JD Flex Header Manual 09030101c
About Headsight Headsight Contact Info Headsight, Inc 3529 Fir 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 This manual is laid out in the order which you should do each step. You may follow the manual from beginning to end, performing all steps which are designated for your head. This icon designates information of which you should take note. This icon designates an important instruction. Disclaimers Headsight, Insight, Foresight, FeatherSight 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. Portions of this product are protected by US Patents 6202395, 6833299, 7310931, and other US and international patents, issued and pending. i
Table of Contents About Headsight Headsight Contact Info Technical Assistance About this Manual How to use this manual Disclaimers Suggestions i i i i i i i 1 Mounting Sensors 1 1.1 JD600F - Standard Sensors 1 1.2 JD900F Standard Sensors 3 1.3 JD600F and 900F - Terrace Sensors 3 1.4 Wands and Cables 4 2 Routing Wiring 6 2.1 Helpful Hint 6 2.2 Wiring Instructions 7 2.2.1 Wiring Overview 7 2.2.2 Right Sensor 7 2.2.3 Left Sensor 8 2.2.4 Center Sensor(s) 9 2.2.5 Finishing Wiring 10 2.3 Wiring Graphic 10 A Sensor Adjustment - Standard 11 Increasing or Decreasing Voltage 11 Adjusting Swing 12 Adjusting Downpressure 12 B Sensor Adjustment Terrace 13 Increasing or Decreasing Voltage 13 Adjusting Down pressure 13 C Parts Information Standard HT8000 14 ii
D Parts Information - Terrace 15 E Warranty Information 16 iii
1 Mounting Sensors Before working under the 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. 1.1 JD600F - Standard Sensors For all JD600F installations you MUST lock up (increase the HydraFlex pressure) the header before connecting the Headsight harness to the combine. The original JD harness must be connected to the combine to change the HydraFlex pressure. 1. Choose locations on header to mount the sensors. o Place outer two as close to the end of the header as possible. o Evenly space other sensors. 2. Locate and remove skid plates at sensor mounting locations. o Remove first available skid on the right side of the header. o Remove the double skid on the left side of the header. o Install the skid removed from the right side into the space created on the left. o Remove any other skids at locations of inner sensors. 1
Insert Sensor Here Insert Skid from Right 3. Mount the sensors in the chosen locations. o Attach Headsight sensor into brackets using hardware B886 o Mount brackets in locations where skids were removed using original hardware. 2
1.2 JD900F Standard Sensors Installation will be easier if sensors are installed BEFORE locking header into rigid position. 1. Choose locations under header to mount the sensors. o Place outer two as close to the end of the header as possible. o Evenly space other sensors. 2. Attach brackets using bolts shown reuse existing nuts. Insert z-shaped support Use these bolts 1.3 JD600F and 900F - Terrace Sensors 1. The end panel float spring on each side must be either removed or totally released. o The weight of the end panel is needed to provide adequate down pressure to penetrate the stubble. 2. Remove the two bolts that secure the crop divider tube to the end panel (from the underside of the tube). 3. Remove the JD divider and insert the new divider/bracket as shown. 4. Insert and tighten the divider mounting bolts removed above. 3
1.4 Wands and Cables Headsight recommends installing the wands as described below for the most grain-saving header height control. This method allows a tilting feederhouse to work more efficiently over uneven ground. It also allows the center of the head to work closer to the ground, reducing both scalping and grain loss. Short Wand Long Wand 1. Install the long wands on the outermost sensor on each side. o Make sure to completely tighten the bolts. 2. Install the short wands on all inner sensors. 3. Attach a protection cable to each wand. o Use a screwdriver to pry open the slit in the rear of the wand. 4
4. Fasten the rear of the cable to a secure location on the header. o Make sure that the cable cannot catch on any moving or solid parts. o Adjust the cable length so that it pulls the arm slightly (1/2 ) back from its original position. Do not leave or store the arms in a flattened or crushed position. They must be stored in a way that they can maintain their curved shape. Crushed Free 5
2 Routing Wiring Properly routing the wiring is the most critical part of the installation process. Please take time to ensure that you have allowed sufficient slack for motion as well as sufficient clearance from moving header parts or crop flow. 2.1 Helpful Hint When routing the wiring, there may be times when you would like to route the wiring through a small hole. You may remove the Weather-Pack connector by using the following procedure. This step is NOT required; it is only shown to aid installation if needed. 1. Record the pin location of each wire color in the connector. o Example: A= Black, B= White, C= Green 2. Release the back cover of the connector and open hinge. 3. Insert provided pin tool over the pin from the front. o Push until the tool stops. 4. Gently pull out wire from the back. 5. Route wire through obstacle. o Flare out tabs on both sides of terminal! 6. Push wire back into original location until it snaps into place. o Gently tug each wire to make sure it is secure. 7. Refasten back cover. 6
2.2 Wiring Instructions 2.2.1 Wiring Overview The general goal is to route the wiring to rear of header near the combine feederhouse electrical connectors. The wiring must be protected from moving parts and from crop flow. Due to operator preferences and header variations there are multiple ways to route the wiring. The following instructions are an example of routing on a 600F header others are similar. 1. Lay out wiring to appropriate sensor location. o Wiring will run from the sensor to the rear of the header near the combine s feederhouse connection. o See the Wiring Graphic below for assistance. 2. Connect the wiring to each sensor. o Ensure connection is properly aligned and seated. o Push gently but firmly until you hear or feel a slight click. o Use included cable clamps to fasten wiring as shown to sensor/bracket. 2.2.2 Right Sensor 1. From sensor -route wiring to outside of right-hand end panel. o Terrace sensors follow divider tube. 2. Follow existing wiring or hoses o Up and to the rear of the header o Across the rear of the header toward the feederhouse connection. 7
3. Push a fish-tape or wire from the left side of the feederhouse to the right through the top channel of the header frame. o There is a lip on the bottom side of the channel, using a deflector as shown may help the fish-tape and wire pass through more easily. 4. Connect the fish-tape to the wiring and pull it through to the left side of the feederhouse. o Cover the electrical connection in electrical tape to prevent damage from dirt or chaff. 2.2.3 Left Sensor 1. From sensor -route wiring to outside of left-hand end panel. o Terrace sensors follow divider tube. 2. Follow existing header control wiring or hoses o Up and to the rear of the header o Across the rear of the header toward the feederhouse connection. 8
2.2.4 Center Sensor(s) 1. Route wiring rearward under header. o Attach to bracket as shown note height sensing rod will move. 2. Fasten wiring to and route with hydraulic lines. 3. Bring rearward through HydraFlex support bracket. o This will help keep wiring out of the crop flow. 9
2.2.5 Finishing Wiring 1. Secure wiring with cable clamps and zip ties approximately every 12-24 throughout path as needed. 2. Wrap and fasten excess wiring in secure location. See the Headsight combine manual for more details about how to install the remaining wiring harness or control box and connecting each individual sensor. 2.3 Wiring Graphic 10
A Sensor Adjustment - Standard Sensor Mounting Increasing or Decreasing Voltage 1. Loosen sensor mounting nuts. 2. Twist sensor to new position using slotted mounting holes. o Twisting sensor clockwise (viewed from the end of the sensor) will increase voltage. o Twisting sensor CCW will decrease voltage. 11
Adjusting Swing For quick adjustments- you may adjust the sensing arm swing by changing the slack in the support cable. (see 1.4 above) 1. Release the spring downpressure (see below). 2. Remove the down stop. 3. Rotate the downstop to a new position. 4. Retighten downstop and spring tension. Adjusting Downpressure 1. Remove spring cover. 2. Loosen indicated nut. 3. Press adjustment bolt toward sensor. o Spring tension will release. 4. Preload spring to a new position. o Use one wrench to turn the adjustment bolt. o Use a second wrench to tighten the nut. o Tightening the bolt (CW) increases spring downpressure. Make sure that the leg of the spring is fully seated in the shaft to prevent rubbing on the cover plate. 5. Reinstall cover plate. 12
B Sensor Adjustment Terrace Increasing or Decreasing Voltage 1. Loosen the screw indicated. 2. Turn calibration shaft to new location. 3. Tighten screw. Adjusting Down pressure 1. Remove retaining pin. 2. Move spring handle to new position. o Raising handle decreases down pressure o Lowering handle increases down pressure 3. Reinsert retaining pin. 13
C Parts Information Standard HT8000 19 1 2 3 4 6 5 7 22 23 18 17 16 15 17 21 23 10 11 20 8 24 14 9 12 13 9 Key# Part# Description Qty Notes 1 HT8117 SHAFT 1 2 HT863 BUSHING 1 left 3 08100121 SNAP RING 1 SH-100-ST 4 HT862 BUSHING 1 right 5 HT2126 MAGNET (in end of shaft) 1 6 HT2128 SENSOR HALL EFFECT 1 7 08200153 SCREW HCW #10-24-1-1/4 2 8 HT8114 COVER 1 right 9 08200150 BOLT FLANGE 5/16 X 1/2 2 10 HT8115 ARM 1 11 HT870 UPSTOP 1 12 08200133 WASHER 5/16 YZ HARD 1 13 08200136 BOLT 5/16 X 1-1/4 Z 1 14 HT8111 COVER 1 left 15 HT840 SPRING 1 16 HT869 ADJUSTING CLIP 1 17 08200145 NUT FLANGE 5/16 2 18 08200109 BOLT 5/16 X 1-1/8 Z 1 19 HT8118 BASE 1 20 082001326 BOLT 5/16 X ¾ Z 1 21 08200102 CLAMP 5/16 3/8 HOLE 1 22 PFBxx WPACK EXT HARNESS AR std polarity, choose xx= 10,17,23,33,or 38 (in ft) 07010103 WPACK MALE PIN AR used with tower 07010101 WPACK TOWER AR used with male pins 07010105 SEAL AR green 07010102 WPACK SHROUD AR used with female pins 07010104 WPACK FEMALE PIN AR used with shroud 23 HT801 WAND, SHORT 1 HT801-Y = yellow, HT801-B = black 24 HT701 WAND, LONG 1 HT701-Y = ylw, HT701-B = blk, HT701-N = nylon 25 HT8000 STANDARD ASSEMBLY 1 includes 1-21 14
D Parts Information - Terrace 17 15 14 1 3 4 11 16 13 2 5 6 7 7 8 12 10 9 11 Key# Part# Description Qty Notes 1 HT627 BOX 1 2 HT726 SPRING 1 3 08100106 PIN 1 DOWNPRESSURE ADJUSTMENT 4 08100107 CLIP PIN 5 HT629 ARM 1 6 HT634 BOLT, DOWN STOP 1 7 08200157 10-24 X ¼ SCREW 3 8 HT630 SHAFT CALIBRATION 1 9 08100110 RETAINING CLIP 10 HT628 COVER 1 11 08200150 5/16-18 X 1/2 1 12 HT2128 HALL EFFECT SENSOR 1 13 HT729 BUSHING BRONZE 1 18 14 08200134 BOLT 5/16 X ¾ 2 15 HT632 STRAP DIVIDER 1 16 08200162 WASHER 5/16 7/8OD 2 17 HT631 DIVIDER YELLOW POLY 1 19 18 HT801- WAND, SHORT 1 -Y = yellow,-b = black,-bu = blue 19 HT701- WAND, LONG 1 -Y = ylw, -B = blk, -N = nylon, -BU = blue HT700 COMPLETE SENSOR ASSY 15
E Warranty Information Statement of Limited Warranty for Grain Products Headsight Inc. (Headsight) warrants its new grain sensors assemblies for a period of twelve (12) months, and its electronic wiring and interface control boxes for a period of twelve (12) month to be free from defects in material and workmanship following the date of purchase by the retail purchaser. 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: o Warranty claims directly resulting from improper installation of the product. o Any product damaged by accident, abuse, misuse, or negligence after shipment from Headsight. o Any unauthorized product alteration or modification. o Any unauthorized repairs made with parts other than genuine Headsight parts. o Any repairs performed by anyone other than Headsight or an authorized Headsight dealer unless specifically authorized by Headsight. Warranty Procedure o Troubleshooting must be done between customer and Headsight through Headsight s technical assistance @ 574.220.5511. o 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. o There is no mileage reimbursement. o Diagnostic time will not be reimbursed except in pre-arranged circumstances. o Warranty claims should be on typical dealer service work order with a number and name to be attached for any future correspondence. o All warranty work must be performed, and claims submitted, within sixty (60) days of the occurrence of the claim and within the warranty period. o All parts removed during warranty repair should be held for a period of 60 days after the warranty claim has been submitted to Headsight. o 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 foods 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, NO FOR ANY SUM IN EXCESS OF THE PRICE RECEIVED FOR THE GOODS FOR WHICH LIABILITY IS CLAIMED. No representative of Headsight or 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: 1/2007rls 16
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