600F / 925x TO LEXIONConnect all wiring to the Insight box and combine. 2. Start the combine. 3. Chose “English”, “Lexion” 4. For ALL flex head conversions, choose Lexion 600/700

600F / 925x TO LEXION Conversion Manual 09040113c

HEADSIGT.COM I 574.546.5022

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About Headsight Headsight Contact Info Headsight, Inc Bremen, IN 46506 Phone: 574-546-5022 Fax: 574-546-5760 Email: [email protected] Web: www.headsight.com

Technical Assistance Phone: 574-220-5511

About this Manual How to use this manual

For new installations, follow all applicable instructions in each of the numbered sections (1, 2, etc) in the order that they are presented in this manual. The information in the lettered appendices (A, B, etc) is for service or advanced settings which you will not need for most installations, but may want to reference in the future.

This icon designates information of which you should take note.

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 [email protected].

Portions of this product are protected by US Patents 6202395, 6833299, 7310931, 7647753 and other US and international patents, issued and pending.

Copyright Headsight, Inc. 2016

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Table of Contents About Headsight ii

Headsight Contact Info ii Technical Assistance ii

About this Manual ii How to use this manual ii Disclaimers ii Suggestions ii

1. COMPONENTS 6

1.1. Multilink 6

1.2. Hydraulics, Dual Valve Assm. 6

1.3. Insight 6

1.4. Header Adapter Harness 6

1.5. Feeder Harness 7

1.6. Hydraflex Cab Control 7

1.7. Belt Speed Control Kit (600FD Only) 7

1.8. Reel F/A Switch Kit (Agco 925x Draper Only) 7

2. Installation 8

2.1. Multilink and Valve Mounting 8

2.2. Insight Box Mounting 8

2.3. Header Connection 9

2.4. Multilink Connection 9

2.5. Reel Enable Connection 10

2.6. Solenoid Connection 10

2.7. Hydraflex Cab Controller 10

2.8. Draper Speed Cab Control (600FD only) 10

2.9. Feeder Harness 11

2.10. Reel Fore/Aft Switch (Agco 925x Only) 11

2.11. Pressure Sensor Bypass Harness (4/500 only) 12

2.12. 12V Power Test 12

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3. Insight Calibration and Settings 14

3.1. Initialize Insight 14

3.2. Calibrate Insight 14

3.3. Insight Settings 15 3.3.1. Tilt Sensitivity 15 3.3.2. Tilt Balance 15

4. 6/700 Series: Combine Settings 16

4.1. Calibration: 6/700 Series 16

4.2. Settings: 6/700 Series 17

5. 4/500 Series: Combine Settings 19

5.1. Calibration: 4/500 Series, 600F/FD headers 19

5.2. Settings: 4/500 Combine 20

5.3. 4/500 High speed drop rate 20

6. AHC Operation: All Combines 21

7. Adjusting Float Pressure 22

A Insight Overview 23

1 Rules of menu navigation 23

2 Meaning of the status light 23

3 Screen contrast adjustment 24

4 Resetting Insight™ to defaults 24

5 Updating Insight Software 24

B Advanced Information 26

1 Theory of Operation 26

2 Basic Requirements 26

3 Reading Voltages 27

C Diagnostics 29

Troubleshooting by Symptom 29

Troubleshooting by Insight Error Code 34

Troubleshooting – Sensors and Harness 40

D 6/700 series Calibration issues 42

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4 Wiring 44

Adapter Header Harness 44

Feeder Harness 45

Multilink 46

12V Power Wire Installation 47

E Parts 55

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1. COMPONENTS

1.1. Multilink Required to allow the connection to the combine

1.2. Hydraulics, Dual Valve Assm. Required to control the hydraulic functions on the header to the combine. See specific manual. Also Includes the Reel Flow fittings.

1.3. Insight Converts the AHC system on the header to the Lexion combine.

1.4. Header Adapter Harness This harness is installed on the Header, between the Insight, Lexion multilink, valve assm, and the JD header connection. For connector details See “Wiring” in the Appendix

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1.5. Feeder Harness This harness is installed on the combine, between the cab and the Multilink. Connects to the Cab Controller(s) and the Header Adapter. For connector details See “Wiring” in the Appendix

1.6. Hydraflex Cab Control Mounts in the cab to display and adjust the Hydraflex Pressure.

1.7. Belt Speed Control Kit (600FD Only) Mounts in the cab to display and adjust the draper belt speed. See Draper Speed Kit Installation manual.

1.8. Reel F/A Switch Kit (Agco 925x Draper Only) Mounts in the cab to allow F/A control of the Reel on AGCO heads.

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2. Installation

Make sure a cable routing is done so no wiring can bind or pinch. Tie up all loose cabling. Properly installed wiring is the most critical aspect of a trouble-free installation. For more information on the harnesses, see A.5, Wiring

2.1. Multilink and Valve Mounting 1. Mount the Headsight Multilink

assembly on the header. (shown with combine connected). Photo shows one suggested mounting position.

2. See the Specific Installation Guide for the Dual Valve assembly for details on the next steps.

3. Mount the hydraulic valve assembly to the head.

4. Route the pressure and tank hoses from the valves to the multilink.

5. Disconnect the smaller hoses from the OEM Header Single point and connect them to the valve assembly.

6. Install the Reel Flow couplings into the Multilink and connect the Reel Drive hoses.

2.2. Insight Box Mounting 1. Hold Insight unit (or mounting bracket if

supplied) at rear of header near the Multilink and feederhouse electrical connection on combine and mark mounting hole locations.

2. Drill mounting holes using ¼“ drill bit.

3. Secure box to header

o Use provided tie straps or ¼” bolts.

o Box must be within reach of the header electrical connector and the Multilink.

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4. Connect the 24 pin connector on the adapter Header harness to the Insight box using an allen wrench

2.3. Header Connection 1. Remove the C clip holding the OEM header electrical connector in the JD

single-point plate. Remove the connector from the plate, and press fit the two loose connector bodies together. Connectors may be ziptied together if necessary.

2.4. Multilink Connection

1. Connect Insight™ header harness to header side of multilink block

o The plug marked Y410 should connect to the receptacle marked with the GREEN arrow in picture at right (VS1)

o The plug marked Y401 should connect to the receptacle marked with the RED arrow in picture at right (VS2)

2. Make sure Y424 (16 pin Round) is tied so that it is easily accessible when connecting/disconnecting the header

3. Connect Y111 and Y112 (Lights) together.

4. Connect Y407 and Y408 (Valve Functions) together.

C-Clip

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2.5. Reel Enable Connection

This step is only applicable to Multilink assemblies provided by Headsight®.

1. To Enable reel drive flow, connect the mating 1p Weatherpack connectors, Y517 & Y518.

2.6. Solenoid Connection 1. There are two sets of solenoid connections, Reel Lift & Reel F/A (shown).

Follow the steps below to correctly attach them.

o Connect Y411 to the Reel Lift Solenoid

o Connect Y412 to the Reel Lower Solenoid

o Connect Y413 to the Reel Fore Solenoid

o Connect Y414 to the Reel Aft Solenoid

o If any function acts in reverse, swap the connections at the solenoids.

2.7. Hydraflex Cab Controller 1. Use the included suction mount to attach the Control to

the right cab window above the console. Place in an easy to see and reach location.

2.8. Draper Speed Cab Control (600FD only) 1. Use the included suction mount to attach the Control to

the right cab window above the console. Place in an easy to see and reach location.

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2.9. Feeder Harness 1. Open the Right hand Console inside the cab (bolt under Cebis monitor).

2. Route the 12 pin connectors Y225 (and Y246 for FD heads) of the Feeder Harness up into the cab using the access point on the floor of the console housing

3. Route the harness across under the cab and down the Multilink Pigtail.

4. Making sure to leave sufficient wire to connect to the header harness, cable tie the feeder harness up to the multilink pigtail and across the cab.

5. Route the feeder harness Y225 (and Y246 for FD heads) out the back of the console and around to connect to the Cab Controls

6. Connect Y225 into the Hydraflex controller firmly (until latch clicks).

7. (600FD heads only): Connect Y246 into the Belt speed controller firmly (until latch clicks).

NOTE: Y225 and Y246 are keyed differently—only the correct plug will connect to the correct controller.

8. Attach the Feeder Harness Y423 to Y424 at the Header Adapter.

2.10. Reel Fore/Aft Switch (Agco 925x Only)

1. Mount the Reel Fore/Aft switch assm. to the right side of the console, or as desired.

2. Connect Y542 on the switch wiring harness to the Reel Fore/Aft switch assm..

3. Connect Y533 to Y534 on the Cab controller harness (either cut off or coil up excess switch harness wiring)

4. Connect Y380 (red) on the power adapter to a 30A capable battery power source in the cab.

5. Connect Y379 (black) to a good cab ground.

6. Connect Y569 to Y570 on the power adapter.

7. Make sure there is a 20A min. fuse in the power

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adapter.

2.11. Pressure Sensor Bypass Harness (4/500 only)

IMPORTANT: Many Headsight systems require the use of a Pressure Bypass Harness. This is needed for OFF-GROUND height control only. When operating in Flex Mode, this wire does not need to be installed. If already installed, the 2 pin jumper plug must be installed in Headsight pressure sensor harness when Insight™ is disconnected, such as when a flex head is being operated.

1. Do not use the pressure bypass with the 600F or 600FD headers operating “On-Ground” in Flex mode

2. If the Pressure Bypass is installed for another application, make sure the Y402J jumper plug is installed when operating the 600F/FD in flex mode.

2.12. 12V Power Test

Complete the tests below to determine if you need to do the update. (Update should be very rare.)

1. Turn on engine. Make sure the Roading switch is in field mode.

o If the Insight box turns on

You do not need to install the power wire. - Go to Next Section.

o If the Insight box does not turn on

Make sure the Adapter harness is plugged into VS2. Then continue with step 2.

2. Disconnect the Combine Multilink and use a voltmeter to measure pin 9 of the B housing on the Combine Multilink.

o There is no 12V on pin B9

Find and repair 12V supply problem on combine (most likely issue!)

o There is 12V on pin B9

XB-9

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Go to “12V Power Wire Install” in the Appendix. Install/repair the wiring on the header, or in the header multilink.

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3. Insight Calibration and Settings

3.1. Initialize Insight

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 of the appendix for basic information about how to use the Insight box.

1. Connect all wiring to the Insight box and combine.

2. Start the combine.

3. Chose “English”, “Lexion”

4. For ALL flex head conversions, choose Lexion 600/700 combine (even if you are running a 400 or 500 series.)

5. Choose the number of height sensors

• For JD 600F Hydraflex, choose 3. • For JD 600FD Flex Draper, choose 4. • For Agco 925x Flex Draper, choose 2. (the OEM head module

sums the other sensors together).

3.2. Calibrate Insight

When you initialize Insight, you will be led directly to this calibration routine. If you wish to recalibrate at any other time – choose “>>Perform Calibration” on the Insight main menu.

1. Park the combine on a level and smooth surface – preferably a cement driveway or shop floor.

2. Follow on-screen instructions.

o “Raise Header” - Press Enter

Raise the head high enough that NO sensors touch the ground:

Press Enter

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o “Lower Header” - Press Enter

Lower the head ALL the way down onto the skids. Make sure that both ends of the header are flat on the ground. Use blocks if

necessary. Press Enter

If an error appears on the Insight box – see the Diagnostics section of this manual.

3.3. Insight Settings

3.3.1. Tilt Sensitivity • To change this setting go to >>Settings>>Tilt Sensitivity in the Insight™ box

o Default setting is 50. o Adjust combine Tilt Sensitivity first (when available) o If the head is to jumpy from side to side

Decrease sensitivity. o If you would like the head to be more responsive

Increase sensitivity.

o Press Enter to save value

3.3.2. Tilt Balance • To change this setting go to >>Settings>>Tilt Balance in the Insight™ box

o Default setting is 50. o Make certain ALL other possible causes of head running out of level

are eliminated first Insight/sensors not calibrated on flat level surface Combine not calibrated on same surface as Insight Header not adjusted correctly frame to snoot angle (snoot angle

steeper on one end) o If the head will still not run level

Increase to tilt head to right. Decrease value to tilt head to left.

Press Enter to save value o The setting must be reset to 50 every time before doing a combine

header calibration.

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4. 6/700 Series: Combine Settings

4.1. Calibration: 6/700 Series

IMPORTANT: To insure a proper calibration, make sure your combine has the latest Lexion recommended software and the feeder to header latching mechanism is tight with minimal play. See Appendix for more information.

1. Start Combine

2. Use the Scroll knob and ESC to navigate the menus as shown:

3. Get to the HHC "Learning End Stops"

o Choose on the main display – Press the Scroll knob to OK

o Choose – Press OK



4. The screen should read "Start learning procedure with "OK"

5. Follow on-screen instructions.

6. You may also wish to calibrate other relevant items such as "Lateral Float End Stops" and "Reel End Stops". See your Lexion Owners Manual.

7. Also adjust working position to about 50%

Scroll/OK Escape

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8. After calibration, the right bar graph (feeder position) should read 0-100 as the head is moved full stroke.

9. After calibration, the left graph should read:

o 0 with the head all the way down hard.

o 50 as the header frame begins to lift off the ground

o 100 as the cutterbar just leaves the ground

o 0-49 is the header lift pressure

o 50-100 is the header AHC sensors.

10. If the numbers on the graphs are close to this, the calibration is good.

4.2. Settings: 6/700 Series

Properly setting the combine is essential to having responsive header control. You should become very familiar with the steps in this section.

Set the high speed drop rate as high as you like without causing head “hunting”. If the head “hunts”, decrease the drop rate. You may need to set this before calibration if it is too fast.

1. Perform “Learning End Stops” calibration before attempting fine tuning.

2. Start Combine

3. Use the Scroll knob and ESC to navigate the menus as shown:

4. Get to the HHC "Sensitivity CAC"

o Choose on the main display – Press the Scroll knob to OK


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5. All Settings have a range of -50 to +50

6. "Cutting Height Adjustment" is actually height sensitivity. It should be adjusted just below the point the head will "hunt".

7. Adjust the "Lateral leveling" to increase/decrease lateral response. It should be adjusted just below the point the head will "rock" side to side.

8. Set "fast manual raising" to 5-6 seconds Full down to full up.

9. Set "fast manual lowering" to 8-10 seconds full up to full down.

10. Set "Automatic drop rate" slow enough to eliminate "hunting".

11. Suggesting starting values are shown in the picture below. Your values may vary. See your Lexion Owner’s manual for more information

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5. 4/500 Series: Combine Settings

5.1. Calibration: 4/500 Series, 600F/FD headers

This section applies to ALL 400 and 500 combines when operating a Flex Head in Flex mode.

1. Start Combine

2. Make sure that the Headsight Bypass harness is either not installed, or is disconnected from the header harness and has the Y402J jumper in place.

3. Adjust the CAC setting

o Choose on the harvest display – Press OK

o Choose “Header” – Press OK

o Choose “Sensitivity CAC” – Press OK

o Adjust setting as suggested for a flex platform in the Lexion Owner’s Manual. Increasing the setting should weight height over tilt.

4. Raise head almost up, and speed up motor.

5. Choose “Cutt. Height Limits” – Press OK

6. Follow on-screen instructions. (If head drops too fast, see 4.3.

o Raise header

o Lower header

7. After calibration, the right bar graph (feeder position) should read “empty” to “full” as the head is moved full stroke.

8. After calibration, the left graph should read:

o Nearly “empty” with the head all the way down hard.

o Nearly “full” as the cutterbar just leaves the ground

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9. If the graphs operate as suggested, the header sensors are working properly and the calibration is good.

5.2. Settings: 4/500 Combine

Properly setting the combine is essential to having responsive header control. You should become very familiar with these steps.

1. Perform “Cutting Height Limits” calibration before attempting fine tuning.

2. Set CAC setting

o For On-Ground operation of a flex head, do not install the Pressure Bypass. Adjust the CAC to an appropriate setting exactly as if you were operating a Lexion header (see Lexion Owner’s Manual).

o Choose on the harvest display – Press OK

o Choose “Header” – Press OK

o Choose “Sensitivity CAC” – Press OK

Adjust setting as suggested for a flex platform in the Lexion Owner’s Manual. Increasing the setting should weight height over tilt.

o Always redo “Cutting Height Limits” calibration after changing Sensitivity CAC. Insight must be in >>Setup >>Combine Cal Mode.

5.3. 4/500 High speed drop rate 1. Use the high speed drop rate valve adjustment

knob on the main valve block.

o Turn OUT (counterclockwise) to slow down, IN (CW) to speed up.

o If the speed is to fast – hunting will occur.

o If the speed is to slow – the system will not be responsive enough.

2. Common range is 8-10 seconds from header full up to full down in automatic mode.

High speed

drop rate valve

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6. AHC Operation: All Combines

Operate the Headsight system exactly like you would use a Lexion system. Further details may be found in the combine operator’s manual.

1. Engage header and separator clutch (700 shown, 400-500 similar)

2. Choose desired cutting height setpoints

o Lower the head to the desired cutting height (must be within the sensor travel range)

o Press and hold the “Left Side” button until the caret resets to point to the top of the dark bar in the Left graph (Active Header Height)

Tap button once and redo above to set 2nd position.

The “greyed” caret is selected.

o To set a higher “feeder position”, press and hold the “Right Side” button until the caret resets to point to the top of the dark bar in the Right graph (feeder Positon)

Tap button once and redo above to set 2nd position.

3. Press left side of header raise/lower button to enter active HHC. Press again to switch to 2nd setting.

o The “Left Side” button (arrows to dot) is Active Header Height (AHC). It should be used for all heads with height sensors on the head

o The “Right Side” button (arrows to lines) is “Feeder Position” (Return to Cut or RTC). It should be used only for heads with NO height sensors, or to raise the head to a preset height for turning, etc.

AHC RTC

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7. Adjusting Float Pressure

The pressure changes fairly slowly. Hold the Increase or decrease button for 5-10 seconds to see if pressure changes.

1. To increase the pressure, press and hold the Increase pressure button.

2. To decrease the pressure, press and hold the Decrease pressure button.

3. The LED pressure indicator shows the approximate pressure in the float system. The green bar show the normal operating range of the header in flex mode.

o Running near the bottom of the green area means MORE ground pressure (less hydraulic pressure holding up the cutterbar). Use this area for dry, hard conditions.

o Running near the top of the green area means LESS ground pressure (more hydraulic pressure holding up the cutterbar). Use this area for wet, soft conditions.

o Raising the pressure all the way up should “lock up” the cutterbar for rigid mode.

4. The LED pressure indicator can also show the deck plate position on a corn head if the header is equipped with a Headsight conversion and deck plate sensor.

Pressure Increase

Pressure Decrease

LED Pressure indicator

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A Insight Overview

1 Rules of menu navigation • When in a menu (selection arrow appears to left side)

o Enter chooses the selected menu choice

o Esc backs up one menu level

o Up moves up within the menu choices displayed

o Down moves down within the menu choices displayed • When in a screen which allows setting of parameters

o Enter backs up to last menu level AFTER saving

o Esc backs up to last menu level WITHOUT saving

o Up increases the value

o Down decreases the value

2 Meaning of the status light ● Solid Green

o System is operating o No errors detected

● Solid Red o System is NOT operating o No height or tilt signals are sent to combine o You have changed settings which require re-calibration of Insight™,

are currently in a menu which will force a re-calibration if you make any changes, or are in calibration mode

●+● Solid Green with Flashing Red o System is operating o An error has been detected o Repair problem then clear errors

●+● Flashing Red o System is operating o A sensor has been ignored o See note in Troubleshooting by Error - ER16 o Repair system – Recalibrate Insight™

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3 Screen contrast adjustment

• To increase contrast: + o Press and hold Esc o Press Up to increase contrast (while holding Esc)

• To decrease contrast: + o Press and hold Esc o Press Down to decrease contrast (while holding Esc)

4 Resetting Insight™ to defaults

• To reset ALL settings + for 5 seconds o Press and hold Esc then o Press and hold Enter while holding Esc o Hold both for 5 seconds

5 Updating Insight Software

Updating software may cause the Foresight option to be disabled. If you have purchased Foresight, contact Headsight before updating software.

1. You will need:

o SD memory card

o Means of loading SD memory card either

A computer with an SD memory card drive

A computer with USB drive and a USB to SD card adapter

A pre-loaded SD card from Headsight

o Small Allen wrench or screwdriver

2. Load SD card with new software files

o Place insighte and insightf in the root directory of the SD card

For example - E:\insighte and NOT E:\my_folder\insighte

DO NOT change the file names

3. If you do not have the new files you may

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o Request updated software by email from [email protected]

o Download updated software from www.headsight.com (when available)

o Request pre-loaded SD card from Headsight, Inc

4. Disconnect all header connections from the combine

5. Remove 4 screws from the rear of the Insight™ box – remove rear cover

6. Insert programmed SD card into SD card slot on rear of board

7. Power Insight™

o Connect all wiring to combine

o Turn on keyswitch

8. Wait for software to download

o Yellow light on connector will blink while download is in progress

o Green light will turn on solid when download is complete

9. Verify update is successful

o Go to >>About Insight>>Software Version and read software version number

10. Remove power from Insight™

o Turn off key

11. Remove SD card

12. Reinstall rear cover

13. Fasten with screws

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B Advanced Information

1 Theory of Operation A review of the following points will help the service technician to

understand the complete system which will help when diagnosing specific problems.

1. Each sensor returns a variable voltage depending on its height.

o high height = high voltage (approximately 4 volts)

o low height = low voltage (approximately 1 volt)

2. Each sensor has 3 wires

o red = 5V power

o black = ground

o white = signal returned to the combine

varies between approximately 1.0 and 4.0 volts

3. The Insight box adjusts the signals as need then sends them on to the combine using the same combine wiring as an OEM system would use.

o All sensors are scaled to an appropriate range for the combine (1-4V).

o Insight will reverse the direction of the sensor swing if needed.

o The lowest of all the sensors is sent to the pressure sensor bypass on the combine...

o The right and left sensors are sent to the respective combine inputs.

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.

2 Basic Requirements

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. Each sensor must meet basic requirements for the combine to accept the calibration.

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o Signal must always be between .3 and 4.7 volts.

o Signal must change more than 1.0 volts from raised to lowered position for each sensor.

3 Reading Voltages

On the Insight Box: Sensor Voltage

1. From the Main Menu, go to >>Diagnostics >>Disp Sensor Voltages

• This shows the 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

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• 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 On the Insight Box: Output Voltage

3. To read the “sensor” Outputs being sent to the combine, see >>Diagnostics>>Detailed Diagnostics>>(parameter of interest)

o Left Height Output = in volts

o Right Height Output = in volts

o Pressure Height Out = in volts (Affects Types 1-3 only)

On Combine:

4. You must have a Service Tool plugged into the Diagnostic ports to read voltages on a Lexion combine

5. To determine if the sensor voltages are getting to the combine, watch the Left bar graph on the display while raising and lowering the header. See the appropriate “Combine Settings” section for details.

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C Diagnostics Nearly every problem with header control can be resolved by one of the following simple steps:

• Make sure each sensor meets basic requirements discussed in Advanced Info Section

• Properly set and calibrate the Insight box • Properly calibrate the combine • Enable appropriate AHHC function • Properly adjust the combine settings for electronics and hydraulics.

Troubleshooting by Symptom

Symptom Problem Solution Header is too jumpy Calibration not properly

completed Recalibrate Insight box and Combine

Combine improperly set See Combine Settings Section 4/500 Decrease Fast Drop 6/700 Reduce Auto Drop rate

Decrease sensitivity Pressure Bypass installed when not needed.

See instructions above.

Header responds to slowly Calibration not properly completed

Recalibrate Insight box and Combine

Combine improperly set See Combine Settings Section

4/500 Increase Fast Drop 6/700 Increase Auto Drop rate

Increase sensitivity Pressure Bypass not installed when needed.

See instructions above.

Combine Header Cal Fails (Cutting Height Limits) or

Header not properly connected

Verify that Insight harness is attached to VS2, and Insight box has power.

Insight Has Errors Repair error, clear error codes

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(Learning End stops) Cycle key

Recalibrate Insight

Insight Outputs are not correct >>Diagnostics>>Detailed Diagnostics>>Left/Right Height Output 0.8-1.2V head fully lowered

3.8-4.2V sensors off ground

Recalibrate Insight on flat surface.

Reset Insight: See Insight Overview for details

Insight defective

Combine computer needs to be reset (4/500 Series only)

Disconnect header Multilink with key on, motor running. Turn off key/motor. Reconnect Header

Turn on key, start engine.

Lift Pressure Sensor Error in combine (4/500 Series only)

Pressure Bypass not connected (when applicable)

Connect Pressure Bypass harness to Insight Harness (2 pin WP)

Pressure Bypass harness not assembled correctly

See “Pressure Bypass Wiring”

Pressure Bypass Jumper not installed

Install jumper for headers w/o Insight box

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

Insight Bypass Output Incorrect

Call Headsight

Cannot operate head low enough

Calibration not properly completed

Perform Insight and Combine calibration on flat level surface

Contact Headsight regarding optional products Foresight and/or Feathersight

Cannot operate head high enough

Calibration not properly completed

Perform Insight and Combine calibration on flat level surface Install extensions on corn sensors.

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Header works upward, then dives to ground (4/500 Series only)

Slow Lower non-functional Test combine manual slow lower mode. Turn OFF Thresher & Header Use RTC and AHC buttons to test slow raise/lower modes. Head should raise and lower slowly. If not, repair OEM header lift valve assm.

Header dives to ground and recovers entering crop

Lower Rate set too High

See Combine Specific Settings

6/700 Series: To much play in feeder to header coupling (due to a quirk in early combine SW, calibration does not work correctly with too much play)

Combine SN’s starting with C67, C68, or C69 Update combine to VBM 3.6.3 or above. All others: Block front of feeder so feeder cannot continue down after Header frame touches the ground.

No Automatic operation Wiring not connected, or calibration not completed.

See Installation/ Calibration/ Settings sections of manual

Header control not enabled See Operation section

Insight box settings or calibrations incorrect

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

Power supply from combine less than 10V to Insight.

Roading switch on, Turn to field mode.

Test pin B9 at the combine Multilink for 12V.

Insight box needs to be reset

See Insight Overview for details

Insight box/wiring failure >>Diagnostics>>Detailed Diagnostics>>Left/Right Height Output

0.8-1.2V head fully lowered 3.8-4.2V sensors off ground

Combine Problem Contact your Lexion Service Center.

Height works but not Tilt Increase Tilt Sensitivity. >>Setup>>Tilt Sensitivity Increase Tilt sensitivity

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Press Check Rare combine problem Call Headsight to increase Max

Combine Tilt.

Head rocks back and forth

Tilt Sensitivity too high Adjust sensitivity in combine

On Insight: >>Setup>>Tilt Sensitivity Decrease Tilt sensitivity Press Check

Insight/Combine not calibrated properly (do Cal on flat surface)

For Insight, Perform Calibration.

Header tips wrong way (Once head is moved off level, it continues all the way in either direction)

Left and Right sensor harnesses reversed

Connect sensor harnesses to correct plugs on Y adapter.

Head tips all the way one direction

Improperly adjusted sensors Adjust the sensors to both be about 1-1.2V when sitting flat on the ground

Sensor harness improperly wired

See “Diagnostics: Sensor and Harness”, note about reversed wires in connectors.

Poor connection Check harness and connectors for cut/torn wire or loose terminals Make sure terminals are properly latched, not “pushed back”, in connector body

Sensor or Harness fault See Troubleshooting: Sensor & Harness

Header runs slightly out of level

Insight or Combine not calibrated correctly

Perform Insight Cal and combine Header Cal. on flat surface

Header not adjusted correctly

Make sure the frame to snoot angle adjustment is the same across the width of the head Lower and tilt head until snoot

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tips just touch on a flat surface. Make sure frame is level to ground within 1” from left to right. Readjust snoots if necessary.

All the above fails to correct problem:

>>Settings>>Tilt Balance Adjust balance to level Head (must be reset to 100 before calibrating combine)

Display dim, blank, or hard to read

Screen contrast improperly adjusted

See Insight Settings

Weak power supply to Insight™ box

See 1.3 12V Power Test

Short in sensors powered by 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 Insight will need reset after correction of wiring short

Control box failure Contact Headsight

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Troubleshooting by Insight Error Code

Error Code Problem Solution ER11

Left sensor signal less than 0.3V

Left sensor temporarily disconnected.

Repair wiring or bad connector Calibrate Insight Box Calibrate Combine

Wiring open Check sensor harness for pinched/broken wiring

Sensor failure See sensor test instructions

ER12 Left sensor signal greater

than 4.7V

Wiring problem Ground wire to sensor is open Signal short to power Calibrate Insight Box Calibrate Combine


ER13

Left sensor swing less than 0.6V

Left sensor mechanical range is restricted

Verify sensor is not obstructed in swing Verify sensor can collapse fully with header lowered Adjust down stop to allow greater range

Sensor failure See sensor test instructions ER16

Left sensor expected but

not detected

Left sensor not properly connected

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

Not enough swing during Cal

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

Incorrect number of sensors selected in setup

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


See sensor troubleshooting instructions

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Control box /wiring failure Contact Headsight

ER17

Left sensor detected but not expected


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

Harness wiring error Verify that no other wires contact PIN7 of connector Y101


ER21 Left Center sensor signal

less than 0.3V





ER22 Left Center sensor signal

greater than 4.7V

Wiring problem Ground wire to sensor is open Signal shorted to power Calibrate Insight Box Calibrate Combine


Left Center sensor swing less than 0.6V




Left Center sensor

expected but not detected






Go to >>Initial Setup>>Number Sensors and choose the

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correct number of sensors




ER27

Left Center sensor detected but not expected





ER31 Center sensor signal less

than 0.3V





ER32

Center sensor signal greater than 4.7V



Center sensor swing less than 0.6V




Center sensor expected

but not detected




Make sure sensor meets requirements in - Advanced Information - Basic

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Requirements section of this manual






ER37

Center sensor detected but not expected





ER41 Right Center sensor signal

less than 0.3V





ER42 Right Center sensor signal

greater than 4.7V



Right Center sensor swing less than 0.6V




Right Center sensor

expected but not detected


Verify harness is connected to sensor Verify harness is connected properly to control box harness Verify that signal wire (Pin B white wire of sensor cable) is connected to PIN14 of

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connector Y101 (Insight box)








ER47

Right Center sensor detected but not expected





ER51 Right sensor signal less

than 0.3V





ER52 Right sensor signal greater

than 4.7V



Right sensor swing less than 0.6V




Right sensor expected but


Verify harness is connected to sensor Verify harness is connected

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not detected properly to control box harness Verify that signal wire (Pin B white wire of sensor cable) is connected to PIN9 of connector Y101 (Insight box)








ER57

Right sensor detected but not expected





ER61 Aux sensor signal less than

0.3V



ER62 Aux sensor signal greater

than 4.7V



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Troubleshooting – Sensors and Harness To properly test the wiring and sensors on the header, follow the steps below in order. Use a Volt Meter as needed. The sensor connector pattern is as follows:

• Pin A is Ground (Black or Lt Blue) • Pin B is Signal (White) • Pin C is 5V (Green or Pink)

A very common problem during install is to reverse the wires at the connector after removing the plug to route the cables. Make sure that the wires/voltages are as shown. If A & C are reversed, the voltages will swing backwards.

The following requirements must be met before testing: • Combine engine running • Header connected • On 9x00/10 combines the DAM switch must be on, the Feeder clutch must be on, and seat safety must remain closed

Symptom Problem Solution

Bad Harness Wiring Disconnect Sensor Plug

(Measure voltage on harness plug at sensor)

1. Measure C to Frame Ground Voltage should be 5V

If not, check harness for continuity or short on 5V wire Check Combine/Insight 5V source

2. Measure C to A Voltage should be 5V

If not check harness for continuity on ground wire Check combine sensor ground source

2. Jump C to B in harness plug Voltage should be 5V (For Insight systems, see “Diagnostics/Display Sensor Voltages”. For all others, use Combine Diagnostics*)

If not check signal wire for broken harness or bad connection

4. All of the above are correct

Harness & combine connections pass test.

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If you have a Headsight Sensor tester, use it to test the sensor. For all other:

5. Verify sensor is connected to extension harness Sensor voltage should be 0.5- 4.5V (For Insight systems, see “Diagnostics/Display Sensor Voltages”. For all others, use Combine Diagnostics*)

If sensor cannot be adjusted to achieve a voltage within the range, replace sensor.

*Note: See Combine Specific Diagnostics

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D 6/700 series Calibration issues

Symptom: When the CAC system is engaged, the header dives into the ground, then recovers to the preset height.

Cause: For machines with 2011-2014 OEM Lexion software, play in the connection between the header and feeder house can cause the calibration process to not work correctly. If your feeder can drop more than ½” after the header solid frame (not flex cutterbar skids) touches the ground, it is recommended that you use one of the two following solutions. Stubble stompers mounted so they contact the ground during calibration can also cause this issue.

Solution 1: 6/700 series combines with SN’s starting with C67, C68, or C69 and later should have the software updated to at least VBM 3.6.3 to eliminate this issue. Earlier machines, such as shown in pictures, see solution 2.

Solution 2: 1. Remove or chain up any stubble stompers so they do not carry header

weight during calibration.

2. Use blocks under the feeder faceplate to stop further movement downward during the calibration process. The block height should be enough to stop the feeder just as the solid frame of the head contacts the

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ground (not flex cutterbar skids). See arrows. This procedure works for all 6/700 combines on corn or rigid headers.

NOTE: Some heads with floating adapters (for example draper heads) can also experience this symptom. Limiting downward over-travel on the float adapter during calibration (Solution 2 above) may solve or reduce this issue. Make sure Float mode is locked out in Off-ground (Rigid) operation.

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4 Wiring

Adapter Header Harness

Connector Description Connects to Y202 31 pin Deutsch Header connector – header single-point Y112 4 pin WP Multilink: Y111 Lights Y424 16 pin AMP CPC Adapter Feeder Harness Y101 24 pin DT Insight™ Control box Y150 12 pin DT Diode Module (HT9223 DP) Y408 12 pin DT Multilink: Y407 Valve Functions Y401 7 pin C016 (AHC) Multilink: VS2 Y410 7 pin C016 (REEL) Multilink: VS1 Y411/2 2 pin DT set Reel Lift solenoids Y413/4 2 pin DT set Reel F/A solenoids

Y424

Y411 Y412

Y150

Y101

Y202

Y401

Y410

Y413 Y414

HT9223 DP

Y408 Y112

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Feeder Harness

Connector Description Connects to Y423 16 pin AMP CPC Adapter Header Harness Y225 12 pin DT A code Hydraflex Cab Control Y246 12 pin DT B code Belt Speed Control (Not shown, 600FD only) Y534 2 pin WP Reel F/A (Agco 925x only)

Y225

Y423

Y534

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Multilink

Connector Description Connects to VS1 Reel sensors Y410 if equipped VS2 AHHC Y401 VS3 AutoPilot Y409 if equipped Y111 Lights Y112 Y517 Reel Drive Y518 Y518 Reel Drive Y517 Y407 Valve Functions Y408

Y517 Y518 Y111

Y407

VS2 VS3

VS1

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12V Power Wire Installation

This step SHOULD NOT be required for Headsight supplied Multilink Assemblies. Complete the test below to determine if you need to do this step.

1. Make sure to do the test for combine power in Section 1.3 12V Power Test.

o There is 12V on pin B9, continue to step 2

2. Connect the combine Multilink to the header, and start the

engine. Measure power on VS2, pin 6

o There is 12V on VS2, pin 6

STOP. Do NOT disassemble Multilink. Check for Insight adapter harness fault.

o There is NO 12V on VS2, pin 6

Continue to Step 3. Install Jumper or repair the wiring in the Header Multilink.

3. Turn off the engine

4. Open the Multilink Assembly:

o Remove any hoses or wiring in way of disassembly

o Remove 5 socket head bolts from housing

o Pull housing assembly away from face plate

5. Install the provided jumper for the 12V power source

o Snap insert 1 notch apart and Insert large pin to XB pin 9, close insert. If there is already a pin, splice the wires.

o Insert small pin to VS2 pin 6.

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o Connect small pin to VS2 pin 6

6. See pictures for pin location

7. Replace pin inserts in proper cavities of plate:

8. Reassemble the Multilink Assembly:

o Reassembly of housing is easier if you remove the screws holding the VS1-3 plugs onto the housing, and temporarily pull excess wiring out thru the housing

o Reassemble housing to plate, making absolutely sure no wires are pinched under the housing. Wires like to get pinched in the “center” of the housing, and around the pin insert pegs

o The housing should sit snug against the plate without drawing up the bolts.

o Install the 5 socket head bolts into housing

o If removed, coil excess wiring back into housing and reinstall screws in VS1-3.

o Replace any hoses/harnesses removed for access.

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Header Adapter Schematics

50

51

Feeder Adapter Schematic

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Multilink Diagram

53

54

Header Multilink Mechanical

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E Parts

Key# Part# Description Qty Notes 1 QP0-CA12-31Q-H Adapter Header Harness 1 2a HT9817-FDR Adapter Feeder Harness AR Adapter for 600FD heads 2b HT9870-FDR Adapter Feeder Harness AR Adapter for 600F, AGCO 925x heads 3 INSIGHT AHC Interface 1 4 HT9993 Hydraflex Cab Control 1 5 CA500MLHYD Multilink Assm. 1 6 HT9210 Belt Speed Control AR 600FD Only (not shown) 7 HT9300 Power adapter AR 925x header only (not shown) 8 HT9897 F/A switch kit AR 925x header only (not shown) 9 HT9896 F/A switch harness AR 925x header only (not shown)

2

3 4 5

1

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Documents

600F / 925x TO LEXIONConnect all wiring to the Insight box and combine. 2. Start the combine. 3. Chose “English”, “Lexion” 4. For ALL flex head conversions, choose Lexion 600/700