FOLD CONTROL FOR 600FC Conversion Manual 09040122b HEADSIGHT.COM 574.546.5022
About Headsight Headsight Contact Info Headsight, Inc. 4845 3B Road Bremen, IN 46506 Phone: 574-546-5022 Fax: 574-546-5760 Email: info@headsight.com Web: www.headsight.com Technical Assistance Phone: 574-220-5511 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 574-546-5022 or email info@headsight. com. Headsight s products are protected by one or more of the following US Patents 6202395, 6833299, 7310931, 7647753 and other patents pending. Copyright Headsight, Inc. 2017 i
Table of Contents About Headsight i About this Manual i Installation 1 Header Adapter Harness Mounting 2 For John Deere Combines, 60 Series and Up 3 For CNH and JD 50 Series Combines 3 Fold Controller and Cab Harnesses 4 For John Deere Combines, 60 Series and Up 5 For CNH Combines 5 Calibration 6 Operation 7 Adjusting Deck Plate Position 7 Folding the Wings 8 Advanced Information 9 Theory of Operation 9 Header Adapter Harness 10 Cab Controller and Feeder Harness 11 Cab Power Adapter 12 Diagnostics 13 Troubleshooting by Symptom 13 Parts 15 STATEMENT OF LIMITED WARRANTY 17 ii
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. Installation 1
Installation This kit allows 600FC header to operate on 60 and 70 Series combines, do not use combines deck plate resume feature, and do not change machine address settings to a folding head. Make sure the cable routing is done so no wiring can bind or pinch. Tie up all loose cabling. Properly installed wiring is the most critical aspect of a trouble-free installation. For harness details, see Wiring section of this manual. Header Adapter Harness Mounting 1. Remove the C clip holding the OEM header electrical connector in the JD single-point plate. 2. Remove the connector from the plate, and connect to Y202 on the adapter. Press the two connector bodies together; secure with the HT2259 bracket & zipties. 2
For John Deere Combines, 60 Series and Up 1. Route Y201 up to the new JD single point adapter and install into the adapter with the C clip removed in Header Adapter Harness Mounting, step 2. 2. Tie Y182 (5 pin) so it will be easy to connect during header hookup. Installation For CNH and JD 50 Series Combines 1. Mount the HT2250 bracket and the Header adapter harness to the rear of the head near the left of the feederhouse. JD heads 2016 have a check valve block added in the Reel F/A circuit on the head. This check valve must be removed for proper motion on older combines, or the combine must have the internal check valve removed. The symptom is a jerky motion of the Reel F/A circuit. 3
Installation Fold Controller and Cab Harnesses 1. Use the included suction mount to attach the Fold Controller to the right cab window above the console. Place it in an easy to see and reach location 2. Connect Y225 on the HT9819-Cab harness into the controller. Make sure it is fully seated (clicks) 1. Remove the shields on the left side of the combine feeder house. 2. Route Y183 out of the cab and across under the cab to the left side of the feeder. JD: through the cab access point on the right side floor CNH: Exit right side cab door, or drill access hole in cab floor if necessary 3. Follow existing OEM wiring down the feederhouse to connect to Y182 beside the JD single point. 4
For John Deere Combines, 60 Series and Up 1. Connect Y569 to Y570 on the power adapter harness. 2. Connect Y251 to the Power Bar. Located to the right of the operators seat 3. Reinstall the shields on the left side of the combine feeder house. Installation For CNH Combines 1. Install the included seat switch power adapter inline to the OEM seat switch connector. Varies by combine: Y351-Y354 for all prior to 2013 Y571-Y572 for all 2013--> Located behind or to the right of the operators seat 2. Connect Y569, Y570 (power adapter to Cab harness.) 5
Calibration Calibration It is recommended that when the user first powers up the device, that CALIBRATION be done. Follow the steps below to calibrate. See Operation for how to operate the functions. 1. Make sure the wings are fully unfolded, so the corn head is in field mode. 2. The deck plates must be all the way closed (as narrow as possible). 3. Press the Hidden Button (shown by red circle) and wait a couple of seconds. The whole deck plate display will blink 10 times if the calibration is successful. If there is a problem, the deck plate LEDs will not blink 10 times If the Deck Plate voltages are in the range of 0.25-2.5 volts, when the Deck Plates are fully closed and the Fold Arms are in the range of 2.5-4.75 volts, when the arms are all the way down, the system will calibrate if the Hidden Button is pressed. If the voltages are out of these ranges, the system will not CALIBRATE and the deck display will not blink. 4. Note: If calibration is not performed, default values will be used. If LED display of Deck Plates do not match the mechanical motion correctly, perform the calibration. 6
Operation Adjusting Deck Plate Position The controller will turn on in Deck Plate mode as long as the wings are fully down in field mode. 1. Press the Deck Plate Select Button If the Head is fully unfolded, the controller should switch to Deck Plate mode The bar graph will show the relative position of the deck plates. When the deck plates are fully closed, only the bottom LED should be lit When the deck plates are fully open, all 10 LEDs should be on. 2. Use the Reel Fore/Aft switch to adjust the deck plate position Operation 3. If the wings are not all the way down and the Deck Select button is pressed, the Fold LEDs will flash rapidly 10 times. Applies only to 12 row heads This will happen every time the Deck Button is pressed, as long as the wings are not all the way down. You must fully unfold the wings before operating the deck plates. 7
Folding the Wings 1. Press the Fold Select Button The controller should switch to Fold Mode The 3 Fold LEDs will blink as long as the controller remains in Fold Mode The controller will remain in fold mode until: Any button is pressed For 6 minutes To disable Fold Mode when LEDs are blinking, press the Fold Select button again Operation 2. Use the Reel Fore/Aft switch to fold or unfold the wings. 3. If the wings are not all the way down when the controller is not flashing Fold Mode, the top LED will be ON to indicate the wings are still folded. This occurs when: On 12 row heads only The timer has expired, or Fold mode was deselected by pressing the Fold Select button To re-enable Fold, press Fold Select again. 4. The bottom LED on the deck plate bar graph will also illuminate to show that the controller has power when: The timer has expired and no other buttons have been pressed. No other indicators are currently ON. 8
Advanced Information Theory of Operation The fold controller is designed to control operation of the folding function of the JD 600FC headers when the combine is not equipped to operate the fold select signal. It is also required to allow the deck plates to adjust using the same combines. The fold controller is designed to make operation of the functions as safe as possible, while being logical in operation. It is to be calibrated to the specific header, to better provide these functions. It reads both the deck plate position sensor, and the left wing sensor. 1. The controller will default to deck plate mode on startup, as long as the wings are in field position. 2. It will not allow the deck plates to move when the head is folded up more than 0.25V on the fold sensor. 3. It will only enter fold mode when specifically requested by the operator 4. Fold mode automatically shuts off after 6 minutes, or after a power cycle. 5. All actual motion is done with the Reel F/A control on the combine. Advanced Info 9
Header Adapter Harness NOTES: Y201 COMBINE L H HEIGHT P07 L H FLOAT P03 R H HEIGHT P09 SENSOR V+ P20 SENSOR GND P10 RS RIGHT P01 RS LEFT P02 RS V+ P23 RS GND P24 SWITCHED 12V P04 CHASSIS GND P12 LFT HZD LT P13 RIGHT HZD LT P14 STUBBLE LTS P15 HDR REC 1 P16 HDR REC 3 P17 HEADER REC 4 P18 HEADER REC 2 P28 SHAFT SPEED P29 DECK PLATE P31 Y182 FOLD CTRL GROUND A LEFT WING B FOLD SEL C DECK SEL D DECK PLATE E 041 LEFT HGT TAN 043 CTR HGT TAN 045 RIGHT HGT TAN 050 SENSOR PWR PINK 100 SENSOR GND Lt BLUE 782 CROP 2 R WHT 781 CROP 1 L WHT 750 SENSOR V+ PINK 700 SENSOR GND Lt BLUE 012 12V POWER RED 022 CHASSIS GND BLK 031 LEFT HZD LT YEL 032 RIGHT HZD LT Dk. GRN 033 STUBBLE LTS BRN 072 HDR REC 2 ORG 117 SHAFT SPEED GRY 111 DECK PLATE YEL 216 L WING Lt GRN 137 SWAP 2 Dk BLU 150 SWAP 3 PUR 111 DECK PLATE YEL Advanced Info Y202 HEADER P25 RT C SENSOR P07 LEFT HGT SNR P03 L C SENSOR P09 RT HGT SNR P20 SENSOR V+ P10 SIGNAL GND P01 RS RIGHT P02 RS LEFT P23 RS V+ P24 RS GND P04 SWITCHED 12V P12 CHASSIS GND P13 LEFT HZD LT P14 RIGHT HZD LT P15 STUBBLE LTS P16 HDR SEL 1 P17 HDR SEL 3 P18 HDR SEL 4 P28 HDR SEL 2 P29 SHAFT SPEED P31 DECK PLATE P25 RT WING P05 LEFT WING P06 FOLD SEL P11 DECK SEL P31 DECK PLATE HT9819-HDR 2 10
Cab Controller and Feeder Harness Advanced Info NOTES: Y225 FOLD CONTROLLER 12V POWER P06 CHASSIS GND P05 FOLD SENSE P01 FOLD SEL P03 DECK SEL P04 DECK SENSE P12 Y570 POWER 12V POWER GROUND 12V SAFETY BATTERY A B C D 012 12V POWER RED 14g 023 CHASSIS GND BLK 12g 719 12V ENABLE ORG 016 BATTERY RED 12g Y569 POWER A 12V POWER B GROUND C 12 SAFETY D BATTERY 012 12V POWER RED 16g 023 CHASSIS GND BLK 16g 001 SIGNAL GND BLK 18g 216 L WING Lt GRN 137 SWAP 2 Dk BLU 150 SWAP 3 PUR 111 DECK PLATE YEL 2 CORRECTED KEY - Y246->Y225 10.2.17 JHK Y183 FOLD CTRL A GROUND B LEFT WING C FOLD SEL D DECK SEL E DECK PLATE HT9819-CAB 2 11
Cab Power Adapter NOTES: CAB POWER FOR JD 50+ Y251 JD POWER SWITCHED 12V C GROUND B BATTERY A ORG BLK Y570 POWER A 12V POWER B GROUND RED C 12V SAFETY D BATTERY HT9306 1 Advanced Info 12
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 NO LEDs on controller No 12V Power to Controller Make sure power adapter is installed, and has 12V. No power to controller plug Test red to black wire in Y248 Deck Plates will not adjust Deck plate display shows on controller Deck Plate Mode not selected Wings not fully unfolded Select Deck Plate Mode Unfold wings Completely Calibration wrong, or not completed. See Calibration section of manual Wiring not connected at head Connect Y182 to Y183 Wiring incorrectly installed See Installation Wing sensor or wiring defective Find and repair problem Head will not fold Y225 not fully installed Fold Mode not selected Timer expired, LEDs not blinking Calibration wrong, or not completed. Make sure Y225 is fully snapped into controller. Select Fold Mode Reselect Fold Mode See Calibration section of manual Diagnostics Wiring not connected at head Connect Y182 to Y183 Wiring incorrectly installed See Installation 13
Symptom Problem Solution Deck plate will not operate (Bar graph does not show) Wiring not connected Connect Y182 to Y183 Deck Plate Mode not selected Select Deck Plate Mode Wings not fully unfolded, top LED on Calibration wrong, or not completed. Unfold wings Completely See Calibration section of manual Deck Plate display does not function Top folded LED on, but wings are fully down in field mode. Wiring not connected Defective Deck plate sensor or wiring on header Y248 not fully installed Backprobe Y248, pin 1: Should be 0.5-4.5V and change with deck plate motion. Wiring not connected Controller not calibrated, or sensor has moved since caibration Sensor disconnected, or wire broken Sensor failed Connect Y182 to Y183 Test and repair sensor or wiring Make sure Y225 is fully snapped into controller. If voltage changes with actual movement, suspect defective controller. If not, find broken wire in harness. Connect Y182 to Y183 Redo Calibration Find and repair connection Check left wing sensor for proper operation and adjustment Diagnostics Sensor signal wire shorted to Ground NO signal to controller Find and repair short Backprobe Y248 pin 12. Should be 0.5-4.5V and change with wing motion. If so, suspect defective controller. If not, find broken wire in harness. 14
Parts 4 2 1 3 ITEM QTY. PART NUMBER DESCRIPTION 1 1 HT9819 -HDR Header Adapter Harness 2 1 HT9819-CAB Cab & Feeder Harness 3 1 Ht9306 Cab Power Adapter 4 1 HT9215 Fold Controller Parts 15
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STATEMENT OF LIMITED WARRANTY For Headsight Products Headsight Inc. (Headsight) warrants its new products to be free from defects in material and workmanship for a period of twelve (12) consecutive months following the date of purchase by the retail purchaser. Headsight Inc. (Headsight) warrants its new corn sensors assemblies for a period of thirty-six (36) months. Headsight warrants genuine Headsight replacement parts and components to be free from defects in material and workmanship for a period of six (6) consecutive months following the date of purchase or the remainder of the original equipment warranty period, whichever is longer. Headsight s obligation under these warranties shall be limited to repairing or replacing, free of charge to the original purchaser, any part that, in Headsight s judgment, shows evidence of such defect. Limitations to Warranty This warranty does not cover: Warranty claims directly resulting from improper installation of the product. Any product damaged by accident, abuse, misuse, or negligence after shipment from Headsight. Any unauthorized product alteration or modification. Any unauthorized repairs made with parts other than genuine Headsight parts. Any repairs performed by anyone other than Headsight or an authorized Headsight dealer unless specifically authorized by Headsight. Warranty Procedure Troubleshooting should be done between farmer/dealer and Headsight through our technical assistance @ 574.220.5511. Labor reimbursement will occur only pre-arranged through Headsight technical assistance and be scheduled to a flat rate basis or reasonable time allowance in Headsight s judgment. There is no mileage reimbursement. Diagnostic time will not be reimbursed except in pre-arranged circumstances. Warranty claims should be on typical dealer service work order with a number and name to be attached for any future correspondence. All warranty work must be performed, and claims submitted, within thirty (30) days of the occurrence of the claim and within the warranty period. All parts removed during warranty repair must be returned to Headsight with Headsight s Return Form within thirty (30) days of the occurrence of the claim and within the warranty period. Headsight, Inc. reserves the right to either inspect the product at the original retail purchaser s location or require it to be returned to Headsight, Inc. for inspection. Limitation of Liability Headsight makes no express warranties other than those, which are specifically described herein. Any description of the goods sold hereunder, including any reference to buyer s specifications and any descriptions in circulars and other written material published by Headsight is for the sole purpose of identifying such goods and shall not create an express warranty that the goods shall conform to such description. THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES EXPRESSED OR IMPLIED. There are no implied warranties of merchantability or fitness of a particular purpose. This warranty states Headsight s entire and exclusive liability and buyer s exclusive remedy or any claim for damages in connection with the sale of furnishing of Headsight products, their design, suitability for use, installation or operation, or for any claimed defects herein. HEADSIGHT WILL IN NO EVENT BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES WHATSOEVER, NOR FOR ANY SUM IN EXCESS OF THE PRICE RECEIVED FOR THE GOODS FOR WHICH LIABILITY IS CLAIMED. No representative of Headsight nor any dealer associated with Headsight has the authority to change the items of this warranty in any manner whatsoever, and no assistance to purchaser by Headsight in the repair of operation of any Headsight product shall constitute a waiver of the conditions of this warranty, nor shall such assistance extend or revive it. Headsight reserves the right to make improvements in design or changes in specifications at any time, without incurring any obligation to owners of units previously sold. Warranty: 1/2017 17
P 574.546.5022 F 574.546.5760 4845 3B Rd Bremen, IN 46506 info@headsight.com www.headsight.com