DirectCommand Installation Ag Leader Technology Note: Indented items indicate parts included in an assembly listed above Part Name/Description Part Number Quantity Direct Command Kit 4100532 1 Cable Installation Kit 2000901-1 1 Quick Reference Card 2002831-38 1 Dielectric Grease 2002872 1 Dust Receptacle 12 Pin Green 2002975-12C 1 Dust Receptacle 8 Pin Green 2002975-8C 1 CAN Y-Splice 4000137 1 CAN Terminator 4000141 1 CAN Bus Line 6 in. 4000218-006 1 Liquid Product Control Module 4000394 1 CAN Bus Stub 8 in. 4000450-1 1 Implement Plug 4000495-1 1 Boom Valve Relay Module 4000840 1 High Current Power Splitter 4001013 1 Hardi-DirectCommand Adapter 4001250-6 1 Switch Input 9 Sections 4001252 1 European Cigarette Power Cable 4001336-5 1 Power Cable 4002016-12 1 Hardware Kit 2 4101243-02 1 Auxiliary Input Module Kit 4100506 1 Deutsch Dust Plug 12-pin 2002899-12N 1 CAN Y-Splice 4000137 1 CAN Bus Stub 1 ft. 4000219-1 1 Auxiliary Input Module 4000437 1 Cab Box Kit` 4100513 1 Barbed Locking Retainer 2002267 2 Cab Box 4000598 1 Cab Box Lid 4000599 1 RAM Rail Mount Kit 5 Arm 4100101 1 RAM 201U 5 Arm 4000279 1 RAM 2461U Base 4000280 1 RAM 235U Base, Double U-Bolt 4000281 1 PN: 2005865 Rev. E January 2014 Page 1 of 16
Ag Leader Technology DirectCommand Installation Important Notices Section Contents 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 515-232-5363 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 Sprayers using more than five boom sections will need to order an additional Boom Valve Relay Module, PN: 4000840 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. Section Heading Page Common Components 3 Component and Cable Layout 3-5 Section Sprayers 4 Component and Cable Layout 6-7 Section Sprayers 5 Safety Notices 6 Installing the Display 7 Installing the Control Modules 8 Installing the CAN Bus Harness 11 Installing the Power Cables 12 Installing the Rate Control Cables 13 Setting Up the Display 15 Page 2 of 16 January 2014 PN: 2005865 Rev. E
DirectCommand Installation Ag Leader Technology Common Components 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: 4000141 2. Plug (Not all applications) PN: 4000136 3. Y-Splice PN: 4000137 Modules 1. Boom Valve Relay Module PN: 4000840 2. Liquid Product Control Module PN: 4000394 3. Auxiliary Input Module PN: 4000437 PN: 2005865 Rev. E January 2014 Page 3 of 16
Ag Leader Technology DirectCommand Installation Component and Cable Layout 3-5 Section Sprayers Page 4 of 16 January 2014 PN: 2005865 Rev. E
DirectCommand Installation Ag Leader Technology Component and Cable Layout 6 & 7 Section Sprayers PN: 2005865 Rev. E January 2014 Page 5 of 16
Ag Leader Technology 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 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 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 16 January 2014 PN: 2005865 Rev. E
DirectCommand Installation Ag Leader Technology Installing the Display Parts required for procedure: (1) Ag Leader INTEGRA Display PN: 4002000 or (1) EDGE Display PN: 4001500 or (1) InSight Display PN: 4001000 From RAM Rail Mount Kit 4100101 (1) RAM 201U 5 Arm PN: 4000279 (1) RAM 2461U Base PN: 4000280 (1) RAM 235U Base, Double U-Bolt PN: 4000281 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 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. NOTE: Do not remove the Hardi Spray II Switch box, 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: 4000281 to the arm where the existing console was previously mounted. PN: 2005865 Rev. E January 2014 Page 7 of 16
Ag Leader Technology DirectCommand Installation 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: 4000280 to the back of the display using four of the Phillips Pan Head Screws and lock washers. 7. Use the 5 RAM Arm PN: 4000279 to mount the display to the previously mounted RAM Base. Installing the Control Modules Parts required for procedure: From DirectCommand Kit (1) Hardware Kit 2 PN: 4101243-02 (1) Liquid Product Control Module PN: 4000394 (1) Boom Valve Relay Module PN: 4000840 From Auxiliary Input Module Kit (1) Auxiliary Input Module PN: 4000437 From Cab Box Kit (1) Cab Box PN: 4000593 (2) Barbed Locking Retainer PN: 2002267 Optional Part ordered separately for 6 or 7 Section Sprayers (1) Boom Valve Relay Module PN: 4000840 Step-by-Step instructions for installing the Control Modules 1. Using the following diagram, drill two 9/32 holes for mounting the Boom Valve Relay module in the Cab Box, PN: 4000593. NOTE: If only one Boom Valve Relay Module is required, drill the holes in the end of the Cab Box that holds the Liquid Control Module, if two Boom Valve Relay Modules are required, drill holes in both ends of the Cab Box. Page 8 of 16 January 2014 PN: 2005865 Rev. E
DirectCommand Installation Ag Leader Technology Cab Box drilling template 2. De-burr the holes drilled out, and remove any metal fillings from the Cab Box. NOTE: The Cab Box may be secured to the cab floor mat using the barbed nylon retainers. The following three steps are for that purpose. At the operators discretion you may leave the box unsecured for easier transport from vehicle to vehicle. 3. Position the Cab Box on the floor; mark the location of the mounting holes in the bottom of the box on the floor mat. Location of mounting holes PN: 2005865 Rev. E January 2014 Page 9 of 16
Ag Leader Technology DirectCommand Installation IMPORTANT: Make sure to keep the Cab Box out of the operator s area, preventing module damage and/or a hazard to the operator. 4. Remove the box, and cut a 1/2" slot in the floor mat on the marked locations. 5. Using the Nylon Barbed Locking Retainers, PN: 2002267, secure the Cab Box to the floor by pressing them through the holes of the Cab Box, and into the rubber floor mat underneath. 6. Mount the Liquid Control Module, PN: 4000394 in the bottom of the Cab Box, using the nuts included with the Cab Box. 7. Mount the Auxiliary Input Module, PN: 4000437 on the end of the Cab Box next to the Liquid Control Module, using the 1/4" hardware included in the DirectCommand Kit. 8. Mount the Boom Valve Relay Module, PN: 4000840 in the bottom of the Cab Box, next to the Liquid Control Module using the nuts and washers provided with the Cab Box. 9. If using two Boom Valve Relay Modules, mount the second Boom Valve Relay Module in the end of the Cab Box, next to the first Boom Valve Relay Module. Cab Box with all modules installed NOTE: If the sprayer requires two of the Boom Valve Relay Modules, the modules should be installed so the receptacles marked BOOM OUT are opposite each other to make the cable installation easier. Page 10 of 16 January 2014 PN: 2005865 Rev. E
DirectCommand Installation Ag Leader Technology Installing the CAN Bus Harness Parts required for procedure: From DirectCommand Kit (1) CAN Y-Splice PN: 4000137 (1) CAN Terminator PN: 4000141 (1) CAN Bus Line 6 in. PN: 4000218-006 (1) CAN Bus Stub 8 in. PN: 4000450-1 From Auxiliary Input Module Kit (1) CAN Y-Splice PN: 4000137 (1) CAN Bus Stub 12 in. PN: 4000219-1 From Display Kit or Display Cable Kit PN: 4100814 (1) Power Control Relay PN: 4000708-1 (1) Display Cable PN: 4001608-12 Step-by-Step instructions for installing the CAN Bus Harness 1. Connect the Power Control Relay, PN: 4000708-1, to the square 4-pin Weatherpack Shroud on the Display Cable, PN: 4001608-12. Press the Power Control Relay until the latch clicks, locking the relay in place. 2. Connect the round 28-pin connector on the Display Cable 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. 3. Route the opposite end of the Display Cable into the Cab Box. 4. Connect the single end of the CAN Y-splice PN: 4000137, from the Auxiliary Input Module Kit into the 4-pin CAN connector on the Display Cable. 5. Connect the black 4-pin plug on the 12-in. CAN Bus Stub, PN: 4000219-1 into the gray side of the CAN Y-Splice. 6. Plug the opposite end of the CAN Bus Stub into the receptacle labeled CAN BUS on the Auxiliary Input Module. 7. Connect one end of the 6-in. CAN Bus Line PN: 4000218-006 to the black side of the CAN Y-Splice. 8. Connect the single end of the CAN Y-splice from the DirectCommand Kit into the opposite end of the CAN Bus Line. 9. Connect the CAN Terminator, PN: 4000141, to the black side of the Y- Splice. PN: 2005865 Rev. E January 2014 Page 11 of 16
Ag Leader Technology DirectCommand Installation 10. Connect the black 4-pin plug on the 8-in. CAN Bus Stub, PN: 4000450-1 into the gray side of the CAN Y-Splice. 11. Plug the opposite end of the CAN Bus Stub into the receptacle labeled CAN BUS on the Liquid Control Module. Installing the Power Cables Step-by-Step instructions for installing the Power Cables Parts required for procedure: From DirectCommand Kit (1) High Current Power Splitter PN: 4001013 (1) European Cigarette Power Cable PN: 4001336-5 (1) Power Cable PN: 4002016-12 1. Connect the ring terminals on the Power Cable, PN: 4002016-12 to the battery terminals. Connect the fused wires to the positive lead, and connect the black wires to the battery or chassis ground. 2. Route the opposite end of the power cable into the cab and into the Cab Box. 3. Connect the 3-pin Weatherpack tower on the power cable, to the mating shroud on the Display Cable. 4. Connect the 2-pin Receptacle on the High Current Power Splitter, PN: 4001013 to the 2-pin gray plug on the power cable. 5. Connect one of the 2-pin plugs into the 2-pin receptacle coming from the Liquid Control Module. 6. Connect the 2-pin Weatherpack shroud on the European Cigarette Power Cable to the mating tower on the Display Cable. 7. Connect the Cigarette lighter style plug coming from the Spray II Switch Box into the mating receptacle on the European Cigarette Power Cable. Page 12 of 16 January 2014 PN: 2005865 Rev. E
DirectCommand Installation Ag Leader Technology Installing the Rate Control Cables Parts required for procedure: From DirectCommand Kit (1) Deutsch Dust Receptacle 12-pin PN: 2002975-12C (1) Deutsch Dust Receptacle 8-pin PN: 2002975-8C (1) Implement Plug PN: 4000495-1 (1) Boom Valve Relay Module Cable PN: 4000869-3 (1) Hardi Adapter Cable PN: 4001250-6 (1) Switch Input Cable PN: 4001252 From Auxiliary Input Module Kit (1) Deutsch Dust Plug 12-pin PN: 2002899-12N 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: 4000869-3, into the second plug on the High Current Power Splitter 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. NOTE: If installing two Boom Valve Relay Modules, consider the module in the bottom of the Cab Box module number one for sections 1-5. Consider the module on the end of the Cab Box, module number two for sections 6 and 7. 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 number one in the bottom of the Cab Box. 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 number two on the end of the Cab Box. 5. If only one Boom Valve Relay Module is used, cover the second green 8- pin plug with a dust receptacle, PN: 2002975-8C. 6. Connect the green 12-pin Deutsch plug on the Switch Input Cable, PN: 4001252 to the mating receptacle on the Auxiliary Input Module marked SWITCH A. 7. Plug the 12-pin Dust Plug PN: 2002899-12N into to the mating receptacle on the Auxiliary Input Module SWITCH B. PN: 2005865 Rev. E January 2014 Page 13 of 16
Ag Leader Technology DirectCommand Installation 8. If the Hardi factory control cable is connected to the Spray II Switch box, depress the locking tab and disconnect it. Plug the male 39-pin connector of the Hardi Adapter Cable, PN: 4001250-6 into the switch box. 9. Reconnect the Hardi control cable into the opposite side of the tee on the Hardi Adapter Cable. 10. Route the opposite end of the Hardi Adapter Cable into the Cab Box. 11. 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. 12. 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. 13. If only one Boom Valve Relay Module is used, cover this 12-pin plug with Dust Receptacle PN: 2002975-12C. 14. Connect the gray 6-pin plug to the receptacle labeled RADAR on the Auxiliary Input Module. 15. Connect the gray 8-pin plug to the receptacle labeled CHANNEL 1 on the Liquid Control Module. 16. Connect the green 12-pin DTM plug on the Hardi Adapter Cable into the mating receptacle on the Switch Input Cable. 17. Connect the black 12-pin plug on the Implement Plug, PN: 4000495-1 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. 18. Bundle all cables in the Cab Box. Reinstall the Cab Box Lid, PN: 4000599 on the Cab Box, making sure not to pinch any cables. Fasten the lid into place with the 1/4-turn thumbscrews. Page 14 of 16 January 2014 PN: 2005865 Rev. E
DirectCommand Installation Ag Leader Technology Setting Up the Display 1. Refer to the Quick Reference Guide, PN: 2002831-38 for setting up the Display. 2. Enter the default settings from the following chart for the initial sprayer setup. Setting Name Control Valve Configuration** Valve Response 1 Valve Response 2 Response Threshold Allowable Error Default Value Bypass Servo or Calibrated Reflow 100% 40% 2 2% 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. 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 PN: 2005865 Rev. E January 2014 Page 15 of 16
Ag Leader Technology DirectCommand Installation 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 4-160 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 3.785. Example: 225 / 3.785 = 59.45 **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. Page 16 of 16 January 2014 PN: 2005865 Rev. E