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, 9609806 and other patents pending.
Table of Contents About Headsight ��������������������������������������������������������������������������������������������� i About this Manual ������������������������������������������������������������������������������������������� i Installation �������������������������������������������������������������������������������������������������� 1 Required Equipment ������������������������������������������������������������������������������������� 1 Control Unit ����������������������������������������������������������������������������������������������� 2 Main Harness ��������������������������������������������������������������������������������������������� 2 Header Harness ������������������������������������������������������������������������������������������� 5 Calibration ��������������������������������������������������������������������������������������������������� 6 Sensor Calibration ��������������������������������������������������������������������������������������� 6 Settings ������������������������������������������������������������������������������������������������������� 8 Combine Settings �����������������������������������������������������������������������������������������...
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.
Complete the installation portion of the header manual before continuing. Control Unit 1. Connect the two mounting brackets together with two ¼" x ½" bolts and nuts. 2. Remove the two 5/16" head screws from under the outer lower edge of the armrest console. 3.
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JD main harness until the Y in the Headsight® harness is just about to start under the left side of the cab as shown. • Ziptie harness to existing cables at point indicated 4.
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• Secure along the shift cable and pipes to reach the JD Logic Module • Disconnect the OEM plug from the Logic Module, and connect it to Y822 on the Headsight® main harness • Plug Y821 into the Logic Module 14.
The Y204 header connector mates to OEM headers set up for JD 9x50 combines. Mate the header plug to either existing OEM header connector, or to the Headsight® Header harness supplied with the Header Kit. For installation instructions, see the Header Sensor Installation Guide.
5. Disconnect all drive shafts from the header. Sensor Calibration New Headsight® sensors are pre-calibrated at the factory; you may skip this step. Recalibrate the sensors if you are unsatisfied with the operating range of the system, if any of the components of the system are replaced, or once annually.
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• If the Auto [Cal] light does not just turn on at the lowest point: • Loosen the nuts or screws which hold the HIGHER sensor (the hall effect sensor or potentiometer, not the entire sensor assembly) • Twist the sensor to a new position; stop when the Auto [Cal] light turns on •...
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. Set the automatic drop rate as high as you like without causing head “hunting”. If the head “hunts”, decrease the automatic drop rate.
Operation Control Unit Layout 1. Head Height knob: • Adjusts Head Height; MODE must be set to HGT or HGT & TILT 2. Height Sensitivity knob: • Adjusts Height Sensitivity, MODE must be set to HGT or HGT & TILT 3.
Enabling Height Control When using the Headsight® system, the MODE switch replaces the OEM DAM & Contour Master switches (if equipped) to turn ON/OFF the height control system. The OEM switches should be left OFF. Turn OFF the MODE switch any time you do not want the header to auto lower or raise.
2. Find and mark the minimum acceptable height as noted below; do not operate below this point. Because the Headsight™ control unit is designed to work with many OEM sensors, it may be possible for the operator to choose a height that is too low for operation – meaning that the sensors would never send a raise signal.
Advanced Information 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, wide headers may need to adjust the orifices. Only change orifices if the system cannot be set properly by using the sensitivity adjustment on the contour-master card.
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. Sensors Further information on sensors is available in the Header manual. • Each sensor returns a variable voltage to the control unit depending on its height •...
(Head should tilt same direction If not, reverse Orange and Blue as indicator LED on control unit wires in Y823 & Y824 indicates) Headsight system defective Repair or replace Control Unit Header rocks back and forth, or Tilt Sensitivity improperly Adjust Tilt sensitivity...
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Solenoid connections not See Installation and make sure properly installed Y821 & Y822 are connected properly Headsight system defective Replace or repair Headsight system See raise/lower diagnostics to test No automatic operation - height Y825 & Y826 not connected to...
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Unit 12V lacking or not 12V: Repair wire on combine No LEDs on control unit light up connected properly See Wiring, Y822 No 12V: check/replace Headsight wiring or controller Headsight control unit defective Repair or replace Headsight control unit...
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Symptom Problem Solution Head will not Lower Wiring not connected See Installation, Settings sections of manual Head raises all the way to top Height position set too High Adjust Height Position knob on controller Raise LED lit with head off the Sensor stuck and unable to Remove obstruction ground...
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Manual lower switch does not Test wiring from OEM Manual Repair as needed engage auto height lower wire to control unit (Dk. Green wire in Headsight harness) Should be 12V when raise switch is pressed Control unit defective Repair or replace control unit...
OEM wiring defective Test Manual Raise operation disengage auto height Press header raise (Raise LED does not come on) Defective Headsight harness Test wiring to controller for continuity Manual Lower switch does not OEM wiring defective Test Manual Lower operation...
Voltages”. For all others, use Combine Diagnostics*) All of the above are correct Harness & combine connections pass test. If you have a Headsight Sensor Verify sensor is connected to If sensor cannot be adjusted tester, use it to test the sensor. extension harness...
Parts ITEM QTY. PART NUMBER DESCRIPTION HT9114 Control Unit HT9112 Top Mounting Bracket for (1) HT9110 Lower Mounting Bracket for (1) HT9121 Main Harness...
• 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.
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