25xx combines: 31 pin round (shown) 3. Remove the screws holding the cab wiring access plate to the lower right corner of the cab and pull whole unit outward. 4. Make sure the HT9223-DP Diode Module is installed on Y From inside the cab, place cab interface harness so the end with the loose wires and Y338 plug extends out the access plate hole. 3

9 Reel Lower wire From Conn. 2, remove the Lt. Blue wire labeled 453 from term 9 Insert it into position A of Y337 (the 3 pin round connector provided with the adapter harness Installation 6. Carefully use the included blue plastic wire removal tool to perform the following steps. See illustrations below. (2100 s wires & terminal # s are the same.) Insert the loose Dark Green wire into the spot on Conn. 2 (pin 9) vacated by wire 453 Reel Raise wire From Conn. 2, remove the Lt. Blue wire labeled 458 from term 8 Insert it into position B of Y337 Insert the loose Dark Blue wire into the spot on Conn. 2 (pin 8) vacated by wire V power wire From Conn. 2, remove the Red wire labeled 445 from term 18 Immediately insert it into position C of Y337 Insert the loose Red wire into the spot on Conn. 2 (pin 18) vacated by wire Drill holes, and mount Y338 flanged receptacle into cab access plate. 8. Attach the Black wire to any good Ground in the Fuse panel. 9. From outside cab, reinstall connector access plate bolts. 10. Plug in Conn. 2. 4

10 Installation Cab Adapter Harness: Read through these instructions carefully before beginning! For the Hydraflex platform to function properly we need to break into the control circuitry for the reel raise/lower. To do that we will remove several wires from the Reel Raise/Lower switch connector body, reroute, and replace them with other wires from the adapter harness. 1. Remove the electrical console access panel on the right side of the cab. Open the cab window. 2. From inside the electrical console, insert Y225 of the Cab interface harness through an access hole on the front edge of the electrical console and route it up to the Cab Controller. 3. Identify and unplug the switch connector shell from under the OEM reel raise/lower switch and carefully make the following substitutions: Remove OEM Gray wire from the switch connector and insert it into the Silver coded 1p plug body provided Insert the Headsight Lt. Blue wire with the female terminal into the Gray wire s OEM location on the switch connector Remove the OEM Pink/White wire and insert it into the Black coded 1p plug body Insert the Headsight WHITE wire with the female terminal back into the Pink/White stripe OEM location on the switch connector Remove the OEM Red/Green stripe wire on the end of the short loop (not the one with 2 wires) and insert it into the Red coded 1p plug body Insert the Headsight RED wire with the female terminal back into the Red/Green stripe OEM location on the switch connector 4. Reinstall the switch connector block back onto the switch. 5. Connect the color coded 1p plugs to the correct mating plug on the Headsight cab harness. 6. Attach the black wire to any good ground in the electrical console. 7. Make sure the diode module is installed on Y After installing the Feeder harness and testing the system, reinstall electric console access plate. 5

11 Feeder House Harness: 1. For the 14xx-1688, route the Y339 (9p plug) up from under the cab into the Electrical console area and connect it to the cab harness connector Y For the 21xx-25xx, connect Y339 to Y338 at the cab connector panel. 3. Route the feeder house harness around under the front of the cab and down the OEM feeder house wiring to the left front corner near the OEM electrical connections. If your combine DOES HAVE Field-Tracker (lateral tilt) Remove the two white plugs from rear of round grey 5 pin Deutsch plug on the combine (Field Tracker plug) pins D and E. Leave the existing wires in place If your combine DOES NOT HAVE Field-Tracker Use the 5 pin plug included with the feeder harness 4. Press the pin on the red wire of the Headsight feeder house harness into Pin D of the 5 pin plug until you hear a click. 5. Insert the pin on the black wire into pin E of the five pin plug. 6. Connect Y231 to the header harness. Make sure the cabling is properly secured. 7. After testing the system, reinstall electric console access plate. Installation Draper Speed Kit, 600FD only Install the Draper Speed kit assembly as per instructions with kit. The instructions are for a different combine, but the installation is similar. 1. Install all Cab and feeder components. 2. Connect the power adapter. 3. Connect Y247 to Y248 on the header adapter harness. 6

12 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. 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 CIH If you have a IH 1420->1688, choose If you have a CIH 21xx, 23xx,or 25xx, choose Choose the number of height sensors For JD 600F flex head conversion, choose 3 For JD 600FD flex head conversion, choose 4 For standing grain, enter the number of ground sensors 7

13 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 skids touch the ground: Press Enter 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. Use blocks if necessary. Press Enter 3. If an error appears on the Insight box, see Advanced Information, Adjusting Sensors or Diagnostics. Calibration Combine Ground Calibration (21-25xx Only) A full-combine calibration must be completed if a component of the header control system on the combine is changed. See combine operators manual for details. 1. Start Combine (!!!!!CYCLE KEY off/on before starting calibration if engine is running!!!!!) 2. Set the Reel Selector switch to Auto or Manual, not Corn. 3. Set the AHC mode to HT. 4. Rev engine to full throttle. 5. Lower header to ground and hold down button for 2-3 seconds. 6. Raise header all the way without releasing the raise button. If calibration is done correctly, the header will pause momentarily just AFTER the sensor arms leave the ground continue to hold the raise button until reaching the top of the stroke 7. If the header does not pause or if the cornerpost display shows S1 : Cycle the combine key off and back on Check to make sure sensors are properly calibrated (see above). If the header still does not pause or the display still shows S1 Go to Troubleshooting by Symptom Combine calibration fails If you are testing Insight on a machine other than the one on which it will be used and powering the Headsight system with a battery pack, you MUST connect the ground of the battery pack to the frame of the header 8

14 CaseIH Series Full-Cal (Perform Only If Needed) Calibration 1. Perform calibration over a ditch; feederhouse MUST be fully lowered to stops during this procedure. 2. Start engine while holding both Engine and Speed buttons. Screen will display Hdr 3. Release Engine and Speed buttons. Screen will display r302 or similar then Screen will display CAL 4. Press header raise button. Screen will display 1 5. Press header raise button. Screen will display 2CYL This refers to the number of feederhouse lift cylinders Press header raise button to select 2 lift cylinders OR Press header lower button to move to 3CYL then header raise to select Screen will display hd 1 6. Press header raise button. Screen will display CONC 7. Press header lower button. Screen will display dn 8. Turn Height knob fully counterclockwise. press header raise to continue. Feeder will lower fully! Screen will display ---- Wait about 30 seconds Screen will display UP 9. Turn Height knob fully clockwise, press header raise to continue. Feeder will raise fully! Screen will display ---- Wait about 30 seconds Screen will display CAL 10. Cycle Reel Auto/Manual switch to exit. 11. Connect Combine to Header. 12. Return to Calibration Section of this manual. 9

15 CaseIH 21-25xx Series, Tricking Ground Cal The combine expects the sensors or skidpads to be completely off the ground when it pauses during the Header Ground cal. Only perform this procedure if the combine does not raise the head high enough so that the sensors leave the ground before pausing during calibration. 1. Identify the Header Raise solenoid. There is a small hole in the end cap that allows access to the actual valve spool Press in on the spool using a 1/8" Allen wrench or similar small tool May take some force if stuck or rusty Head should raise; this is the service override function 2. Cycle Key Off-On. 3. Lower the head fully to the ground and hold the down button for 3 seconds. 4. Using the service override on the header lift valve, raise header until sensors/skidpads are just off the ground. 5. Press and hold header raise button until header reaches the top of the stroke. Calibration 10

16 Settings Insight Settings Settings Tilt Sensitivity 1. To change this setting go to >>Settings>>Tilt Sensitivity in the Insight box Default setting is 50. Adjust combine Tilt Sensitivity first (when available) If the head is to jumpy from side to side Decrease sensitivity. If you would like the head to be more responsive Increase sensitivity. Press Enter to save value Combine Settings Properly setting the combine is essential to having responsive header control. You should become very familiar with the steps in this section. ALWAYS perform the combine ground calibration if available before adjusting settings. Set each of the following settings as high as you prefer without causing head hunting. If the head hunts, decrease the appropriate setting. 1. Set the automatic drop rate ( 21-25xx inside armrest.) Common range is 8-10 seconds from full up to full down in auto mode 2. Set the automatic raise rate ( 21-25xx inside armrest.) Common range is 5-7 seconds from full down to full up in auto mode 3. Open the hydraulic accumulator. 4. Set height sensitivity. 5. Set tilt sensitivity and gain. 11

17 CaseIH 14xx 1688 series controls 1. Height position knob Turning right increases (Turning left decreases) header height setting in automatic height control mode 2. Height sensitivity knob Turning right increases (Turning left decreases) header height sensitivity Increase sensitivity to increase height control performance Decrease sensitivity to reduce height hunting of header 3. Header control mode selector switch AUTO: Height Sensing Mode Automatically controls header height based on ground-contacting sensors MANUAL: Manual Mode Operator controls header height. Auto mode is off 1 2 Settings 3 12

18 Settings CaseIH controls 1. Header control mode selector switch M: Manual Mode Operator controls header height - No Auto mode RTC: Return to Cut Mode Automatically returns to preset height based on feederhouse position sensor FLOAT: Float Mode Automatically adjusts header height based on pressure in header lift cylinders HT: Height Sensing Mode Automatically controls header height based on ground-contacting sensors 2. Height position knob Turning right increases/turning left decreases header height setting in automatic height control mode 3. Height sensitivity knob Turning right increases (Turning left decreases) height sensitivity Increase sensitivity to increase height control performance Decrease sensitivity to reduce height hunting of header 4. Field-Tracker enable switch A: enables automatic Field-Tracker (lateral tilt) control M: Operator controls header lateral tilt. Auto mode is off 5. Lateral tilt balance knob Turning right tilts header to right (Turning left tilts header to left) as baseline for operating mode Use this knob to set the header parallel to the ground on level terrain 6. Tilt sensitivity knob Turning right increases (turning left decreases) lateral tilt sensitivity. Sensitivity adjusts the allowable difference between the sensors before combine decides to tilt header Increase sensitivity to increase lateral tilt performance Decrease sensitivity to reduce tilt hunting of header 7. Tilt gain knob Turning right increases (Turning left decreases) the gain Gain adjusts the amount that the header will tilt (time the tilt valve will fire) once the combine decides to tilt (see knob F) Increase gain for increased tilt response (especially on narrow headers) Decrease gain to reduce tilt hunting or on wider headers 8. Reel Mode Selector Switch A: Automatic Mode Reel speed to changes automatically with ground speed M: Manual Mode Operator controls reel speed Corn: Disables reel function Header must be calibrated in the same mode as it will be operated in the field The height range and sensitivity may vary between settings 13

19 8 Settings

20 Operation Series 1. Set header height mode switch to Auto. 2. If equipped, set Field Tracker switch to Auto. 3. Turn on separator and header clutch. 4. Lower header. Operation CIH Series 1. Set height mode selector switch to HT. 2. Set Field-Tracker enable switch to A. 3. Turn on separator and header clutch. 4. Press lower button

21 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) 16

22 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 17

23 Advanced Information Field Tracker: Adjusting Feeder Position Switch 1. Identify the FT position trip switch xx: Adjustable spring trigger switch on top left corner of feeder house Must not contact the pivot brace when the head is lowered into operating position It should contact when the head is raised above operating position Adjust the switch so that it trips about 1 foot above normal field operating range 14-16xx: Mercury switch on left side of feederhouse If desired, tilt the switch so that it trips about 1 foot above normal operating range. 2. If this switch is not set properly, the FT system will not switch between field and headland mode. If you can rock the head from side to side with the Tilt Balance knob in the cab, the FT system is in field mode If you cannot rock the head from side to side with the Tilt Balance knob in the cab, the FT system is most likely in headland mode Advanced Info 18

24 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 combine 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. 1. Signal must always be between 0.5 and 4.5 volts. 2. Signal must change more than 1.0 volts from raised to lowered position for each sensor. Advanced Info 19

25 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 From main menu, go to >> Diagnostics>>Detailed Diagnostics>> (parameter of Interest). This shows actual voltage being sent to the combine. 1. Height Sig Out = X.XVolts 2-3V with head fully lowered 5-6V with head raised Pressure/aux Sensor Height Sig Out Tilt Signal Out Tilt Sens In Height SignalOUTPUT =2.0V 20

26 2. Tilt Signal Out = X.XXVolts 4.0V with head level Increases toward 5V as head is rocked left Decreases toward 3V as head is rocked right Values dependent on Tilt Sensitivity (see below) Note: sensors must be in operating range for voltage to change Tilt SignalOUTPUT =3.97V On the Insight Box : Tilt Sensitivity From main menu, go to >> Diagnostics>>Detailed Diagnostics>>Tilt Sens In. This voltage comes from the combine. 3. Tilt Sens In = X.XXVolts Dependent on Tilt Sensitivity knob in combine Typically 3.0V-3.8V 3.0V = Max. sensitivity (knob fully CW) 3.8V = Min. sensitivity (knob fully CCW) If the value exceeds 4.0V, call Headsight for instructions Tilt Sensitivity IN =3.02V Advanced Info 21

27 Wiring and Diagrams Header Interface Harness Y202 Y202 Y232 Y248 Y301 Y302 Y306 Y304 Connector Description Connects to Y pin for appl. OEM flex platform Y pin Deutsch Interface unit Y301 3 pin Deutsch Combine height circuit Y302 5 pin Deutsch Combine tilt circuit Y232 4 pin Amp Hydraflex controls Y248 3 pin WeatherPack Belt Speed (600FD only) Y304 3 pin WeatherPack Hazard Lights Y306 1 pin WeatherPack Stubble Lights (if desired) Advanced Info 22

28 Feederhouse Harness T1 Y339 Y231 Advanced Info Connector Description Connects to T1 Deutsch terminals Insert into 5 pin Tracker plug on Feeder Y231 4 pin AMP CPC Header Adapter Harness Y232 Y339 9 pin AMP CPC Cab Interface Harness Y338 23

29 Cab Interface Harness: 21xx-25xx Y150 GND Y338 Y225 To Conn.2 Y336 Y337 Connector Description Connects to Conn.2 OEM cab conn. Replace OEM wires in Conn. 2 GND ¼" Ring Terminal Any suitable ground Y pin Deutsch Cab Controller Y336 3 pin Deutsch Y337 Y337 3 pin Deutsch Insert OEM wires removed from Conn. 2 Y338 9 pin Amp Feederhouse Harness Y pin Deutsch HT9223-DP Diode Module Advanced Info 24

30 Cab Interface Harness: 14-16xx Y338 Y141 Switch OEM wires Y141 Y225 GND Advanced Info Connector Description Connects to Switch OEM Switch conn. Replace OEM wires at Reel Switch GND ¼" Ring Terminal Clean Chassis Ground Y141 4 pin Deutsch Diode Module Y pin Deutsch Cab Controller Y338 9 pin Amp Feederhouse Harness 25

31 Header Adapter Schematic Y101 INSIGHT P11 HGT SIGNAL P18 TILT IN LOW P16 TILT SIGNAL P17 TILT IN HI P4 12V POWER P6 GROUND P2 HGT SNS V+ P3 HGT SNS GND P7 LEFT HGT P13 L C HGT P8 CENTER HGT P14 R C HGT P9 RIGHT HGT Advanced Info NOTES: Y301 HEIGHT HGT REF HI A HEIGHT SIGNAL B HGT REF LO C Y302 FIELD TRACKER TILT REF LO A TILT SIGNAL B TILT REF HI C SWITCHED 12V D GROUND E Y304 HZD LIGHTS LEFT HZD LT A CHASSIS GND B RIGHT HZD LT C Y306 STUBBLE STUBBLE LTS A Y248 BELT SPEED DRAPER + A DRAPER - B BELT SPEED C Y232 FLEX CONTROL REEL SELECT P01 FLEX SELECT P02 FLEX PRESSURE P03 P HEIGHT A Lt GRN R1-1k, 1 2 W 302 HEIGHTC Lt GRN CRIMP AND SOLDER R2-1K, 1 2 W CRIMP AND SOLDER 031 LEFT HAZARD YEL 022 CHASSIS GND BLK 032 RIGHT HAZARD Dk GRN 033 STUBBLE LTS BRN Y202 HEADER P13 LEFT HZD LT P12 CHASSIS GND P14 RIGHT HZD LT P15 STUBBLE LT SENSOR V+ P20 SENSOR GND P10 LEFT HGT P07 CENTER HGT P03 RT C HGT P DRAPER + WHT 131 DRAPER - BRN 124 BELT SPEED GRY RIGHT HGT P09 P26 DRAPER + P27 DRAPER - P29 SHAFT SPEED 078 REEL SELECT PUR 079 FLEX SELECT ORG 091 FLEX PRESSURE GRY P21 REEL SELECT P19 FLEX SELECT P05 FLEX PRESSURE 125 HEIGHT SIGNAL WHT 303 TILT IN A Lt BLUE 122 TILT BALANCE GREY 304 TILT IN B PINK V POWER RED 001 SIGNAL GND BLK 050 SENSOR PWR PNK 100 SENSOR GND Lt BLU 081 LEFT SENSOR WHT 082 L C SENSOR WHT 084 CENTER SENSOR WHT 086 RT C SENSOR WHT 087 RIGHT SENSOR WHT 033 STUBBLE LTS BRN Y307 STUBBLE LTS A STUBBLE LTS HT9805-HDR 5 26

32 Feederhouse Harness NOTES: Y229 CAB BULKHEAD REEL SELECT P01 FLEX SELECT P02 PRESSURE P03 12V POWER P04 GROUND P REEL SELECT PUR 079 FLEX SELECT ORG 091 FLEX PRESSURE GRY V POWER RED 020 CHASSIS GND BLK Advanced Info Y231 HEADER P01 REEL SELECT P02 FLEX SELECT P03 PRESSURE Y322 FT RCPT D 12V POWER E GROUND HT9804-FH 3 27

33 Cab Adapter Schematic: 21-25xx DP1 HT9223-DP AUX FLEX + VALVE + P10 P03 P02 D7 D6 REFERENCE ONLY OEM COMBINE C2--23,25xx NOTE: SAME PIN #'S IN 24p RECT. PLUG PIN 8 (458 Lt BLUE) PIN 9 (453 Lt BLUE) C2 P18 (445 RED) SIGNAL VALVE P01 REEL + P04 REEL SEL P05 REEL - P06 VALVE - P09 D1 D2 D3 D4 REAR VIEW 322 REEL - Lt GRN NC P REEL + Lt BLU FLEX - P V POWER RED D5 AUX AUX P11 P12 D8 Y150 DP-1 REEL - P06 DIODE PACK, REFERENCE ONLY REEL + P04 SOL - P09 SOL + P01 REEL SELECT P05 FLEX - P08 FLEX + P REEL SELECT PUR 145 FLEX - BRN 144 FLEX + TAN 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 NOTES: USED FOR ALL CIH21-25xx COMBINES w/600f, FD. USE WITH HT9223 DIODE PACK 3 ADDED DIODE PACK DESIGN JHK 4 CHANGED Y333 TO Y338-ADDED JHK 5 CHANGE Y140->Y JHK MOVE TO Y337 REFERENCE ONLY DO NOT MAKE OEM WIRNG TO C2 A B 453, FROM p9 9 OEM REEL LOWER 458, FROM p8 8 OEM REEL RAISE 445, FROM p18 C 18 12V EOP (F21) DO NOT PROVIDE WIRES Y336 OEM WIRING A REEL LOWER Y337 OEM WIRES REEL LOWER A 453, FROM p9 OEM REEL LOWER B REEL RAISE REEL RAISE B 458, FROM p8 OEM REEL RAISE C 12V POWER 12V POWER C 445, FROM p18 12V EOP (F21) 323 REEL - SOL Dk GRN 321 REEL + SOL Dk BLU V POWER RED T1 OEM C2 P09 REEL - SOL P08 REEL + SOL P18 12V POWER 078 REEL SELECT PUR Y338 BULKHEAD P01 REEL SELECT P03 PRESSURE P02 FLEX SELECT P04 12V POWER P05 GROUND Y230 GROUND P1 GROUND HT9805-CAB PIN Advanced Info 28

34 Cab Adapter Schematic: 14-16xx NOTES: Y329 12V POWER P V POWER RED 16G GROUND P CHASSIS GND BLK 16G FLEX - P FLEX - BRN FLEX + P FLEX + TAN FLEX SELECT P FLEX SELECT ORG PRESSURE P FLEX PRESSURE GRY Y225 LIGHTBAR HEATSHRINK COLOR CODE AS SHOWN 1p PACKARD 56 CONN. SETS D4 1N5404 P56 18g MALE SPADE OEM PNK/WHT 24" 18G PNK OEM RED/GRN 12" 16G RED V POWER RED OEM GRY 24" 18G GRY PLUG VIEWED FROM WIRE SIDE OEM WIRING PATTERN NEW WIRING PATTERN NEW RED SOME 1688 ONLY NEW WHITE SOME 1688 ONLY OEM PNK/WHT OEM OEM FORWARD FORWARD NEW Lt BLU OEM GRY OEM RED/GRN OEM RED/GRN HEADER RAISE/LOWER SWITCH PLUG DT04-4P-RT DIODE PACK REEL + Lt BLU Y141 DT-RT01 P04 FLEX - P03 FLEX + P02 REEL + P01 REEL SELECT 078 REEL SELECT PUR Y338 BULKHEAD P01 REEL SELECT P03 PRESSURE P02 FLEX SELECT P04 12V POWER P05 GROUND Y230 GROUND A GROUND Advanced Info 24" 18G Lt BLUE 24" 18G WHT 36" 16G RED P56 18g FEMALE TERM. 145 FLEX - BRN 144 FLEX + TAN HT9804-CAB 4 29

35 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 Insight not properly calibrated Recalibrate Insight Header is too jumpy or responds too slowly Calibration is not properly completed (21-25xx Only) Recalibrate combine Combine Ground-calibration fails (21-25xx only) (Also see Common Combine Problems) Drop/Raise rate set incorrectly Combine computer needs reset Combine improperly set Insight not calibrated Wrong combine choice Insight failure See Combine Settings. Cycle key on combine Cycle key on combine Make sure Insight is calibrated and has a green light >>Setup>>Combine select: Make sure the check mark is by CIH, IH14-16xx or 21-25xx as appropriate. Check Insight for errors Height Sensor is not properly connected Feeder position sensor defective Full calibration required Check Insight Output: >>Diagnostics.>>Detailed Diagnostics>>Height Output ~ 2-3V with header down ~ 5-6V with header raised Check wiring to sensor See Common Combine Problems Follow procedure in manual, making sure to allow feeder to lower fully. Diagnostics 30

36 Symptom Problem Solution Insight not calibrated correctly Cannot operate header low enough Combine not calibrated properly (21-25xx only) Calibrate header on flat level surface. Perform combine Full-Cal and Ground Cal 21-25xx only: Out of range. Combine limits travel to 15-85% of calibrated range. Cannot operate header high enough Insight not calibrated correctly Combine not calibrated properly (21-25xx only) Calibrate header on flat level surface. Perform combine Full-Cal and Ground Cal If combine does not lift head off ground before pausing during Cal, see Common Combine Problems 21-25xx only: Out of range. Combine limits travel to 15-85% of calibrated range. Head will not Lower Error detected Find and repair error Head raises all the way to top Wiring not connected, or calibration not completed See Installation/ Calibration/ Settings sections of manual Cutterbar locked up Release pressure in cutterbar Sensing rod stuck up Repair mechanical linkage/ return spring on cutterbar Height sensor failed or misadjusted. >>Diagnostics>>Display Sensor Voltages. If voltage not correct: Adjust sensor Replace sensor Diagnostics Head will not Raise Head drops all the way to ground Center ~ 1-4V as cutterbar travels through stroke (see Theory of Operation) Wiring not connected, or calibration not completed. Height sensor failure >>Diagnostics>>Display Sensor Voltages. Center ~ 1-4V as cutterbar travels through stroke (see Theory of Operation) Repair wiring on head See Installation/ Calibration/ Settings sections of manual If voltage not correct: Adjust sensor Replace sensor Repair wiring on head 31

37 Symptom Problem Solution No Automatic operation height Combine not calibrated properly (21-25xx only) Perform combine Full-Cal and Ground Cal If combine does not pause during Cal, see Common Combine Problems Combine not in HT Mode Turn switch to HT See Combine Settings & Operation. Wiring, connection, or sensor or Insight failure Check Insight for errors. Check Insight Output: >>Diagnostics.>>Detailed Diagnostics>>Height Output ~ 2-3V with header down ~ 5-6V with header raised Combine does not detect header height system. Measure A-B & B-C in Y301 with plug disconnected. Both should = ~1KΩ Broken wire between Insight and Y301 If not, replace Insight Adapter harness. Repair or replace Insight Adapter harness Measure Y101 pin 11 to Y301 B (white wire). Should be < 5Ω Combine Problem Contact your CIH Service Center. Diagnostics 32

38 Symptom Problem Solution Height works but not Tilt Wrong combine choice >>Setup>>Combine select: Make sure the check mark is by CIH, IH14-16xx or 21-25xx as appropriate. Lateral tilt not enabled Turn on Field Tracker Wiring not connected properly Feederhouse position switch improperly adjusted Insight failure Verify Y302 is properly connected See Common Combine Problems Check Insight for errors Check Insight Output: >>Diagnostics.>>Detailed Diagnostics>>Tilt output Combine Problem ~4.0 volts when head is level, and swing smoothly as head is tilted on ground. Typical range 3-5V at Max tilt sensitivity Contact your CIH Service Center. Head Tilts completely to one side Left & Right Inputs reversed See Installation Sensors Mixed up See Installation. Make sure each sensor corresponds to the correct reading in >>Diagnostics>>Display Sensor Voltages. Insight not calibrated, or defective sensor/harness on header Check Insight for trouble codes Improper Sensitivity voltage from combine >>Diagnostics>>Detailed Diag.>>Tilt Sense In. Value should be V. If not, fix wiring on combine. Diagnostics Head operates slightly to one side Tilt very sluggish or very jumpy Balance off Head not calibrated correctly Incorrect Tilt Sens. input from combine Adjust Balance knob in combine Calibrate header on flat level surface. >>Diagnostics>>Detailed Diag.>>Tilt Sens In Adjust the Tilt Sensitivity knob in the combine through the range while reading the voltage at the Insight. Typical readings: MAX: MIN: If not, Call Headsight 33

39 Common Combine Problems Symptom Problem Solution Combine will not calibrate Bad Feederhouse Pot Set header control mode selector switch to RTC and activate system. If feeder height cannot be adjusted full range, suspect defective feeder pot. Other problem Replace feeder pot (upper left corner) and do a combine Full Cal Note: Combine AHC HT mode will operate with a defective feeder sensor, but it will not calibrate See Troubleshooting by Symptom - Calibration fails Field Tracker does not follow ground, or head does not Self Level when raised Field Tracker switch defective or misadjusted. See Advanced Information/ Field Tracker: Adjusting Feeder Position Switch. Relay bad in combine Swap/ replace Field Tracker relays in console Other combine problem Contact your CIH Service Center. S1 error code appears AFTER the header pauses and resumes movement during header ground calibration Header did not raise high enough before pausing Insight Output incorrect See Advanced Instructions / Tricking Ground Cal >>Diagnostics>>Detailed Diagnostics>>Height output 21-25xx: 2V down, 6Vup 14-16xx: 3V down, 5V up Height Sensor is not properly connected Check Insight for trouble codes Feeder position sensor defective See Combine will not calibrate above. Other AHC problem See Troubleshooting by Symptom - Calibration fails S1 and Hdr displayed alternately on combine corner post during combine startup Combine does not detect header height system. No resistive load Measure A-B & B-C in Y301 with plug disconnected. Verify header connections are connected. If not, replace Insight adapter harness. Diagnostics Both should = ~1KΩ Insight Box not set up Setup and calibrate Insight S0 displayed on combine corner post Feeder Position potentiometer circuit failure Repair sensor or wiring 34

40 Symptom Problem Solution Wrong combine choice Header very Jumpy: 14-16xx only No Accumulator / Accumulator not set correctly Setup/Combine select: Make sure the check mark is by CIH, IH14-16xx Install Accumulator Open accumulator valve 1-2 turns Drop/Raise rate set incorrectly Check Charge pressure See Combine Settings. Diagnostics 35

41 Reel/Hydraflex Diagnostics Symptom Problem Solution Reel does not Raise or Lower Wiring not connected properly Verify that Y231/Y232 are connected at header to feeder Verify Y238/Y239 are connected Make sure CONN 2 wiring is installed properly (See Installation) Diode Module Not installed 21-25xx: Make sure the HT9223 module is installed on Y xx: Make sure RT01 is installed on Y141 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 CONN 2 wiring is installed properly (See Installation) Plug not seated Make sure Y225 fully seated in Hydraflex control No 12V to Y225 Check pin 6 (red wire) No Ground to Y225 Defective control Check that Y230 is grounded to a clean ground. Check pin 5 (black wire) at Y225 Call Headsight. Diagnostics 36

42 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 Y231/Y232 are connected at header to feeder Verify Y202 is connected to head Make sure the CONN 2 wiring is installed properly (See Installation) 21-25xx: Make sure the HT9223 module is installed on Y xx: Make sure RT01 is installed on Y141 Make sure Y225 fully seated in Hydraflex control 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 37

43 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 Sensor failure Wiring problem Sensor failure Left sensor mechanical range is restricted Sensor failure 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) Not enough swing during cal Incorrect number of sensors selected in setup Sensor failure 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 Diagnostics Control box /wiring failure Contact Headsight 38

44 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 Sensor failure Wiring problem Sensor failure Left Center sensor mechanical range is restricted Sensor failure 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 39

45 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 Sensor failure 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 ER32 Center sensor signal greater than 4.7V Wiring open Sensor failure 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 Diagnostics Sensor failure See sensor test instructions 40

46 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 Sensor failure 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 Sensor failure 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 Diagnostics 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 Sensor failure See sensor test instructions 41

47 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 Sensor failure 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 Sensor failure 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 Sensor failure See sensor troubleshooting instructions 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 Diagnostics Control box /wiring failure Contact Headsight 42

48 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 Sensor failure Wiring problem Sensor failure Right sensor mechanical range is restricted Sensor failure 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 Diagnostics Incorrect number of sensors selected in setup Sensor failure Go to >>Initial Setup>>Number Sensors and choose the correct number of sensors See sensor troubleshooting instructions Control box /wiring failure Contact Headsight 43

49 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 Sensor failure Wiring problem Sensor failure 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 44

50 Parts ITEM QTY. PART NUMBER DESCRIPTION 1 1 INSIGHT Interface Unit 2 1 HT9805-HDR Header Harness 3 1 HT2259 Retaining Clip 4 1 HT9993 Cab Controller 5A AR HT9805-CAB Cab Harness: 21-25xx 5B AR HT9804-CAB Cab Harness: HT9804-FH Feeder Harness Parts 45