Headsight HHC JD xx20 series Cmbine Manual 09010105
Abut Headsight Headsight Cntact Inf Headsight, Inc Bremen, IN 46506 Phne:574-546-5022 Fax: 574-546-5760 Email: inf@headsight.cm Web: www.headsight.cm Technical Assistance Phne: 574-220-5511 Abut this Manual Hw t use this manual Fr new installatins, fllw all applicable instructins in each f the numbered sectins (1,2,etc) in the rder that they are presented in this manual. The infrmatin in the lettered appendices (A,B, etc) is fr service r advanced settings which yu will nt need fr mst installatins, but may want t reference in the future. This This icn designates infrmatin f which yu shuld take nte. icn designates an imprtant instructin. Disclaimers Headsight, Insight, Fresight, FeatherSight and TrueSight are trademarks f Headsight, Inc. All ther trademarks are prperty f their respective wners. Prtins f this prduct are prtected by US Patents 6202395, 6833299, 7310931, and ther US and internatinal patents, issued and pending. i
Table f Cntents Abut Headsight Headsight Cntact Inf Technical Assistance Abut this Manual Hw t use this manual Disclaimers i i i i i i 1. Installatin 1 1.1. Cntrl Unit 1 1.2. Main Harness 1 1.3. Pwer & Switch 3 1.4. Header Cnnectin 4 2. Calibratin 5 2.1. Sensr Calibratin 5 3. Settings 7 3.1. Harvester Settings 7 3.1.1. Aut drp rates 7 3.1.2. Hydraulic accumulatr 8 4. Operatin 9 4.1. Cntrl Unit Layut 9 4.2. Enabling Height Cntrl 9 4.3. Adjusting Header Height 9 4.4. Adjusting Height Sensitivity 10 4.5. Adjusting Tilt Sensitivity (Optinal) 10 A. Thery f Operatin 11 B. Trubleshting..by Symptm 13 C. Trubleshting Cmmn Harvester Prblems 16 D. Wiring 17 ii
E. Parts 18 F. Warranty Infrmatin 19 iii
Installatin Cmplete the installatin prtin f the header manual befre cntinuing. 1.1. Cntrl Unit 1. Munt the U bracket in the cab in an accessible pint within reach f the harnessing. Make sure t leave rm fr the harness t plug int the back f the cntrller. 2. Munt the cntrl unit t the U bracket using the tw ¼ x ½ blts and nuts prvided. Adjust angle as necessary. 1.2. Main Harness ON/OFF Switch Fuse Keyed Pwer Grund Cntrl Unit 16 pin 31 pin Header Cnnectin Header Lights Feed T Slenid Main Harness Harness CABLE ROUTING NOTE: Cable ruting prperly takes time, but is essential t lng life f electrical cntrls. Take the time t fully understand the ruting requirements, and carefully rute and tie all cables in safe lcatins away frm heat, wear, r pinch pints. Feeder Engage (Purple) 1
1. Remve the access plate in the right frnt crner f the cab flr and ntch it fr the cable t g thru. Rute the 16 pin plug end f the cable up t the cntrller. The pwer and grund wires stay in the cab. 2. Rute the remainder f the harness acrss under the cab clear f the valve and brake levers. 3. Rute the end f the main cable that has the 31 pin rund plug dwn thrugh the feederhuse pivt pint alng with the JD feederhuse wiring. Make sure t leave a little slack fr mtin. Rute the cable alng with the feederhuse wiring 4. Secure with zip ties, making sure all wiring is firmly held and nt able t be rubbed r pinched. 5. Rute the cable end with the 3 pin WP back alng the step area t the electric slenid valve bdy. 6. Cnnect the shrt slenid harness t the end f the main harness and t the slenid valve bdies. Cnnect the Plug with the GREEN wire t the slenid pinting OUT frm the cmbine. Cnnect the plug with the BROWN wire t the INNER slenid. Cnnect the black wire t any grund blt. Slenid cnnectins 7. Rute the shrt end f the main 2
harness with the purple and red wire t the feeder psitin switch. (OEM switch shwn) Cnnect the Red wire t the COM Cnnect the Purple wire t the switch terminal that is cnnected t COM when the header is DOWN. The purple wire must be 12V t activate the system 8. A lights feed cnnectr (4 pin WP) is included n the harness. If s desired, wires can be ruted t this plug frm the cmbine lights switches t activate the header hazard and stubble lights. Black Lights Grund Yellw Left Hazard Green Right Hazard Brwn Stubble Lights 1.3. Pwer & Switch 1. Rute the Black wire t any chassis grund blt 2. Munt the switch included in the cnsle as shwn and rute the RED wire t the NO cnnectin f the switch. (bttm term. as munted) 3. Rute the ORANGE wire with the fuse hlder frm the COM term f the switch t any clean key-switched pwer surce. Cnnect as needed. 3
1.4. Header Cnnectin 1. The 31 pin header cnnectr mates t OEM JD 50 series headers. Mate the header plug t either existing OEM header cnnectr, r t the Headsight Header Y cable supplied with the Header Kit. Fr installatin instructins see the Header Sensr Installatin Guide. Adapter harnesses are available t cnnect OEM Headers with preexisting OEM sensrs t the Headsight height cntrl. Cntact Headsight fr the crrect part number fr yur specific applicatin. OEM Header cnnectin w/ Sensrs Headsight Adapter cable Headsight Header Cnnectr n Cmbine 4
2. Calibratin Befre wrking under the header always: 1. Perfrm all harvester and header manufacturer safety precautins fr servicing header. 2. Insert stp t prevent mvement f header. 3. Set harvester parking brake. 4. Discnnect all drive shafts frm the header. 2.1. Sensr Calibratin Yu will nt need t calibrate the sensrs fr brand-new installatins because they are pre-calibrated at the factry. Yu may recalibrate the sensrs if yu are unsatisfied with the perating range f the system. Yu shuld perfrm calibratin if any f the cmpnents f the system are used, r nce annually. This step will require 2 peple. Its purpse is t level the sensrs s the cntrl system sees the same grund height fr each. 1. Attach all harness and sensr wiring. 2. Pwer the header cntrl system. Start the engine. Set the MODE switch t HGT. 5
3. Mve (any) ne sensr arm back t the lwest psitin t which the grund culd push the sensr during nrmal peratin. This psitin shuld nt be t the mechanical limit and will vary slightly depending n header type and angle. The ACTIVE [CAL] light shuld just turn n at this lw psitin. Yu will nt be able t adjust OEM sensrs (such as JD) prperly. If yu cannt adjust the sensrs as described belw, use a vltmeter t set all sensr vltages equal, and read the nte under 4.3 Adjusting header height. If the ACTIVE [CAL] light des nt just turn n at the lwest pint: Lsen the nuts r screws which hld the sensr (the hall effect sensr r ptentimeter NOT the entire sensr assembly) and twist the sensr t a new psitin which des just turn n the CAL light. Mre details may be fund in the header manual. Lwer Raise 4. Repeat step 3 fr each sensr perfrm seasnally. All sensrs shuld be set t within abut 0.2V f equal. 5. If needed, adjust the dwn stps fr an equal hang angle fr all sensrs. 6
3. Settings 3.1. Harvester Settings Prperly setting the cmbine is essential t having respnsive header cntrl. Yu shuld becme very familiar with the steps in this sectin. Set the autmatic drp rate as high as yu like withut causing head hunting. If the head hunts, decrease the autmatic drp rate. See wner s manual fr lcatin f drp rate valve and accumulatr. 3.1.1. Aut drp rates 1. Adjust the aut drp rate valve adjustment n the flw valve under the cab. The drp rate shuld be slw enugh that the head des nt dive and recver r bunce. If the speed is t fast hunting will ccur. If the speed is t slw the system will nt be respnsive enugh. AUTO Drp Rate 7
3.1.2. Hydraulic accumulatr If yu d nt have any accumulatr, please cntact either yur lcal dealer r Headsight t install ne. It will result in much imprved peratin and less stress t bth yu and the machine in all situatins, manual r aut. 1. If yur accumulatr has a valve: Clse the accumulatr valve all the way Open the accumulatr valve 1 full turn (frm clsed psitin). Opening the accumulatr t far will give slppy respnse. Nt pening the accumulatr far enugh will give a jerky respnse. Typical Accumulatr & valve Nte: the JD xx20 series has the accumulatr munted inside the right frame rail next t the transmissin. 8
4. Operatin 4.1. Cntrl Unit Layut Head Height Adjustment See 4.3 Height Sensitivity Adjustment See 4.4 Tilt Sensitivity Adjustment See 4.5 Mde Switch Selects Operating Mde Directinal Indicatr Lights Aut/Cal Light See Appx. A 4.2. Enabling Height Cntrl 1. Turn MODE switch t HGT r HGT & TILT. 2. Turn ON the AUTO switch yu installed n the cnsle. 3. Lwer the header until the feeder switch engages. The AUTO light shuld nw be lit. 4. T disable, use the manual raise lever t lift the head until the feeder switch disengages. The Aut Light shuld be ff. 4.3. Adjusting Header Height 1. Turn the head height knb n the cntrl unit with header cntrl engaged. Clckwise = higher 9
Cunter-clckwise = lwer 2. Find and mark the minimum acceptable height as nted belw, d nt perate belw this pint. Because the Headsight cntrl unit is designed t wrk with many OEM sensrs, it may be pssible fr the peratr t chse a height that is t lw fr peratin meaning that the sensrs wuld never send a raise signal. T test if the height yu have chsen is t lw, engage the system, then tap the lwer buttn n the hydr handle. If the header bunces back up t its riginal psitin, the chsen height is fine. If the header stays in the new psitin, the height chsen is t lw d nt perate header cntrl at r belw this height. 4.4. Adjusting Height Sensitivity 1. Increase height sensitivity (turn CW) fr mre respnsive perfrmance. 2. Decrease height sensitivity (turn CCW) t reduce hunting. Yu MUST set yur accumulatr and drp rate befre adjusting the sensitivity knb. 4.5. Adjusting Tilt Sensitivity (Optinal) 1. Increase tilt sensitivity (turn CW) fr mre respnsive perfrmance. 2. Decrease tilt sensitivity (turn CCW) t reduce hunting. Yu may need t adjust the hydraulic flw rate befre adjusting the sensitivity knb. The head shuld take at least 5 secnds t tilt fully frm ne side t the ther, mre fr wider heads. This is set by rifices in the valves. 10
A. Thery f Operatin A review f the fllwing pints will help the service technician t understand the cmplete system which will help when diagnsing specific prblems. 1. Cntrl Unit: Frnt Panel Cntrls The cntrl unit cntains bth the height cntrl analysis circuitry, and the interface t wrk with the manual cntrls f the harvester. The MODE switch allws the user t turn the system ff, r perate height cntrl withut lateral tilt. The cntrl unit will nt activate the utputs unless the Mde switch is n, the OEM header switch is n, and the manual header lwer switch has been pressed. The lights n the cntrl unit are visual indicatrs t the peratr. The fur directinal lights indicate that slenid utput is activated. The ACTIVE [CAL] light perfrms tw functins. During sensr calibratin, it acts as a lw pint indicatr t help set all sensrs at the same pint. During peratin, it will light when the height cntrl system is activated. 2. Sensrs Further infrmatin n sensrs is available in the Header manual. Each sensr returns a variable vltage t the cntrl unit depending n its height. high height = high vltage (apprximately 4 vlts) lw height = lw vltage (apprximately 1 vlt) Each sensr has 3 wires (clrs f OEM sensr wires vary) red = 5V pwer black = grund white = signal returned t the cntrl unit (varies between apprximately 1.0 and 4.0 vlts) 11
3. Height Operatin Head Height The cntrl unit cmpares the lwest (mst smashed) sensr t the desired height chsen with the height knb. If any sensr has a lwer vltage (is nearer the grund) than the height setpint vltage the bx energizes the raise utput. This means that any ne sensr can raise the head. If all sensrs have a higher vltage (are farther frm the grund) than the height setpint vltage plus the deadband chsen by the sensitivity knb the cntrl unit energizes the lwer utput. This means that all sensrs must agree t lwer the head. Raise Pint Lwer Pint Deadband Sensitivity Tilt The sensitivity knbs n the cntrl unit adjust the size f the deadband. The deadband is a small area where the system will neither raise nr lwer (r tilt). This helps prevent the header frm hunting. The left and right sensr signals are cmpared and a tilt utput is enabled as needed. The tilt sensitivity knb sets the deadband. 12
B. Trubleshting..by Symptm The fllwing trubleshting guide is t be used as fllws: Dentes a prblem. Read thrugh the prblems and select the ne that mst clsely represents yur prblem.? Asks a questin. Read thrugh the pssible ptins and select the ne that best describes yur system s peratin. Dentes a pssible slutin. Test each slutin in the rder given, as a slutin may depend n prper peratin f previus slutins. Gives further explanatin r testing instructins. Header is t jumpy r respnds t slwly Harvester is imprperly set. See Settings sectin adjust drp rate and accumulatr. Sensrs need t be recalibrated. See Sensr Calibratin sectin. N autmatic peratin - height Wiring is nt cnnected prperly Header cntrl is nt enabled with cab cntrls. See Operatin sectin fr instructins abut hw t enable.? If ACTIVE LED is lit n the cntrl unit. Slenid cnnectins nt prperly wired. Suspect defective Headsight system. Test Headsight system by fllwing raise/lwer diagnstics belw.? If NO LEDs are lit n the cntrl unit: Ensure fuse is nt blwn and cntrl unit has gd grund and 12V. 13
Suspect defective Headsight cntrl bx. Head drps all the way t grund. Height psitin knb set t lw. Rtate knb CW until head raises. Raise/Lwer Slenids cnnected backward. Reverse plugs.? If lwer LED is n with the head n the grund: ALL sensrs are discnnected Recnnect sensrs. Bad grund circuit t sensrs. Repair. Plarity is reversed t hall effect sensrs. Shuld be +5VDC n pin C (red wire) f sensrs. All sensrs and/r wiring have failed. Diagnse/Replace.? If raise LED is n with the head n the grund: Defective wiring t raise slenid. Head raises all the way t tp. Height psitin knb set t high. Rtate knb CCW until head lwers. Raise/Lwer Slenids cnnected backward. Reverse plugs.? If raise LED is lit with the head ff the grund. Sensr stuck up under head. remve bstructin. Defective sensr r harness (any sensr signal < 1V). Discnnect all sensrs frm cntrl bx then cnnect and perate ne sensr at a time t identify defective sensr(s). Sensr wiring plarity reversed Check wiring plarity t ptentimeter sensrs (pin C = +5V except sme grain sensrs) +5V wire brken t sensr Sensr signal wire (white) shrted t grund. Defective sensr.? If lwer LED is n with the head ff the grund. 14
Test wiring t lwer slenid Open aut drp rate valve Head raises ver bstacle but des nt lwer. Fllw instructins in Head raises all the way t the tp. Height sensitivity knb n the light bar set t lw. Rtate knb CW t narrw deadband. Aut drp rate valve t far clsed Open valve Harvester nt receiving lwer signal. Test wiring t lwer slenid. Slenid shuld be at 12V when lwer LED is lit. Head lwers t selected height but des nt raise ver bstacles. Fllw instructins in Head drps all the way t grund. Height sensitivity knb n light bar set t lw. Rtate CW t narrw deadband. Defective sensr r harness Any single sensr defective r discnnected will cause the head t nt raise ver an bstacle seen nly by that sensr. Other sensrs shuld functin nrmally. Cmbine nt receiving raise signal. Test wiring t raise slenid. Slenid shuld be at 12V when raise LED is lit. Raising Head des nt disengage aut height. Test feeder switch. Purple wire shuld be OFF (0V) when raised. Defective cntrl unit. Lwering Head des nt engage aut height. Test feeder switch. Purple wire shuld be ON (12V) when lwered. Defective cntrl unit. 15
C. Trubleshting Cmmn Harvester Prblems Head jumps and jerks whle harvester Unpened r discharged accumulatr Test accumulatr as described in harvester wner s manual Replace r recharge as necessary 16
D. Wiring 17
E. Parts 1 2 4 3 PARTS KEY Key# Part# Descriptin Qty Ntes 1 HT9118LT CONTROL UNIT 1 08 W/MODE SWITCH 2 HT9112 TOP MOUNTING BRACKET FOR (1) 1 3 HB4-HH20-M MAIN HARNESS 1 4 HB4-HH20-S SOLENOID HARNESS 1 5 SPDT SW SPDT SWITCH 1 NOT SHOWN 18
F. Warranty Infrmatin Statement f Limited Warranty fr Crn Prducts Headsight Inc. (Headsight) warrants its new crn sensrs assemblies fr a perid f thirty-six (36) mnths, and its electrnic wiring and interface cntrl bxes fr a perid f twelve (12) t be free frm defects in material and wrkmanship fllwing the date f purchase by the retail purchaser. Headsight warrants genuine Headsight replacement parts and cmpnents t be free frm defects in material and wrkmanship fr a perid f six (6) cnsecutive mnths fllwing the date f purchase r the remainder f the riginal equipment warranty perid, whichever is lnger. Headsight s bligatin under these warranties shall be limited t repairing r replacing, free f charge t the riginal purchaser, any part that, in Headsight s judgment, shws evidence f such defect. Limitatins t Warranty This warranty des nt cver: Warranty claims directly resulting frm imprper installatin f the prduct. Any prduct damaged by accident, abuse, misuse, r negligence after shipment frm Headsight. Any unauthrized prduct alteratin r mdificatin. Any unauthrized repairs made with parts ther than genuine Headsight parts. Any repairs perfrmed by anyne ther than Headsight r an authrized Headsight dealer unless specifically authrized by Headsight. Warranty Prcedure Trubleshting must be dne between custmer and Headsight thrugh Headsight s technical assistance @ 574.220.5511. Labr reimbursement will ccur nly pre-arranged thrugh Headsight technical assistance and be scheduled t a flat rate basis r reasnable time allwance in Headsight s judgment. There is n mileage reimbursement. Diagnstic time will nt be reimbursed except in pre-arranged circumstances. Warranty claims shuld be n typical dealer service wrk rder with a number and name t be attached fr any future crrespndence. All warranty wrk must be perfrmed, and claims submitted, within sixty (60) days f the ccurrence f the claim and within the warranty perid. All parts remved during warranty repair shuld be held fr a perid f 60 days after the warranty claim has been submitted t Headsight. Headsight, Inc. reserves the right t either inspect the prduct at the riginal retail purchaser s lcatin r require it t be returned t Headsight, Inc. fr inspectin. Limitatin f Liability Headsight makes n express warranties ther than thse, which are specifically described herein. Any descriptin f the gds sld hereunder, including any reference t buyer s specificatins and any descriptins in circulars and ther written material published by Headsight is fr the sle purpse f identifying such fds and shall nt create an express warranty that the gds shall cnfrm t such descriptin. THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES EXPRESSED OR IMPLIED. There are n implied warranties f merchantability r fitness f a particular purpse. This warranty states Headsight s entire and exclusive liability and buyer s exclusive remedy r any claim fr damages in cnnectin with the sale f furnishing f Headsight prducts, their design, suitability fr use, installatin r peratin, r fr any claimed defects herein. HEADSIGHT WILL IN NO EVENT BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES WHATSOEVER, NO FOR ANY SUM IN EXCESS OF THE PRICE RECEIVED FOR THE GOODS FOR WHICH LIABILITY IS CLAIMED. N representative f Headsight nr any dealer assciated with Headsight has the authrity t change the items f this warranty in any manner whatsever, and n assistance t purchaser by Headsight in the repair f peratin f any Headsight prduct shall cnstitute a waiver f the cnditins f this warranty, nr shall such assistance extend r revive it. Headsight reserves the right t make imprvements in design r changes in specificatins at any time, withut incurring any bligatin t wners f units previusly sld. Warranty: 1/2007 19
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