AGCO Combine Manual 09010401i 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 Basic Harness Only Systems 2 Insight Systems 3 Insight Box Mounting 3 Insight Box Power Wire 3 Feathersight Option Installation (if equipped) 4 Feathersight Pressure Sensor Option Installation 5 Hydraulic Response Kit (optional) 6 Calibration 7 Setup Insight Box 7 Calibrate Insight 7 Standard Calibration 7 Foresight Calibration (if equipped) 8 Feathersight Calibration (if equipped) 9 Combine Ground Calibration 10 AGCO MY2009-up, except Rxx and Sxx 10 AGCO MY2003-2008 all, and Rxx & Sxx 11 AGCO F6 MY1998-2002 12 Settings 13 Combine Settings 13 All - Hydraulic accumulator 13 AGCO MY2009 - up, except Rxx and Sxx 14 AGCO MY1998-2008 all, Rxx and Sxx 15 Insight Settings 16 Tilt Algorithm Selection 16 Tilt Sensitivity 17 Feathersight - HP Balance 17 Operation 18 Enabling Height Control 18 AGCO 2009 - up except Rxx and Sxx 18 AGCO 1998-2008. Rxx and Sxx 19 Overview 20 Insight Navigation 20 How to Navigate 20 Meaning of Status Light 20 Screen Contrast Adjustment 20 Resetting Insight to Defaults 21 Updating Insight Software with USB Drive 21 Advanced Information 22 Theory of Operation 22 Basic Requirements 22 ii
Reading Voltages 23 Before you Start 23 On the Insight Box 23 AGCO MY2009 - up 24 AGCO 1998-2008. Rxx and Sxx 24 Diagnostics 25 Troubleshooting by Symptom 25 Troubleshooting by Insight Error Codes 29 Parts 41 STATEMENT OF LIMITED WARRANTY 42 iii
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
Complete the installation portion of the header manual before continuing. Basic Harness Only Systems Harness only systems do not use the Insight box. After completing this section go directly to Combine Ground Calibration section. If you have an Insight box skip this section and proceed to the next section. 1. Connect sensor wiring to main Headsight harness. Sensor location as viewed from operator s seat Installation Left Center Right 2 Sensor X X 3 Sensor X X X *L-Left, C-Center, R-Right 2. Connect 31 pin Y311 connector to combine. L C R Deck 3. Connect remaining Y312 connector to header. If you have no Y312 connector, you may connect warning /stubble lights using wire labels 2
Installation Insight Systems Insight Box Mounting Skip steps 2-4 if the Header manual already had you mount Insight box. 1. Connect Insight box to main Headsight harness. 2. Hold box at rear of header so Headsight harness can reach feeder house electrical connection of combine and mark mounting hole locations. 3. Drill mounting holes using 1/4 drill bit. 4. Secure box to header using hardware provided. 5. Connect sensor wiring to main Headsight harness. Sensor location as viewed from operator s seat Left Left Center Center Right Center Right 2 Sensor X X 3 Sensor X X X L C R 4 Sensor X X X X 5 Sensor X X X X X L LC C *L-Left, LC-Left Center, C-Center, RC-Right Center, R-Right RC R 6. Connect 31 pin Y311 connector to combine. 7. Connect remaining Y312 connector to header. If you have no Y312 connector, you may connect warning /stubble lights using wire labels 8. If your header harness has mating 1 pin Weatherpack plugs on purple wires, connect the plugs for hydraulic reel drive only. Otherwise, leave them disconnected. Insight Box Power Wire 1. If your kit includes a power wire, route it from the header connector into the cab (follow existing wiring) and attach it to the Spare Fuse location on the board in the fuse panel. 2. Attach the black wire to a ground bolt in the fuse compartment. 3. Connect the Power wire to the header harness 2 pin Deutsch At front of feederhouse 3
Feathersight Option Installation (if equipped) Feathersight is an optional module to improve the performance of grain systems. It uses both height sensors and the feeder house pressure sensor to allow seamless control from off ground to on ground harvesting. Massey Ferguson95x0 and Challenger 5x0C Installation 1. If combine already has a feederhouse pressure sensor connect Y harness in-line with combine feeder house pressure sensor on main valve block. If combine does not have a feeder house pressure sensor follow steps in next section 2. Connect harness to sensor 3. Carefully route harness to front of combine near header connector and attach with zip ties. 4. Connect harness to main insight wiring (4 pin, round AMP connector) Massey Ferguson 95x0 and Challenger 5x0C 4
Installation Feathersight Pressure Sensor Option Installation All other Agco Combines 1. Perform all combine and header manufacturer safety precautions for servicing header. 2. Remove header from combine. 3. Insert stop to prevent movement of header. 4. Release all pressure in hydraulic cylinders. Lower feeder house against lock and hold button for 10 seconds 5. Turn off combine and remove key from ignition. 6. Set combine parking brake. 7. Disconnect all drive shafts from header. For Gleaner R6x, R7x, and all Sxx 8. Install pressure sensor in valve block behind front wheel Remove plug from valve block in location shown Screw sensor into port 9. Connect harness to sensor. 10. Carefully route harness to front of combine near header connector attaching with zip ties. 11. Connect harness to main insight wiring (4 pin round AMP connector) For Gleaner MY98-09, Massey Ferguson and Challenger 5x0C 12. Install pressure sensor in lift port on left hand lift cylinder. Remove line from cylinder Install provided T fitting in line Attach provided pressure sensor Reattach hydraulic line and ensure o-rings are properly seated 13. Connect harness to sensor. 14. Carefully route harness to front of combine near header connector attaching with zip ties. 15. Connect harness to main insight wiring (4 pin round AMP connector) 5
Hydraulic Response Kit (optional) Headsight strongly recommends you purchase our Hydraulic Response Kit for the best header control on R65-S8 Series Combines. For more information or to purchase please contact your Headsight Dealer or Call the Headsight Sales line. Installation 6
Calibration Calibration 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 AGCO Choose the MY range Choose the Header type Choose the number of height sensors 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 sensors touch the ground and press enter Lower Header all the way down on the skids and press enter Go to Combine Ground Calibration section of this manual. If an error appears on the Insight box - see the Diagnostic section of this manual. 7
Foresight Calibration (if equipped) Foresight is an optional module to improve the performance of corn systems very near the ground. Each Insight box comes with a 5 hour free trial of Foresight. 1. Park the combine on a smooth, level surface - preferably a cement driveway or shop floor. If you are unable to find a smooth surface, disable Foresight and perform the standard calibration 2. Adjust the snout tips height. The snouts should be level across the head and touch the ground at the same point The snouts should touch the ground when the skid plates are 4-6 off the ground for most headers 3. Enable Foresight on the Insight Box. Go to >>Setup>>Optional Modules>>Foresight>>Enable Foresight Calibration If you would like to purchase Foresight, contact Headsight. 4. Set the Foresight Gain. >>Setup>>Optional Modules>>Foresight>>Set Foresight Gain, in the Insight box The initial gain setting depends on the header dimensions. To the right are example settings For other headers and/or sensor combinations, the proper setting may be determined by: Headsight Sensors Wand Length Gain Position 1 (no extension) 3.5 Position 2 3.1 Position 3 2.8 Position 4 (Longest) 2.5 Gain = Snout Length Contact Distance 5. Fine tune the gain setting. Increase the gain for greater responsiveness near the ground Decrease the gain if the header seems jumpy near the ground ONLY If the header is jumpy with the points in the air, the combine needs readjusted NOT Foresight 6. Return to the main menu by pressing escape three times. 7. Select >>Calibration - Follow on-screen instructions. Raise Header all the way so that NO sensors touch the ground and press enter Put Snout Tips On The Ground until they just barely touch the ground and press Lower Header all the way down on the skids and press enter Go to Combine Ground Calibration section of this manual. enter If an error appears on the Insight box - see the Diagnostic section of this manual. 8
Feathersight Calibration (if equipped) Feathersight is an optional module to improve the performance of grain systems. It uses both height sensors and the feeder house pressure sensor to allow seamless control from off ground to on ground harvesting. Calibration Insight automatically enables the pressure sensor when detected during calibration. If no pressure sensor was detected during calibration, Feathersight is not calibrated or enabled Pressure sensing may be manually enabled or disabled by selecting >>Setup>>Optional Modules>>Feathersight>>Feathersight Enable 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 sensors touch the ground and press Lower Head to 4in. until the skids are 4 off the ground and press enter Lower Header all the way down on the skids and press enter Go to Combine Ground Calibration section of this manual enter If an error appears on the Insight box - see the Diagnostic section of this manual. 9
Combine Ground Calibration A full combine calibration must be completed on new installations or if a component of the header control system is changed on the combine. See combine operators manual for details. AGCO MY2009-up, except Rxx and Sxx Header Setup 1. With Insight calibrated, park on level ground. 2. Disengage header control and header clutch. Calibration 3. On the touch screen, press Misc,Then press. 4. Select the proper header selection. Header Calibration 1. With Insight calibrated, park on level ground. 2. Disengage header control and header clutch. 3. On the touch screen, press Misc,Then press. 4. Press header. 5. Follow the on screen instructions. During the calibration the readings should be similar to those shown 6. If calibration is successful, the following should appear. the last item will only by checked if combine is equipped with the Float option. 10
AGCO MY2003-2008 all, and Rxx & Sxx Calibration 1. With Insight calibrated, park on level ground. 2. Disengage header control and header clutch. 3. Increase engine speed to above 2200rpm. 4. Press and hold until the following LEDs flash. Lower header, Tilt auto mode Previously selected auto height mode 5. Lower header to minimum height. 6. Press button until lower header stops flashing and raise header starts flashing. 7. Raise header to maximum height. 8. Press button until raise header LED turns off. 9. Wait for tilt left LED to flash then tilt header to maximum left position. 10. Press button until tilt header left LED stops flashing and tilt header right LED starts flashing. 11. Tilt header to maximum right position. 12. Press button until the following LEDs flash. Raise header, Lower header, Height auto mode Right header, Left header, Tilt auto mode 13. Center header and press to exit calibration and save all calibration values. 11
AGCO F6 MY1998-2002 1. With Insight calibrated, park on level ground. 2. Disengage header control and header clutch 3. Raise header to maximum position 4. Press and hold hidden button under the C of ControL until the LED starts flashing 5. Lower header to minimum height 6. Press and hold hidden button under the L of ControL until the LED starts flashing 7. Raise header to maximum position 8. Tilt header completely left using balance switch below tilt sensitivity knob 9. Continue pressing tilt left switch -Press and hold hidden button under the C of ControL until the LED starts flashing 10. Tilt header completely right using balance switch below tilt sensitivity knob 11. Continue pressing tilt right switch -Press and hold hidden button under the L of ControL until the LED starts flashing Calibration 12
Settings Combine Settings Properly setting the combine is essential to having responsive header control. You should become very familiar with the steps in this section. Settings Always perform the combine ground calibration before adjusting settings. Set each sensitivity setting by increasing till header bouncing occurs then decreasing till header becomes stable. Set the automatic drop rate to 6-8 seconds from full up to full down in auto mode Set the automatic raise rate to 5-7 seconds from full down to full up in auto mode Open hydraulic accumulator Set height sensitivity Set tilt sensitivity All - Hydraulic accumulator Headsight strongly recommends you replace the ¼ turn OEM valve shown with a multiple turn valve for improved tuning capability. See Accumulator Valve Replacement section of this manual. 1. Find the accumulator It is located either near the left front wheel or on right side of combine near the hydraulic valve stack. 2. The accumulator valve should be: Open far enough to reduce jerking of the header when it is raised or lowered Closed far enough to avoid sloppy response. 3. Adjust the installed needle valve 1-2 turns open. Fine tune to take the shock out of the system without causing sluggish response. 13
AGCO MY2009 - up, except Rxx and Sxx Header Drop/Raise Rates 1. Press,,. 2. Adjust Max Up PWM for 5-6 seconds from full down to full up. 3. Adjust Max Down PWMfor 8-10 seconds from full up to full down. 4. Adjust Max RIGHT PWM 5-6 seconds from full left tilt to full right tilt. 5. Adjust Max LEFT PWM 5-6 seconds from full right tilt to full left tilt. 6. Fine tuning settings in field for the best header response. Settings Header Height Sensitivity 1. Press,,. 2. Adjust Sensitivity as high as possible without causing height control to hunt. 3. Fine tuning settings in field for the best header response. Header Tilt Sensitivity 1. Press,,. 2. Adjust Sensitivity as high as possible without causing header tilt to hunt. 3. Fine tuning settings in field for the best header response. 14
Settings AGCO MY1998-2008 all, Rxx and Sxx Automatic Drop Rate 1. Use the adjustment bolt on lower valve of hydraulic valve stack on right-hand side of combine Common range is 8-10 seconds from full up to full down in auto mode Set drop rate as high as possible without causing height hunting Raise rate 1. Adjustment bolt on raise valve of hydraulic valve stack on right-hand side of combine. Common range is 5-7 seconds from full down to full up Set raise rate as high as possible without causing height hunting Height Sensitivity 1. Use height sensitivity knob. Set Sensitivity as high as possible without causing height hunting Tilt Sensitivity 1. Use tilt sensitivity knob. Set Sensitivity as high as possible without causing lateral hunting Tilt Gain Adjustment (MY1998-2002 only) This procedure is rarely needed, but is described here for reference. These instructions only apply to MY1998-2002 machines. 1. Set tilt gain as high as possible without causing tilt hunting 2. Press and hold both hidden C and L of ControL for 3 seconds Auto header height and tilt LEDs will flash 3. Press left manual tilt switch Present gain setting will flash on LEDs Gain is from 1 (low) to 8 (high) gain 4. Turn tilt sensitivity knob to new setting There are 8 settings from low (counter clockwise) to high (clockwise) 5. Press left manual tilt to save new tilt gain setting New setting will be flashed on LEDs from 1 to 8 6. Press both C and L of ControL to save new setting and exit tilt gain adjustment mode 15
Insight Settings Tilt Algorithm Selection Headsight offers two algorithm choices for controlling lateral tilt. The choice of tilt algorithm is only available for 4 and 5 sensor systems. To change this setting go to >>Setup>>Tilt Options in the Insight menu. Use 2 sensor tilt (default setting) when harvesting: Across terraces Standard conditions Use 4 sensor tilt when harvesting: Parallel to terraces Parallel to ditches With irrigation tracks Settings Outer 2 sensor tilt (default setting) Outer sensor on each side controls lateral tilt Keeps the outer two sensors the same distance from the ground All sensors control height Any sensor can cause the header to raise, all need to agree to lower the header Keeps the header s highest point closer to the ground but header may be higher on average Outer 4 sensor tilt Outer TWO sensors on EACH side control lateral tilt Keeps the closest of each outer pair of sensors the same distance from the ground All sensors control height Any 1 can raise, all need to agree to lower Keeps the header closer to the ground on average but may have one end higher 16
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 50. Feathersight - HP Balance This setting is only applicable of you have installed and calibrated the optional Feathersight module. Settings 1. To change this setting go to >>Setup>>Optional Modules>>Feathersight>>HP Balance in the Insight box. What to know: This setting is the percentage of the height response determined by the height sensors as contrasted with the height response determined by the pressure sensor Changing this setting will not affect the tilt response This setting is only available when an auxiliary (pressure) sensor is detected during Insight calibration The default value is 65 when an auxiliary (pressure) sensor is detected and 100 if no auxiliary (pressure) sensor is detected Setting Hints: To increase the height response for the height sensors, increase the HP Balance To increase the height response for the pressure sensor, decrease the HP Balance If you know that you intend to run with the header always on the ground, you may want to decrease the HP Balance If you know that you intend to run with the header always in the air, you may want to increase the HP Balance or recalibrate Insight with the pressure sensor disconnected to disable the pressure sensing mode 17
Operation After calibrating Insight and combine, operate the Headsight system exactly like you would use a AGCO system. Enabling Height Control AGCO 2009 - up except Rxx and Sxx 1. Turn on separator and header clutches. 2. Using the Select Switch, select auto header height mode. Operation 3. Enable auto tilt. 4. Press header lower button. 5. Adjust Height as desired with knob. 18
AGCO 1998-2008. Rxx and Sxx 1. Turn on separator and header clutches. 2. Enable auto header height and auto header tilt modes. and (MY2003-2008) 3. Enable auto header height and auto header tilt modes. and (MY1998-2002) Operation 4. Press header lower button. 5. Adjust Height as desired with knob. 19
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 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) Overview 20
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 with USB Drive Updating software may cause the Foresight option to be disabled. If you have purchased Foresight, contact Headsight before updating software. Overview 1. You will need: USB drive Means of loading USB Stick (computer with USB) 2. Load USB drive with new software files Place insightf.hex in the root directory of USB drive (ex. E:\insightf.hex) Do not change file names 3. If you do not have the new files you may Download updated software from www.headsight.com Order pre-loaded USB drive from Headsight, Inc. 4. Remove cap from USB on front of Insight controller 5. Insert USB drive card into USB slot on front of Insight 6. Power Insight Turn on key switch 7. Wait for software to download Yellow light will blink while download is in progress Green light will turn on solid when download is complete 8. Verify update is successful Go to >>About Insight>>Software Version and read software version number 9. Remove USB drive 10. Install cap on USB on front of Insight controller 11. Remove power from Insight Turn off key 21
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. 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. Advanced Info 22
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 Advanced Info 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 0.0 0.0 0.0 0.0 0.0 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 23
AGCO MY2009 - up 1. Press Misc, then. 2. Select VMM 4 or VMM 3 depending on your machine. The header height left and right pots should read 4.0V head up, and about 1.5V head down never below 0.7V or above 4.2V AGCO 1998-2008. Rxx and Sxx 1. Press Wrench. 2. Read voltages for Header Right and Header Left. Advanced Info 24
Diagnostics Troubleshooting by Symptom Nearly every problem with the header control system on AGCO 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 Combine does not supply 12V to pin 4 of the Insight connector Follow solution for problem: No 12V power available on pin 4 of Insight plug Solid red Wiring is not connected properly or calibration has not been completed 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 Symptom Problem Solution AHHC Diagnostics No automatic operation height or tilt Wiring is not connected properly Check wiring from sensor to combine Diagnostics (If the Insight box does not have a green status light, go to Insight Status Light Diagnostics ) Header control is not enabled with cab controls Wrong HHC mode selected Sensor are out of range (Direct Wire Systems only) See Operation section of this manual Turn on AHHC, see Operation section of this manual Read sensor inputs to combine: Pin 9 and 10 (31 pin on MY2007+) Pin E and F (13 pin on MY2003-2006) Pin D and E (6 pin on MY1998-2002) All values should be approximately 3.8V with header raised and 1.2V with header lowered 25
Symptom Problem Solution AHHC Diagnostics Header is to jumpy or responds to slow Combine is improperly set See - Setting section of this manual Head Jumps and Jerks whole combine No 12V power available on pin 4 of Insight plug to power Insight box Insight needs to be recalibrated Drop rate too fast Unopened accumulator Discharged accumulator Power wire PFI-AG13-P is not installed Power wire is installed incorrectly There is a wiring problem in power wire harness See Calibration section of this manual Drop rate must be set to 6-8 seconds, raise rate 5-7 seconds (Combine Settings section of this manual) Open accumulator valve 1-2 turn Test accumulator as described in combine owner s manual, replace or recharge as necessary Install power wire Correct installation of power wire Repair or replace power wire harness Symptom Problem Solution Lateral Tilt Diagnostics Head rocks side to side Poor Insight calibration Recalibrate Insight box and combine lateral tilt Combine tilt sensitivity to high Adjust tilt sensitivity PWM flow rate to high (2009 - up except Rxx and Sxx) See Settings section of this manual Diagnostics 26
Symptom Problem Solution Lateral Tilt Diagnostics Header is not level with later tilt enabled and: Header tilts completely to one side 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 Poor Insight calibration 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 Verify 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 Perform Insight Calibration and combine Contour-Master Calibration (See Calibration section of this manual) Diagnostics Height control works but lateral tilt does not (If the Insight box does not have a green status light, go to Insight Status Light Diagnostics ) Turn on power to Insight box. In the Insight box go to >>Diagnostics >>Detailed Diagnostics>>Left & Right Outputs. Voltage range should be 1.2-3.8V and decrease as the head is lowered PWM flow rate to high (2009 - up except Rxx and Sxx) Caution: header may move unexpectedly with auto header height control engaged! If the box outputs are correct, service the combine If box outputs are incorrect, reset the Insight box to defaults (see overview section of this manual). Then recalibrate Insight box and combine. If problem persists, replace Insight box See Settings section of this manual 27
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
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 ER12 Left 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. 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 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 Diagnostics Signal (white) is shorted to power (green) wire Sensor polarity is reversed. To check, go to >>Diagnostics>>Detailed Diagnostics>>Left Sensor 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 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 29
Error Code Problem Solution ER13 Left sensor swing less than 0.6V ER16 Left sensor expected but not detected Left sensor mechanical range is restricted Left sensor not properly connected 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) ER17 Left sensor detected but not expected 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 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 Harness wiring error Control box / wiring failure Verify that no wires contact PIN7 of connector Y101 (Insight box) Contact Headsight Diagnostics 30
Error Code Problem Solution Sensor temporarily disconnected Reconnect sensor, Calibrate Insight box ER21 Left Center sensor signal less than 0.3V 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 ER22 Left Center 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 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 Diagnostics Sensor polarity is reversed. To check, go to >>Diagnostics>>Detailed Diagnostics>>Left Center Sensor Sensor failure 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 31
Error Code Problem Solution ER23 Left Center sensor swing less than 0.6V ER26 Left Center sensor expected but not detected Left Center sensor mechanical range is restricted Left Center sensor not properly connected 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 PIN13 of connector Y101 (Insight box) ER27 Left Center sensor detected but not expected 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 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 Harness wiring error Control box / wiring failure Verify that no wires contact PIN13 of connector Y101 (Insight box) Contact Headsight Diagnostics 32
Error Code Problem Solution Sensor temporarily disconnected Reconnect sensor, Calibrate Insight box ER31 Center sensor signal less than 0.3V 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 ER32 Center 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 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 Diagnostics Sensor polarity is reversed. To check, go to >>Diagnostics>>Detailed Diagnostics>>Center Sensor Sensor failure 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 33
Error Code Problem Solution ER33 Center sensor swing less than 0.6V ER36 Center sensor expected but not detected Center sensor mechanical range is restricted Center sensor not properly connected 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 PIN8 of connector Y101 (Insight box) ER37 Center sensor detected but not expected 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 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 Harness wiring error Control box / wiring failure Verify that no wires contact PIN8 of connector Y101 (Insight box) Contact Headsight Diagnostics 34
Error Code Problem Solution Sensor temporarily disconnected Reconnect sensor, Calibrate Insight box ER41 Right Center sensor signal less than 0.3V 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 ER42 Right Center 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 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 Diagnostics Sensor polarity is reversed. To check, go to >>Diagnostics>>Detailed Diagnostics>>Right Center Sensor Sensor failure 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 35
Error Code Problem Solution ER43 Right Center sensor swing less than 0.6V ER46 Right Center sensor expected but not detected Right Center sensor mechanical range is restricted Right Center sensor not properly connected 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 PIN14 of connector Y101 (Insight box) ER47 Right Center sensor detected but not expected 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 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 Harness wiring error Control box / wiring failure Verify that no wires contact PIN14 of connector Y101 (Insight box) Contact Headsight Diagnostics 36
Error Code Problem Solution Sensor temporarily disconnected Reconnect sensor, Calibrate Insight box ER51 Right sensor signal less than 0.3V 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 ER52 Right 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 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 Diagnostics Sensor polarity is reversed. To check, go to >>Diagnostics>>Detailed Diagnostics>>Right Center Sensor Sensor failure 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 37
Error Code Problem Solution ER53 Right sensor swing less than 0.6V ER56 Right sensor expected but not detected Right sensor mechanical range is restricted Right sensor not properly connected 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 PIN9 of connector Y101 (Insight box) ER57 Right sensor detected but not expected 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 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 Harness wiring error Control box / wiring failure Verify that no wires contact PIN9 of connector Y101 (Insight box) Contact Headsight Diagnostics 38
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 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 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 Diagnostics Sensor polarity is reversed. To check, go to >>Diagnostics>>Detailed Diagnostics>>Pressure/Aux Sensor Sensor failure 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 39
Error Code Problem Solution ER63 Aux sensor swing less than 0.6V ER66 Aux sensor expected but not detected Aux sensor mechanical range is restricted Aux sensor not properly connected 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 PIN19 of connector Y101 (Insight box) ER67 Aux sensor detected but not expected 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 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 Harness wiring error Control box / wiring failure Verify that no wires contact PIN19 of connector Y101 (Insight box) Contact Headsight Diagnostics 40
Parts 1 2 3 4 ITEM QTY. PART NUMBER DESCRIPTION 1 AR INSIGHT Insight Control Box 2 AR * * * * 3 AR AR 4 AR AR PFI-AG13-P PFI-AGF6-P HT2260 08100108 Insight Harness Insight Harness Insight Harness Insight Harness Power Harness Adapter for Flat 6 Single Point Cover Snap Ring *all parts vary for each application, please call for more information Parts 41