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 4100578 1 Cable Installation Kit 2000901-1 1 37-pin Serial Connector Hood 2002702-37 1 Quick Reference Card Liquid 2002831-38 1 Dielectric Grease 2002872 1 Deutsch Dust Plug 12 pin 2002899-12N 1 Deutsch Dust Cap 8 pin 2002975-8C 1 Installation Instructions 2005930 1 CAN Bus Dust Plug 4000136 1 CAN Y-Splice 4000137 2 CAN Bus Line 6 in. 4000218-006 1 CAN Bus Stub 1 ft. 4000219-1 1 Liquid Product Control Module 4000394 1 Auxiliary Input Module 4000437 1 CAN Bus Stub 8 in. 4000450-1 1 Implement Plug 4000495-1 1 Implement Cable 4000726-12 1 Boom Valve Relay Module 4000840 1 Boom Valve Relay Module Cable 4000869-3 1 Switch Input Cable 10 Section 4001711 1 Jobcom Tee Cable 4001568-1 1 SafeTrack Flow Control Cable 4001569-5 1 Implement Adapter Cable 4001979-3 1 Power Cable 4002016-12 1 Hardware Kit 2 4101243-02 1 Cab Box Kit 4100513 1 Dome Plug 2002268 1 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 Display Mount 4000280 1 RAM 235U Base, Double U-Bolt 4000281 1 PN: 2005930 Rev. G January 2014 Page 1 of 18
Ag Leader Technology DirectCommand Installation 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 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: 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. If the sprayer is equipped with more than five boom sections, you will need to purchase and install an additional Boom Valve Relay Module, PN: 4000840. Page 2 of 18 January 2014 PN: 2005930 Rev. G
DirectCommand Installation Ag Leader Technology Section Contents Common Components Section Heading Page Common Components 3 Component and Cable Layout 5 Safety Notices 6 Installing the Display 7 Installing the Cab Cables 8 Installing the Control Modules 10 Installing the CAN Bus Harness 11 Installing the Flow Control Cables 12 Setting up the Display 17 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 PN: 2005930 Rev. G January 2014 Page 3 of 18
Ag Leader Technology DirectCommand Installation 1. Boom Valve Relay Module PN: 4000840 2. Liquid Product Control Module PN: 4000394 3. Auxiliary input Module PN: 4000437 Deutsch DT Style Connectors Deutsch DTM Style Connectors Page 4 of 18 January 2014 PN: 2005930 Rev. G
DirectCommand Installation Ag Leader Technology Component and Cable Layout PN: 2005930 Rev. G January 2014 Page 5 of 18
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 18 January 2014 PN: 2005930 Rev. G
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 (1) RAM 201U 5 Arm PN: 4000279 (1) RAM 2461U Display Mount 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. If applicable, run the sprayer one last time to make sure all of the rate control components are in working order. Verifying functionality will help with any potential troubleshooting issues after the installation. 3. If this is a new installation, use the Hardi mounting kit to configure an arrangement that will mount the Spray II switchbox, the HC 5500 controller and the RAM Mount for the Ag Leader Display. Note: The Hardi HC 5500 Controller remains connected to the DirectCommand system to perform sprayer calibration and control the SafeTrack turning and stability feature. 4. Take the RAM Base, Double U-bolt PN: 4000281 from the RAM Rail Mount Kit. Use the two U-bolts, nuts and washers to fasten the mount to the rail where the Ag Leader Display will be mounted. 5. Attach the square RAM Mount, PN: 4000280 to the back of the Display using the four 6mm Phillips pan head screws and lock washers provided in the RAM Rail Mount Kit. 6. Using the 5 RAM Arm, PN: 4000279, mount the Display in a convenient place in the cab for operation, but out of the operator s line of sight while driving. PN: 2005930 Rev. G January 2014 Page 7 of 18
Ag Leader Technology DirectCommand Installation Installing the Cab Cables Parts required for procedure: From DirectCommand Kit (1) Cable Installation Kit PN: 2000901-1 (1) CAN Bus Dust Plug PN: 4000136 (1) CAN Bus Y-Splice PN: 4000137 (1) Implement Adapter Cable PN: 4001979-3 (1) Power Cable PN: 4002016-12 From Display Kit or Display Cable Kit 4100814 (1) Power Control Relay PN: 4000708-1 (1) Display Cable PN: 4001608-12 Step-by-Step instructions for installing the Cab Cables 1. 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. 2. Route the opposite end of the Display Cable towards the back of the tractor cab. 3. Plug the Power Control Relay, PN: 4000708-1 into the mating connector on the Display Cable. Press together until the latch clicks locking the Power Control Relay to the Display Cable. 4. Connect the Power Cable, PN: 4002016-12 to the tractor batteries using the following figure. Connect the fused wires to a +12 volt battery post and the black wires to the ground battery post. IMPORTANT: Verify which battery configuration is used before connecting power cable. Connecting the power cable incorrectly could cause damage to the Ag Leader display or to the battery. Page 8 of 18 January 2014 PN: 2005930 Rev. G
DirectCommand Installation Ag Leader Technology 5. Route the opposite end of the power cable into the tractor cab, through a suitable opening. Make sure to avoid pinch points and sharp edges, and allowing extra slack as needed. PN: 2005930 Rev. G January 2014 Page 9 of 18
Ag Leader Technology DirectCommand Installation 6. Connect the 3-pin Weatherpack tower of the Power Cable to the mating shroud on the Display Cable. 7. Connect the single end of the CAN Y-Splice, PN: 4000137 to the 4- pin connector on the end of the Display Cable. 8. Use the CAN Bus Dust Plug, PN: 4000136 to cap the gray side of the CAN Bus Y-Splice. NOTE: To properly install the CAN Bus connectors, firmly pinch the metal clip against the plastic connection, allowing the connectors to be connected as needed, and then release the clip. 9. Connect the black 4 pin connector on the Implement Adapter Cable, PN: 4001979-3 to the black side of the CAN Y-splice. 10. Connect the gray 2-pin receptacle on the Implement Adapter Cable to the 2-pin plug on the Power Cable. 11. Route the 16-pin AMP connector out of the cab and towards the implement hitch. 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) Auxiliary Input Module PN: 4000437 (1) Boom Valve Relay Module PN: 4000840 From Cab Box Kit (1) Cab Box Installation Instructions PN: 2005905 (1) Cab Box PN: 4000598 Step-by-Step instructions for installing the Control Modules 1. On the sprayer, decide on a location to mount the Cab Box, close to the Hardi Jobcom Box. Drill any mounting holes necessary. 2. Refer to the Cab Box Installation Instructions for details on modifying the Cab Box for the Boom Valve Relay Module. Page 10 of 18 January 2014 PN: 2005930 Rev. G
DirectCommand Installation Ag Leader Technology 3. Mount the Liquid Control Module, PN: 4000394 and Auxiliary Input Module, PN: 4000437 using the ¼ hardware in the Cab Box Kit and mount the Boom Valve Relay Module PN: 4000840 with the ¼ hardware provided in the DirectCommand Kit NOTE: The Liquid Control Module and the Auxiliary Input Module are mounted in the same end of the cab box. NOTE: If the sprayer requires two of the Boom Valve Relay Modules, mount the modules so the receptacles marked BOOM OUT are opposite of each other, this will make cable installation easier. Installing the CAN Bus Harness Step-by-Step instructions for installing the CAN Bus Harness Parts required for procedure: From DirectCommand Kit (1) CAN Bus Y-Splice PN: 4000137 (1) CAN Bus Line 6 in. PN: 4000218-006 (1) CAN Bus Stub 1 ft. PN: 4000219-1 (1) CAN Bus Stub 8 in. PN: 4000450-1 (1) Implement Cable PN: 4000726-12 1. Connect the 16-pin AMP connector on the Implement Cable, PN: 4000726-12 to the mating connector on the Implement Adapter Cable. 2. Route the opposite end of the Implement Cable towards the Cab Box mounted on the sprayer. NOTE: If the Implement Cable is not long enough to reach from the Cab Box to the mating connector on the tractor, additional extension cables may be purchased as required. Part numbers are listed in the table below. 4000724-6 6 ft. Implement Extension Cable 4000724-12 12 ft. Implement Extension Cable Optional Implement Extension Cables 3. Connect one of the gray 2-pin plugs on the Implement Cable into the mating 2-pin receptacle on the red and black wires coming from the Liquid Control Module. 4. Remove the CAN Bus Terminator connected to the Y-splice on the end of the Implement Cable and save for later installation. PN: 2005930 Rev. G January 2014 Page 11 of 18
Ag Leader Technology DirectCommand Installation 5. Connect the black 4-pin connector on the 1 ft. CAN Bus Stub, PN: 4000219-1, to the gray side of the Y-splice on the Implement Cable. 6. Connect the gray 4-pin plug on the CAN Bus Stub to the mating receptacle on the Auxiliary Input Module labeled CAN BUS. 7. Connect one end of the CAN Bus Extension Cable, PN: 4000218-006 to the black side of the Y-Splice on the Implement Cable. 8. Connect the single end of the Y-Splice, PN: 4000137 provided in the DirectCommand Kit into the opposite end of the CAN Bus Extension Cable. 9. Plug the black 4-pin connector of the 8-in CAN Bus Stub, PN: 4000450-1, into the gray side of the CAN Y-Splice. 10. Plug the gray 4-pin plug on the CAN Bus Stub into the mating receptacle on the Liquid Product Control Module labeled CAN BUS. 11. Connect the Terminator, removed previously from the Implement Cable, into the black side of the last Y-splice. Installing the Flow Control Cables Parts required for procedure: From DirectCommand Kit (1) 37-pin Serial Connector Hood PN: 2002702-37 (1) Deutsch Dust Plug 12-pin PN: 2002899-12N (1) Deutsch Dust Cap PN: 2002975-8C (1) Implement Plug PN: 4000495-1 (1) Boom Valve Relay Module Cable PN: 4000869-3 (1) Switch Input Cable 10 Section PN: 4001711 (1) Jobcom Tee Cable PN: 4001568-1 (1) SafeTrack Flow Control Cable PN: 4001569-5 From Cab Box Kit (1) Cab Box Lid PN: 4000599 Step-by-Step instructions for installing the Flow Control Cables 1. Remove the four thumbscrews to open the Hardi Jobcom Box. 2. Locate the 37-pin connector indicated in the picture below, and loosen the two screws to disconnect the connector from the circuit board. Page 12 of 18 January 2014 PN: 2005930 Rev. G
DirectCommand Installation Ag Leader Technology Arrow points to the connector to remove 3. Remove the two small screws and clips on the 37-pin connector, these will be replaced in the next step. 4. Install the black hood and thumbscrews, PN: 2002702-37 on the 37-pin connector removed before. Be careful not to pinch any of the wires while installing the connector hood, and snap the hood shut. Installing the Connector Hood 5. Connect the Jobcom Tee Cable, PN: 4001568-1 to the 37-pin receptacle on the circuit board that the sprayer cable was previously connected too. Tighten the two screws to hold the connector in place. 6. Connect the sprayer cable to the second 37-pin connector on the Jobcom Tee Cable. Tighten the thumbscrews to lock the two connectors together. PN: 2005930 Rev. G January 2014 Page 13 of 18
Ag Leader Technology DirectCommand Installation 7. Using a 1-3/4 hole saw, cut an opening in the side of the Jobcom Box. 8. Remove the panel nut from the 35-pin Deutsch Receptacle on the Jobcom Tee cable. 9. Insert the receptacle through the 1-3/4 hole and reinstall the panel nut on the connector. 10. Plug the 12-pin gray plug on the Boom Valve Relay Cable, PN: 4000869-3, into the mating receptacle on the Liquid Control Module labeled BOOM. 11. Connect the second gray 2-pin plug from the Implement Cable into the 2-pin receptacle on the Boom Valve Relay Cable. NOTE: If installing two Boom Valve Relay Modules, consider the module in the bottom of the Cab Box, Module 1 for boom sections 1 through 5, and the module on the side of the Cab Box as Module 2 for boom sections 6 through 10. 12. Connect the green 8-pin plug labeled SECTIONS 1-5 on the Boom Valve Relay Module Cable into the mating receptacle on Module 1 labeled BOOM IN. 13. If using two Boom Valve Relay Modules, connect the green 8-pin plug labeled SECTIONS 6-10 on the Boom Valve Relay Module Cable into the mating receptacle on Module 2 labeled BOOM IN. 14. If only one Boom Valve Relay Module is used, cover the SECTIONS 6-10 plug on the Boom Valve Relay Module with the Green Dust Cap, PN: 2002975-8C. 15. Connect the black 12-pin plug on the Implement Plug, PN: 4000495-1 into the receptacle marked AUXILIARY on the Liquid Product Control Module. NOTE: The Jumper wire installed on the Implement Plug must remain installed for proper product application. 16. Connect the 12-pin plug on the 10 Section Switch Input Cable, PN: 4001711, into the mating receptacle labeled SWITCH A on the Auxiliary Input Module. Page 14 of 18 January 2014 PN: 2005930 Rev. G
DirectCommand Installation Ag Leader Technology 17. Connect the green 12-pin DTM plug on the SafeTrack Flow Control Cable, PN: 4001569-5 to the mating receptacle on the Switch Input Cable. 18. Insert the 12-pin Dust Plug, PN: 2002899-12N into the brown 12- pin receptacle marked SWITCH B on the Auxiliary Input Module. 19. Plug the gray 6-pin plug on the Flow Control Cable into the receptacle labeled RADAR on the Auxiliary Input Module. 20. Connect the green 12-pin DT plug marked SECT 1-5 into the Receptacle marked BOOM OUT on Boom Valve Relay Module 1. 21. If two Boom Valve Relay Modules are used, remove the dust cap on the green 12-pin DT plug marked SECT 6-10, and connect the plug to BOOM OUT on Boom Valve Relay Module 2. 22. Connect the gray 8-pin plug to the receptacle marked CHANNEL 1 on the Liquid Control Module. 23. Route the remaining connectors on the Flow Control Cable out of the Cab Box. 24. Connect the 35-pin plug to the receptacle mounted on the Jobcom Box. Rotate the plug to align it, and then twist the locking ring to lock the connector in place. Jobcom Box with 35-pin connections installed PN: 2005930 Rev. G January 2014 Page 15 of 18
Ag Leader Technology DirectCommand Installation 25. Route the 2-pin plug underneath the sprayer platform to the Flow Control Valve Connection. 26. If necessary, disconnect the flow control valve from the current sprayer cabling. Connect the 2-pin plug from the SafeTrack Flow Control Cable into the mating receptacle for the flow control valve. Flow Control Valve Connection 27. Reinstall the Cab Box Lid, PN: 4000599 with the provided 1/4-turn thumbscrews. 28. Reinstall the cover of the Jobcom Box. 29. Secure all cables with zip ties away from moving parts, pinch points and sharp edges. Reinstall any shields or paneling removed during installation. Page 16 of 18 January 2014 PN: 2005930 Rev. G
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. 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 the Ag Leader Display is set to the correct measuring units by going to the Console/General tab under the Setup Menu. Choose either Imperial (Gallons) or Metric (Liters). All information needs to be in the same measuring units when entered. If the operator changes the standard setting in the General tab after set up is complete, the Display will change all the settings to the selected measurement units. NOTE: The Ag Leader Display boom widths can be programmed as either feet or meters. Take the number of spray nozzles times the spacing on each boom section to calculate the boom section widths. Setting Name Control Valve Configuration Valve Response 1 Valve Response 2 Default Value Bypass Servo 100 40 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. PN: 2005930 Rev. G January 2014 Page 17 of 18
Ag Leader Technology DirectCommand Installation Response Threshold Allowable Error Flowmeter Cal** 2 2% **See Note 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 This is the pulses per gallon through the flow meter. Imperial Units Flow Meter Style Flow Rates Flow Meter Cal One Outside Groove 2-30 gal/min 485 No Groove 4-70 g/min 225 Two Outside Grooves 4-160 g/min 475 Metric Units Flow Meter Style Flow Rates Flow Meter Cal One Outside Groove 7-114 l/min 128.13 No Groove 15-265 l/min 59.5 Two Outside Grooves 15-606 l/min 125.5 NOTE: To switch between units adjust flow meter cal by a factor of 3.785. When switching from Gallons per Minute to Liters per Divide by 3.785, when switching from Liters per Minute to Gallons per Minute, multiply by 3.785 **Verify that the Flowmeter calibration number is correct by checking the information on the flow meter against the Hardi setup manual. If it becomes necessary to change the default settings, make changes to one value at a time so that changes can be evaluated accurately. Page 18 of 18 January 2014 PN: 2005930 Rev. G