JD 9000-600F Cnversin Cmbine Manual 09040114a
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. Suggestins If yu have any suggestins t imprve this manual please call 574-546-5022 r email inf@headsight.cm. 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 Suggestins i i i i i i i 1. Installatin 1 1.1. Interface Bx Munting 1 1.2. HydraFlex Light Bar 2 1.3. Feeder Harness 3 2. Calibratin 4 2.1. Cmbine Activatin (Insight nly) 4 2.1.1. Standard Activatin: 91-up DAM (see nte) 4 2.1.2. Activatin: 89-90 DAM (except as abve) 5 2.2. Initialize Insight 6 2.3. Calibrate Insight 6 2.3.1. Sensr Calibratin 6 2.4. Cmbine Cntur-Master Calibratin 7 3. Settings 8 3.1. Cmbine Settings 8 3.1.1. Autmatic drp rate 8 3.1.2. Hydraulic accumulatr 9 4. Operatin 10 4.1. Enabling height cntrl 10 4.1.1. 9x00 and 9x10 series 10 4.2. Adjusting header height 11 4.3. Adjusting height sensitivity 11 4.4. Adjusting Flat Pressure 12 ii
A Insight Overview 13 1 Rules f menu navigatin 13 2 Meaning f the status light 13 3 Screen cntrast adjustment 14 4 Resetting Insight t defaults 14 5 Updating Insight Sftware 14 B Advanced Infrmatin 16 1 Changing Tilt Orifices 16 2 Cnnecting the 9 pin T t a 6pin cmbine Hydr Handle cnnectr 17 C Diagnstics 19 1 Thery f Operatin 19 2 Trubleshting..by symptm 20 3 Trubleshting..cmmn cmbine prblems 24 4 Trubleshting by Insight errr cdes 25 5 Reading vltages n the Insight bx 29 D Parts 30 iii
1. Installatin 1.1. Interface Bx Munting 1. Fr either style f interface ( black bx, Insight), hld interfacebx at rear f header within reach f feederhuse electrical cnnectin n cmbine and mark munting hle lcatins. 2. Secure bx t header Drill munting hles using ¼ drill bit. Use prvided tie straps r ¼ blts. Bx must be within reach f the header electrical cnnectr. 3. Attach cnnectr munting plate t header within reach f cmbine electrical cnnectr. Drill munting hles using ¼ drill bit. Use prvided ¼ blts. Bx must be within reach f the header electrical cnnectr. 4. Remve the OEM header cnnectr frm the single pint and press the tw cnnectrs tgether. Use the included clip and zip ties t prevent separatin. 5. Attach black grund wire t header frame. Required fr all cmbines mdel 1990 and earlier. 6. Cnnect the 24 pin rectangular plug t the bttm f the Insight bx. 7. Mate remaining cnnectrs t cmbine and header 16pin OEM Header cnnectr (frm cmbine) 9 pin Feeder Harness (installed in 1.3) 1
1.2. HydraFlex Light Bar 1. Munt the HydraFlex Light Bar n the right cab windw in the general area shwn, near the crner pst display 2. Cnnect the Cab Harness t the back f the light bar 3. Unblt the electrical access panel frm the rear right crner f the cab. 4. Measure 2 ¼ frm tp and right side f access panel and drill a new 7/8-1 access hle in the panel. A step drill r hle saw is preferred. Make sure t mve wiring away frm behind the drill. 5. Frm inside the cab, rute the 9 pin rund cnnectr n the cab harness back thru the rear crner access hle and ut t the access panel. 6. Remve the blt hlding the cnnectr clip and insert the 9 pin cnnectr under the clip. Reinstall the cnnectr clip. 7. Install the grund terminal nt the OEM grund blt just inside the access panel. Install it under the large OEM ring terminal fr best results. Retighten grund terminal. 8. Reinstall the access panel and blts. 2
9. Discnnect the OEM hydr handle cnnectrs under the cab cnsle. This is a 9 r 6 pin cnnectr as shwn. 10. If yur cmbine has the 6 pin (early) Hydr cnnectr, see App. A fr infrmatin n switching these cnnectrs befre prceeding. 11. Tee the Headsight cab harness cnnectrs int the OEM Hydr cnnectrs. 1.3. Feeder Harness 1. Cnnect either end f the Cab harness t t newly installed 9 pin cnnectr in the access panel 2. Rute the feeder harness t the frnt f the feeder Under the cab fllwing pipes Dwn thru the pivt pint with OEM feeder harness Fllw OEM feeder harness t frnt f feeder, next t OEM header plug. 3
2. Calibratin Befre wrking under the header always: 1. Perfrm all cmbine and header manufacturer safety precautins fr servicing header. 2. Insert stp t prevent mvement f header. 3. Set cmbine parking brake. 4. Discnnect all drive shafts frm the header. 2.1. Cmbine Activatin (Insight nly) T pwer the Insight Bx fr setup and calibratin, different cmbines require different prcedures. Please fllw the crrect prcedure fr yur year cmbine. 2.1.1. Standard Activatin: 91-up DAM (see nte) This prcedure als applies t earlier cmbines that have had header stubble lights wiring added t the OEM header cnnectin. 1. Make sure all cnnectrs and harnessing is installed. 2. Turn the Dial-A-Matic switch OFF t prevent DAM activatin. 3. Start the engine. 4. Turn n the header stubble lights if the cmbine is equipped. This allws the Insight bx t receive pwer withut requiring the header and separatr t be engaged. 5. The LCD display shuld nw be active n the Insight bx. 4
2.1.2. Activatin: 89-90 DAM (except as abve) 1. Install the pwer bypass harness PFI- JD10-P n the feeder. Disassemble the shell n the back f the OEM cmbine header plug. Insert the lse scket thru the back shell and int cavity 15 n the OEM Header plug. (Where the Brwn wire is shwn in the picture). Rute the Pwer wire up the feeder, arund the pivt, and frward under the cab. Cnnect the 2 pin plug t the plug shwn next t the hrn under the cab. 2. Make sure all ther cnnectrs and harnessing is installed. 3. Pwer the Insight bx. Turn the Dial-A-Matic switch OFF. Start the engine. The LCD display shuld nw be active n the Insight bx. 4. The pwer bypass harness can remain cnnected during peratin. Cnnecting the cmbine t a newer head with Stubble lights will mean the lights will be n whenever the cmbine key is n this shuld nt be a prblem. 5
2.2. Initialize Insight These steps must be perfrmed the first time the Insight bx is pwered up and each time it is reset. They d nt need t be redne each time the Insight bx is calibrated. Read the Insight Overview sectin f the appendix fr basic infrmatin abut hw t use the Insight bx. 1. Chse Language 2. On the Insight bx. Chse Jhn Deere Chse 9x00/10 & xx20 DAM 3. Chse the number f height sensrs Fr JD flex head cnversin, chse 3 Fr ther heads, enter the number f grund sensrs. 4. Chse Header Type (if needed) Chse the apprpriate Header type ONLY chse Flex if the head is t be perated in flex mde, nt lcked up in rigid mde. 2.3. Calibrate Insight When yu initialize Insight, yu will be led directly t this calibratin rutine. If yu wish t recalibrate at any ther time chse >>Perfrm Calibratin n the Insight main menu. 2.3.1. Sensr Calibratin 1. Park the cmbine n a level and smth surface preferably a cement driveway r shp flr. 2. Fllw n-screen instructins. Raise Header - Press Enter Raise the head high enugh that NO sensrs tuch the grund: Press Enter 6
If manual. Lwer Header - Press Enter Lwer the head ALL the way dwn nt the skids. Make sure that bth ends f the header are flat n the grund. Use blcks if necessary. Press Enter an errr appears n the Insight bx see the Diagnstics sectin f this 2.4. Cmbine Cntur-Master Calibratin This calibratin shuld be dne each time a cmbine equipped with Cntur-Master has been used n anther header with a minimum f nce per seasn. This calibratin allws the cmbine t learn hw t level the head. 1. Cmplete the sensr calibratin prcedure abve. 2. Start the engine and attach the header. 3. Engage the header clutch. 4. Turn ff the Cntur-Master switch n the armrest. 5. Lwer header t the grund (n a level surface) fr 2 secnds. 6. Press header raise buttn. 7. Turn n the Cntur-Master switch after the sensrs have left the grund (while cntinuing t raise the header). 8. If the header des nt run level, retry the calibratin. 7
3. Settings 3.1. Cmbine 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. Fr 20 series cmbines see wners manual fr lcatin f drp rate valve and accumulatr 9000-9010 series are shwn. 3.1.1. Autmatic drp rate 1. Use the autmatic drp rate valve adjustment knb n the main valve blck. Turn in all the way then ut ½ turn fr initial guess. If the speed is t fast hunting will ccur. If the speed is t slw the system will nt be respnsive enugh. 2. Cmmn range is 6-8 secnds frm header full up t full dwn in autmatic mde. Aut drp rate valve Manual drp rate valve The maximum autmatic drp rate is limited by the manual drp rate. 8
3.1.2. Hydraulic accumulatr 1. Clse the accumulatr valve all the way 2. 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. Accumulatr valve 9
4. Operatin 4.1. Enabling height cntrl 4.1.1. 9x00 and 9x10 series 1. Turn Dial-a-Matic switch ON. 2. Engage header clutch. 3. Press header lwer buttn. 4. On all 9x00 and 9x10 Jhn Deere cmbines, the manual raise switch shuld ALWAYS verride/shutff aut height cntrl. If nt, test / replace the D-A-M cntrl bard in the cmbine. 10
4.2. Adjusting header height If a Light Bar is nt cnnected, preset raise and lwer pints are used, allwing basic peratin at ne midrange height. 1. Turn the height psitin knb n the light bar with header cntrl engaged. Clckwise = higher Cunter-clckwise = lwer LED Height indicatr Height sensitivity knb Height Psitin knb Because the Headsight bx 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 n the light bar is t lw d nt perate header cntrl at r belw this height. 4.3. 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 the drp rate and accumulatr befre adjusting sensitivity knb. 11
4.4. Adjusting Flat Pressure The pressure changes fairly slwly. Hld the Increase r decrease buttn fr 5-10 secnds t see if pressure changes. LED Pressure indicatr Pressure Increase Pressure Decrease 1. T increase the pressure, press and hld the Increase pressure buttn. 2. T decrease the pressure, press and hld the Decrease pressure buttn. 3. The LED pressure indicatr shws the apprximate pressure in the flat system. The green bar shw the nrmal perating range f the header in flex mde. Running near the bttm f the green area means MORE grund pressure (less hydraulic pressure hlding up the cutterbar). Use this area fr dry, hard cnditins. Running near the tp f the green area means LESS grund pressure (mre hydraulic pressure hlding up the cutterbar). Use this area fr wet, sft cnditins. Raising the pressure all the way up shuld lck up the cutterbar fr rigid mde. Yu may need t increase system pressure in lder cmbines t d s. 4. The LED pressure indicatr will als shw the deck plate psitin n a crn head if the header is equipped with a Headsight cnversin and deck plate sensr. 12
A Insight Overview 1 Rules f menu navigatin When in a menu (selectin arrw appears t left side) Enter chses the selected menu chice Esc backs up ne menu level Up mves up within the menu chices displayed Dwn mves dwn within the menu chices displayed When in a screen which allws setting f parameters Enter backs up t last menu level AFTER saving Esc backs up t last menu level WITHOUT saving Up increases the value Dwn decreases the value 2 Meaning f the status light Slid Green System is perating N errrs detected Slid Red System is NOT perating N height r tilt signals are sent t cmbine Yu have changed settings which require re-calibratin f Insight, are currently in a menu which will frce a re-calibratin if yu make any changes, r are in calibratin mde + Slid Green with Flashing Red System is perating An errr has been detected Repair prblem then clear errrs + Flashing Red System is perating A sensr has been ignred See nte in Trubleshting by Errr - ER16 Repair system Recalibrate Insight 13
3 Screen cntrast adjustment T increase cntrast: + Press and hld Esc Press Up t increase cntrast (while hlding Esc) T decrease cntrast: + Press and hld Esc Press Dwn t decrease cntrast (while hlding Esc) 4 Resetting Insight t defaults T reset ALL settings + fr 5 secnds Press and hld Esc then Press and hld Enter while hlding Esc Hld bth fr 5 secnds 5 Updating Insight Sftware Updating sftware may cause the Fresight ptin t be disabled. If yu have purchased Fresight, cntact Headsight befre updating sftware. 5. Yu will need: SD memry card Means f lading SD memry card either A cmputer with an SD memry card drive A cmputer with USB drive and a USB t SD card adapter A pre-laded SD card frm Headsight Small Allen wrench r screwdriver 6. Lad SD card with new sftware files Place insighte and insightf in the rt directry f the SD card Fr example - E:\insighte and NOT E:\my_flder\insighte DO NOT change the file names 7. If yu d nt have the new files yu may Request updated sftware by email frm inf@headsight.cm 14
Dwnlad updated sftware frm www.headsight.cm (when available) Request pre-laded SD card frm Headsight, Inc 8. Discnnect all header cnnectins frm the cmbine 9. Remve 4 screws frm the rear f the Insight bx remve rear cver 10. Insert prgrammed SD card int SD card slt n rear f bard 11. Pwer Insight Cnnect all wiring t cmbine Turn n keyswitch 12. Wait fr sftware t dwnlad Yellw light n cnnectr will blink while dwnlad is in prgress Green light will turn n slid when dwnlad is cmplete 13. Verify update is successful G t >>Abut Insight>>Sftware Versin and read sftware versin number 14. Remve pwer frm Insight Turn ff key 15. Remve SD card 16. Reinstall rear cver 17. Fasten with screws 15
B Advanced Infrmatin 1 Changing Tilt Orifices The purpse f changing the rifices is t decrease/increase the maximum speed that the Cntur-Master can tilt. The factry cnfiguratin will be satisfactry fr mst cnditins. Hwever, wide headers may need t adjust the rifices. Only change rifices if the system cannt be set prperly by using the sensitivity adjustment n the cntur-master card. The target tilt speed is 5-8 secnds frm full right t full left fr mst machines. 1. Using 1/8 allen wrench remve riginal rifice frm valve blck in tilt cylinder supply lines. Keep rifice in secure lcatin fr later use if needed. 2. If tilt speed is t fast install an rifice that is smaller than the riginal rifice remved. 3. If tilt speed is t slw install an rifice that is larger than the riginal rifice remved, r remve rifice cmpletely 16
2 Cnnecting the 9 pin T t a 6pin cmbine Hydr Handle cnnectr Early mdel 9000 series level-land cmbines had a 6 pin cnnectr n the Hydr handle. This must be change t allw cnnectin f the 9 pin T cnnectin. 1. Tls Needed: An Amp Multimate pin remval tl. 2. Identify the crrect cnnectr n the Headsight Cab harness T. 9 pin Orange Female receptacle with Male pins. 3. Remve pins 6 & 7 frm this cnnectr These pins are nt reinstalled. Fld them back and tape them. Remving these first lessens cnfusin amng multiple lt. green wires. 4. Remve pins 1-5 frm this cnnectr These pins will be reinstalled in the same # cavity n the 6 pin cnnectr later. 5. Discnnect the OEM Hydr handle plug under the Cntrl Panel. 6. Identify the crrect cnnectr n the OEM Hydr handle cnnectr set. See arrw. 6 pin Orange female receptacle with Male pins. On harness t main wiring, nt cable t hydr handle. 7. Remve 1 pin at a time frm this cnnectr, and reinstall in the same cavity n the 9 pin remved in step 4 abve. Ding them ne at a time will prevent cnfusin. Pin 1, 6p (wire # 015) t pin 1, 9p Pin 2, 6p (wire # 437) t pin 2, 9p Pin 3, 6p (wire # 425) t pin 3, 9p Pin 4, 6p (wire # 408) t pin 4, 9p Pin 5, 6p (wire # 409) t pin 5, 9p 17
8. Reinstall the 5 wires n the Headsight T int the same cavity n the 6 pin remved in step 7 abve. Ding them ne at a time will prevent cnfusin. Red wire # 015A t pin 1, 6p Lt. Green wire # 437A t pin 2, 6p Lt. Green wire # 425A t pin 3, 6p Yellw wire t pin 4, 6p Dk. Green wire t pin 5, 6p 9. Tee the Headsight cab harness cnnectrs int the OEM Hydr cnnectrs. 6 pin n Hydr handle cable t 6 pin newly installed n Headsight T 9 pin newly installed n OEM cab wiring t 9 pin n Headsight T. 18
C Diagnstics 1 Thery f Operatin All JD Dial-a-Matic (20/00/10 series) cmbines height cntrl systems wrk in a similar way. A review f the fllwing pints will help the service technician t understand the cmplete system which will help when diagnsing specific prblems. 1. Each sensr returns a variable vltage t the cntrl bx at the rear f the header depending n its height. high height = high vltage (apprximately 4 vlts) lw height = lw vltage (apprximately 1 vlt) 2. Each sensr has 3 wires 5V pwer grund signal returned t the cntrl bx (varies between apprximately 1.0 and 4.0 vlts) 3. The Iterface bx cmpares the center input (cutterbar) sensr t the desired height chsen n the light bar in the cab. If the height sensr has a lwer vltage (is nearer the grund) than the height setpint vltage the bx sends a raise signal t the cmbine n pin #5 f the 16 pin header cnnectr. If the height sensr has a higher vltage (are farther frm the grund) than the height setpint vltage plus the deadband chsen by the sensitivity knb the bx sends a lwer signal t the cmbine n pin #3 f the 16 pin header cnnectr. 4. The sensitivity knb n the light bar adjusts the size f the deadband. The deadband is a small area where the system will neither raise nr lwer. This helps prevent hunting f the header. 5. The lights n the light bar are visual indicatrs f head psitin t the peratr. If a Light Bar is nt cnnected, preset raise and lwer pints are used, allwing basic peratin at ne midrange height. 19
6. The left and right sensr signals are scaled t the crrect range (0.5-4V) then sent n t the cmbine n pins 7 and 9 respectively fr Cntur-Master peratin. The fllwing symbls are used in the trubleshting guide: Dentes a prblem r symptm. Read thrugh the prblems and select the ne that mst clsely represents yur prblem. A questin r cnditin needed fr the fllwing steps that the technician must answer. Read thrugh the pssible ptins and select the ne that mst clsely represents yur prblem. A pssible answer t the previus questin r prblem Evaluate each pssible answer t determine the cause f the prblem. Answers are given in rder frm mst t least likely. Gives further explanatin r testing instructins. 2 Trubleshting..by symptm Header is t jumpy r respnds t slwly Cmbine is imprperly set. See Settings sectin adjust drp rate and accumulatr. Sensrs need t be recalibrated. See Calibratin sectin. 20
Header is nt level with Cntur-Master enabled. If the header tilts cmpletely t ne side: Verify that the individual sensr wiring is cnnected t the main wiring harness at the rear f the header prperly. This symptm will ccur if the Left and Right sensr wiring are in the incrrect psitin. See Installatin sectin fr details. Check individual sensrs If the header is slightly ut f level but functins crrectly: Verify that all sensrs can mve freely thrugh the entire range. Verify that all sensrs are cnnected, functining and calibrated as per the Calibratin sectin f this manual. Recalibrate cmbine Cntur-Master. -See Calibratin sectin. Height cntrl wrks but Cntur-Master des nt Mate all cnnectrs and engage system. Keep ne persn in the seat and all cnnectrs mated (remve back shell and prbe thrugh rear f cnnectr). Under >>Diagnstics>>Detailed Diagnstics>>Left & Right Outputs shuld be 0.5-4 vlts and change as the sensrs are mved. Service cmbine. If utputs are nt as described abve Recalibrate sensrs Reset r replace Insight. N autmatic peratin - height r tilt Wiring is nt cnnected prperly Header cntrl is nt enabled with cab cntrls. See Operatin sectin fr instructins abut hw t enable. If Insight is pwered and Green Light is n: D-A-M lp nt wired in Headsight harness (9000-10) 21
Unplug 16 pin header plug and measure cntinuity acrss Pins 4 & 11 in the Headsight half. Pins must be <5 Ohms (shrt circuit). Cmbine D-A-M bster bx defective ( 20 series nly). Test / repair bster bx Suspect defective Insight system. Test Headsight system by fllwing raise/lwer diagnstics belw. If Insight is NOT pwered (n lights): Ensure black grund wire is securely attached t the header frame (cmbines 90). Cmbine des nt supply 12V n pin 4 f the header cnnectr. Fllw steps in Trubleshting..cmmn cmbine prblems belw Suspect defective Insight r main harness. Head drps all the way t grund. Height psitin knb n light bar set t lw Rtate knb CW until head raises. Cmbine nt receiving raise signal. Under >>Diagnstics>>Detailed Diagnstics>>D-A-M Outputs Set the height psitin knb n the Light bar at MAX. When the head is fully n the grund, Raise shuld be ON. If abve is true, but head des nt mve, check Cmbine fr cnnectin/peratin issues. Cntact Headsight Head raises all the way t tp. Height psitin knb n light bar set t high. Rtate knb CCW until head lwers. Sensr stuck up under head. remve bstructin. 22
Insight LED flashing Green/Red r Red Defective sensr r harness (any sensr signal < 1V). Trublesht sensr Cmbine nt receiving lwer signal. Under >>Diagnstics>>Detailed Diagnstics>>D-A-M Outputs Set the height psitin knb n the Light bar at MIN. With the head raised up, Lwer shuld be ON. If abve is true, but head des nt mve, check Cmbine fr cnnectin/peratin issues. Cntact Headsight Head raises ver bstacle but des nt lwer. Height psitin knb n light bar set t high. Rtate knb CCW until head lwers. Height sensitivity knb n the light bar set t lw. Rtate knb CW t narrw deadband. Sensr stuck up under head. remve bstructin. Feederhuse psitin chain mis-adjusted ( 00-20 series). Cmbine nt receiving lwer signal. Under >>Diagnstics>>Detailed Diagnstics>>D-A-M Outputs Set the height psitin knb n the Light bar at MIN. With the head raised up, Lwer shuld be ON. If abve is true, but head des nt mve, check Cmbine fr cnnectin/peratin issues. Cntact Headsight Head lwers t selected height but des nt raise ver bstacles. Height psitin knb n light bar set t lw Rtate knb CW until head raises. Height sensitivity knb n light bar set t lw. 23
Rtate CW t narrw dead band. 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 lwer signal. Under >>Diagnstics>>Detailed Diagnstics>>D-A-M Outputs Set the height psitin knb n the Light bar at MAX. When the head is fully n the grund, Raise shuld be ON. If abve is true, but head des nt mve, check Cmbine fr cnnectin/peratin issues. Cntact Headsight 3 Trubleshting..cmmn cmbine prblems Unpened r discharged accumulatr - Head jumps and jerks whle cmbine. Test accumulatr as described in cmbine wner s manual Replace r recharge as necessary N 12 Vlts available n the header plug. Check OEM harness n feeder huse fr damaged wires. Fr JD9x00-9x10 series test with One persn n the seat in the cab DAM switch in psitin 1,2,r 3. Header clutch engaged. If still n 12V Replace DAM relay in armrest. Test/Replace DAM switch. Fr xx00-xx20 series test as abve and als: 24
Make sure feeder huse psitin chain is prperly adjusted t pull rcker free f switch under cab. Check switch fr prper peratin. The Jhn Deere D-A-M cmbines nly prvide pwer t the Height Cntrl system when the Feeder Huse Switch is engaged and the D-A-M rtary Switch is NOT OFF. If these switches are n and Pin 4 f the cmbine header cnnectr is nt 11-14 Vlts, have the cmbine serviced. Manual raise switch des nt disengage aut height. Replace relays n D-A-M cntrller bard in cmbine. On all 9000 and 9010 Jhn Deere cmbines, the manual raise switch shuld ALWAYS verride/shutff aut height cntrl. If nt, test / replace the relays n the D-A-M cntrl bard in the cmbine. This is nt a Headsight prblem. Manual lwer switch des nt engage aut height. Test Headsight system as described in N peratin Test cmbine 12 V supply as abve. If all systems appear t be wrking, with bth raise and lwer signals sent t the cmbine. Check OEM raise/lwer wiring Test D-A-M cntrller bard in cmbine. 4 Trubleshting by Insight errr cdes ER11 Sensr 1 (left) signal less than 0.3V Sensr 1 ut f adjustment r temprarily discnnected. Adjust sensr until minimum vltage is greater than 0.3V accrding t sensr calibratin instructins Lw vltage is with the header n the grund fr standard plarity fully raised plarity is reversed Calibrate Headsight Bx Calibrate Cmbine Wiring shrt Check sensr harness fr pinched/brken wiring Sensr failure 25
See sensr test instructins ER12 Sensr 1 (left) signal greater than 4.7V Sensr 1 ut f adjustment This errr will be displayed if a sensr that is enabled becmes temprarily discnnected fr hardware versin 1 Adjust sensr until maximum vltage is less than 4.7V accrding t sensr calibratin instructins High vltage is with the header fully raised fr standard plarity n the grund fr reversed plarity Calibrate Headsight Bx Calibrate Cmbine Sensr failure See sensr test instructins ER13 Sensr 1 (left) swing less than 0.6V Sensr 1 mechanical range is restricted Verify sensr is nt bstructed in swing Verify sensr can cllapse fully with header lwered Adjust upstp t allw greater range Sensr failure See sensr test instructins ER16 Sensr 1 (left) expected but nt detected Sensr 1 nt prperly cnnected Verify harness is cnnected t sensr 1 Verify harness is cnnected prperly t cntrl bx harness Verify that signal wire (Pin B white wire f sensr cable) is cnnected t PIN7 f cnnectr Y101 (Headsight bx) Incrrect number f sensrs selected in setup G t >>Initial Setup>>Num Sensrs and chse the crrect number f sensrs Sensr failure See sensr trubleshting instructins Cntrl bx /wiring failure Cntact Headsight If any f these errrs (ERx6) ccurs during peratin Insight will effectively smash the affected sensr causing the header t raise 26
Yu may temprarily ignre the affected sensr WITHOUT repairing it by clearing the errr cdes (Diagnstics>Clear Errr Cdes) Height cntrl will functin using the unaffected sensrs Tilt cntrl will functin if the affected sensr is NOT used fr determining tilt psitin If the sensr is used fr tilt yu will need t disable the lateral tilt functin f the cmbine If yu repair the prblem THEN clear the errr, the affected sensr will nt be ignred After repairing the prblem, yu MUST recalibrate Insight t re-enable the ignred sensr ER17 Sensr 1 (left) detected but nt expected Incrrect number f sensrs selected in setup G t >>Setup>>System Select and chse the crrect number f sensrs Harness wiring errr Verify that n wires cntact PIN7 f cnnectr Y101 Cntrl bx /wiring failure Cntact Headsight ER21 Sensr 2 (left-center) signal less than 0.3V Fllw prcedures f ER11, substitute sensr 2 fr sensr 1 ER22 Sensr 2 (left-center) signal greater than 4.7V Fllw prcedures f ER12, substitute sensr 2 fr sensr 1 ER23 Sensr 2 (left-center) swing less than 0.6V Fllw prcedures f ER13, substitute sensr 2 fr sensr 1 ER26 Sensr 2 (left-center) expected but nt detected Fllw prcedures f ER16, substitute sensr 2 fr sensr 1 Substitute PIN13 fr PIN7 ER27 Sensr 2 (left-center) detected but nt expected Fllw prcedures f ER17, substitute sensr 2 fr sensr 1 Substitute PIN13 fr PIN7 ER31 Sensr 3 (center) signal less than 0.3V Fllw prcedures f ER11, substitute sensr 3 fr sensr 1 ER32 Sensr 3 (center) signal greater than 4.7V Fllw prcedures f ER12, substitute sensr 3 fr sensr 1 ER33 Sensr 3 (center) swing less than 0.6V Fllw prcedures f ER13, substitute sensr 3 fr sensr 1 ER36 Sensr 3 (center) expected but nt detected Fllw prcedures f ER16, substitute sensr 3 fr sensr 1 Substitute PIN8 fr PIN7 27
ER37 Sensr 3 (center) detected but nt expected Fllw prcedures f ER17, substitute sensr 3 fr sensr 1 Substitute PIN8 fr PIN7 ER41 Sensr 4 (right-center) signal less than 0.3V Fllw prcedures f ER11, substitute sensr 4 fr sensr 1 ER42 Sensr 4 (right-center) signal greater than 4.7V Fllw prcedures f ER12, substitute sensr 4 fr sensr 1 ER43 Sensr 4 (right-center) swing less than 0.6V Fllw prcedures f ER13, substitute sensr 4 fr sensr 1 ER46 Sensr 4 (right-center) expected but nt detected Fllw prcedures f ER16, substitute sensr 4 fr sensr 1 Substitute PIN14 fr PIN7 ER47 Sensr 4 (right-center) detected but nt expected Fllw prcedures f ER17, substitute sensr 4 fr sensr 1 Substitute PIN14 fr PIN7 ER51 Sensr 5 (right) signal less than 0.3V Fllw prcedures f ER11, substitute sensr 5 fr sensr 1 ER52 Sensr 5 (right) signal greater than 4.7V Fllw prcedures f ER12, substitute sensr 5 fr sensr 1 ER53 Sensr 5 (right) swing less than 0.6V Fllw prcedures f ER13, substitute sensr 5 fr sensr 1 ER56 Sensr 5 (right) expected but nt detected Fllw prcedures f ER16, substitute sensr 5 fr sensr 1 Substitute PIN9 fr PIN7 ER57 Sensr 5 (right) detected but nt expected Fllw prcedures f ER17, substitute sensr 5 fr sensr 1 Substitute PIN9 fr PIN7 ER61 Sensr 6 (aux sensr) signal less than 0.3V Fllw prcedures f ER11, substitute sensr 6 fr sensr 1 ER62 Sensr 6 (aux sensr) signal greater than 4.7V Fllw prcedures f ER12, substitute sensr 6 fr sensr 1 ER63 Sensr 6 (aux sensr) swing less than 0.6V Fllw prcedures f ER13, substitute sensr 6 fr sensr 1 ER66 Sensr 6 (aux sensr) expected but nt detected Fllw prcedures f ER16, substitute sensr 6 fr sensr 1 Substitute PIN15 fr PIN7 ER67 Sensr 6 (aux sensr) detected but nt expected Fllw prcedures f ER17, substitute sensr 6 fr sensr 1 Substitute PIN15 fr PIN7 28
5 Reading vltages n the Insight bx 7. Frm the main menu, g t >> Diagnstics>>Disp Sensr Vltages This shws real-time the vltage cming frm each sensr. 8. Fr mre infrmatin abut the sensr histry and status see >>Diagnstics>>Detailed Diagnstics>>(chse the item f interest) The infrmatin fund in the detailed diagnstics menu is in mst cases simple and straightfrward. The sensr detailed diagnstic screens cntain a lt f infrmatin as described belw: Sensr 1 = 2.52V Max= 3.91V SetH= 3.93V Min= 1.02V SetL=1.21V Enabled=Y ReVersed=Y Sensr # = n.nnv # = which sensr 1=L, 3=C, 5 = R etc N.NN = signal frm sensr in vlts Max = n.nnv N.NN = the maximum vltage frm this sensr after calibratin Min = n.nnv N.NN = the minimum vltage frm this sensr after calibratin Enabled = x x = is this sensr enabled t cntrl height? Yes r N SetH = n.nnv N.NN = the raised vltage set-pint recrded during calibratin SetL = n.nnv N.NN = the lwered vltage set-pint recrded during calibratin Reversed = x X = is the plarity f this sensr reversed? Yes r N 29
D Parts 1 2 3 4 5 Key# Part# Descriptin Qty Ntes 1 HT999LB-07 HYDRA LIGHTBAR 1 2 knbs 2 HT9801-CAB CAB HARNESS 1 Hyrdaflex cnversin harness 3 HT9801-FH FEEDER HARNESS 1 Hydraflex Feedr harness 4 INSIGHT CONTROL BOX 1A Insight Cntrl unit 5 QP0-JD10-31Q HARNESS 1A Insight adapter cnversin fr 600F heads 6 HP0-JD10-31Q BLACK BOX 1B Black bx cnversin cmplete w/ harness (nt shwn) replaces 4 & 5) 30
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