john deere 50/60/70/s-series - headsight.com · 3 installation insight® systems insight® box...

HEADSIGHT.COM | 574.546.5022

Combine Manual09010101k

JOHN DEERE 50/60/70/S-SERIES

i

Copyright Headsight, Inc. 2017

About Headsight

Headsight Contact InfoHeadsight, Inc. 4845 3B Road Bremen, IN 46506 Phone: 574-546-5022 Fax: 574-546-5760 Email: [email protected] Web: www.headsight.com

Technical AssistancePhone: 574-220-5511

About this Manual

How to use this manualThe 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.

DisclaimersHeadsight®, Horizon®, Pinpoint®, Insight®, Foresight®, Feathersight® Truesense™ and Truesight® are trademarks of Headsight, Inc. All other trademarks are property of their respective owners.

SuggestionsIf you have any suggestions to improve this manual please call 574-546-5022 or email [email protected].

Headsight’s products are protected by one or more of the following US Patents 6202395, 6833299, 7310931, 7647753, 9609806 and other patents pending.

ii

Table of ContentsAbout Headsight �� iAbout this Manual �� iInstallation �� 1

“Basic” Harness Only Systems �� 2Insight® Systems �� 3

Insight® Box Mounting �� 3Feathersight® Option Installation (if equipped) �� 4Feathersight® Pressure Sensor Option Installation �� 5Magic Power Boost Connectors �� 6

Calibration �� 7Setup Insight® Box �� 7Calibrate Insight® �� 7

Standard Calibration �� 7Foresight® Calibration (if equipped) �� 8Feathersight® Calibration (if equipped) �� 9

Combine Ground Calibration ��10JD S-Series ��10JD 70-Series ��11JD 50 and 60-Series ��12

Settings ��13Combine Settings ��13

S-Series Combines ��1370 Series Combines ��1360 Series STS Combines ��1350 and 60 Non-STS Series ��14

Insight® Settings ��16Tilt Algorithm Selection ��16Tilt Sensitivity ��17Feathersight® - HP Balance ��17

Operation ��18Enabling Height Control ��18

S-Series ��1850/60/70 Series ��19

Overview ��20Insight® Navigation ��20

How to Navigate ��20Meaning of Status Light ��20Screen Contrast Adjustment ��20Resetting Insight® to Defaults ��21Updating Insight® Software with USB Drive ��21

Advanced Information ��22Theory of Operation ��22Basic Requirements ��22

iii

Reading Voltages ��23Before you Start ��23On the Insight® Box��23S-Series Combines ��2470 Series Combines ��2450 and 60 Series Combines ��25

Diagnostics ��26Troubleshooting by Symptom ��26Troubleshooting by Insight® Error Codes ��30

Parts ��37STATEMENT OF LIMITED WARRANTY ��38

1

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.

2

Installation

Complete the installation portion of the header manual before continuing. If you have a “Basic” Harness Only System, you may ignore the sections and steps in this manual designated “Insight”.

“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

Left Center Right2 Sensor X X3 Sensor X X X

*L-Left, C-Center, R-Right

2. Connect 31 pin Y311 connector to combine.

3. Connect remaining Y312 connector to header.• If you have no Y312 connector, you may connect

warning /stubble lights using wire labels

DeckCLR

3

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 Right2 Sensor X X3 Sensor X X X4 Sensor X X X X5 Sensor X X X X X

*L-Left, LC-Left Center, C-Center, RC-Right Center, R-Right

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

RC RCLCL

RL C

4

Installation

Feathersight® Option Installation (if equipped)S550-S670, 70 Series, and 60 Series STS only

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)

S550-S670 70 Series and 60 Series STS only

S680 and S690

1. Route Feathersight harness following existing combine harnesses and hoses from header connector to pressure sensor at valve block just in front of left front tire.

2. Remove factory cover over valve block assembly.

3. Unplug factory harness from pressure sensor and plug in supplied y-harness to sensor.

4. Connect factory wiring to y-harness and Feathersight harness.

5. Connect 4 pin round amp connector to main Insight or Horizon Harness

6. Secure all harnesses with zip ties.

7. Install factory cover over hydraulic valve assembly.

5

Installation

Feathersight® Pressure Sensor Option Installation 50 Series and 60 Series non STS


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



7. Disconnect all drive shafts from header.

8. 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

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)

6

Installation

Magic Power Boost Connectors

Your harness may be equipped with Magic Power Boost connectors Y246, Y247 and Y248. If these connectors are present follow the instructions below.

1. For all John Deere Stalkmaster™ 12 row and larger heads connect Y246-Main to Y248-OEM.

2. For all other heads connect Y246-Main to Y247-HS.

7

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 “John Deere”• Choose the “50/60/70/S”• 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.

8

Calibration

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

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:

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 enter• “Lower Header” all the way down on the skids and press enter• Go to Combine Ground Calibration section of this manual.


Headsight Sensors Wand Length Gain Position 1 (no extension) 3.5 Position 2 3.1 Position 3 2.8 Position 4 (Longest) 2.5

9

Calibration

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.

• 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 enter• “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


10

Calibration

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.

JD S-Series

Press menu.

3. Press combine.

4. Press combine.

5. Press for calibrations.

6. Select Feeder House Raise Speed in calibration box and press

enter.

7. Follow instructions to calibrate and press enter to save calibration.

8. Select Header in calibration box and press enter.


10. For S680 and S690 machines only select Feeder House Tilt Speed

and press enter.


11

Calibration

JD 70-Series

1. Rotate knob until diagnostic is highlighted on screen and press until it shows calibrations.

2. Rotate knob until Feeder house speed is highlighted in calibrations

box and press

3. Rotate knob until is highlighted and press

4. Follow calibration instructions and press after every step and at end of calibration to save.

5. Only press to cancel or quit calibration.

6. Rotate knob until diagnostic is highlighted on screen and press until it shows calibrations.

7. Rotate knob until header is highlighted in calibrations box and

press

8. Rotate knob until is highlighted and press

9. Follow calibration instructions and highlight after every step and at end of calibration to save.

10. Only press to cancel or quit calibration.

12

Calibration

JD 50 and 60-Series

1. Press Diagnostics button on cornerpost.

2. Press Up until the screen reads “CAL”.

3. Press Enter.

4. Press Up until the screen reads “Hdr”.

5. Press Enter – screen will read “Hdr – dn”.

6. Lower the header completely to the ground.

7. Press Cal – screen will read “Hdr – up”.

8. Raise the header to the top of its stroke.

9. Press Cal – screen will read “EOC”.

10. Press Enter.

11. Press Esc until returned to the main screen.

13

Settings

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.

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

S-Series CombinesSet the AHHC height and tilt sensitivity• Press the header button repeatedly until AHHC sensitivity or contour master sensitivity displays.• Use scroll knob to adjust sensitivity.

70 Series CombinesSet the AHHC height and tilt sensitivity • Press the header button repeatedly until AHHC sensitivity or contour master sensitivity displays.• Use scroll knob to adjust sensitivity

60 Series STS CombinesSet the automatic drop rate• Use the knob under the operator’s right-hand armrest.

14

Settings

50 and 60 Non-STS Series

To test the automatic drop rate – you must disconnect the wiring to the auto drop rate valve. Reconnect the wire after testing.

Set the automatic drop rate• Use the adjustment on the valve block.• Turn in all the way then out ½ turn for initial guess.• If the speed is to fast – hunting will occur.• If the speed is to slow – the system will not be

responsive enough. • Common range is 6-8 seconds from header full up to

full down in automatic mode.

Set the hydraulic accumulator.• Close the accumulator valve all the way• Open the accumulator valve 1 full turn (from closed position). • Opening the accumulator to far will give sloppy response. • Not opening the accumulator far enough will give a jerky response.• Close the accumulator valve all the way, then open it 1 full turn.

Changing Tilt Orifices

The purpose of changing the orifices is to decrease/increase the maximum speed that the Contour-Master can tilt. The factory configuration will be satisfactory for most conditions. However, orifices may need to be adjusted for wide headers. Only change orifices if the system cannot be set properly by using the sensitivity adjustment on Insight or the Contour-Master card.

1. Manually move header from full right tilt to full left tilt.• The target tilt speed is 5-8 seconds• If not correct go on to step 2


3. Remove header from combine.

4. Insert stop to prevent movement of feederhouse.

5. Release all pressure in hydraulic cylinders.• Lower feeder house against lock and hold button for

10 seconds to relieve hydraulic pressure



15

Settings

8. Using 1/8” allen wrench – remove original orifice from valve block in tilt cylinder supply lines.

• Keep orifice in secure location for later use if needed.

9. If tilt speed is too fast – install an orifice that is smaller than the original orifice removed.

10. If tilt speed is too slow – install an orifice that is larger than the original orifice removed, or remove orifice completely

JD orifice availability:• .26” Z60904 (Original on 50/60 series)• .31” H135777 (Original on 00/10 series)• .46” H149804

16

Installation

Insight® Settings

Tilt Algorithm SelectionHeadsight 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

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

17

Installation

Tilt SensitivityIf 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.

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

18

Operation

Operation

After calibrating Insight, operate the Headsight system exactly like you would use a John Deere system.

Enabling Height Control

S-Series

1. Press menu.

2. Press combine.

3. Press combine.

4. Press head.

5. Press to access height control options.

6. Check appropriate box’s.

7. Engage header clutch .

8. Press 2 or 3 resume button on hydro handle to engage AHHC.

9. Turn the AHC dial on the armrest with header control engaged.• Clockwise = higher• Counter-clockwise = lower

19

Operation

50/60/70 Series

1. Press on cornerpost to enable the icon.

2. Press on cornerpost to enable the icon.

3. Engage header clutch.

4. Ensure that the header float option is disabled

5. Press 2 or 3 resume button on hydro handle to engage AHHC.

6. Turn the AHC dial on the armrest with header control engaged.• Clockwise = higher• Counter-clockwise = lower

20

Overview

Overview

Insight® Navigation

How to NavigateWhen 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 LightSolid 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 AdjustmentTo 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)

21

Overview

Resetting Insight® to DefaultsTo 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 DriveUpdating software may cause the Foresight option to be disabled. If you have purchased Foresight, contact Headsight before updating software.

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

22

Advanced Info

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 sensors 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.

23

Advanced Info

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

On the Insight® Box1. 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 = 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

3. To read the Insight output voltages the combine receives, see >>Diagnostics>>Detailed Diagnostics>>(parameter of interest).

• Left Height Output• Right Height Output

Sensor Voltages

L LC CTR RC R0.0 0.0 0.0 0.0 0.0

Left Sens =0.00VMax=0.00V SetH=5.00VMin=0.00V SetL=0.00VEnabled=N Reversed=N

Insight box scales voltages received to what combine needs to function

24

Advanced Info

S-Series Combines

1. Press menu.

2. Press message center

3. Press addresses.

4. Select LC1 in devices box.

5. Press arrow down till you see address 21-Left, 22-center, 24-right

70 Series Combines

1. Press menu.

2. Scroll to when highlighted press



5. Scroll to when highlighted and press

6. Scroll to when highlighted and press untill desire address is displayed.

7. Address 28 left, 29 center, and 30 right voltage.

25

Advanced Info

50 and 60 Series Combines

1. Press Diagnostics button on cornerpost.

2. Press Up until the screen reads “E01”.

3. Press Enter.

4. Press Up until you see address 22-Left, 24-center, 26-right

26

Diagnostics

Diagnostics

Troubleshooting by Symptom

Nearly every problem with the header control system on JD combines may be resolved by one of the following simple steps:

• Make sure each sensor meets basic requirements discussed in Advanced Info section• Properly calibrate Insight box• Properly calibrate combine• Enable appropriate HHC functions• Properly set combine electronics and/or hydraulics

Symptom Problem SolutionHeader is too jumpy or responds too slowly

Calibration is not properly completed

Combine is improperly set

Recalibrate Insight box and combine

See Combine Setting Section

Combine quick calibration fails Insight is not properly calibrated

Header is not properly connected

Insight box detected an error

Full calibration required

Combine does not recognize header.

Verify all sensors are free to move through full range during calibration

Verify that sensors swing through similar range during Insight calibration and combine calibration

Verify all combine harnesses are properly connectedCycle key switch off – on then recalibrate

Repair error, clear error codes on InsightCycle key switch off – on then recalibrate

Make sure to fully lower the feeder house

Verify that 50/60/70/S is chosen on the Insight box and that a header type has been selected

27

Diagnostics

Symptom Problem SolutionCannot operate header low enough

Calibration not properly completed

Perform combine Full-Cal, Quick Cal or Header Cal

Contact Headsight for information regarding optional products Foresight and/or Feathersight.

Cannot operate header high enough.

Calibration not properly completed

Perform combine Quick-Cal or Header Cal

For corn heads: verify that the extensions are installed at the proper position.

No automatic operation – height or tilt

Wiring is not connected properly or calibration has not been completed.

Header control is not enabled with cab controls.

Insight settings or calibration incorrect.

Power supply from combine less than 11V to Insight.

Insight box needs to be reset

Insight box/wiring failure

Combine problem

See Installation/Calibration section of manual

See Operation section for instructions about how to enable.

Verify that the proper combine and header type have been selected.Redo “Perform Calibration” on Insight box

Measure power supply voltage with key on.Pin 4 of connector Y101 on Insight boxPin 4 of header connector Y311

See Insight Overview for details.

Read sensor input values on combine monitorSee “Reading Voltages” section

Measure voltage on pins 7,3 and 9 of header connector with key on.All values should be approximately 4V with header raised – 1V with header lowered.

Contact your JD service technician

28

Diagnostics

Symptom Problem SolutionHeight works but not Tilt Verify combine display had

header icon with wavy line under header not straight line (Flagship combines only)

Verify wiring is connected as follows

Combine software problem

See Operation manual section

Read sensor input values to combine at sensor diagnostics area of combine screen

Pin 7 of Y311 header connector to Pin 10 of Y101 on the Insight box to “Left” on the combine screen

Pin 9 of Y311 to Pin 12 of Y101 to “Right”

Pin 3 of Y311 to Pin 11 of Y101 to “Left Center” and “Right Center”

Have a JD technician update the combine header control software.

Header is not level with header control engaged.

If the header tilts completely to one side:

If the header runs slightly out of level but functions correctly:

Wiring connected improperly 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.

Perform Insight Cal and combine Quick-Cal or Header Cal.

29

Diagnostics

Symptom Problem SolutionDisplay dim, blank, or hard to read

Screen contrast improperly adjusted

Weak power supply to Insight™ box

Short in sensors powered by Insight box

Control box failure

See Insight Settings

Measure supply voltage with Insight connected – some combines do not maintain enough power under electrical load. Examples of causes for weak power supply includeEngine startupEngaging an electric feeder reverser

Insight will need reset after correction of wiring short

Reversed polarity to hall-effect sensors may cause this symptomIndividually disconnect sensors to isolate problem – screen will regain contrast when faulty sensor is disconnected

Correct short in wiring

Insight will need reset after correction of wiring short

Contact HeadsightInsight box does not power up Power wire needs to be in pin 31

of connector Y311 for Headsight systems made before 2008

Control box failure

Move Headsight combine power wire from pin 29 to pin 31

Measure voltage across pin 4 (power) and pin 6 (ground) of y101 on Insight box.

30

Diagnostics

Troubleshooting by Insight® Error Codes

Error Code Problem SolutionER11

Left sensor signal less than 0.3VLeft sensor temporarily disconnected.

Wiring open

Sensor failure

Repair wiring or bad connectorCalibrate Insight BoxCalibrate Headsight BoxCalibrate Combine

Check sensor harness for pinched/broken wiring

See sensor test instructionsER12

Left sensor signal greater than 4.7V

Wiring problem

Sensor failure

Ground wire to sensor is openSignal short to powerCalibrate Insight BoxCalibrate Headsight BoxCalibrate Combine


Left sensor swing less than 0.6VLeft sensor mechanical range is restricted

Sensor failure

Verify sensor is not obstructed in swingVerify sensor can collapse fully with header loweredAdjust down stop to allow greater range


Left sensor expected but not detected

Left sensor not properly connected

Not enough swing during cal

Incorrect number of sensors selected in setup

Sensor failure

Control box /wiring failure

Verify harness is connected to sensor 1Verify harness is connected properly to control box harnessVerify that signal wire (Pin B white wire of sensor cable) is connected to PIN7 of connector Y101 (Insight box)

Make sure sensor meets requirements in - Advanced Information - Basic Requirements section of this manual

Go to >>Initial Setup>>Number Sensors and choose the correct number of sensors

See sensor troubleshooting instructions

Contact Headsight

31

Diagnostics


Left sensor detected but not expected


Harness wiring error


Go to >>Setup>>System Select and choose the correct number of sensors

Verify that no wires contact PIN7 of connector Y101

Contact HeadsightER21

Left Center sensor signal less than 0.3V

Left Center sensor temporarily disconnected.

Wiring open

Sensor failure




Left Center sensor signal greater than 4.7V

Wiring problem

Sensor failure



Left Center sensor swing less than 0.6V

Left Center sensor mechanical range is restricted

Sensor failure


See sensor test instructions

32

Diagnostics


Left Center sensor expected but not detected

Left Center sensor not properly connected



Sensor failure


Verify harness is connected to left center sensorVerify harness is connected properly to control box harnessVerify that signal wire (Pin B white wire of sensor cable) is connected to PIN13 of connector Y101 (Insight box)




Contact Headsight

ER27Left Center sensor detected but

not expected







Center sensor signal less than 0.3V

Center sensor temporarily disconnected.

Wiring open

Sensor failure




Center sensor signal greater than 4.7V

Wiring problem

Sensor failure



33

Diagnostics


Center sensor swing less than 0.6V

Center sensor mechanical range is restricted

Sensor failure



Center sensor expected but not detected

Center sensor not properly connected



Sensor failure






Contact Headsight

ER37Center sensor detected but not

expected







Right Center sensor signal less than 0.3V

Right Center sensor temporarily disconnected.

Wiring open

Sensor failure




34

Diagnostics


Right Center sensor signal greater than 4.7V

Wiring problem

Sensor failure



Right Center sensor swing less than 0.6V

Right Center sensor mechanical range is restricted

Sensor failure



Right Center sensor expected but not detected

Right Center sensor not properly connected



Sensor failure






Contact Headsight

ER47Right Center sensor detected but

not expected






Contact Headsight

35

Diagnostics


Right sensor signal less than 0.3V

Left sensor temporarily disconnected.

Wiring open

Sensor failure




Right sensor signal greater than 4.7V

Wiring problem

Sensor failure



Right sensor swing less than 0.6V

Right sensor mechanical range is restricted

Sensor failure



Right sensor expected but not detected

Right sensor not properly connected



Sensor failure






Contact Headsight

36

Diagnostics


Right sensor detected but not expected







Sensor 6 (aux sensor) signal less than 0.3V

Wiring open

Sensor failure



Sensor 6 (aux sensor) signal greater than 4.7V

Wiring problem

Sensor failure

Ground wire to sensor is open


37

Parts

Parts

ITEM QTY. PART NUMBER DESCRIPTION1 AR INSIGHT Insight Control Box2 AR QC5-JD73-04

HC3-JD53-304HC3-JD63-04

QJ5-JD63-31Q

Insight HarnessInsight HarnessInsight HarnessInsight Harness

3 ARAR

HT225208100108

Single Point CoverSnap Ring

4 ARAR

HT2250B2250

BracketBracket Hardware Kit

*all parts vary for each application, please call

for more information

1 2

34

38

STATEMENT OF LIMITED WARRANTY

For Headsight® Products Headsight Inc. (Headsight) warrants its new products to be free from defects in material and workmanship for a period of twelve (12) consecutive months following the date of purchase by the retail purchaser.

Headsight Inc. (Headsight) warrants its new corn sensors assemblies for a period of thirty-six (36) months.

Headsight warrants genuine Headsight replacement parts and components to be free from defects in material and workmanship for a period of six (6) consecutive months following the date of purchase or the remainder of the original equipment warranty period, whichever is longer.

Headsight’s obligation under these warranties shall be limited to repairing or replacing, free of charge to the original purchaser, any part that, in Headsight’s judgment, shows evidence of such defect.

Limitations to Warranty

This warranty does not cover:• Warranty claims directly resulting from improper installation of the product.• Any product damaged by accident, abuse, misuse, or negligence after shipment from Headsight.• Any unauthorized product alteration or modification.• Any unauthorized repairs made with parts other than genuine Headsight parts.• Any repairs performed by anyone other than Headsight or an authorized Headsight dealer unless specifically authorized

by Headsight.

Warranty Procedure• Troubleshooting should be done between farmer/dealer and Headsight through our technical assistance @

574.220.5511. • Labor reimbursement will occur only pre-arranged through Headsight technical assistance and be scheduled to a flat rate

basis or reasonable time allowance in Headsight’s judgment. • There is no mileage reimbursement. • Diagnostic time will not be reimbursed except in pre-arranged circumstances.• Warranty claims should be on typical dealer service work order with a number and name to be attached for any future

correspondence. • All warranty work must be performed, and claims submitted, within thirty (30) days of the occurrence of the claim and

within the warranty period.• All parts removed during warranty repair must be returned to Headsight with Headsight’s Return Form within thirty (30)

days of the occurrence of the claim and within the warranty period.• Headsight, Inc. reserves the right to either inspect the product at the original retail purchaser’s location or require it to be

returned to Headsight, Inc. for inspection.

Limitation of LiabilityHeadsight makes no express warranties other than those, which are specifically described herein. Any description of the goods sold hereunder, including any reference to buyer’s specifications and any descriptions in circulars and other written material published by Headsight is for the sole purpose of identifying such goods and shall not create an express warranty that the goods shall conform to such description.

THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES EXPRESSED OR IMPLIED. There are no implied warranties of merchantability or fitness of a particular purpose. This warranty states Headsight’s entire and exclusive liability and buyer’s exclusive remedy or any claim for damages in connection with the sale of furnishing of Headsight products, their design, suitability for use, installation or operation, or for any claimed defects herein. HEADSIGHT WILL IN NO EVENT BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES WHATSOEVER, NOR FOR ANY SUM IN EXCESS OF THE PRICE RECEIVED FOR THE GOODS FOR WHICH LIABILITY IS CLAIMED.

No representative of Headsight nor any dealer associated with Headsight has the authority to change the items of this warranty in any manner whatsoever, and no assistance to purchaser by Headsight in the repair of operation of any Headsight product shall constitute a waiver of the conditions of this warranty, nor shall such assistance extend or revive it.

Headsight reserves the right to make improvements in design or changes in specifications at any time, without incurring any obligation to owners of units previously sold. Warranty: 1/2017

P 574.546.5022 • F 574.546.57604845 3B Rd • Bremen, IN [email protected]

john deere 50/60/70/s-series - headsight.com · 3 installation insight® systems insight® box...

Documents