JD 9000 TO JD 600F. Conversion Manual b HEADSIGHT.COM

Transcription

1 JD 9000 TO JD 600F 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 Insight Box Mounting 2 HydraFlex Light Bar 3 Light Bar Feeder Harness 5 Calibration 6 Before Calibration 6 MY91-current Dial-A-Matic 6 MY89-90 Dial-A-Matic 6 MY83-89 xx20 w/dial-a-matic 7 Setup Insight Box 8 Calibrate Insight 8 Standard Calibration 8 Combine Contour Calibration 9 Settings 10 Combine Settings 10 Set the automatic drop rate 10 Set the hydraulic accumulator 10 Checking and Changing Tilt Speed Orifices 11 Insight Settings 11 Tilt Sensitivity 11 Operation 12 Enabling Height Control 12 9x00 and 9x10 Series II with AHC / DAM Series 12 Adjusting Header Height 13 Adjusting Height Sensitivity 13 Adjusting Float Pressure 14 Overview 15 Insight Navigation 15 How to Navigate 15 Meaning of Status Light 15 Screen Contrast Adjustment 15 Resetting Insight to Defaults 16 Updating Insight Software 16 Advanced Information 17 Theory of Operation 17 Basic Requirements 17 Reading Voltages 18 Before you Start 18 On the Insight Box 18 ii

5 9 pin to a 6pin combine Hydro Handle 19 Diagnostics 20 Troubleshooting by Symptom 20 Common Combine Problems 27 Troubleshooting by Insight Error Codes 29 Schematics 41 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 Insight Box Mounting 1. Hold 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 bolts Installation 3. Attach connector mounting plate to header within reach of combine electrical connector. Drill mounting holes using ¼ drill bit Use provided bolts 4. Remove the OEM header connector from the single point and connect to 31 pin connector on main harness. Use the included clip and zip ties to prevent separation. 5. Attach black ground wire to header frame. Required for all combines model 1990 and earlier 6. Connect the 24 pin rectangular plug to the bottom of the Insight box. 7. Mate remaining connectors to combine and header 16 pin OEM Header connector (from combine) 9 pin Feeder Harness (installed in 1.3) 8. Connect OEM 16 pin connector from combine to main harness connector mounted in step 3. For 20-series and older combines with 9 pin connector install the 9 to 16 pin adapter and mount the ground strap to a clean header frame ground 2

8 Installation HydraFlex Light Bar 1. Mount the HydraFlex light bar on the right cab window, near the corner post display 2. Connect the Light bar cab harness to the back of the light bar 3. Unbolt the electrical access panel from the right rear corner of the cab. 4. Measure 2 ¼ from top and right side of access panel and drill a new 7/8-1 access hole in the panel. A step drill or hole saw is preferred. Make sure to move wiring away from behind the drill. 5. From inside the cab, route the 9 pin round connector on the light bar cab harness back through the rear corner access hole and out to the access panel. 6. Remove the bolt holding the connector clip and insert the 9 pin connector under the clip. Reinstall the connector clip. 3

9 7. Install the ground terminal onto the OEM ground bolt just inside the access panel. Install it under the large OEM ring terminal for best results Retighten ground terminal 8. Reinstall the access panel and bolts. Installation 9. Disconnect the OEM hydro handle connectors under the cab console. This is a 9 or 6 pin connector as shown If your combine has the 6 pin (early) Hydro connector, see Advanced Information of this manual for switching these connectors before proceeding 10. Connnect the ligh bar cab harness connectors inline with the OEM Hydro connectors. 4

10 Installation Light Bar Feeder Harness 1. Connect either end of the light bar feeder harness to newly installed 9 pin connector in the access panel. 2. Route the light bar feeder harness to the front of the feeder. Under the cab following pipes Down through the pivot point with OEM feeder harness Follow OEM feeder harness to front of feeder, next to OEM header plug Connect the 9 pin light bar feeder harness to mating connector previously installed on head. 5

11 Calibration Before Calibration To power the Insight Box for setup and calibration, different combines require different procedures. Please follow the correct procedure for your year combine. MY91-current Dial-A-Matic Calibration 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 harnesses are installed. 2. Turn the Dial-A-Matic switch OFF to prevent DAM activation. 3. Start the engine. 4. Turn on the header stubble lights if the combine is equipped. 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. MY89-90 Dial-A-Matic 1. Install the power bypass harness PFI-JD10-P on the feeder. Disassemble the shell on the back of the OEM combine header plug Insert the loose socket thru the back shell and into cavity 15 on the OEM Header plug. (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 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 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 MY83-89 xx20 w/dial-a-matic Calibration 1. Clean and disconnect the booster box plug on the sidewall of the grain tank next to the hydraulic tank. 2. Make sure all other connectors and harnesses are installed. 3. Power the Insight box. Turn the Dial-A-Matic switch ON Start the engine Manually lower the header until the header sensors are 6-8 clear of the ground (12-18 clearance for flex conversions) Adjust the chain switch until the switch is on The LCD display should now be active on the Insight box 4. After completing all calibration steps, reconnect the Booster box. 7

13 Setup Insight Box 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 for basic information about how to use the Insight box. 1. Connect all wiring to Insight box and combine as described in previous section. 2. Start Combine. 3. On the Insight box. Choose Language Choose John Deere Choose 9x00/10 & xx20 DAM Choose Flex Conversion Choose if HEADER has: Choose Level Land Header if header is equipped with only a height sensor Choose ContourMaster Header if header has height and contour sensors This question does not relate to how combine is equipped Contour Master Sensor Calibration Calibrate Insight When you initialize Insight, you will be led directly to this calibration routine. If you wish to recalibrate at any time - select >>Perform Calibration on the Insight main menu. Standard Calibration 1. Park the combine on a smooth, level surface - preferably a cement driveway or shop floor. 2. Follow on-screen instructions. Raise Header all the way so that NO skids touch the ground and press enter Lower Header all the way down on the skids and press enter Go to Combine Contour Calibration section of this manual If an error appears on the Insight box - see the Diagnostic section of this manual. 8

14 Combine Contour Calibration Calibration For combines with Contour Master, this calibration should be done at the beginning of each season and also every time a different header is put on. This calibration allows the combine to learn how to level the head. 1. Start the engine and attach the header. 2. Engage the header clutch. 3. Turn off the Contour-Master switch on the armrest. 4. Lower header to the ground (on a level surface) for 2 seconds. 5. Press header raise button. 6. Turn on the Contour-Master switch after the sensors have left the ground (while continuing to raise the header). 7. 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. Automatic, drop rate, accumulator and tilt speed must all be properly adjusted for good header performance. Always perform the combine contour calibration before adjusting settings. Set each sensitivity setting by increasing till header bouncing occurs then decreasing till header becomes stable. For 20 series combines see owners manual for location of drop rate valve and accumulator series are shown. Settings Set the automatic drop rate Use the adjustment on the valve block marked A 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 Common range is 6-8 seconds from header full up to full down in automatic mode (Some combines may need to be 8-12 seconds) B A The maximum automatic drop rate is limited by manual drop rate marked B. Set the hydraulic accumulator Close the accumulator valve all the way Open the accumulator valve 1 full turn (from 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 Checking and Changing Tilt Speed 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, orfices may need to be adjusted for wide headers. Only change orifices if the system cannot be set properly by using the sensitivity adjustment on Insight or the Contour-Master card. Settings 1. Manually move header from full right til to full left tilt. The target tilt speed is 5-8 seconds If not correct go on to step 2 2. Perform all combine and header manufacturer safety precautions for servicing header. 3. Remove header from combine. 4. Insert stop to prevent movement of feederhouse. 5. Release all pressure in hydraulic cylinders. Lower feeder house against lock and hold button for 10 seconds to relieve hydraulic pressure 6. Turn off combine and remove key from ignition. 7. Set combine parking brake. 8. 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. 9. If tilt speed is too fast install an orifice that is smaller than the original orifice removed. 10. If tilt speed is too slow install an orifice that is larger than the original orifice removed, or remove orifice completely JD orifice availability:.26 Z60904 (Original on 50/60 series).31 H (Original on 00/10 series).46 H Insight Settings Tilt Sensitivity If the head is too jumpy from side to side decrease sensitivity. If you would like the head to be more responsive increase sensitivity. To change this setting go to >>Settings>>Tilt Sensitivity in the Insight box. The range is from 5 to 95 with a default setting of

17 Operation Enabling Height Control 9x00 and 9x10 Series 1. Turn Dial-a-Matic switch ON. 2. Engage header clutch. 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. Operation II with AHC / DAM Series Adjust the chain length on the DAM switch under the cab to turn on header control above the height at which the header first contacts the ground. 1. Turn Auto/Dial-a-Matic switch ON. 2. Lower header until height control engages (adjust chain if necessary). 3. Make sure AHC/DAM turns off when head is raised up (adjust chain if necessary). 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. The bright LEDs show setpoints (controlled by the knobs) and the current sensor position. The AHC should attempt to keep the current sensor position between the setpoints. LED Height Indicator Height Sensitivity Knob Height Position Knob 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 operation meaning that 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 header bounce. You MUST set the drop rate and accumulator before adjusting sensitivity knob LED Height Indicator Height Sensitivity Knob Height Position Knob 13

19 Adjusting Float Pressure The pressure changes fairly slowly. Hold the Increase or decrease button for seconds to see if pressure changes. 1. To increase the pressure, press and hold the Pressure Pressure Increase Increase button. 2. To decrease the pressure, press and hold the Pressure Decrease button. LED Pressure Indicator 3. The LED Pressure Indicator shows the approximate pressure in the float system. The green bar show the normal operating range of the header in flex mode. Pressure Decrease Running near the bottom of the green area means MORE ground pressure (less hydraulic pressure holding up the cutterbar). Use this area for dry, hard conditions Running near the top of the green area means LESS ground pressure (more hydraulic pressure holding up the cutterbar). Use this area for wet, soft conditions Raising the pressure all the way up should lock up the cutterbar for rigid mode. You may need to increase system pressure in older combines to do so Operation 14

20 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 Overview 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 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) 15

21 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 Updating software may cause the Foresight option to be disabled. If you have purchased Foresight, contact Headsight before updating software. 1. You will need: SD memory card (2GB or less) Means of loading SD memory Card (computer with SD memory card drive, or usb drive with a usb to SD card memory adapter, or preloaded SD memory card from Headsight) Small allen wrench or screwdriver 2. Load SD card with new software files Place insightf.hex in the root directory of SD card (ex. E:\insightf.hex) Do not change file names 3. If you do not have the new files you may Download updated software from Request pre-loaded SD card from Headsight, Inc. 4. Disconnect all header connections from combine 5. Remove 4 screws from rear of Insight box - remove rear cover 6. Insert programmed SD card into SD card slot on rear of board 7. Power Insight Connect all wiring to combine Turn on key switch 8. Wait for software to download Yellow light will blink while download is in progress Green light will turn on solid when download is complete 9. Verify update is successful Go to >>About Insight>>Software Version and read software version number 10. Remove power from Insight Turn off key 11. Remove SD card 12. Reinstall rear cover Fasten with screws Overview 16

22 Advanced Information Theory of Operation A review of the following points will help the service technician to understand the complete system which will help diagnosing specific problems. 1. Each sensor returns a variable voltage depending on header height. High header height = high voltage (approximately 4 volts) Low header height = low voltage (approximately 1 volt) 2. Each sensor has 3 wires: A: blue = ground B: white = signal returned to combine (varies1-4 volts) C: pink = 5 volt power 3. The Insight box adjusts signals as needed then sends them to combine using the same combine wiring as OEM system would use. All sensors are scaled to an appropriate range for combine Insight will reverse the direction of swing if needed Insight box reads all senors and sends signals to combine that will cause appropriate height and or tilt response If Foresight is enabled - the Insight box magnifies the voltage change below the point where the snout tips touch the ground 4. 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. Advanced Info 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 (to meet the requirements) and then recalibrate the Insight box. See the header manual for sensor adjustment instructions. Sensor output voltage must always be between.3 and 4.7 volts Sensor output voltage must change more than 1.0 volts from raised to lowered position for each sensor 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 1. From main menu, go to >> Diagnostics>>Disp Sensor Voltages This shows real-time voltage coming from each sensor. 2. For more information about sensor history and status see >>Diagnostics>>Detailed Diagnostics>>(parameter of interest) Sensor Voltages L LC CTR RC R 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 3. For more information about Insight output voltage to combine see >>Diagnostics>>Detailed Diagnostics>>(output of interest) Dial-A-Matic OUTPUT Raise=OFF Lower=OFF 18

24 9 pin to a 6pin combine Hydro Handle Early model 9000 series level-land combines had a 6 pin connector on the Hydro handle. This must be change to allow connection of the 9 pin T connection. Advanced Info 1. Tools Needed: An Amp Multimate pin removal tool. 2. Identify the correct connector on the Headsight Cab harness T. 9 pin Orange Female receptacle with Male pins 3. Remove pins 6 & 7 from this connector These pins are not reinstalled Fold them back and tape them Removing these first lessens confusion among multiple light green wires 4. Remove pins 1-5 from this connector These pins will be reinstalled in the same # cavity on the 6 pin connector later 5. Disconnect the OEM Hydro handle plug under the Control Panel. 6. Identify the correct connector on the OEM Hydro handle connector set. See arrow. 6 pin Orange female receptacle with Male pins On harness to main wiring, not cable to hydro handle 7. Remove 1 pin at a time from this connector, and reinstall in the same cavity on the 9 pin removed in step 4 above. Doing them one at a time will prevent confusion. Pin 1, 6p (wire # 015) to pin 1, 9p Pin 2, 6p (wire # 437) to pin 2, 9p Pin 3, 6p (wire # 425) to pin 3, 9p Pin 4, 6p (wire # 408) to pin 4, 9p Pin 5, 6p (wire # 409) to pin 5, 9p 8. Reinstall the 5 wires on the Headsight Tee into the same cavity on the 6 pin removed in step 7 above. Red wire # 015 to pin 1, 6p Lt. Green wire # 437 to pin 2, 6p Lt. Green wire # 425 to pin 3, 6p Yellow wire to pin 4, 6p Dk. Green wire to pin 5, 6p 9. Tee the Headsight cab harness connectors into the OEM Hydro connectors. 6 pin on Hydro handle cable to 6 pin newly installed on Headsight Tee 9 pin newly installed on OEM cab wiring to 9 pin on Headsight Tee 19

25 Diagnostics Troubleshooting by Symptom Nearly every problem with the header control system on JD 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 contour Enable appropriate HHC functions Properly set combine electronics and/or hydraulics Symptom Problem Solution Insight Status Light Diagnostics (Status not green) No light D-A-M switch is not on, and/ or feederhouse clutch is not engaged Turn on the D-A-M switch and engage feederhouse clutch Solid red Ground wire is not connected (only applies to MY90 and older machines) Combine does not supply 12V on pin 4 of the header connector Wiring is not connected properly or calibration has not been completed Ensure black ground wire is securely attached to the header frame Follow solution for problem: No 12V power available on pin 4 of header plug in Common Combine Diagnostic section See Installation and Calibration sections of manual Flashing Red or Green/Red Insight box has detected an error Correct problem, clear error codes, and recalibrate Insight box Diagnostics 20

26 Diagnostics Symptom Problem Solution AHHC Diagnostics Header does not move in AHHC mode (If the Insight box does not have a green status light, go to Insight Status Light Diagnostics ) Defective light bar D-A-M switch is not on, and/ or feederhouse clutch is not engaged Lower button was not pressed to enable Wrong combine type selected in the Setup menu of the Insight box D-A-M loop is not wired in Headsight harness (applies only to 9x00-9x10 series) Combine D-A-M module defective (applies only to xx20 series only) Feederhouse position chain is misadjusted (applies only to xx00 and xx20) Combine is not receiving a lower signal. To check, set the height position knob on the light bar at min. When the head is fully raised, the lower signal should be on. The signal can be viewed on the Insight box. Go to >>Diagnostics>>Detailed Diagnostics>>Raise/Lower Output Power supply from combine less than 10V to Insight. Wire shorted on head Insight box needs to be reset Combine Problem Go to: Light Bar Diagnostics Turn on the D-A-M switch and engage feederhouse clutch Press lower button to enable Verify that 9x00/10 & xx20 D-A-M is chosen on the Insight box and that the correct header type has been selected Unplug 16 pin header plug and measure continuity across pins 4 & 11 of connector Y221. Resistance must be <5 Ohms Test / repair D-A-M module Check combine operators manual for instructions on adjusting feederhouse position chain If lower signal is on but header does not lower, check connections and combine for an issue (see Common Combine Diagnostics) See No 12V power available in Common Combine Problems See Multiple sensors failed See Insight Overview for details Contact your JD Service Center. 21

27 Symptom Problem Solution AHHC Diagnostics Multiple Sensors failed or have errors at once Header dives to ground and recovers entering crop No power to Insight box (Initial setup/activation) No power to Insight box (Field Operation) No 5V power or Ground to head Make sure Insight has power. Disconnect 31p header connector and measure from pins 10 to 20 on the Insight Adapter Harness, should be 5V Bad Harness on header Reconnect 31p header plug. Measure across outer wires at any sensor plug for 5V. If Insight goes blank, or no 5V is available at any one sensor: Lower Rate set too High Accumulator too far open or discharged Stubble Lights are OFF (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, Measure pin4 to 10 in above connector for 12V DAM switch or Feeder Clutch not ON Power supply from combine less than 10V to Insight. No Ground Measure pin4 to 10 in above connector for 12 If not then: Repair Adapter harness Replace Insight Find broken or shorted wire in header harness. (It is very common to find harnesses with all the insulation removed by rodents in the crosstube.) See Combine Specific Settings Adjust/check accumulator Turn on Stubble Lights. 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 See No 12V power to Header in Common Combine Problems Repair combine ground wire Pre- 90: Make sure adapter ground wire is attached to head. Diagnostics 22

28 Symptom Problem Solution AHHC Diagnostics Head drops all the way to ground or head lowers but will not raise (If the Insight box does not have a green status light, go to Insight Status Light Diagnostics ) Height position knob on light bar set too low Height sensitivity knob on light bar set too low Height sensor misadjusted or failed Wiring not connected or calibration not complete Combine is not receiving a raise signal. To check, set the height position knob on the light bar at max. When the head is fully lowered, the raise signal should be on. The signal can be viewed on the Insight box. Go to >>Diagnostics>>Detailed Diagnostics>>Raise/Lower Output Relay bad on DAM board (Level Land combines only) CM card defective (CM combines) Raise wire broken (pin 3 in header plug) Rotate knob CW until head raises Rotate knob CW to narrow deadband - until head responds See Advanced Information section of this manual See Installation or Calibrations sections of this manual If raise signal is on but header does not raise, check connections and combine for an issue Replace Relay Replace CM control card Repair wire on combine Diagnostics 23

29 Symptom Problem Solution AHHC Diagnostics Head raises all the way up or head raises but will not lower (If the Insight box does not have a green status light, go to Insight Status Light Diagnostics ) Cannot operate header high enough or low enough Header is too jumpy or responds too slowly Height position knob on light bar set too high Cutterbar locked up Wiring not connected or calibration not complete Sensing cross rod siezed up Height sensor misadjusted or failed Combine is not receiving a lower signal. To check, set the height position knob on the light bar at min. When the head is fully raised, the lower signal should be on. The signal can be viewed on the Insight box. Go to >>Diagnostics>>Detailed Diagnostics>>Raise/Lower Output Feederhouse position chain is misadjusted (applies only to xx00 and xx20) Relay bad on DAM board (Level Land combines only) CM card defective (CM combines) Poor Insight calibration Hright postion set to high or low Poor Insight calibration Combine drop rate, accumulator, or sensitivity levels are improperly set Height Sensitivity impropely set Rotate knob CCW until head lowers Decrease cutterbar pressure See Installation or Calibrations sections of this manual Repair mechanical linkage or broken return spring on cross rod See Advanced Information section of this manual If lower signal is on but header does not lower, check connections and combine for an issue Lower wire broken (pin 5 in header plug) Repair wire Feederhouse position chain is misadjusted (applies only to xx00 and xx20) Replace Relay Replace CM control card Recalibrate Insight box Adjust Height Position knob on light bar Recalibrate Insight box See Combine Setting section of this manual See Adjusting Height Sensitivity in Operations section of this manual Diagnostics 24

30 Symptom Problem Solution Contour-Master Diagnostics Height works but not Tilt Combine Contour Master switch is off Insight Outputs to combine incorrect >>Diagnostics>>Detailed Diagnostics>>Right/Left Height Outputs Voltage should be: 1.1V completely on ground 4.1V off ground Contour Master system on head missing or defective >>Diagnostics>>Display Sensor Voltages L & R ~ 1-4V as cutterbar travels thru stroke (see Theory of Operation) Increase Tilt Sensitivity Combine Contour Master system in not functioning Turn on Combine Contour Master switch Recalibrate Insight If not: Adjust sensors Replace sensor(s) Repair wiring on head >>Setup>>Tilt Sensitivity Increase Tilt sensitivity Repair combine wiring or Combine Contour Master card. Head rocks side to side Poor Insight calibration Recalibrate Insight box and combine contour master Wrong orifices installed Refer to Changing Tilt Orficies section of manual Tilt Sensitivity too high Adjust sensitivity on CM card On Insight: >>Setup>>Tilt Sensitivity Decrease Tilt sensitivity Press Check Diagnostics 25

31 Symptom Problem Solution Contour-Master Diagnostics Header is not level with Contour- Master enabled and Header tilts completely to one side (If the Insight box does not have a green status light, go to Insight Status Light Diagnostics ) Header is not level with Contour- Master enabled and Header runs slightly out of level but functions correctly (If the Insight box does not have a green status light, go to Insight Status Light Diagnostics ) Wiring connected improperly Improperly adjusted sensors Sensor harness improperly wired Poor connection Poor Insight calibration or Combine Contour Master calibraiton Header float not working correctly Improperly adjusted sensors Verify that the individual sensor wiring is connected to the main wiring harness at the rear of the header properly See Installation section for details. This symptom will occur if the Left and Right sensor wiring are in the incorrect position Adjust the sensors to both be about 1-1.2V when sitting flat on the ground See Diagnostics: Sensor and Harness, note about reversed wires in connectors Check harness and connectors for cut/torn wire or loose terminals Perform Insight Calibration and combine Contour-Master Calibration (See Calibration section of this manual) Verify float range across entire cutterbar is the same and that all sensors can move freely through their entire range. Verify that all sensors are connected, functioning and calibrated per calibration section of this manual Diagnostics 26

32 Symptom Problem Solution Light Bar diagnostics No lights (5 LED light bar only) AHHC height range is not working correctly AHHC sensitivity is not working correctly Power is not being supplied to light bar (Pin 1 of connector Y223 should be 5V) Defective light bar Light bar disconnected or failed Go to >>Diagnostics>>Detailed Diagnostics>>Height Setting IN, Light bar disconnected or failed Go to >>Diagnostics>>Detailed Diagnostics>>Height Sensitivity, Check harness from the Insight box If 5V is being supplied but light bar has no lights, replace light bar Make sure light bar has power, Verify wiring is not cut or disconnected Voltage should be between 1-4V. If not replace Light bar or fix wiring Make sure light bar has power, Verify wiring is not cut or disconnected Voltage should be between 1-4V. If not replace Light bar or fix wiring Common Combine Problems To Test AHC Power on all DAM combines, the following steps are required: One person on the seat in the cab DAM switch in position 1,2,or 3. Header clutch engaged. The John Deere D-A-M combines only provide power to the Height Control system when the Feeder House Switch is engaged and the DAM rotary Switch is NOT OFF. If these switches are on and Pin 4 of the combine header connector is not Volts, have the combine serviced. Diagnostics Symptom Problem Solution Common Combine Diagnostics Header bounces Drop rate too fast Drop rate recommended be set to 6-8 seconds (Some combines may need to be 8-12 seconds) Head Jumps and Jerks whole Unopened accumulator Open accumulator valve 1 turn combine Discharged accumulator Test accumulator as described in combine owner s manual, replace or recharge as necessary 27

33 Symptom Problem Solution Common Combine Diagnostics 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 Raise, lower, or both raise and lower will not work Manual raise switch does not disengage auto height control Manual lower switch does not engage auto height control when D-A-M switch is on and feederhouse clutch is engaged 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 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 Find and fix damaged wires If there is still no 12V available on the header plug, replace relay in the armrest and if necessary replace D-A-M switch Check combine operators manual for instructions on adjusting feederhouse position chain, and if necessary, replace switch See AHHC Diagnostics Contact JD dealer for service Repair combine wiring (on feederhouse) or replace D-A-M card in combine See solution for problem: No 12V available on pin 4 of header plug Symptom Problem Solution General Insight Problem Display dim, blank, or hard to read Screen contrast improperly adjusted See Insight Settings Power is not being maintained during electrical load because of a bad power supply or ground Reversed sensor polarity Short in sensors powered by Insight box Control box failure Test that 12V is available on pin 4 of header plug to power Insight box Reversed polarity to hall-effect sensors may cause this symptom Individually disconnect sensors to isolate problem screen will regain contrast when faulty sensor is disconnected Correct short in wiring and clear error codes Contact Headsight Diagnostics 28

34 Troubleshooting by Insight Error Codes Error Code Problem Solution ER11 Left sensor signal less than 0.3V Sensor temporarily disconnected Reconnect sensor, Calibrate Insight box Power or ground wire open. To check: disconnect the sensor under the snout and measure the voltage between the power (green), and ground (black) wire If 5V is not being supplied: Repair wiring or connector, Calibrate Insight Box, Calibrate combine Coutour- Master Diagnostics ER12 Left sensor signal greater than 4.7V Signal wire is broken. To check: disconnect the sensor under the snout and use a short jumper wire to temporarily connect power (green), to signal (white) wire. In the Insight box, go to >>Diagnostics>>Display Sensor Voltages Sensor failure Ground (black) wire that runs to the sensor is open. Signal (white) is shorted to power (green) wire Sensor polarity is reversed. To check, go to >>Diagnostics>>Detailed Diagnostics>>Left Sensor Sensor failure If the Insight box does not display 5.0V for the Left sensor, find the break in the signal (white) wire, Repair wire, Remove jumper wire and reconnect sensor, Calibrate Insight Box, Calibrate combine Contour- Master Use Headsight sensor tester to check sensor or, plug sensor into a working sensor location to test sensor voltage range with Insight box Repair wiring or bad connector, Calibrate Insight box, Calibrate combine Contour- Master Repair wiring or bad connector, Calibrate Insight box, Calibrate combine Contour- Master If Reversed = Y, Swap the power (green) and ground (black) wires in the connector that mates to the sensor Use Headsight sensor tester to check sensor or, plug sensor into a working sensor location to test sensor voltage range with Insight box 29

35 Error Code Problem Solution ER13 Left sensor swing less than 0.6V ER16 Left sensor expected but not detected ER17 Left sensor detected but not expected Left sensor mechanical range is restricted Left sensor not properly connected Not enough swing during calibration Incorrect number of sensors selected in initial setup Sensor failure Control box / wiring failure Incorrect number of sensors selected in setup Harness wiring error Control box / wiring failure Verify sensor is not obstructed in swing, Verify sensor can collapse fully with header lowered, Adjust down stop to allow greater swing, and recalibrate sensor to 4.0V with header raised Verify sensor wire is connected to correct location on harness (see Installation Insight Box mounting section of manual), Verify that signal wire (Pin B white wire of sensor cable) has continuity with PIN7 of connector Y101 (Insight box) Make sure sensor meets voltage requirements in: Advanced Info - Basic Requirements section of this manual Go to >>Setup>>Number of Sensors and choose the correct number of sensors Use Headsight sensor tester to check sensor or, plug sensor into a working sensor location to test sensor voltage range with Insight box Contact Headsight Go to >>Setup>>Number of Sensors and choose the correct number of sensors Verify that no wires contact PIN7 of connector Y101 (Insight box) Contact Headsight Diagnostics 30

36 Error Code Problem Solution Sensor temporarily disconnected Reconnect sensor, Calibrate Insight box ER21 Left Center sensor signal less than 0.3V ER22 Left Center sensor signal greater than 4.7V Power or ground wire open. To check: disconnect the sensor under the snout and measure the voltage between the power (green), and ground (black) wire Signal wire is broken. To check: disconnect the sensor under the snout and use a short jumper wire to temporarily connect power (green), to signal (white) wire. In the Insight box, go to >>Diagnostics>>Display Sensor Voltages Sensor failure Ground (black) wire that runs to the sensor is open. Signal (white) is shorted to power (green) wire Sensor polarity is reversed. To check, go to >>Diagnostics>>Detailed Diagnostics>>Left Center Sensor If 5V is not being supplied: Repair wiring or connector, Calibrate Insight Box, Calibrate combine Coutour- Master If the Insight box does not display 5.0V for the Left Center sensor, find the break in the signal (white) wire, Repair wire, Remove jumper wire and reconnect sensor, Calibrate Insight Box, Calibrate combine Contour- Master Use Headsight sensor tester to check sensor or, plug sensor into a working sensor location to test sensor voltage range with Insight box Repair wiring or bad connector, Calibrate Insight box, Calibrate combine Contour- Master Repair wiring or bad connector, Calibrate Insight box, Calibrate combine Contour- Master If Reversed = Y, Swap the power (green) and ground (black) wires in the connector that mates to the sensor Diagnostics ER23 Left Center sensor swing less than 0.6V Sensor failure Left Center sensor mechanical range is restricted Use Headsight sensor tester to check sensor or, plug sensor into a working sensor location to test sensor voltage range with Insight box Verify sensor is not obstructed in swing, Verify sensor can collapse fully with header lowered, Adjust down stop to allow greater swing, and recalibrate sensor to 4.0V with header raised 31

37 Error Code Problem Solution ER26 Left Center sensor expected but not detected ER27 Left Center sensor detected but not expected Left Center sensor not properly connected Not enough swing during calibration Incorrect number of sensors selected in initial setup Sensor failure Control box / wiring failure Incorrect number of sensors selected in setup Harness wiring error Control box / wiring failure Verify sensor wire is connected to correct location on harness (see Installation Insight Box mounting section of manual), Verify that signal wire (Pin B white wire of sensor cable) has continuity with PIN13 of connector Y101 (Insight box) Make sure sensor meets voltage requirements in: Advanced Info - Basic Requirements section of this manual Go to >>Setup>>Number of Sensors and choose the correct number of sensors Use Headsight sensor tester to check sensor or, plug sensor into a working sensor location to test sensor voltage range with Insight box Contact Headsight Go to >>Setup>>Number of Sensors and choose the correct number of sensors Verify that no wires contact PIN13 of connector Y101 (Insight box) Contact Headsight Diagnostics 32

38 Diagnostics Error Code Problem Solution Sensor temporarily disconnected Reconnect sensor, Calibrate Insight box ER31 Center sensor signal less than 0.3V ER32 Center sensor signal greater than 4.7V ER33 Center sensor swing less than 0.6V Power or ground wire open. To check: disconnect the sensor under the snout and measure the voltage between the power (green), and ground (black) wire Signal wire is broken. To check: disconnect the sensor under the snout and use a short jumper wire to temporarily connect power (green), to signal (white) wire. In the Insight box, go to >>Diagnostics>>Display Sensor Voltages Sensor failure Ground (black) wire that runs to the sensor is open. Signal (white) is shorted to power (green) wire Sensor polarity is reversed. To check, go to >>Diagnostics>>Detailed Diagnostics>>Center Sensor Sensor failure Center sensor mechanical range is restricted If 5V is not being supplied: Repair wiring or connector, Calibrate Insight Box, Calibrate combine Coutour- Master If the Insight box does not display 5.0V for the Center sensor, find the break in the signal (white) wire, Repair wire, Remove jumper wire and reconnect sensor, Calibrate Insight Box, Calibrate combine Contour- Master Use Headsight sensor tester to check sensor or, plug sensor into a working sensor location to test sensor voltage range with Insight box Repair wiring or bad connector, Calibrate Insight box, Calibrate combine Contour- Master Repair wiring or bad connector, Calibrate Insight box, Calibrate combine Contour- Master If Reversed = Y, Swap the power (green) and ground (black) wires in the connector that mates to the sensor Use Headsight sensor tester to check sensor or, plug sensor into a working sensor location to test sensor voltage range with Insight box Verify sensor is not obstructed in swing, Verify sensor can collapse fully with header lowered, Adjust down stop to allow greater swing, and recalibrate sensor to 4.0V with header raised 33

39 Error Code Problem Solution ER36 Center sensor expected but not detected Center sensor not properly connected Not enough swing during calibration Verify sensor wire is connected to correct location on harness (see Installation Insight Box mounting section of manual), Verify that signal wire (Pin B white wire of sensor cable) has continuity with PIN8 of connector Y101 (Insight box) Make sure sensor meets voltage requirements in: Advanced Info - Basic Requirements section of this manual ER37 Center sensor detected but not expected Incorrect number of sensors selected in initial setup Sensor failure Control box / wiring failure Incorrect number of sensors selected in setup Harness wiring error Control box / wiring failure Go to >>Setup>>Number of Sensors and choose the correct number of sensors Use Headsight sensor tester to check sensor or, plug sensor into a working sensor location to test sensor voltage range with Insight box Contact Headsight Go to >>Setup>>Number of Sensors and choose the correct number of sensors Verify that no wires contact PIN8 of connector Y101 (Insight box) Contact Headsight Diagnostics 34

40 Diagnostics Error Code Problem Solution Sensor temporarily disconnected Reconnect sensor, Calibrate Insight box ER41 Right Center sensor signal less than 0.3V ER42 Right Center sensor signal greater than 4.7V ER43 Right Center sensor swing less than 0.6V Power or ground wire open. To check: disconnect the sensor under the snout and measure the voltage between the power (green), and ground (black) wire Signal wire is broken. To check: disconnect the sensor under the snout and use a short jumper wire to temporarily connect power (green), to signal (white) wire. In the Insight box, go to >>Diagnostics>>Display Sensor Voltages Sensor failure Ground (black) wire that runs to the sensor is open. Signal (white) is shorted to power (green) wire Sensor polarity is reversed. To check, go to >>Diagnostics>>Detailed Diagnostics>>Right Center Sensor Sensor failure Right Center sensor mechanical range is restricted If 5V is not being supplied: Repair wiring or connector, Calibrate Insight Box, Calibrate combine Coutour- Master If the Insight box does not display 5.0V for the Right Center sensor, find the break in the signal (white) wire, Repair wire, Remove jumper wire and reconnect sensor, Calibrate Insight Box, Calibrate combine Contour- Master Use Headsight sensor tester to check sensor or, plug sensor into a working sensor location to test sensor voltage range with Insight box Repair wiring or bad connector, Calibrate Insight box, Calibrate combine Contour- Master Repair wiring or bad connector, Calibrate Insight box, Calibrate combine Contour- Master If Reversed = Y, Swap the power (green) and ground (black) wires in the connector that mates to the sensor Use Headsight sensor tester to check sensor or, plug sensor into a working sensor location to test sensor voltage range with Insight box Verify sensor is not obstructed in swing, Verify sensor can collapse fully with header lowered, Adjust down stop to allow greater swing, and recalibrate sensor to 4.0V with header raised 35

41 Error Code Problem Solution ER46 Right Center sensor expected but not detected ER47 Right Center sensor detected but not expected Right Center sensor not properly connected Not enough swing during calibration Incorrect number of sensors selected in initial setup Sensor failure Control box / wiring failure Incorrect number of sensors selected in setup Harness wiring error Control box / wiring failure Verify sensor wire is connected to correct location on harness (see Installation Insight Box mounting section of manual), Verify that signal wire (Pin B white wire of sensor cable) has continuity with PIN14 of connector Y101 (Insight box) Make sure sensor meets voltage requirements in: Advanced Info - Basic Requirements section of this manual Go to >>Setup>>Number of Sensors and choose the correct number of sensors Use Headsight sensor tester to check sensor or, plug sensor into a working sensor location to test sensor voltage range with Insight box Contact Headsight Go to >>Setup>>Number of Sensors and choose the correct number of sensors Verify that no wires contact PIN14 of connector Y101 (Insight box) Contact Headsight Diagnostics 36

42 Diagnostics Error Code Problem Solution Sensor temporarily disconnected Reconnect sensor, Calibrate Insight box ER51 Right sensor signal less than 0.3V ER52 Right sensor signal greater than 4.7V ER53 Right sensor swing less than 0.6V Power or ground wire open. To check: disconnect the sensor under the snout and measure the voltage between the power (green), and ground (black) wire Signal wire is broken. To check: disconnect the sensor under the snout and use a short jumper wire to temporarily connect power (green), to signal (white) wire. In the Insight box, go to >>Diagnostics>>Display Sensor Voltages Sensor failure Ground (black) wire that runs to the sensor is open. Signal (white) is shorted to power (green) wire Sensor polarity is reversed. To check, go to >>Diagnostics>>Detailed Diagnostics>>Right Center Sensor Sensor failure Right sensor mechanical range is restricted If 5V is not being supplied: Repair wiring or connector, Calibrate Insight Box, Calibrate combine Coutour- Master If the Insight box does not display 5.0V for the Right Center sensor, find the break in the signal (white) wire, Repair wire, Remove jumper wire and reconnect sensor, Calibrate Insight Box, Calibrate combine Contour- Master Use Headsight sensor tester to check sensor or, plug sensor into a working sensor location to test sensor voltage range with Insight box Repair wiring or bad connector, Calibrate Insight box, Calibrate combine Contour- Master Repair wiring or bad connector, Calibrate Insight box, Calibrate combine Contour- Master If Reversed = Y, Swap the power (green) and ground (black) wires in the connector that mates to the sensor Use Headsight sensor tester to check sensor or, plug sensor into a working sensor location to test sensor voltage range with Insight box Verify sensor is not obstructed in swing, Verify sensor can collapse fully with header lowered, Adjust down stop to allow greater swing, and recalibrate sensor to 4.0V with header raised 37

43 Error Code Problem Solution ER56 Right sensor expected but not detected Right sensor not properly connected Not enough swing during calibration Incorrect number of sensors selected in initial setup Verify sensor wire is connected to correct location on harness (see Installation Insight Box mounting section of manual), Verify that signal wire (Pin B white wire of sensor cable) has continuity with PIN9 of connector Y101 (Insight box) Make sure sensor meets voltage requirements in: Advanced Info - Basic Requirements section of this manual Go to >>Setup>>Number of Sensors and choose the correct number of sensors Sensor failure Use Headsight sensor tester to check sensor or, plug sensor into a working sensor location to test sensor voltage range with Insight box ER57 Right sensor detected but not expected Control box / wiring failure Incorrect number of sensors selected in setup Harness wiring error Control box / wiring failure Contact Headsight Go to >>Setup>>Number of Sensors and choose the correct number of sensors Verify that no wires contact PIN9 of connector Y101 (Insight box) Contact Headsight Diagnostics 38

44 Diagnostics Error Code Problem Solution ER61 Aux sensor signal less than 0.3V Sensor temporarily disconnected Reconnect sensor, Calibrate Insight box ER62 Aux sensor signal greater than 4.7V ER63 Aux sensor swing less than 0.6V Power or ground wire open. To check: disconnect the sensor under the snout and measure the voltage between the power (green), and ground (black) wire Signal wire is broken. To check: disconnect the sensor under the snout and use a short jumper wire to temporarily connect power (green), to signal (white) wire. In the Insight box, go to >>Diagnostics>>Detailed Diagnostics>>Pressure/Aux Sensor Sensor failure Ground (black) wire that runs to the sensor is open. Signal (white) is shorted to power (green) wire Sensor polarity is reversed. To check, go to >>Diagnostics>>Detailed Diagnostics>>Pressure/Aux Sensor Sensor failure Aux sensor mechanical range is restricted If 5V is not being supplied: Repair wiring or connector, Calibrate Insight Box, Calibrate combine Coutour- Master If the Insight box does not display 5.0V for the Aux sensor, find the break in the signal (white) wire, Repair wire, Remove jumper wire and reconnect sensor, Calibrate Insight Box, Calibrate combine Contour- Master Use Headsight sensor tester to check sensor or, plug sensor into a working sensor location to test sensor voltage range with Insight box Repair wiring or bad connector, Calibrate Insight box, Calibrate combine Contour- Master Repair wiring or bad connector, Calibrate Insight box, Calibrate combine Contour- Master If Reversed = Y, Swap the power (green) and ground (black) wires in the connector that mates to the sensor Use Headsight sensor tester to check sensor or, plug sensor into a working sensor location to test sensor voltage range with Insight box Verify sensor is not obstructed in swing, Verify sensor can collapse fully with header lowered, Adjust down stop to allow greater swing, and recalibrate sensor to 4.0V with header raised 39

45 Error Code Problem Solution ER66 Aux sensor expected but not detected ER67 Aux sensor detected but not expected Aux sensor not properly connected Not enough swing during calibration Incorrect number of sensors selected in initial setup Sensor failure Control box / wiring failure Incorrect number of sensors selected in setup Harness wiring error Control box / wiring failure Verify sensor wire is connected to correct location on harness (see Installation Insight Box mounting section of manual), Verify that signal wire (Pin B white wire of sensor cable) has continuity with PIN19 of connector Y101 (Insight box) Make sure sensor meets voltage requirements in: Advanced Info - Basic Requirements section of this manual Go to >>Setup>>Number of Sensors and choose the correct number of sensors Use Headsight sensor tester to check sensor or, plug sensor into a working sensor location to test sensor voltage range with Insight box Contact Headsight Go to >>Setup>>Number of Sensors and choose the correct number of sensors Verify that no wires contact PIN19 of connector Y101 (Insight box) Contact Headsight Diagnostics 40

46 Schematics Diagnostics 41

47 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 Diagnostics 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 1N V POWER RED 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 1N5404 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 42

48 OEM HYDRO HANDLE HARNESS REFERENCE ONLY DO NOT MAKE 9p METRIMATE PLUG w/sckts 12V TO HYDRO OEM HEAD RAISE OEM HEAD LOWER OEM REEL RAISE OEM REEL LOWER OEM TILT L OEM TILT R C Y226 HYDRO HANDLE 12V POWER HEADER RAISE HEADER LOWER REEL RAISE REEL LOWER TILT LEFT TILT RIGHT P01 P02 P03 P04 P05 P06 P V POWER RED 16G 437 HDR + Lt GRN 425 HDR - Lt GRN 408A REEL + YEL 409A REEL - Dk GRN 141 REEL LOWER BRN 426 TILT L Lt GRN 427 TILT RT Lt GRN 140 REEL RAISE WHT 141 REEL LOWER BRN 140 REEL RAISE WHT 408A REEL + YEL 409A REEL - Dk GRN 409A REEL - Dk GRN 144 FLEX + TAN 145 FLEX - BRN 078 REEL SELECT Dk BLU Y225 LIGHTBAR PRESSURE FLEX SELECT FLEX + FLEX - GROUND 12V POWER P01 P02 P03 P04 P05 P FLEX PRESSURE GRY 079 FLEX SELECT ORG 144 FLEX + TAN 145 FLEX - BRN 020 CHASSIS GND BLK 16G V POWER RED 16G Y230 GROUND GROUND HGT SET P10 SENS SET P11 HGT SIGNAL P HGT SET PUR 121 HGT SENS SET YEL 125 HGT SIGNAL WHT NOTES: USED FOR ALL JD 9000, 9010 COMBINES w/600f, FD. MUST INCLUDE DP1 DIODE PACK r3 ADDED DIODE PACK DESIGN JHK Y227 OEM C518 P01 12V POWER P02 HEADER RAISE P03 HEADER LOWER P04 REEL RAISE REFERENCE ONLY DO NOT MAKE C518C 9p METRIMATE RECT. w/pins V TO HYDRO OEM HEAD RAISE OEM HEAD LOWER OEM REEL RAISE OEM CONSOLE HARNESS P05 REEL LOWER 5 OEM REEL LOWER P06 TILT LEFT 6 OEM TILT L P07 TILT RT 7 OEM TILT R Y150 DP-1 P09 VALVE - DIODE PACK, REFERENCE ONLY DP1 HT9223-D NC P10 GND P03 P05 VALVE + P04 REEL + P07 REEL - REEL SEL P02 REEL - P01 REEL + P04 VALVE + P05 P01 REEL - P06 FLEX + P08 FLEX - FLEX + P06 VALVE - P09 FLEX - P08 REEL - P07 P02 REEL SELECT P03 GROUND NC P11 NC P REEL SELECT Dk BLU Y228 BULKHEAD P04 REEL SELECT P05 PRESSURE P02 FLEX SELECT P06 GROUND A P03 HGT SET P07 SENS SET P08 HGT SIGNAL HT9801-CAB 5 Diagnostics 43

49 079 FLEX SELECT ORG 120 HGT SET PUR 078 REEL SELECT Dk BLU 091 FLEX PRESSURE GRY 020 CHASSIS GND BLK 121 HGT SENS SET YEL 125 HGT SIGNAL WHT Diagnostics NOTES: Y229 CAB BULKHEAD FLEX SELECT P02 HGT SET P03 REEL SELECT P04 PRESSURE P05 GROUND P06 SENS SET P07 HGT SIGNAL P08 Y224 HEADER P02 FLEX SELECT P03 HGT SET P04 REEL SELECT P05 PRESSURE P06 GROUND P07 SENS SET P08 HGT SIGNAL REFERENCE ONLY DO NOT MAKE HDR Y202 PRESSURE SIG 5 HYDRA VALVE REEL VALVE HT9801-FH 2 44

50 Parts ITEM QTY. PART NUMBER DESCRIPTION 1 1 INSIGHT Insight Control Unit 2 1 HT9991 Hydraflex Lightbar 3 1 HT9801-JD10-CAB Cab Harness 4 1 QP0-JD10-31Q Main Harness 5 1 HT9801-JD10-FH Feederhouse Harness 6 1 HT9203 Diode Pack 7 1 HT Series Clip 8 1 BCBOX Hardware Parts 45