Draper 625D Manual

GRAIN
INSTALLATION MANUAL
JOHN DEERE
6/700D
09030104g
HEADSIGHT.COM | 574.546.5022
About Headsight
Headsight Contact Info
Headsight, Inc.
4845 3B Road
Bremen, IN 46506
Phone: 574-546-5022
Fax: 574-546-5760
Email: info@headsight.com
Web: www.headsight.com
Technical Assistance
Phone: 574-220-5511
About this Manual

How to use this manual
The instructions in this manual are in the order that they should be completed for new installations.
Complete all applicable instructions in each section before proceeding. Note that some sections
are labeled to indicate they only apply to certain machines or applications. An index is available
in the front of the manual to help find technical information for previously installed systems.
This icon designates information This icon indicates a special tool

of which you should take note. needed for a given task.
This icon designates an

important instruction.
Suggestions
If you have any suggestions to improve this manual please call 574-546-5022 or email info@headsight.com.
Disclaimers
HEADSIGHT, HORIZON, PINPOINT, FORESIGHT, FEATHERSIGHT, TRUESENSE, TERRAHAWK,
INSIGHT, the Headsight logo, the Horizon logo, and Terrahawk logo are trademarks of
Headsight, Inc. All other trademarks are property of their respective owners.
Protected by one or more of the following patents and published applications:

US6883299; US7310931; US7647753; US9609806; US9609806; US10222410;
US10244680; EP2955993(DE,ES,FR,IT,UK); EP2956851 AU2004203614;
BR112015019262; BR112015019286; CA2900987; CA2900994; WO20180152266
Copyright Headsight, Inc. 2021

Table of Contents
Installation�� 01
Terrace Sensors (if equipped)��02
Standard Sensors ��04
Install Sensor Wands and Cables ��06
Routing Wiring��07
Extension Harness Length Table�� 07
Removing Wires for Tight Access�� 07
Routing Wiring-Terrace Sensor (If Equipped)�� 08
Routing Wiring-Standard Undermount Sensors�� 09
Finishing Wiring �� 11
Install Controller�� 12
Install Horizon Bridge (Horizon Only)�� 13
OEM JD Display �� 13
Install Feathersight® �� 14
Calibration�� 15
Insight® Systems�� 15
Initial Setup �� 15
Feathersight® Calibration�� 15
Horizon Systems�� 16
Connecting Base & Bridge�� 16
Initial Setup �� 17
Calibrate Horizon �� 18
Combine Calibration�� 19
GS4/4600 - JD S700 Series�� 19
JD S600 Series �� 20
JD 70 Series�� 21
Settings �� 22
Combine Configuration��22
S600 & S700-Series�� 22
70 Series �� 22
Combine Settings��23
GS4/4600 - S700-Series Combines�� 23
S600-Series and 70-Series Combines�� 23
Horizon & Insight Settings��24
Tilt Algorithm Selection�� 24
Tilt Sensitivity�� 25
Tilt Balance�� 25
Feathersight® - HP Balance �� 26
Advanced Machine �� 26
Operation �� 27
Enabling Height Control �� 27
GS4/4600 - S700 Series�� 27
GS3 or GS2 - S600 Series�� 28
70 Series �� 29
iv
Overview�� 30
Insight® Navigation��30
How to Navigate�� 30
Meaning of Status Light �� 30
Screen Contrast Adjustment�� 31
Resetting Insight® to Defaults�� 31
Updating Insight® Software with USB Drive�� 31
Updating Software��32
Updating with Techlink™ App �� 32
Updating with USB �� 32
Status Light��33
WIFI��33
Advanced Information�� 34
Theory of Operation��34
Sensors - Basic Requirements�� 35
Insight Diagnostics Screens��36
Sensor Voltages �� 36
Output Voltages�� 36
Horizon Diagnostics Screens��37
Overview�� 37
Detailed Sensor Voltages�� 37
Signals�� 37
Errors�� 37
Access Combine Settings ��38
70 Series Combines �� 39
Enhanced Near Ground Performance��40
S700 & S600 Series Combines�� 40
70 Series Combines �� 40
Sensor Adjustment��41
Standard Sensor�� 41
Terrace Sensor �� 42
Diagnostics�� 43
Troubleshooting Overview��43
Troubleshooting—Sensors and Harnesses�� 44
Troubleshooting by Symptom��45
Troubleshooting by Insight® Error Codes�� 51
Troubleshooting by Horizon® Error Codes�� 57
Parts�� 60
Insight System��60
Horizon System�� 61
Mounting Brackets and Harness��62
Terrace Sensor��63
Standard (Undermount) Sensor��64
FCC and IC Compliance Statements�� 66
v
Statement of Limited Warranty �� 67
vi
Installation
Installation
Before working on combine or 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.
JD combines and heads 2016 have the check valve for the deck plate circuit
moved to the head. Older heads may need to have this block added to prevent
deck plate drift on newer combines. Older combines may need the check valve
removed to prevent jerky motion with newer heads. See your JD dealer.
01
Terrace Sensors (if equipped)
Installation
1. Line up holes of sensor and mounting bracket with spring

installed short leg up and long leg back in mounting bracket.
SHORT
• Use HT7152 bracket
LONG
2. Insert pin and secure with retaining ring clip.
3. Install cable clamp on sensor harness & leveling bolt A A

as shown in pictures, and install bolt in sensor body.
• Clamp should be under jam nut against sensor body
4. Adjust leveling bolt A until sensor is level and tighten

jam nut down against clamp & sensor body.
• Make sure clamp stays in position shown
5. Tighten bolt B holding clamp on side of sensor.

A
02
Installation
6. Raise poly end shield.
7. Remove factory yellow metal crop

divider and retain hardware.
8. Mount terrace sensor assembly to holes where

yellow crop divider was previously mounted.
9. Repeat steps for other side.
03
Standard Sensors
Installation
1. To determine mounting locations, mount outer

sensors first, mounting out as far as possible
(if not equipped with terrace option).
• Mount all inner sensors as evenly spaced
as possible across the head.
2. Hold bracket in place on top side of skid, under

the draper belt for each sensor. Avoid double thick
metal and plastic skid tab if poly is present.
3. Slide bracket forward to bend in skid and mark bracket

along back edge of skids as a depth reference.
4. Flip over and place bracket on underside of skid

aligning depth mark with the cutterbar. Mark four
mounting holes using the bracket as a template.
5. Drill four ¼” pilot holes at each location marked.
6. If head is equipped with poly use a 3/4” hole

saw to remove poly at four holes.
7. Drill four pilot holes out to 3/8”
04
Installation
8. Mount sensor to bracket with supplied
hardware at three locations (A). C
• Install wire clamp B
• Install zip ties C
A
A
A, B
9. Mount sensor and bracket to head leaving

hardware loose to aid in routing wiring.
10. Tighten hardware after wiring installation.

• Be sure not to pinch wiring
If you do not have poly skids on the head, adding them at least on the skids
where the sensor bolts on is advised so bolt heads do not drag material.
05
Install Sensor Wands and Cables
Installation
1. Use hardware provided and fasten wand to sensor.

• Install long wands on all terrace sensors
using M8 x 25 flange bolts.
• If terrace sensors are not used install long wands on
outer standard sensors with M8 x 30 hex bolts
• Install short wands on all inner sensor with M8 x 30 hex bolts
2. Attach a tether cable to each wand.

• Use a screwdriver to pry open the slit in the rear of the wand
Tether cables are not used on terrace sensors.
3. Fasten the rear of the cable to a secure location on

the header.
• Make sure that the cable cannot catch
on any moving or solid parts
• Adjust the cable length so that it pulls the arm
slightly (½”) back from its original position
Do not leave or store the arms in a flattened or crushed position. They

must be stored in a way that they can maintain their curved shape.
06
Routing Wiring
Installation
1. Select appropriate wiring from chart below and mark blue connector with sensor position.
Properly routing the wiring is the most critical part of the installation process.
Please take time to ensure that you have allowed sufficient slack for motion
as well as sufficient clearance from moving header parts or crop flow.
Terrace sensors add a PFB10 extension harness to route from the sensor back to
the end panel and an additional standard extension harness to route to near the
feederhouse. All undermount sensors use only one standard extension harness.
Extension Harness Length Table

Standard Sensor Extension - PFBxx (xx = length in feet)
Header Width Left Left Center Center Right Center Right

25' 17' 10' 10’ 10' 23'
30' 17' 10' 10’ 17' 23'
35' 17' 10' 17’ 23' 33'
40' 23' 10' 17’ 23' 38'
Removing Wires for Tight Access

When routing the wiring, there may be times when you would like to route the wiring
through a small hole. You may remove the Weatherpack connector by using the following
procedure. This step is NOT required; it is only shown to aid installation as needed.
1. Release wire retaining clip on each connector. Insert

removal tool and pull each wire out of connector.
2. Flare connector terminal tabs using removal tool.
3. Reinstall wires in connector body:

• Black or Blue into A
• White into B
• Green or Pink into C
4. Latch wire retaining clip.
5. Connect wiring harness to sensor.
07
Routing Wiring-Terrace Sensor (If Equipped)
Installation
1. Connect a PFB10 (10’) harness to each sensor

and route through end divider snout.
2. Zip tie sensor connector with latch clip down

in terrace bracket. Leave enough slack for
sensor to trip back and not pinch harness.
3. Route harness back underneath poly end divider and fasten

harness to inside of poly divider with screw and wire clamp.
4. Route around gearbox and fasten with two

larger clamps to existing hardware.
5. Route back through holes (marked A ) and route with

hydraulic hoses to rear upper tube.
6. Connect left extension harness and fish wire

to hole in top tube, left of feederhouse.
7. Using a burr bit and a die grinder make a path for

wiring in divider so wire will not get pinched.
• Lower end divider
8. Repeat steps for right sensor.
9. Reinstall all safety shields and verify all hardware is tight.
08
Routing Wiring-Standard Undermount Sensors
1. Install protective conduit on wiring coming from sensor.
Sensor Adjustment
2. To aid installing conduit on sensor wiring without
damaging wire insulation, tape a wrench big enough
to open conduit wider then wiring harness.
3. Insert box end of wrench into conduit using as a

guide to slide conduit over wiring. Remove wrench
and repeat for all other standard mount sensors.
4. Route harness thru bracket hole and clamp

conduit to side of sensor bracket as pictured.
• For Outer sensors, route toward end of head
• For Inner sensors, route toward closest
under header support channel
09
Outer Undermount Sensors (If Equipped)
Sensor Adjustment
1. Route conduit and harness outside of head

• clamp to back side of knife drive mount plate.
2. Route back through holes (marked A ) and route with

hydraulic hoses to rear upper tube.
Wiring for two sensor kits connects directly to JD gauge wheel sensor wiring.
Disconnect wheel sensor and connect Headsight sensor in its place.
3. Connect proper extension harness (see Table) and

fish harness to opening left of feederhouse
4. Repeat steps for other outer sensor.
10
Inner Undermount Sensor Wiring
Sensor Adjustment
1. Route toward closest under-header support channel
2. Drill holes to mount conduit to outside of under- header

support channel just above lip for protection.
3. Connect proper extension harness (see Table).
4. If sensors to left of feederhouse, route up to rear of

head. For sensors to right of feederhouse route to
upper tube and fish to hole left of feederhouse.
Finishing Wiring
1. Secure wiring with cable clamps and zip ties approximately every 12-24” throughout path as needed.
2. Wrap and fasten excess wiring in secure location.
3. Tighten all hardware.
11
Install Controller
Installation
1. Mount Insight or Horizon box mounting bracket to back of

header with hardware provided.
2. Mount Insight or Horizon box to bracket.
3. Connect main wiring harness to Insight or Horizon box.
4. Connect sensor wiring to main Headsight harness.

• Sensor location as viewed from operator’s seat
Left Left Center Center Right Center Right
2 Sensor X X
3 Sensor X X X L LC RC R
C
4 Sensor X X X X
5 Sensor X X X X X
*L-Left, LC-Left Center, C-Center, RC-Right Center, R-Right
5. Remove factory harness from existing single point latch plate.
6. Install Insight or Horizon harness into

OEM single point latch plate.
7. If equipped, connect mating plug to OEM

header connector removed in step 1.
• Secure with bracket and zip ties provided.
12
Install Horizon Bridge (Horizon Only)
Installation
If you are installing a Truesight 2 system with VT display option you
will not need to install a bridge. The Truesight 2 control unit will act as a
Bridge unit, follow instructions in Truesight 2 installation manual.
OEM JD Display
John Deere S700 - GS4 Command Center/4600
1. Use CAN bridge harness HT9411.
2. Connect Y936 to diagnostic connector.
3. Connect Y569 of HT9411 to Y570 of HT9306.
4. Connect HT9306 to cab power strip.
5. Leave Y570 on HT9411 disconnected.
6. Set bridge on floor in cab corner.
John Deere S600 - GS3 Command Center/2630

2. Remove cup holder insert.
3. Connect Y902 to Horizon bridge.
4. Connect Y936 to diagnostic connector in cup holder.
5. Connect Y569 to Y570.
6. Place bridge under cup holder and reinstall cup holder.
John Deere 70-Series

2. Connect Y902 to Horizon bridge.
3. Connect Y936 to diagnostic connector

in right rear lower cab corner.
4. Connect Y569 of HT9411 to Y570 of HT9306.
5. Connect HT9306 to cab power strip.
6. Leave Y570 on HT9411 disconnected.
7. Set bridge on the floor in the cab corner.
13
Install Feathersight®
Installation
Components
• PFCxx exptension harness
• Y Adapter
• All models thru 2019 - FR-TEE-MP
• All Modesl 2020 & up - FR-TEE-AS16
All 70 Series and S550, S660, S670, S760, S770

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

and plug in supplied y-harness to sensor.
3. Connect factory wiring to y-harness

and Feathersight harness.
4. Connect 4 pin round

amp connector to main Insight or Horizon Harness.
5. Secure all harnesses with zip ties.
S680 and S690, S780, S790

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.
14
Calibration
Calibration
Insight® Systems
Initial Setup
These steps must be performed the first time the Insight box is powered up and each time
it is reset. They do not need to be redone each time the Insight box is calibrated. Read the
Insight Overview section for basic information about how to use the Insight box.
1. Connect all wiring to Insight box and combine as described in previous section.
2. Start Combine.
3. On the Insight box.

• Choose language
• Choose “John Deere”
• Choose “50/60/70/S”
• Choose the Header Type
• Choose the number of height sensors
Feathersight® Calibration
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
• Park the combine on a smooth, level surface -
preferably a cement driveway or shop floor.
4. 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
• “Fully Lower Header” all the way down on the skids and 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.
15
Horizon Systems
Connecting Base & Bridge

Calibration
Horizon only needs to be linked at initial setup or any time a unit is replaced. If you already
have or have installed a Truesight 2 system use the next section to connect units.
5. Select VT application “Horizon Bridge”.

• See Operation section of this manual to find Horizon Bridge VT application
6. Select serial number of Horizon base unit to which you want to connect.
7. Wait until screen says “Linked” and Loading of Pools has completed.
8. Go back to main menu and select VT application “Horizon”.

• See Operation section of this manual to find Horizon VT Applications
16
Initial Setup
If Horizon does not appear, temporarily remove any USB memory
attached to the display monitor and cycle power.
Calibration
Most Screens include Help pages that can be accessed by pressing the ? button. These
pages contain further information about the items displayed on the current screen.
1. Power up Horizon by turning on combine ignition key.
2. Select VT application “Horizon”.

• See Operation section of this manual to
find Horizon VT Applications
3. Follow on screen choices, and setup

for your specific Horizon kit.
• Combine Make - John Deere
• Combine Model - Choose model number of combine
• Head Select- Choose Grain
• Header App - None
• Sensor Type - Choose Poly Arm
• Sensor Count - Number of Height Sensors
• Sensor Mode - Choose Feathersight
Initial Setup appears until all the initial requirements are met.
17
Calibrate Horizon
For the best header control and calibration score, always make sure the header angle is
set correctly. Calibrate on a hard level surface preferably use a driveway or shop floor.
Calibration
For all JD S-Series combines with HFAT (Hydraulic Fore/Aft Tilt

option) make sure “Feeder House Fore/Aft Tilt Range” calibration has
been completed on combine before Horizon calibration.
1. Select Horizon VT application.
2. Level header to the ground
3. Select Calibrate on the display.
4. De-select EasyCal Mode (if selected).
5. Raise header and select OK.

• Follow on screen prompts
• Calibration score will be calculated at end
• Save Calibration if satisfied with score, if not satisfied
with score repeat Calibration - See chart below
6. Go to the combine ground calibration section in this manual.
Calibration Score
Best Performance 90-100
Good Performance 80-89
Fair Performance 70-79
Unreliable Performance 0-69
18
Combine Calibration
A full combine calibration must be completed on new installations or if a component of the
Calibration
header control system is changed on the combine. See combine operators manual for details.
GS4/4600 - JD S700 Series
1. Press Menu.
2. Press Machine Settings.
3. Press for calibrations.
4. Select Header.
5. Select Feeder House Raise Speed Calibration.
6. Follow instructions to calibrate.
7. Select Header Calibration.
9. Select “Header Tilt Speed Calibration” on only the S780 and S790 Machines.
19
JD S600 Series
Calibration
Press menu.
1. Press combine.
2. Press combine.
3. Press for calibrations.
4. Select Feeder House Raise Speed in calibration box and press
enter.
5. Follow instructions to calibrate and press enter to save calibration.
6. Select Header in calibration box and press enter.
8. For S680 and S690 machines only select Feeder House Tilt Speed
and press enter.
20
JD 70 Series
Calibration
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.
21
Settings
Combine Configuration
Settings
S600 & S700-Series

1. See Advanced Information: Access Combine settings if you are
not familiar with changing machine addresses.
• Change Address LC1-152 to “00” (only change last two digits)
• Change Address LC1-147 to “10001000”
2. Set header float position to “1”.
70 Series
1. See page 34 if you are not familiar with changing machine addresses.
• Change LC1-136 to “100000”
• Change LC1-138 to “499300”
2. Set header float position to “1”.
22
Combine Settings
Properly setting the combine is essential to having responsive header

control. You should become very familiar with the steps in this section.
Settings
Always perform the initial combine ground calibration before adjusting
settings. Set each sensitivity setting by increasing till header bouncing
occurs then decreasing till header becomes stable.
• Set height sensitivity, start at 100

• Set tilt sensitivity, start at 70-100
• Set float position to “1”
GS4/4600 - S700-Series Combines
3. Press the button below the screen.
4. Press on desired setting.

• Then press + or - to adjust or type on
desired number higher or lower
S600-Series and 70-Series Combines

1. Set 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.
2. Press the header setting button and set draper

float position to “1”.
23
Horizon & Insight Settings
Tilt Algorithm Selection

Settings
Headsight offers two algorithm choices for controlling lateral tilt. The choice
of tilt algorithm is only available for 4 and 5 sensor systems.
For Horizon, got to >>Setup>>Settings>>Lateral Tilt

• Select L & R for 2 sensor tilt.
• Select L & R and LC & RC for 4 sensor tilt.
For Insight: go to >>Setup>>Tilt Options
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
24
Tilt Sensitivity
If the head is too jumpy from side to side – decrease sensitivity. If you
would like the head to be more responsive – increase sensitivity.
Settings
For Horizon, got to >>Setup>>Settings>
• Tilt sensitivity range - 0-200, 100 is Default
For Insight, got to >>Settings>>Tilt Sensitivity
• Tilt sensitivity range - 0-100, 50 is default
Always increase combine tilt sensitivity before

increasing Insight or Horizon tilt sensitivity
Tilt Balance
If the head is consistently running higher on one end than the other, Tilt
Balance manually tweaks the combine height inputs to level it out. Use
tilt balance only after eliminating other possible solutions.
For Horizon, got to >>Setup>>Settings>
For Insight, got to >>Settings>>Tilt Balance
1. Before adjusting tilt balance,

• Double check to make sure head frame is level and snouts are adjusted correctly
• Re-calibrate Insight or Horizon box on a flat, level surface
• Re-calibrate combine on a flat, level surface
2. If head is still not running level, adjust the tilt balance setting.
• Default tilt balance value is 100
• Lowering the tilt balance number will lower the left end of the head
• Raising the tilt balance number will lower the right end of the head
3. Tilt balance setting will only last until the next calibration.
• Do not recalibrate combine without resetting tilt balance to 100
25
Feathersight® - HP Balance
This setting is only applicable if you have installed, turned
on, and calibrated the Feathersight® option.
Settings
For Insight: go to >>Setup>>Optional

Modules>>Feathersight>>HP Balance
What to know:
• This setting is the percentage of the height response
determined by the height sensors – the remaining
response is 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 Horizon™ 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 Horizon™ with the
pressure sensor disconnected to disable the pressure sensing mode
Advanced Machine
Outer Sensor Compensation
• Grain - Terrace sensor systems only
• Set Inner sensor distance behind cutterbar
• Value must be negative
• Set Outer sensor distance In front of cutterbar

• Value must be Positive
Header Pitch Compensation

• Grain - For use with heads with Fore-Aft pitch on header
• JD 6/7xxD - use 270 mV
26
Operation
After calibrating Insight, operate the Headsight system
exactly like you would use a John Deere system.
Operation
Enabling Height Control
GS4/4600 - S700 Series
1. Press the button below the screen
2. Check the settings for AHHC.

• Height Resume should be ON
• Height Sensing should be ON
• Lateral Tilt should be
3. Engage header clutch.
4. Press 2 or 3 resume button

on hydro handle to engage AHHC.
5. Turn the AHC dial on the armrest with header

control engaged.
• Clockwise = higher
• Counter-clockwise = lower
27
GS3 or GS2 - S600 Series
1. Press menu.
Operation
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.
28
70 Series
1. Press on cornerpost to enable the icon.
Operation
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.
29
Overview
Insight® Navigation
How to Navigate
Overview
When in a menu (selection arrow appears to left side)

• Enter: chooses the selected menu choice
• Esc: backs up one menu level
• Up: moves up within the menu choices displayed
• Down: moves down within the menu choices displayed
When in a screen which allows setting of parameters

• Enter: saves value and exits to menu
• Esc: backs up to last menu level without saving
• Up: increases the value
• Down: decreases the value
Meaning of Status Light

Solid Green:
• System is operating
• No errors detected
Solid Red:
• System is NOT operating
• No height or tilt signals are sent to combine
• You have changed settings which require calibration of Insight, are currently in a menu
which will force a calibration if you make any changes, or are in calibration mode
Solid Green with Flashing red:

• An error has been detected
• Repair problem then clear errors
Flashing Red:
• A sensor has been ignored
• See note in Troubleshooting by Error - ER16
• Repair system - Recalibrate Insight
No Light:
• No 12V or Ground to box
• Box Failure
30
Screen Contrast Adjustment
To change contrast:
• Press and hold Esc + Up or Down to increase or decrease contrast
Resetting Insight® to Defaults

To reset all settings hold + for 5 seconds
Overview
Updating Insight® Software with USB Drive
Updating software may cause the Foresight option to be disabled. If you have
purchased Foresight, contact Headsight before updating software.
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
31
Updating Software
Updating with Techlink™ App

1. Download Headsight Techlink App on your iPad or iPhone
from the Apple store.
• Must have Horizon 2.4.0 or later software
• Must have Boot Loader 1.3.5 or later
Overview
• Login, following on screen instructions

• Go to “Help Info” to learn how to use app
Updating with USB

1. Download latest version from website.
2. Unzip files, copy file insght2.bin onto root directory on USB flash drive.
3. Unplug Bridge unit in the cab while the Base update is being applied.
4. Plug USB flash drive into USB port on Horizon base on header.
• If unit is not yet powered up, cycle key on combine
• Base unit should start blinking yellow shortly after applying power. If this doesn’t
happen, unplug and plug the single point connector on the feederhouse
5. Wait until Horizon base has a green indicator light (should be no longer than 5 min.)
6. You can now safely remove the USB flash drive.

• Be sure to replace USB cover cap to reseal box
7. Place USB stick in the Bridge unit.
8. Plug connector back into the Bridge unit.
9. Wait until Horizon bridge has a green indicator light (should be no longer than 5 min.)
10. Unplug USB when a green light is displayed on the Bridge unit.
• Be sure to replace USB cover cap to reseal box
11. Wait for Horizon Bridge pool to appear on VT.
• A power cycle might be needed after update
12. Your units are now updated. Please verify that your Horizon initial settings are correct.
• If a drop down menu is displayed, select the serial number of the base unit (the base applications should
start loading after the bridge indicates a “linked” status)
If your Horizon units fail to update you must do a complete format on USB drive
to a (FAT) file type and then recopy insght2.bin to root directory. If Horizon
box continues to blink orange for more then 6 minutes or has a red light during
update, install Boot Loader Update file before the main update file.
32
Status Light
LED Blink sequences
• Loading Data from USB: rapid yellow blink (approx. every 0.1 sec)
• Unit looking for VT: green LED, blinks twice a second
• Normal Operation: green LED, blinks every 3 second
• User Interaction required (Update): rapid green blink (an
alarm mask will prompt the user on the VT)
Overview
• 12V power low: Red/yellow blink
• 5V supply low: 2 slow, 3 fast Green blinks
(Bridge only)
• Sending updates to VT: green LED blinks fast 3 times, then off 1 time
WIFI
Changing a WIFI channel is only needed when there is signal interference from
another device. Renaming is only needed if you want a custom WIFI name.
1. Select SETUP>>WIFI on Horizon VT application.
2. Rename network by selecting box “Network Name”.
3. Switch channel by selecting drop down box “Channel”.
4. Cycle power after any WIFI changes have been made.

• Be sure that Horizon unit power cycles to save changes
33
Advanced Information
Theory of Operation
A review of the following points will help the service technician to understand
the complete system, which will help diagnose specific problems.
Sensor voltage = Horizon output voltage =

Advanced Info
Horizon input voltage Combine sensor input
Insight or Horizon scales

voltages received to what
combine needs to function
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:
• black or lt blue= ground
• white = signal returned to combine (typically varies 1-4 volts)
• green or pink = 5 volt power
3. The Horizon base 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
• Horizon reads all sensors and sends signals to combine that will cause
appropriate height and or tilt response
• If Foresight is enabled - the Horizon magnifies the voltage change below
the point where the snout tips touch the ground
4. Read the “sensor” inputs to the combine in the combine diagnostics (as equipped).
See your combine owners manual for more information. These voltages should
be close to the voltages on the Horizon “Combine Inputs” above.
5. 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.
34
Sensors - Basic Requirements
Each sensor must meet basic requirements for Horizon to accept the
calibration. If any sensor does not meet the requirements below,
you must correct it 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
Advanced Info
from raised to lowered position for each sensor.
35
Insight Diagnostics Screens
Sensor Voltages
1. From main menu, go to >> Diagnostics>>Disp Sensor Voltages Sensor Vol
tages
• This shows real-time voltage coming from each sensor.
L LC CTR RC R
0.0 0.0 0.0 0.0 0.0
2. For more information about sensor history and status see

Advanced Info
Left Sens =0.00V

>>Diagnostics>>Detailed Diagnostics>>(parameter of interest) Max=0.00V SetH=5.00V
• Sensor = signal from sensor in volts Min=0.00V SetL=0.00V
• Max = the maximum voltage sent to Insight Enabled=N Reversed=N
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
Output Voltages
1. From main menu, go to >> Diagnostics>>Detailed Pressure/aux Sensor
Diagnostics>> (parameter of Interest).  Left Height Output
• Shows actual voltage being sent to the combine. Center Height Out
• Available selections depend on combine model Right Height Output
2. Left Height Output = X.XVolts

Left Height OUTPUT
• 1.0V with head fully lowered =1.00V
• 4.0V with head raised
Range = (1.0v-4.0V)
3. Center Height Output = X.XVolts

Center Height OUTPUT
Range = (1.0v-4.0V)
4. Right Height Output = X.XVolts

Right Height OUTPUT
Range = (1.0v-4.0V)
Read the sensor inputs to the combine on the combine monitor (as equipped).
See your combine owners manual or below for more infomation. These voltages
should be close to the voltages on the Horizon or Insight “Height Outputs”.
36
Horizon Diagnostics Screens
Overview
• Overview - displays voltages from sensors
and voltages being sent to combine
• Calibration Score
• General reference to calibrated range - black lines on
sensor graphs are high and low calibration points, middle
hash mark is Foresight® calibration point when being
Advanced Info
operated on a corn head with Foresight® turned on
• Dots on graphs: Green - no codes, Yellow - had
code but working, Red - code active
Detailed Sensor Voltages

• Press on any sensor graph
• Max and Min Voltages since last calibration
• High, Mid (used with Foresight), and
Low calibration voltages
• Displays Foresight® Gain setting
• Use Previous and Next to scroll through sensors
and Back to return to previous menu
Signals
• General reference to inputs and outputs of Horizon™
• Displays - Signal, Value, and pin location
on 50 pin connector on Horizon™
Errors
• Displays all error codes since last
calibration or clearing of codes
• Displays active or inactive status for codes
• Allows clearing of codes after problem has been fixed
37
Access Combine Settings
1. Press menu.
Advanced Info
2. Press system.
3. Press diagnostics system.
4. Press system diagnostics.
5. Select left control unit #1.
6. Select diagnostic addresses.
7. Left input voltage is - LC1 21 (left 3 digits) and

Right input voltage is - LC1 24 (left 3 digits)
1. Press menu.
2. Press message center
3. Press addresses.
4. Select LC1 in devices box.
5. Press arrow down till you see address.
6. Left input voltage is - LC1 21 (left 3 digits) and Right input voltage is - LC1 24 (left 3 digits)
38
70 Series Combines
1. Press menu.
2. Scroll to when highlighted press .
Advanced Info
3. Scroll to when highlighted press .
4. Scroll to when highlighted press
5. Scroll to when highlighted and press
6. Scroll to when highlighted and press until desire address is displayed.
7. Left input voltage is - LC1 31 and Right input voltage is - LC1 33
39
Enhanced Near Ground Performance
Be sure to follow all sections of this manual before changing any of these settings,
these address setting changes will have to be changed back before attaching
another header. Proceed only if you feel confident in what you are doing.
S700 & S600 Series Combines

Advanced Info
1. Follow “Access Combine Settings” section of this manual.
2. Adjust Header Height Sensing Deadband LC1-143.

• Lower value increases sensor response
• Higher value decreases sensor response
• Factory default (050050)
3. Adjust Header Height Sensing Gain LC1-144.
• Lower value decreases sensor correction error response
• Higher value increase sensor correction error response
70 Series Combines
1. Follow “Access Combine Settings” section of this manual.
2. Adjust Header Height Sensing Deadband LC1-124.

• Lower value increases sensor response
• Higher value decreases sensor response
3. Adjust Header Height Sensing Gain LC1-125.
• Lower value decreases sensor correction error response
• Higher value increase sensor correction error response
40
Sensor Adjustment
Standard Sensor
Insert header stop to prevent movement.
Increasing or Decreasing Voltage
Advanced Info
1. Remove sensor cover. A
2. Loosen sensor mounting screws A.
3. Twist sensor to new position.

• Twisting sensor clockwise (viewed from the
end of the sensor) will increase voltage.
• Twisting sensor CCW will decrease voltage.
4. Tighten sensor mounting screws A.
5. Reinstall cover plate.
Adjusting Down Pressure

1. Remove spring cover.
2. Loosen indicated nut A.
3. Press adjustment bolt toward sensor.

• Spring tension will release.
4. Preload spring to a new position.
5. Use one wrench to turn the adjustment bolt B. B A
6. Use a second wrench to tighten the nut A.
7. Tightening the bolt (CW) increases spring downpressure.
Make sure that the leg of the spring is fully seated in the
shaft to prevent rubbing on the cover plate.
8. Reinstall cover plate.
41
Terrace Sensor
Insert header stop to prevent movement.
Increasing or Decreasing Voltage

1. Loosen the screws indicated A.
B
2. Turn sensor to new location.
Advanced Info
3. Tighten screws A.
Adjusting Voltage Swing A

A
1. Loosen jam nut B.
2. Turn bolt to adjust.

• Rotating bolt counter-clockwise increases
voltage swing
• Rotating bolt clockwise decreases voltage swing
3. Tighten jam nut B.
Adjusting Down Pressure

1. Loosen jam nut A.
2. Turn bolt to adjust tension.

• Rotating bolt counter-clockwise decreases
down pressure
• Rotating bolt clockwise increases down pressure
3. Tighten jam nut A. A
42
Diagnostics
Before working on combine or under header always:
1. Perform all combine and header manufacturer

safety precautions for servicing header.
2. Insert stop to prevent movement of header.
3. Set combine parking brake.
Diagnostics
4. Turn off combine and remove key from ignition.
5. Disconnect all drive shafts from the header.
Troubleshooting Overview
Several Troubleshooting Sections are available, depending on the type of problem or symptoms.
1. Troubleshooting -Sensors & Harnesses

• Use this section to troubleshoot a specific sensor
that is not working or out of adjustment.
• Typical symptom:
• Sensor fault code displayed - example:
“Err XX, Left sensor > 0.3V”
2. Troubleshooting by Symptom
• Use this section to diagnose poor operation symptoms
• Not usually accompanied by an Error message or Fault Code
• Typical Symptoms
• No app appears on monitor (Horizon Only)
• Header won’t tilt
• Header ‘hunts’
3. Troubleshooting by Error Code (Insight or Horizon)

• Use this section to help determine the problem
when an fault code has been displayed.
43
Troubleshooting—Sensors and Harnesses
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 Blue)

• Pin B is Signal (White)
• Pin C is 5V (Green or Pink)
Diagnostics
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 sensor output voltage will be 4.7V and not change.
The following requirements must be met before testing:

• Key on, combine engine running
• Header connected
Symptom Problem Solution
Bad Harness Wiring Measure C to Frame Ground If not, check harness for continuity or
Disconnect Sensor Plug short on 5V wire
Voltage should be 5V
(Measure voltage on harness plug at Check Combine 5V source
sensor)
Measure C to A If not check harness for continuity on

ground wire
Check combine sensor ground source
Jump C to B in harness plug If not check signal wire for broken
harness or bad connection
(See Reading Voltages: Sensor)

All of the above are correct Harness & combine connections pass
test.
If you have a Headsight Sensor tester, Verify sensor is connected to extension If sensor cannot be adjusted to achieve
use it to test the sensor. For all other: harness a voltage within the range, replace
sensor.
Sensor voltage should be 0.5- 4.5V
(See Reading Voltages: Sensor)
44
Troubleshooting by Symptom
Nearly every problem with the header control system 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 or Horizon box
• Properly calibrate combine AHHC (“Header Cal”)
• Enable appropriate AHHC functions on combine
• Properly set combine electronics and/or hydraulics
Diagnostics
Status Light Diagnostics (Status not green)
No light Combine does not supply 12V to pin 4 Measure power supply voltage with key
of the Insight connector on.
Pin 4 of header connector Y201
Pin 4 of Insight Y101
Pin 30 of Horizon Y901
No Ground Pin 30 of header connector Y201
Pin 6 of Insight Y101
Pin 38 of Horizon Y901
Insight or Horizon defective Replace Controller
Solid red Wiring is not connected properly or See Installation and Calibration
calibration has not been completed sections of manual
Flashing Red or Green/Red Insight box has detected an error Correct problem, clear error codes, and
recalibrate Insight box
45
Horizon CAN & WiFi Diagnostics
No Horizon Bridge App on VT Bridge or TS2 not connected to VT Make sure Bridge is connected to
CAN. correct VT CAN
See Advanced Info/Status Light for
more diagnostics Bridge does not have Power (no LED) Make sure bridge has switched 12V.
ISO or VT not installed/enabled on Install of enable VT

monitor
Truesight 2 is not enabled as “Bridge” Check WIFi setup in TS2
Memory stick interfering (CNH only) Remove memory stick from VT, cycle
Diagnostics
power.
Check for 2nd Display Make sure Horizon is not on other

display
Bridge cannot find Base Base not connected Connect Header to combine
See Advanced Info/Status Light for No 12V power to Base Make sure Base has power.
more diagnostics
Check for power wire properly
installed.
Check power from combine
Some applications, Base LED can
be on, but WiFi not powered. Start
combine engine.
Base connected to BAT not keyed 12V Make sure that Base turns off with key.
Base not broadcasting WiFi Check smartphone Wifi Browser for

“HZN xxxxxxx” network
Other networks interfering. Wifi Move combine away from buildings,

Cameras, Building Wifi, etc etc. Change Wifi Channel. Cycle power
and see if problem is resolved
Base WiFi blocked Move Base away from metal shields

(frames, covers etc), Remove trash.
Base not broadcasting WiFI No 12V Power Make sure Base has 12V power.
Check for power wire properly
No “HZN xxxxxxx” network on installed.
smartphone Wifi Browser Check power from combine
Some applications, Base LED can
See Advanced Info/Status Light for be on, but WiFi not powered. Start
more diagnostics combine engine.
Shorted power system on header Disconnect header wiring, Aux harness,

Header CAN network, etc to see if WiFi
will reappear
Defective Base Call Headsight for further diagnostics
46
AHHC Diagnostics
No automatic operation height or tilt Wiring is not connected properly Check wiring from sensor to combine
Header control is not enabled with cab See Operation section of this manual
controls
(If the box does not have a green status
light, go to “Status Light Diagnostics”) Wrong HHC mode selected Turn on AHHC, see Operation section
of this manual
Power supply from combine less than Check 12V power source
10V to Insight. (Pin 4 in combine plug)
Diagnostics
Insight or Horizon box/wiring failure >>Diagnostics>>Detailed
Diagnostics>>Left/Right Height Output
0.8-1.2V head fully lowered
3.8- 4.2V sensors off ground
Header is too jumpy Combine is improperly set See - Setting section of this manual
Reduce Auto Drop Rate
Decrease sensitivity
Insight or combine needs to be re- See Calibration section of this manual
calibrated
Header responds to slowly Insight or combine needs to be re- See Calibration section of this manual
calibrated
Combine is improperly set See - Setting section of this manual
Increase Auto Drop rate
Increase sensitivity
Combine Header Cal Fails Header not properly connected Verify that Insight harness is attached
and Insight box has power.
Insight Has Errors Repair error, clear error codes
Cycle key
Recalibrate Insight
Combine does not recognize header Verify the JD>>50/60/70/S is chosen
on the Insight box, and that the correct
header type has been selected.
Header Raise Speed Cal Required Perform Header Raise Speed Cal first
(S series only)
Insight Outputs are not correct Recalibrate Insight on flat surface.
>>Diagnostics>>Detailed Reset Insight: See Insight Overview for

Diagnostics>>Left/Right Height Output details
0.8-1.2V head fully lowered Insight defective

3.8- 4.2V sensors off ground
Combine Problem Call your combine service dept.
47
AHHC Diagnostics
Cannot operate head high enough Calibration not properly completed Perform Insight and Combine
calibration on flat level surface
Cannot operate head low enough Calibration not properly completed Perform Insight and Combine
calibration on flat level surface
Special software needed Contact Headsight regarding optional
products Foresight and/or Feathersight
Header dives to ground and recovers Lower Rate set too High See Combine Specific Settings
entering crop
Diagnostics
Head Jumps and Jerks whole combine Drop rate too fast See Combine Settings section of this
manual)
Unopened accumulator Open accumulator valve 1-2 turn
Discharged accumulator Test accumulator as described in

combine owner’s manual, replace or
recharge as necessary

Lateral Tilt Diagnostics
Height works but not Tilt Increase Tilt Sensitivity. >>Setup>>Tilt Sensitivity
Increase Tilt sensitivity
Rare combine problem Call Headsight to increase Max
Combine Tilt.
Head rocks back and forth Tilt Sensitivity too high Adjust sensitivity in combine
>>Setup>>Tilt Sensitivity
Decrease Tilt sensitivity
Press Check
Insight/Combine not calibrated See Calibration Section

properly
(do Cal on flat surface)
Header tips wrong way Left and Right sensor harnesses Connect sensor harnesses to correct
(Once head is moved off level, it reversed plugs on adapter harness.
continues all the way in either direction)
48
Lateral Tilt Diagnostics
Head tips all the way one direction Improperly adjusted sensors Adjust the sensors to both be equal
when sitting flat on the ground
(platform) or when hanging against
stops (corn/grain)
Sensor harness improperly wired See Diagnostics: Sensor and Harness
Spec: Note about reversed wires in
connectors.
Poor connection Check harness and connectors for cut/
torn wire or loose terminals
Make sure terminals are properly
Diagnostics
latched, not “pushed back”, in
connector body
Sensor or harness fault See Diagnostics: Sensor & Harness
Insight box failure >>Diagnostics>>Detailed
Diagnostics>>Left & Right Height
Outputs
1.0V head fully lowered
4.0V sensors off ground
Combine problem Test combine on a different header
Header runs slightly out of level Insight or combine not calibrated Recalibrate Insight and combine on
correctly flat surface
Sensor physically misadjusted Make sure both end sensors mount
the same and hang at the same angle
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 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)
49
General Insight Problem
Display dim, blank, or hard to read Screen contrast improperly adjusted See Insight Settings
Weak power supply to Insight™ box See Installation, 12V Power Test
Short in sensors/wiring powered by Individually disconnect sensors to
Insight box isolate problem – screen will regain
contrast when faulty sensor is
(Reversed polarity to hall-effect disconnected.
sensors may cause this symptom)
Correct short in wiring
Insight will need reset after correction

Diagnostics
of wiring short
Control box failure Contact Headsight
50
Troubleshooting by Insight® Error Codes
Error Code Problem Solution
ER11 Left sensor temporarily disconnected. Repair wiring or bad connector
Left sensor signal less than 0.3V Calibrate Insight Box
Calibrate Combine
Wiring open Check sensor harness for pinched/

broken wiring
Sensor failure See sensor test instructions
ER12 Wiring problem Ground wire to sensor is open
Diagnostics
Left sensor signal greater than 4.7V Signal short to power
Calibrate Insight Box
Calibrate Combine

ER13 Left sensor mechanical range is Verify sensor is not obstructed in swing
restricted Verify sensor can collapse fully with
Left sensor swing less than 0.6V
header lowered
Adjust down stop to allow greater
range
ER16 Left sensor not properly connected Verify harness is connected to sensor 1
Left sensor expected but not detected 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 Go to >>Initial Setup>>Number Sensors

in setup and choose the correct number of
sensors
Sensor failure See sensor troubleshooting

instructions
Control box /wiring failure Contact Headsight

ER17 Incorrect number of sensors selected Go to >>Setup>>System Select and
Left sensor detected but not expected in setup choose the correct number of sensors
Harness wiring error Verify that no wires contact PIN7 of

connector Y101
51
ER21 Left Center sensor temporarily Repair wiring or bad connector
disconnected. Calibrate Insight Box
Left Center sensor signal less than 0.3V
Calibrate Combine

broken wiring

Left Center sensor signal greater than Signal short to power
4.7V Calibrate Insight Box
Calibrate Combine
Diagnostics

ER23 Left Center sensor mechanical range is Verify sensor is not obstructed in swing
Left Center sensor swing less than 0.6V
header lowered
range

ER26 Left Center sensor not properly Verify harness is connected to left
Left Center sensor expected but not connected center sensor
detected Verify harness is connected properly to
control box harness

sensors

instructions

Left Center sensor detected but not in setup choose the correct number of sensors
expected
connector Y101
52
ER31 Center sensor temporarily Repair wiring or bad connector
disconnected. Calibrate Insight Box
Center sensor signal less than 0.3V
Calibrate Combine

broken wiring

Center sensor signal greater than 4.7V Signal short to power
Calibrate Combine
Diagnostics
ER33 Center sensor mechanical range is Verify sensor is not obstructed in swing
Center sensor swing less than 0.6V
header lowered
range

ER36 Center sensor not properly connected Verify harness is connected to center
Center sensor expected but not sensor
detected
Verify harness is connected properly to
control box harness

sensors

instructions

Center sensor detected but not in setup choose the correct number of sensors
expected
connector Y101
53
ER41 Right Center sensor temporarily Repair wiring or bad connector
Right Center sensor signal less than disconnected. Calibrate Insight Box
0.3V Calibrate Combine

broken wiring

Right Center sensor signal greater than Signal short to power
4.7V Calibrate Insight Box
Calibrate Combine
Diagnostics

ER43 Right Center sensor mechanical range Verify sensor is not obstructed in swing
Right Center sensor swing less than is restricted Verify sensor can collapse fully with
0.6V header lowered
range

ER46 Right Center sensor not properly Verify harness is connected to right
Right Center sensor expected but not connected center sensor
control box harness

sensors

instructions

Right Center sensor detected but not in setup choose the correct number of sensors
expected
connector Y101
54
ER51 Left sensor temporarily disconnected. Repair wiring or bad connector
Right sensor signal less than 0.3V Calibrate Insight Box
Calibrate Combine

broken wiring

Right sensor signal greater than 4.7V Signal short to power
Calibrate Combine
Diagnostics
ER53 Right sensor mechanical range is Verify sensor is not obstructed in swing
Right sensor swing less than 0.6V
header lowered
range

ER56 Right sensor not properly connected Verify harness is connected to right
Right sensor expected but not sensor
control box harness

sensors

instructions

Right sensor detected but not in setup choose the correct number of sensors
expected
connector Y101

ER61 Wiring open Check sensor harness for pinched/
broken wiring
Sensor 6 (aux sensor) signal less than
0.3V
55
Sensor 6 (aux sensor) signal greater
than 4.7V Sensor failure See sensor test instructions
ER92 Wiring problem Turn the Tilt sensitivity knob in the

cab to Maximum CW. Read under
Tilt Sensitivity greater than 4.0V
>>Diagnostics>>Detailed Diag.>>Tilt
Sens In, on the Insight box
Reading between 4.0 and 4.5. Call
Headsight for instructions
Reading > 4.5V, Combine problem-

Check wiring on combine
Diagnostics
56
Troubleshooting by Horizon® Error Codes
Error Code Problem
1100.00 Left Wire A too High
1100.01 Left Wire A too Low
1100.03 Left Wire A shorted to High Source
1100.04 Left Wire A shorted to Low Source
1100.05 Left Wire A open
Diagnostics
1101.00 Left Center Wire A too High
1101.01 Left Center Wire A too Low
1101.03 Left Center Wire A shorted to High Source
1101.04 Left Center Wire A shorted to Low Source
1101.05 Left Center Wire A open
1103.00 Center Wire A too High
1103.01 Center Wire A too Low
1103.03 Center Wire A shorted to High Source
1103.04 Center Wire A shorted to Low Source
1103.05 Center Wire A open
1105.00 Right Center Wire A too High
1105.01 Right Center Wire A too Low
1105.03 Right Center Wire A shorted to High Source
1105.04 Right Center Wire A shorted to Low Source
1105.05 Right Center Wire A open
1106.00 Right Wire A too High
1106.01 Right Wire A too Low
1106.03 Right Wire A shorted to High Source
1106.04 Right Wire A shorted to Low Source
1106.05 Right Wire A open
1110.00 Left Wire B too High
1110.01 Left Wire B too Low
1110.03 Left Wire B shorted to High Source
1110.04 Left Wire B shorted to Low Source
57
Error Code Problem
1110.05 Left Wire B open
1111.00 Left Center Wire B too High
1111.01 Left Center Wire B too Low
1111.03 Left Center Wire B shorted to High Source
1111.04 Left Center Wire B shorted to Low Source
1111.05 Left Center Wire B open
1113.00 Center Wire B too High

Diagnostics
1113.01 Center Wire B too Low
1113.03 Center Wire B shorted to High Source
1113.04 Center Wire B shorted to Low Source
1113.05 Center Wire B open
1115.00 Right Center Wire B too High
1115.01 Right Center Wire B too Low
1115.03 Right Center Wire B shorted to High Source
1115.04 Right Center Wire B shorted to Low Source
1115.05 Right Center Wire B open
1116.00 Right Wire B too High
1116.01 Right Wire B too Low
1116.03 Right Wire B shorted to High Source
1116.04 Right Wire B shorted to Low Source
1116.05 Right Wire B open
1130.00 Left Sensor too High
1130.01 Left Sensor too Low
1130.03 Left Sensor shorted to High Source
1130.04 Left Sensor shorted to Low Source
1130.05 Left Sensor open
1130.11 Left Sensor - Error not defined
1130.34 Left Sensor not detected
1131.00 Left Center Sensor too High
1131.01 Left Center Sensor too Low
58
Error Code Problem
1131.03 Left Center Sensor shorted to High Source
1131.04 Left Center Sensor shorted to Low Source
1131.05 Left Center Sensor open
1131.11 Left Center Sensor - Error not defined
1131.34 Left Center Sensor not detected
1132.00 Truesight Sensor too High
1132.01 Truesight Sensor too Low
1132.03 Truesight Sensor shorted to High Source
Diagnostics
1132.04 Truesight Sensor shorted to Low Source
1132.05 Truesight Sensor open
1132.11 Truesight Sensor - Error not defined
1132.34 Truesight Sensor not detected
1133.00 Center Sensor too High
1133.01 Center Sensor too Low
1133.03 Center Sensor shorted to High Source
1133.04 Center Sensor shorted to Low Source
1133.05 Center Sensor open
1133.11 Center Sensor - Error not defined
1133.34 Center Sensor not detected
1135.00 Right Center Sensor too High
1135.01 Right Center Sensor too Low
1135.03 Right Center Sensor shorted to High Source
1135.04 Right Center Sensor shorted to Low Source
1135.05 Right Center Sensor open
1135.11 Right Center Sensor - Error not defined
1135.34 Right Center Sensor not detected
1136.00 Right Sensor too High
1136.01 Right Sensor too Low
1136.03 Right Sensor shorted to High Source
1136.04 Right Sensor shorted to Low Source
1136.05 Right Sensor open
1136.11 Right Sensor - Error not defined
1136.34 Right Sensor not detected
59
Parts
Insight System
1 2
5
3
Parts
ITEM QTY. PART NUMBER DESCRIPTION

1 1 INSIGHT Insight Control Box
2 1 QJ5-JD72-31Q Insight Header Harness
3 1 B3110 Universal Bracket Kit
4 1 HT2259 31 Pin Connector Clip
5 AR FR-MET2 Feathersight Kit (70,S567-Se-
ries)
AR FR-MET2B Feathersight Kit (S680 and
S690, S780 and S790)
*all parts vary for each appli-

cation, please call for more
information
60
Horizon System
3
1 2
4 7
6
8
Parts
1 1 HORIZON-BASE Horizon Control Box (Header)
2 1 HORIZON-BRIDGE Horizon Control Box (Cab)
3 1 ZJ5-JD72-31Q Horizon Header Harness
4 1 HT9411 Horizon Bridge Harness
5 AR HT9306 Power Adapter (70-Series)
6 AR FR-MET2 Feathersight Kit (70,S567-Se-
ries)
AR FR-MET2B Feathersight Kit (S680 and
S690, S780 and S790)
7 1 B3110 Universal Bracket Kit
8 1 HT2259 31 Pin Connector Clip
*all parts vary for each appli-

cation, please call for more
information
61
Mounting Brackets and Harness
1 2 3
4
Parts

1 AR HT7152 Bracket, Terrace
AR B7152-2 Mounting Hardware
2 AR HT8160 Bracket, Undermount
AR B865 Mounting Hardware
3 AR PFBxx (xx=length) Extension Harness
(10,17,23,33,38)
4 AR HT899 Conduit
AR B892 Hardware Kit
62
8 7 6 5 4 3 2 1
6* HT7000_PARTS
H H
5*
3*
8*
7*
2
4*
3 16 18
G 1 G
17
15
Terrace Sensor
25
F F
23 14
4
9
12 13
11
E 10 E
ITEM NUMBER PART NUMBER DESCRIPTION QUANTITY 22
1 HT7117 SHIELD 1
2 08200245 M8-1.25x12, SERRATED FLANGE BOLT 3 5
3 08100102 5/16 CABLE CLAMP, 3/8 HOLE 2
4 08100132 RETAINING RING 2
5 08200119 M8-1.25, SERRATED FLANGE NUT 2
6 08200246 M8-1.25x45 HEX BOLT 1 20
D 7 HT7105 TRIP BACK SPRING 1 D
8 HT7116 PIN 1
21
9 08200247 M10-1.5x30, HEX BOLT 1
10 08200248 M5-0.80x20, SHCS 4 19
11 HT2128 SENSOR 1 24
12 08100144 O-RING, SIZE-210 1
13 HT7101 SENSOR BODY 1
C C
14 08100141 BUSHING 1
15 HT7109 BEARING BLOCK 1
16 HT7104 SPRING 1
17 08100136 O-RING, SIZE-014 1
18 HT7111 SENSOR ARM 1
19 HT631 CROP DIVIDE TIP 1
MATERIAL N/A
20 08200187 M8-1.25x30 SERRATED FLANGE BOLT 2 UNLESS OTHERWISE SPECIFIED
DIMENSIONS ARE IN INCHES
DATE
B 21 08200249 M8-1.25x55 HEX BOLT 1 DIMENSIONS W/O TOL ARE BASIC

AUG 8, 17 B
22 HT7106 SPRING ADJUSTING CLIP 1 THIRD ANGLE
PROJECTION SHEET 1OF 1
23 08200258 M10-1.5 HEX NUT 1
24 HT701-BU LONG WAND, BLUE NYLON 1
25 PFBxx HARNESS (xx - LENGTH IN FT) 1
HEADSIGHT INC.
THE INFORMATION CONTAINED ON THIS DRAWING IS PROPRIETARY TO
LENGTHS: 6, 10, 17, 23, 33, & 38 HEADSIGHT, INC. ANY UNAUTHORIZED USE OF SUCH CONTENTS IS
STRICTLY PROHIBITED.
26* B7000 BOLT KIT, INCLUDES ITEMS WITH AN ASTERISK*
TERRACE SENSOR PARTS
A 27 HT7000 COMPLETE SENSOR ASSEMBLY STANDARD NOTE: SENSOR CALIBRATION A
(ASSEMBLY EXCLUDES ITEMS 1, 20, 24, 25, & 26*) TARGET HIGH VOLTAGE = 4.30V (ACCEPTABLE RANGE 4.20V - 4.35V)
28 HT7001 COMPLETE SENSOR ASSEMBLY FOR SHELBOURNE UNDERMOUNTS TARGET LOW VOLTAGE = 0.70V (ACCEPTABLE RANGE 0.65V - 0.95V) CHG LEVEL
(ASSEMBLY EXCLUDES ITEMS 19, 20, 24, 25, & 26*) HT7000_PARTS 02 C
8 7 6 5 4 3 2 1
63
Parts
8 7 6 5 4 3 2 1
HT8000_PARTS
H H
1
G G
11 13
10 12
2 8 9
7
21 6 F
F
5
3
4
E ITEM NUMBER PART NUMBER DESCRIPTION QUANTITY
E
1 HT8125 SENSOR BODY 1
2 08100101 1/4 CABLE CLAMP, 5/16 HOLE 1
14
Standard (Undermount) Sensor
3 08200241 M6-1.00x6, BHCS 1

4 08200242 M5-0.80x12, SHCS 2
5 HT2128 SENSOR 1 15
6 HT8117 SHAFT 1
D 7 HT862 BUSHING 1 18
D
8 08100121 RETAINING RING 1
9 HT863 BUSHING 1
20
10 HT840 SPRING 1 15
11 HT869 ADJUSTING CLIP 1
12 08200119 M8-1.25, SERRATED FLANGE NUT 1
16
C 13 08200243 M8-1.25x30, HEX BOLT 1 C
14 HT8111 LEFT COVER 1 17
15 08200245 M8-1.25x12, SERRATED FLANGE BOLT 2
16 08200244 M8-1.25x30 BHCS, TORX 1
17 HT8115 ARM 1
18 HT8114 RIGHT COVER 1
19 HT701-B LONG WAND, BLACK POLY 1 MATERIAL N/A
UNLESS OTHERWISE SPECIFIED
HT701-Y LONG WAND, YELLOW POLY
NOV 23, 16 B
DATE
B DIMENSIONS ARE IN INCHES
HT701-BU LONG WAND, BLUE NYLON DIMENSIONS W/O TOL ARE BASIC
19 THIRD ANGLE
PROJECTION SHEET 1OF 1
HT801-B SHORT WAND, BLACK POLY
HT801-Y SHORT WAND, YELLOW POLY
20
HT801-BU
08200187
SHORT WAND, BLUE NYLON
M8-1.25x30 SERRATED FLANGE BOLT 2
HEADSIGHT INC.
THE INFORMATION CONTAINED ON THIS DRAWING IS PROPRIETARY TO
HEADSIGHT, INC. ANY UNAUTHORIZED USE OF SUCH CONTENTS IS
21 PFBxx HARNESS (xx = LENGTH IN FT) 1 STRICTLY PROHIBITED.
LENGTHS: 6, 10, 17, 23, 33, & 38 GRAIN SENSOR PARTS
A NOTE: SENSOR CALIBRATION A
22 HT8000 COMPLETE SENSOR ASSEMBLY TARGET HIGH VOLTAGE = 4.30V (ACCEPTABLE RANGE 4.20V - 4.35V)
(ASSEMBLY EXCLUDES ITEMS 19 & 20) TARGET LOW VOLTAGE = 0.70V (ACCEPTABLE RANGE 0.65V - 0.95V) CHG LEVEL
(ASSEMBLY INCLUDES ITEM 21, PFB10) HT8000_PARTS 04 C
8 7 6 5 4 3 2 1
Parts
64
This Page
Is Intentionally
Left Blank
FCC and IC Compliance Statements
The Horizon Box Contains Transmitter Module ESP32
WARNING: To satisfy FCC RF exposure requirements for mobile transmitting devices, a separation
distance of 20cm or more should be maintained between the antenna of this device and persons during
operation. To ensure compliance, operations at closer distances than this are not recommended.
ATTENTION: This device complies with Part 15 of the FCC rules. Operation is subject to the
following two conditions: (1) this device may not cause harmful interference, and (2) this device must
accept any interference received, including interference that may cause undesired operation.
The FCC requires the OEM to be notified that any changes or modifications not expressly
approved by SyChip, LLC may void the user’s authority to operate the equipment.
While an application of the ESP32 module in a product is not required to obtain a new
FCC authorization for the module, this does not preclude the possibility that some
other form of authorization or testing may be required for that end product.
This device using the integrated antenna has been tested to comply with FCC CFR Part 15. The device
meets the requirements for modular transmitter approval as detailed in the FCC public notice DA00.1407.
ATTENTION: The term “IC” before the certification/registration number only

signifies that the Industry Canada technical specifications were met.
Le terme “IC” devant le numéro de certification /d’enregistrement signifie seulement

que les spécifications techniques Industrie Canada ont été respectées.
This device complies with Industry Canada license-exempt RSS standard(s). Operation is subject to
The following two conditions: (1) this device may not cause interference, and (2) this device must
accept any interference, including interference that may cause undesired operation of the device.
Cet appareil est conforme avec Industrie Canada RSS standard exempts de licence (s).
Son utilisation est soumise à Les deux conditions suivantes: (1) cet appareil ne peut pas
provoquer d’interférences et (2) cet appareil doit accepter Toute interférence, y compris
les interférences qui peuvent causer un mauvais fonctionnement du dispositif.
This device complies with Health Canada’s Safety Code 6 / IC RSS-210. The installer of this device should
ensure that RF radiation is not emitted in excess of the Health Canada’s requirement. Information can be
obtained at: http://www.hc-sc.gc.ca/ewh-semt/pubs/radiation/radio_guide-lignes_direct-eng.php
Cet appareil est conforme avec Santé Canada Code de sécurité 6 / IC RSS-210. Le programme
d’installation de cet appareil doit s’assurer que les rayonnements RF n’est pas émis au-
delà de l’exigence de Santé Canada. Les informations peuvent être obtenues: http://www.
hc-sc.gc.ca/ewh-semt/pubs/radiation/radio_guide-lignes_direct-eng.php
66
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 Liability
Headsight makes no express warranties other than those, which are specifically described herein. Any description of the goods
sold hereunder, including any reference to buyer’s specifications and any descriptions in circulars and other written material
published by Headsight is for the sole purpose of identifying such 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 warran-
ties 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, suit-
ability 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 obli-
gation to owners of units previously sold. Warranty: 1/2020
67
P 574.546.5022 • F 574.546.5760
4845 3B Rd • Bremen, IN 46506
info@headsight.com
www.headsight.com
68

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About this Manual

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Protected by one or more of the following patents and published applications:

Copyright Headsight, Inc. 2021

1. Perform all combine and header manufacturer

2. Insert stop to prevent movement of header.

3. Turn off combine and remove key from ignition.

4. Set combine parking brake.

5. Disconnect all drive shafts from the header.

1. Line up holes of sensor and mounting bracket with spring

2. Insert pin and secure with retaining ring clip.

3. Install cable clamp on sensor harness & leveling bolt A A

4. Adjust leveling bolt A until sensor is level and tighten

5. Tighten bolt B holding clamp on side of sensor.

7. Remove factory yellow metal crop

8. Mount terrace sensor assembly to holes where

9. Repeat steps for other side.

1. To determine mounting locations, mount outer

2. Hold bracket in place on top side of skid, under

3. Slide bracket forward to bend in skid and mark bracket

4. Flip over and place bracket on underside of skid

5. Drill four ¼” pilot holes at each location marked.

6. If head is equipped with poly use a 3/4” hole

7. Drill four pilot holes out to 3/8”

9. Mount sensor and bracket to head leaving

10. Tighten hardware after wiring installation.

1. Use hardware provided and fasten wand to sensor.

2. Attach a tether cable to each wand.

Tether cables are not used on terrace sensors.

3. Fasten the rear of the cable to a secure location on

Do not leave or store the arms in a flattened or crushed position. They

Extension Harness Length Table

Header Width Left Left Center Center Right Center Right

Removing Wires for Tight Access

1. Release wire retaining clip on each connector. Insert

2. Flare connector terminal tabs using removal tool.

3. Reinstall wires in connector body:

5. Connect wiring harness to sensor.

1. Connect a PFB10 (10’) harness to each sensor

2. Zip tie sensor connector with latch clip down

3. Route harness back underneath poly end divider and fasten

4. Route around gearbox and fasten with two

5. Route back through holes (marked A ) and route with

6. Connect left extension harness and fish wire

7. Using a burr bit and a die grinder make a path for

9. Reinstall all safety shields and verify all hardware is tight.

3. Insert box end of wrench into conduit using as a

4. Route harness thru bracket hole and clamp

1. Route conduit and harness outside of head

2. Route back through holes (marked A ) and route with

3. Connect proper extension harness (see Table) and

4. Repeat steps for other outer sensor.

2. Drill holes to mount conduit to outside of under- header

3. Connect proper extension harness (see Table).

4. If sensors to left of feederhouse, route up to rear of

2. Wrap and fasten excess wiring in secure location.

3. Tighten all hardware.

1. Mount Insight or Horizon box mounting bracket to back of

2. Mount Insight or Horizon box to bracket.

3. Connect main wiring harness to Insight or Horizon box.

4. Connect sensor wiring to main Headsight harness.

5. Remove factory harness from existing single point latch plate.