John Deere 1535 – Header Control Unit: Right Stubble Height Sensor Voltage Too High

The Right Stubble Height Sensor (circuit code 454) is reporting a voltage to the Header Control Unit that exceeds 4.5 VDC. This indicates a potential fault with the sensor itself or a short circuit to a power source in the associated wiring, which disrupts the HeaderTrak™ automatic header height control system.

• 9540
• 9560
• 9580
• 9640
• 9660
• 9680
• 9560 STS
• 9570 STS
• 9650 STS
• 9660 STS
• 9670 STS
• 9750 STS
• 9760 STS
• 9770 STS
• 9860 STS
• 9870 STS
• S550
• S660
• S670
• S680
• S690
• CTS
• 600R
• 600F
• 600FD

1. 1

   Visually inspect the right-hand stubble height sensor, linkage, and wiring harness for physical damage, corrosion, or material buildup. Ensure the sensor arm and linkage can move freely without binding.

2. 2

   Verify that the wiring harness is securely connected to the sensor and that the main feeder house-to-header connector is properly seated.

3. 3

   Use the combine's diagnostic system on the cornerpost display (e.g., LC1 Diagnostic Address 24 on S-Series) to view the live voltage from the right header height sensor (cc# 454). Manually move the header or sensor linkage to see if the voltage changes appropriately or remains static at a high value.

4. 4

   Inspect the wiring harness for a short circuit to a power source. Check the Height Sensor Power circuit (cc# 481), which should measure between 4.75 and 5.25 VDC.

1. 1

   De-energize the system

   Turn off the combine and disconnect the battery before beginning any electrical repairs.

2. 2

   Access the sensor

   The stubble height sensors are located on the left and right sides of the header.

3. 3

   Disconnect and remove

   Disconnect the electrical connector from the sensor. Unbolt the sensor and its associated linkage from the header frame.

4. 4

   Install new sensor

   Mount the new sensor and connect the linkage. Ensure all fasteners are torqued to the manufacturer's specification.

5. 5

   Reconnect and test

   Reconnect the electrical harness to the new sensor. Reconnect the battery.

6. 6

   Clear fault codes

   Access the diagnostic menu, view the active codes, and use the 'CLr?' function to clear the 1535.03 fault. Note that some priority 1 codes may not clear until the underlying issue is resolved.

7. 7

   Perform calibration

   Perform a header calibration procedure through the combine's display to teach the control unit the sensor's voltage range from the lowest to the highest position. The calibration process involves moving the header to specific positions as prompted. Failure to calibrate can result in new error codes (e.g., ER72 - voltage greater than 4.5V) and improper operation.