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1 Part Name/Description Part Number Quantity Direct Command Kit Installation Instructions Hardware Kit Large Module Cable Installation Kit Quick Reference Card Dielectric Grease Dust Receptacle 12 Pin Green C 1 Dust Receptacle 8 Pin Green C 1 Poly Enclosure 6.63 in. x 4.68 in. x 2.37in CAN Y-Splice CAN Terminator Plug CAN Bus Line 6in CAN/Power Cable 3 ft Liquid Product Control Module CAN Bus Stub 8 in Implement Plug Boom Valve Relay Module Boom Valve Relay Module Cable 3ft Implement Cable 12 ft Hardi Spray II Breakout Adapter 6 ft Switch Input 9 Sections European Cigarette Power Cable Mounting Plate Dual Module Hood DSUB 37 Pin (Large Mouth) CAN BUS Power Ext. 24ft Mounting Plate Hardi Distribution Box Hardware Kit Auxiliary Input Module Kit Deutsch Dust Plug 12-pin N 1 CAN Y-Splice CAN Plug CAN Bus Stub 1 ft Auxiliary Input Module PN: Rev. C January 2014 Page 1 of 23

2 DirectCommand Installation RAM Rail Mount Kit 5 Arm RAM 201U 5 Arm RAM 2461U Base RAM 235U Base, Double U-Bolt Important Notices You will save time and prevent wrong installation of components by closely following these step-by-step instructions. If you have questions, call Ag Leader Technology at Ext 1. Direction words (LEFT and RIGHT) are commonly used when describing an installation procedure. Interpret direction words as if standing behind equipment and looking forward Signal words (CAUTION, IMPORTANT and NOTE) are provided to draw attention to information that is important for the safe/correct installation and operation of this product. CAUTION will alert you to situations that will impact the physical safety of you or others. IMPORTANT will alert you to the potential for damage to the product or loss of data. NOTE will provide you with additional information to simplify a procedure or clarify a process. This DirectCommand kit fits the following machines: Hardi Sprayers using 39-pin Spray II Switch Box without a JobCom box. The DirectCommand Modules are mounted on the sprayer chassis. Sprayers using more than five boom sections will need to order an additional Boom Valve Relay Module, PN: Read all instructions first to familiarize yourself with the installation procedures. Keep parts list and installation instructions for use as a reference after completing installation. Page 2 of 23 January 2014 PN: Rev. C

3 Section Contents Common Components Section Heading Page Common Components 3 Component and Cable Layout 3-5 Section Sprayers 4 Component and Cable Layout 6-9 Section Sprayers 5 Safety Notices 6 Installing the Ag Leader Display 7 Installing the Power and Cab Cables 8 Installing the Control Modules 10 Installing the Power and CAN BUS Cables 13 Installing the Rate Control Cables 15 Setting Up the Ag Leader Display 22 This section contains illustrations of components common to all Direct Command Installations. Their purpose is to ensure proper identification and installations in the sections that follow. CAN Bus Connectors 1. Terminator PN: Plug (Not all applications) PN: Y-Splice PN: Modules 1. Boom Valve Relay Module PN: Liquid Product Control Module PN: Auxiliary Input Module PN: PN: Rev. C January 2014 Page 3 of 23

4 DirectCommand Installation Component and Cable Layout 3-5 Section Sprayers Page 4 of 23 January 2014 PN: Rev. C

5 Component and Cable Layout 6-9 Section Sprayers PN: Rev. C January 2014 Page 5 of 23

6 DirectCommand Installation Safety Notices CAUTION: Sprayer booms should be lowered to the ground or on mechanical safety stops before starting work. Do not work under sprayer booms supported by hydraulic system only. Turn off machine and wait for all motion to stop before starting work. Set parking brake. CAUTION: Be sure to wear proper eye protection when using any power tools, such as when drilling any mounting holes. IMPORTANT: Check behind vehicle and implement panels for any holes, wiring or controls that could be damaged when drilling any holes. IMPORTANT: Disconnect the Ag Leader Display, DirectCommand components and flow meter from electrical system when welding on equipment or jump starting unit to prevent component damage due to power surges or excessive current. IMPORTANT: If using a non Ag Leader GPS receiver, make sure to install a Null Modem Cable, included in the Display Kit, to prevent damage to the Ag Leader Display or GPS receiver. IMPORTANT: Use Dielectric grease to coat the seals and terminals of each connector that will be exposed to weather or chemicals as you plug them in. NOTE: Be sure to follow the alignment keys on the plugs and the receptacles carefully. Do not use excessive force when mating connectors. Page 6 of 23 January 2014 PN: Rev. C

7 Installing the Ag Leader Display Parts required for procedure: (1) Ag Leader INTEGRA Display PN: or (1) Ag Leader EDGE Display PN: or (1) Ag Leader InSight Display PN: From RAM Rail Mount Kit (1) RAM 201U 5 Arm PN: (1) RAM 2461U Base PN: (1) RAM 235U Base, Double U-Bolt PN: From Display Kit or Display Cable Kit : (1) Power Control Relay PN: (1) Display Cable PN: Step-by-Step instructions for installing the Display 1. Turn on the existing rate control console, if equipped with one, and copy down the boom section widths and flow meter calibration numbers. 2. Run the sprayer one last time to make sure all of the components are in working order before removing the console. Verifying that all of the rate control components work will help with any potential troubleshooting issues after the installation. NOTE: The Hardi flow meter signal output and the Ag Leader Display requirements are both in pulses per unit of product applied. NOTE: Be sure to set the Ag Leader Display to the correct measuring units in the Setup Menu. Choose either Imperial (Gallons) or Metric (Liters). All information has to be in the same measuring standards when entered. If the operator changes the standard in the Setup Menu, after the configuration setup is complete, the Ag Leader Display will change all the settings to the selected measurement standard. NOTE: The Ag Leader Display boom widths may be programmed in feet or meters. Take the number of spray nozzles on each boom section and multiply by the nozzle spacing to calculate the boom section widths. 3. Turn off the existing rate control console. Disconnect the cable from the back of the console and remove the console from the vehicle. PN: Rev. C January 2014 Page 7 of 23

8 DirectCommand Installation NOTE: Do not remove the Hardi Spray II Switchbox; this is required for the DirectCommand Installation. 4. Using the two U-bolts from the RAM Mount kit, attach the RAM Base, Double U-Bolt, PN: to the arm where the existing console was previously mounted. 5. If this is a new installation, use the Hardi mounting kit to configure an arrangement that will mount the Spray II Switchbox and the Double U-bolt RAM mount for the Ag Leader Display. 6. Lay the display on a flat surface. Attach the square RAM Mount, PN: to the back of the display using four of the Phillips Pan Head Screws and lock washers. 7. Use the 5 RAM Arm PN: to mount the Ag Leader display to the previously mounted RAM Base. 8. Connect the round 28-pin connector on the Display Cable, PN: , to the connector on the back of the InSight or EDGE Display, or the connector labeled MAIN on the back of the Ag Leader INTEGRA Display. 9. Connect the Power Control Relay, PN: to the Display Cable at the black 4-pin Weatherpack connector. Press together until the latch clicks, locking the relay together with the Display Cable. Installing the Power and Cab Cables Step-by-Step instructions for installing the Power and Cab Cables Parts required for procedure: From DirectCommand Kit (1) Cable Installation Kit PN: (1) European Cigarette Power Cable PN: (1) Power Cable PN: (1) Cable CAN/Power Implement Connection PN: IMPORTANT: Disconnect the battery ground cable. By not disconnecting the ground cable damage could be done to machine components. 1. Connect the ring-terminated ends of the Power Cable PN: directly to the battery cable. The fused wires go to the positive side and the black wires go to the negative side. Refer to the figure on the next page for different battery configurations and notations for Ag Leader Power and Ag Leader Ground. Page 8 of 23 January 2014 PN: Rev. C

9 2. Find a suitable opening in the floor or rear window area of the cab to route the opposite end of the Power Cable into the cab. 3. Connect the 3-pin Weatherpack plug on the Power Cable to the 3-pin Weatherpack receptacle of the Display Cable, PN: Locate the European Cigarette Power Cable, PN: in the DirectCommand Kit. 5. Connect the 2-pin Weatherpack shroud on the European Cigarette Power cable to the mating tower in the Display Cable. PN: Rev. C January 2014 Page 9 of 23

10 DirectCommand Installation 6. Connect the Cigarette lighter style plug coming from the Spray II Switch Box into the mating receptacle on the European Cigarette Power Cable. 7. Locate the CAN/Power Cable, PN: in the DirectCommand Kit. 8. Connect the gray 2-pin Deutsch power receptacle from the CAN/Power Cable to the mating gray 2-pin plug on the Power Cable, PN: Locate the CAN Y-Splice, PN: and CAN Terminator, PN: in the DirectCommand Kit. NOTE: To properly connect the CAN Bus terminals firmly pinch the metal clip against the plastic connection and then connect and disconnect the CAN Bus terminals as needed. 10. Connect the single end of the CAN Y-Splice to the mating connector on the Display Cable, PN: Connect the 4-pin Cannon Plug from the CAN/Power, PN: into the black side of the CAN Y-Splice. 12. Connect the CAN Terminator, PN: into the gray side of the CAN Y-Splice. 13. Route the opposite end of the CAN/Power Cable, PN: , with the 16-pin Amp CPC plug out of a suitable opening in the rear cab area. 14. Bundle cables and secure them as necessary with cable ties from the Cable Installation Kit, PN: Installing the Control Modules Parts required for procedure: From DirectCommand Kit (1) Liquid Product Control Module PN: (1) Boom Valve Relay Module PN: (2) Mounting Plate Dual Module PN: (2) Hardware Kit Large Module PN: (1) Hardware Kit 7 PN: From Auxiliary Input Module Kit (1) Auxiliary Input Module PN: Page 10 of 23 January 2014 PN: Rev. C

11 Step-by-Step instructions for installing the Control Modules 1. Locate the two Module Mounting Kits, PN: in the DirectCommand Kit. 2. Locate the Liquid Product Control Module, PN: and Boom Valve Relay Module, PN: in the DirectCommand Kit. NOTE: Configurations with greater than 5 boom sections will require a second Boom Valve Relay Module purchased separately. 3. Locate the Auxiliary Input Module, PN: in the Auxiliary Input Module Kit. 4. Find a suitable location on the rear of the sprayer to mount the Control Modules within reach of the Hardi Distribution Box. The recommended location is on the rectangular tubing to the right front of the section valves. Recommending Control Module Mounting Location 5. Using a 5/16 in. bit, drill two holes 6-3/8 in. center to center in the middle of each Dual Module Mounting Plate, PN: to use later for mounting the plates to the sprayer. (Refer to the figure on next page) PN: Rev. C January 2014 Page 11 of 23

12 DirectCommand Installation New Mounting Hole Locations In Dual Module Plate NOTE: If your setup includes a second Boom Valve Relay Module four ¼ in. holes will need to be drilled into one of the Dual Module Mounting Plates to accommodate the second module. Instructions To Mount A Second BVRM To The Mounting Plate. If Only One BVRM Is Needed Skip To Step Using the Boom Valve Relay Module as a template center the module inside the studs used to mount a large control module and drill four ¼ in. holes in one of the Dual Module Mounting Plates. (Refer to the figure on next page) Page 12 of 23 January 2014 PN: Rev. C

13 Mounting Holes For A Second Boom Valve Relay Module 7. Mount the Control Modules to the Module Mounting Brackets with the supplied fasteners included in the Hardware Kit and DirectCommand Kit. 8. Mount the Module Mounting Plates back to back on either side of the rectangular tubing in front of the spray boom. Use the 5/16 in. Cap screws and 5/16 in. hardware included in the kit to fasten the plates. Installing the Power/ CAN Bus Cables Parts required for procedure: From DirectCommand Kit (1) CAN Bus Stub 8 in. PN: (1) Implement Cable 12 ft. PN: (1) CAN BUS Power Ext 24 ft. PN: From Auxiliary Input Module Kit (1) CAN Y-Splice PN: (1) CAN Bus Stub 12 in. PN: Note: To properly connect the CAN connectors firmly pinch the clip against the plastic connection and then mate the ends. Step-by-Step instructions for installing the CAN Bus Cables 1. Locate the Implement Cable, PN: in the DirectCommand Kit. 2. Connect the single end of the CAN Y-splice, PN: into the 4-pin CAN connector on the Implement Cable. PN: Rev. C January 2014 Page 13 of 23

14 DirectCommand Installation 3. Connect the black 4-pin plug on the 12-in. CAN Bus Stub, PN: into the black side of the CAN Y-Splice. 4. Plug the opposite end of the CAN Bus Stub into the receptacle labeled CAN BUS on the Auxiliary Input Module. 5. Connect the black 4-pin plug on the 6 in. CAN Bus Line, PN: into the gray side of the CAN Y-Splice. 6. Plug the opposite end of the CAN Bus Line into the single end of the CAN Y-splice, PN: included in the Auxiliary Input Module Kit. 7. Connect the black 4-pin plug on the 8 in. CAN Bus Stub, PN: into the black side of the CAN Y-Splice. 8. Plug the opposite end of the CAN Bus Stub into the receptacle labeled CAN BUS on the Liquid Control Module. 9. Plug the CAN Terminator Plug, PN: into the gray side of the Y- splice. 10. Connect one of the gray 2-pin Deutsch power plugs from the Implement Cable to the mating power receptacle on the Liquid Product Control Module, PN: Locate the CAN BUS Power Ext. Cable, PN: in the DirectCommand Kit. 12. Connect the black 16-pin AMP CPC receptacle from CAN/Power Cable to the mating black 16-pin Amp CPC plug on the CAN BUS Power Ext. Cable. 13. Route the opposite end CAN BUS Power Ext. Cable toward the front of the sprayer. 14. Locate the CAN/Power, PN: routed out of the rear cab area in a previous section of these installation instructions. 15. Connect the black 16-pin AMP CPC plug from CAN/Power Cable to the mating black 16-pin Amp CPC receptacle on the CAN BUS Power Ext. Cable. 16. If necessary, additional extension cables may be purchased. Refer to the table below for available lengths. Page 14 of 23 January 2014 PN: Rev. C

15 Length Part Number 6 ft ft ft ft Implement Cable Extensions Installing the Rate Control Cables Parts required for procedure: From DirectCommand Kit (1) Deutsch Dust Receptacle 12-pin PN: C (1) Deutsch Dust Receptacle 8-pin PN: C (1) Implement Plug PN: (1) Boom Valve Relay Module Cable PN: (1) Hardi Adapter Cable PN: (1) Switch Input Cable PN: (1) Poly Electronics Enclosure PN: (1) Mounting Plate PN: Hardware Kit 7 PN: From Auxiliary Input Module Kit (1) Deutsch Dust Plug 12-pin PN: N Step-by-Step instructions for installing the Rate Control Cables 1. Connect the 2-pin gray receptacle on the Boom Valve Relay Module Cable, PN: , into the second gray power plug on the Implement Cable. 2. Plug the gray 12-pin plug on the Boom Valve Relay Module Cable into the mating receptacle labeled BOOM on the Liquid Control Module. 3. Plug the green 8-pin Deutsch plug marked Sections 1-5 into the mating receptacle marked BOOM IN on the Boom Valve Relay Module one. 4. If two boom valve modules are used, plug the green 8-pin Deutsch plug marked Sections 6-10 into the mating receptacle marked BOOM IN on the Boom Valve Relay Module two. 5. If only one Boom Valve Relay Module is used, cover the second green 8- pin plug with a dust receptacle, PN: C. 6. Connect the green 12-pin Deutsch plug on the Switch Input Cable, PN: to the mating receptacle on the Auxiliary Input Module marked SWITCH A. PN: Rev. C January 2014 Page 15 of 23

16 DirectCommand Installation 7. Plug the 12-pin Dust Plug PN: N into to the mating receptacle on the Auxiliary Input Module SWITCH B. 8. Find the Hardi Spray II Breakout Adapter, PN: , Poly Electronics Enclosure, PN: , Hardi Distribution Box Mounting Plate, PN: and M5 mounting hardware in the DirectCommand Kit. 9. Locate the Hardi Distribution Box at the rear of the sprayer near the boom section valves. (See figure below) Distribution Box At The Rear of The Sprayer Hardi Distribution Box With The Cover Removed 10. Using a Philips screwdriver remove the cover from the Distribution Box. 11. Loosen the fasteners securing the 37-pin DSUB connector to the distribution circuit board with a small flat-blade screwdriver. Page 16 of 23 January 2014 PN: Rev. C

17 Components Of The Distribution Box 12. Disconnect the 37-pin female DSUB connector from the distribution circuit board. 13. Loosen and remove the locknut from the cordgrip assemble. 14. Carefully slide the locknut over the DSUB connector and set aside to use later in the installation. 15. Remove the 37-pin DSUB connector from the distribution box out through the knockout in the box. 16. Remove the two mounting bolts securing the distribution box mounting plate to the sprayer chassis. Distribution Box Mounting Plate With A Bolt Removed 17. Remove the factory mounting plate from the Hardi Distribution Box by removing the four fasteners. PN: Rev. C January 2014 Page 17 of 23

18 DirectCommand Installation Factory Mounting Plate (Arrows Pointing To Fasteners) 18. Mount the Ag Leader Distribution Box Mounting Plate to the sprayer using the existing holes and fasteners. Ag Leader Distribution Box Mounting Plate 19. Mount the Hardi Distribution Box to the right side of the Ag Leader Mounting Plate using the existing fasteners. 20. Route the 37-pin female DSUB connector from the Hardi Spray II Adapter Cable, PN: into the distribution box through the knockout hole in the side of the Hardi Distribution Box. 21. Slide the locknut, included in the DirectCommand Kit, over the 37-pin female DSUB connector from the previous step. 22. Connect the 37-pin female DSUB connector to the mating 37-pin male DSUB connector on the distribution circuit board. Page 18 of 23 January 2014 PN: Rev. C

19 Female 37-Pin DSUB Connector Mated To Distribution Board 23. Tighten the screws on the 37-pin female DSUB with a small flat blade screwdriver to secure to the circuit board. 24. Slide the cordgrip into the knockout on the side of the distribution box and thread the locknut onto the cordgrip. 25. Adjust the cable position as necessary. 26. Tighten the flange nut on the outside of the cordgrip to keep dust and moisture out of the distribution box. 27. Route the 37-pin male DSUB connector from the Hardi Spray II Breakout Adapter, PN: into the right knockout hole on the Ag Leader Enclosure. 28. Slide the locknut, included in the DirectCommand Kit, over the 37-pin male DSUB connector from the previous step. 29. Push the cordgrip into the knockout on the Ag Leader Plastic Enclosure and thread the locknut onto the cordgrip. 30. Adjust the position of the cable as necessary. 31. Tighten the flange nut on the outside of the cordgrip to secure the cable and keep dust and moisture out of the box. 32. Route the Hardi 37-pin female DSUB connector that was originally PN: Rev. C January 2014 Page 19 of 23

20 DirectCommand Installation connected to the Hardi distribution circuit board into the Ag Leader Plastic Enclosure. 33. Slide the locknut originally connected to the cordgrip over the 37-pin female DSUB connector. 34. Push the cordgrip into the knockout hole on the Ag Leader Plastic Enclosure and thread the locknut onto the cordgrip. 35. Adjust the position of the cable as necessary. 36. Tighten the flange nut on the outside of the cordgrip to secure the cable and keep dust and moisture out of the box. 37. Locate the DSUB Hood Connectors included in the DirectCommand Kit. 38. Install the DSUB Hoods on the male and female 37-pin connectors in the Ag Leader Plastic Enclosure. 39. Connect the mating DSUB connectors from the previous step and using a small flat blade screwdriver tighten the screws to secure the connectors. DSUB Connectors Mated Inside Ag Leader Enclosure With Hoods 40. Reinstall the cover on the Ag Leader Plastic Enclosure. 41. Mount the Ag Leader Enclosure to the left side of the Ag Leader Mounting Plate using the 5mm fasteners included in the DirectCommand Kit. Page 20 of 23 January 2014 PN: Rev. C

21 Electronics Enclosures Secured To Ag Leader Mounting Plate 42. Secure all cables with cables ties included in the Cable Installation Kit, PN: Avoid sharp edges and pinch points that could cause any cable damage. 43. Route the opposite end of the Hardi Spray II Breakout Adapter, PN: toward Ag Leader Control Modules mounted on the boom frame to the right front of the section valves. Control Module Mounting Location 44. Locate the green 12-pin Deutsch plug labeled BVRM 1. Plug this connector into the Boom Valve Relay Module number one receptacle labeled BOOM OUT. PN: Rev. C January 2014 Page 21 of 23

22 DirectCommand Installation 45. Locate the green 12-pin Deutsch plug labeled BVRM 2. If two Boom Valve Relay Modules are used, plug this connector into the Boom Valve Relay Module number two receptacle labeled BOOM OUT. 46. If only one Boom Valve Relay Module is used, cover this 12-pin plug with Dust Receptacle PN: C. 47. Connect the gray 6-pin plug to the receptacle labeled RADAR on the Auxiliary Input Module. 48. Connect the gray 8-pin plug to the receptacle labeled CHANNEL 1 on the Liquid Control Module. 49. Connect the green 12-pin DTM plug on the Hardi Adapter Cable into the mating receptacle on the Switch Input Cable, PN: Connect the black 12-pin plug on the Implement Plug, PN: into the mating receptacle labeled AUXILIARY on the Liquid Control Module. NOTE: Do not remove the jumper wire in the Implement Plug, unless installing an implement switch. 51. Reconnect the battery ground. Setting Up the Ag Leader Display 1. Refer to the Quick Reference Guide, PN: for setting up the Ag Leader Display. 2. Enter the default settings from the following chart for the initial sprayer setup. Setting Name Control Valve Configuration** Valve Response 1 Default Value Bypass Servo or Calibrated Reflow 100% Description Rate control is achieved through actuating a butterfly or ball valve found in the return line to the solution tank. When the valve opens, the flow decreases and when the valve closes, the flow increases. Determines the speed of the servo valve when product control error exceeds the Response Threshold setting. Decreasing the value will cause the servo valve to run slower. Page 22 of 23 January 2014 PN: Rev. C

23 Valve Response 2 Response Threshold Allowable Error 40% 2 2% Determines the speed of the servo valve when product control error is less than the Response Threshold setting. Decreasing the value will cause the servo valve to run slower. Determines where the control system switches between using Valve Response 1 and Valve Response 2 speed settings. Decreasing this value will have the overall effect of speeding up servo valve response. Increasing this value will have the overall effect of slowing down servo valve response. NOTE: Leaving all other valve control settings at the default value and making a small adjustment to this setting is usually all that is required to fine-tune the control system. Determines the percent error that is allowed prior to the product control system making any flow rate corrections. 2-3% is the normal Allowable Error Range. Too low of a setting will cause the system to continually hunt for the target application rate. Too high of a setting will cause excessive application error. Select the proper Flow Meter from the following Table Flowmeter Cal Flowmeter Style Flow Rates Flow Meter Cal One Outside Groove 2-30 g/min 485 No Groove 4-70 g/min 225 Two Outside Grooves g/min 475 NOTE: If the flow meter calibration number is for gallons per minute and you want to apply liters per minute you will need to convert the flow meter cal number by dividing by the conversion factor Example: 225 / = **Control Valve Configuration varies depending on which boom valves are installed on the sprayer. When the boom valve is shut off, if the product is directed back to the tank, the Control Valve Configuration is Calibrated Reflow. When the boom valve is shut off, if the product is deadheaded and the control valve must adjust to maintain correct flow rate through remaining boom sections, the control Valve Configuration is Bypass Servo. PN: Rev. C January 2014 Page 23 of 23

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