Note: Indented items indicate parts included in an assembly listed above Part Name/Description Part Number Quantity Direct Command Kit 4100550 1 Dual Lock 2000052-9 1 Dual Lock 2000053-9 1 Hardware Kit Large Module 2001354-1 1 Quick Reference Card 2002831-38 1 Dielectric Grease 2002872 1 Installation Instructions 2005890 1 Mounting Plate Module 4000244 1 Cable CAN Bus Stub 3 ft 4000318-3 1 Liquid Product Control Module 4000394 1 Cable Implement Plug 4000495-1 1 Cable Radar, DickeyJohn 4000501-1 1 Cable Implement 4000726-12 1 Cable Control/Flow AgChem 4000868-17 1 Cable Boom Section RoGator 4000870-5 1 Cable RoGator Switch Tee MY07-08 4001072-3 1* Cable RoGator Switch Tee MY09 4001964-2 1* Cable Can/High Power W/ Imp. Conn. 4001979-3 1 Cable Power 4002095-6 1 *Either 4001072-3 or 4001964-2 is used depending on sprayer model year. RAM Base Mount 4100100 1 Lockwasher 2002065-06 4 Self Tapping Screw 1/4"x3/4 2002075-25075 4 Phillips Pan Head Screw M6x1.0 2002435-06016 1 RAM 111B Base 4000187 1 RAM 201U Arm 5 4000279 1 RAM 2461U Base 4000280 1 Auxiliary Input Module Kit 4100506 1 Dust Plug Deutsch DT 12 Pin 2002899-12N 1 CAN Y-Splice 4000137 1 Cable CAN Bus Stub 1 ft. 4000219-1 1 Auxiliary Input Module 4000437 1 PN: 2005890 Rev. H December 2013 Page 1 of 17
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 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: Model Year 2007-2009 RoGator Sprayers Model Numbers: 874, 884, SS884, 1074, SS1074, SSC1074, 1084, SSC1084 and 1286C 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 Contents Section Heading Page Common Components 3 Cable and Component Layout 4 Safety Notices 5 Installing the Display 6 Installing the Display Cable 7 Installing the Auxiliary Input Module, Power Cable and Cab Cables 10 Installing the Liquid Product Control Module and External Cabling 13 Setting up the Display 17 Page 2 of 17 December 2013 PN: 2005890 Rev. H
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. Auxiliary Input Module PN: 4000437 2. Liquid Product Control Module PN: 4000394 PN: 2005890 Rev. H December 2013 Page 3 of 17
DirectCommand Installation Component and Cable Layout Page 4 of 17 December 2013 PN: 2005890 Rev. H
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. PN: 2005890 Rev. H December 2013 Page 5 of 17
DirectCommand Installation 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 Mount Kit (4) Split Lock washer 6mm PN: 2002065-06 (4) Self Tapping Screw ¼"x3/4 PN: 2002075-25075 (4) Phillips Pan Head Screw M6x16 PN: 2002435-06016 (1) RAM 111B Base 2 x 6-1/4 PN: 4000187 (1) RAM 201U Arm 5 PN: 4000279 (1) RAM 2461U Base PN: 4000280 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 rate control console. Verifying that all of the rate control components work will help with any potential troubleshooting issues after the installation. NOTE: Swing the right boom away from the transport position to allow easier access to the right hand side of the cab. Lower the boom completely or rest it on mechanical stops. Do not work under sprayer boom supported by hydraulic system only. 3. Turn off the console, disconnect the cable from the back of the console, and remove the console from the cab. 4. Attach the square RAM Display Mount, PN: 4000280 to the back of the Display using four 6mm Phillips pan head screws and lock washers provided in the RAM Mount Kit. 5. Determine a mounting place for the Display that will be a convenient place for operation, but out of the operator s line of sight while driving sprayer. 6. Take the RAM Base Mount, PN: 4000187, and use the 13/32 drill and self-tapping screws as needed to secure the Base Mount. 7. Use the 5 RAM Arm, PN: 4000279 to mount the Display. Page 6 of 17 December 2013 PN: 2005890 Rev. H
Installing the Display Cable Step-by-Step instructions for installing the Display Cable Parts required for procedure: From Display Kit or Display Cable Kit 4100814 (1) Display Cable PN: 4001608-12 NOTE: Model Year 2007 sprayers have a different cab, and require different Display Cable installation than the 2008 and 2009 cabs. The 2007 cabs have a right side window running half the height of the cab. The 2008 and 2009 cabs have a right side window running the complete height of the cab. For Model Year 2007 sprayer installation refer to Steps 1-5. For Model Year 2008 and 2009 sprayer installation, skip to Step 6 on Page 8. 2007 Cab Installation 1. Remove both the rear and side access panels on the right hand side of the cab. 2. Inside the cab, locate the hole close to the floor on the right hand side of the driver s seat. Arrow points to entry hole next to seat 3. Feed the 28-pin AMP connector of the Display Cable, PN: 4001608-12 through the hole and into the right side compartment. Continue to feed the first 10 feet of the cable through the hole, making sure to leave the CAN connection and 9-pin Serial Connection inside the cab. PN: 2005890 Rev. H December 2013 Page 7 of 17
DirectCommand Installation 4. Route the Display Cable up through the console to the upper right corner of the side access panel. Loop the Display Cable towards the Display mounted in the right front corner of the cab. Cable Routing in the front Right Corner of console 5. 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. 2008-2009 Cab Installation 6. Remove the two screws holding the right side cab post cover. Cab Side Post Cover 7. Remove the existing display cable if the sprayer was equipped with a previous rate control system. Page 8 of 17 December 2013 PN: 2005890 Rev. H
8. Remove the access panel from the right rear outside corner of the cab. 9. Starting from the rear corner compartment, route the 28-pin end of the Display Cable, PN: 4001608-12 up the right side post. Make sure to leave all other connections of the Display Cable in the rear compartment. 10. Connect the Display Cable to the back of the Display. Rotate the connector, aligning the cable and firmly tighten the lock ring. Allow some slack in the Display Cable for adjustment of the Display. 11. Reinstall the Right Side Post Cover. Display Cable Routing with Cab Post Cover Reinstalled. Arrow points to where Display Cable exits cab post cover. PN: 2005890 Rev. H December 2013 Page 9 of 17
DirectCommand Installation Installing the Auxiliary Input Module, Power Cable and Cab Cables Parts required for procedure: From DirectCommand Kit (1) Dual Lock PN: 2000052-9 (1) Dual Lock PN: 2000053-9 (1) Hardware Kit Large Module PN: 2001354-1 (1) Module Mounting Plate PN: 4000244 (1) CAN Bus Stub 3 ft. PN: 4000318-3 (1) Radar Adapter Cable PN: 4000501-1 (1) RoGator Switch Cable (MY 07-08) PN: 4001072-3 (1) RoGator Switch Cable (MY 2009) PN: 4001964-2 (1) Power Cable PN: 4002095-6 From Auxiliary Input Module Kit (1) Dust Plug 6-pin PN: 2002899-6 (1) Dust Plug 12-pin PN: 2002899-12N (1) CAN Y-Splice PN: 4000137 (1) Auxiliary Input Module PN: 4000437 From Display Kit or Display Cable Kit 4100814 (1) Power Control Relay PN: 4000708-1 Step-by-Step instructions for installing the Auxiliary Input Module, Power Cable and Cab Cables 1. On 2008 and 2009 machines only, remove the access plug located near the floor under the right hand console. Arrow indicates access plug to remove 2. Cut one of the Dual Lock Strips, PN: 2000052-9 and using an alcohol wipe from the Hardware Kit Large Module, PN: 2001354-1, clean the back of the Module Mounting Plate, PN: 4000244. Remove the white adhesive backing and stick the Dual Lock Strips to the back of the Module Mounting Plate. Page 10 of 17 December 2013 PN: 2005890 Rev. H
3. Cut the second Dual Lock, PN: 2000053-9 strip in half and with the white adhesive backing still on, push these sections onto the Dual Lock installed on the Mounting plate. 4. Remove the white adhesive backing from the Dual Lock, and mount the Module Mounting Plate to the console or seat platform, within 3 feet of the CAN Bus connector on the Display cable. 5. Using the 1/4" nuts, flat washers and lock washers from the hardware kit, install the Auxiliary Input Module, PN: 4000437 on the Module Mounting Plate. 6. Plug the 12 pin brown receptacle on the Auxiliary Input Module marked SWITCH B, with the 12 pin Dust Plug, PN: 2002899-12N. 7. Install the single end of the CAN Y-Splice, PN: 4000137, from the Auxiliary Input Module Kit into the mating connector on the Display Cable. On 2007 machines, this connection will be located on the right side of the driver s seat. On 2008 and 2009 machines, this connection will be located in the rear corner compartment. 8. Connect the black 4-pin connector of the 3 ft. CAN Bus Stub, PN: 4000318-3, into the gray side of the CAN Y-Splice. 9. On 2008 and 2009 machines only, route the opposite end of the CAN Bus Stub into the cab, through the access hole opened in Step 1. 10. Connect the 4-pin Gray Plug of the CAN Bus Stub into the mating connector on the Auxiliary Input Module marked CAN BUS. 11. If no radar cable is used, plug the 6-pin gray receptacle marked RADAR, with the 6-pin Dust Plug, PN: 2002899-6. If the radar will be used, an adapter cable will be installed in a later step. 12. If radar is used, connect the gray 6-pin plug of the Radar Adapter Cable, PN: 4000501-1 to the mating receptacle marked RADAR. 13. Connect the opposite end of the Radar Adapter Cable, to the 4-pin AMP connector from the sprayer harness. 14. Attach the Power Cable, PN: 4002095-6, to the power studs in the back corner compartment. Connect the fused wires to the positive terminal under the red boot and the black wires to the negative terminal. PN: 2005890 Rev. H December 2013 Page 11 of 17
DirectCommand Installation Power and Ground Terminals in Rear Compartment 15. In 2008 and 2009 machines only, connect the 3-pin Weatherpack tower to the mating connector on the end of the Display Cable. 16. In 2007 machines only, route the opposite end of the power cable through the hole located above the power terminals and into the right side compartment. From the right side compartment, route the 3-pin Weatherpack Tower through the same hole the Display Cable was previously routed and connect to the mating shroud on the Display Cable. 17. Connect the Power Control Relay, PN: 4000708-1 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 18. Behind the right-side armrest of the seat, locate the connection with the blue Boom Section Signal Wires. 2007 and 2008 machines will have a round 31-pin Deutsch Connector. 2009 machines will have a rectangular 12-pin Deutsch connector. 19. Disconnect the connection found in the previous step and install the Switch Tee Cable in line with these connectors. 2007 and 2008 machines will use Boom Switch Tee PN: 4001072-3 and 2009 machines will use Boom Switch Tee PN: 4001964-2. NOTE: Only one Boom Switch Tee Cable will be used in each application. The other cable included in the kit may be discarded. Page 12 of 17 December 2013 PN: 2005890 Rev. H
20. Route the opposite end of the Boom Switch Tee Cable towards the Auxiliary Input Module, and connect the green 12-pin plug to the mating receptacle marked SWITCH A. Installing the Liquid Product Control Module and External Cabling Step-by-Step instructions for installing the Liquid Control Module and External Cabling Parts required for procedure: From DirectCommand Kit (1) Liquid Product Control Module PN: 4000394 (1) Implement Plug PN: 4000495-1 (1) Implement Cable PN: 4000726-12 (1) Flow Control Cable PN: 4000868-17 (1) Boom Section Control Cable PN: 4000870-5 (1) Can/High Power Cable W/ Imp. Conn. PN: 4001979-3 From Auxiliary Input Module Kit (1) CAN Bus Stub 1 ft. PN: 4000219-1 1. On the CAN Bus/High Current Power Cable, PN: 4001979-3 route the 2-pin Deutsch receptacles, and CAN Bus Connector into the rear corner compartment. Make sure to leave the 16-pin Round AMP Connector on the outside of the cab. On 2007 machine only, continue routing cable into the side compartment along side the Power Cable previously installed and into the cab. Bottom arrow indicates hole to route CAN/Power Cable into Rear Compartment. Top arrow points to hole to route cable into the side compartment on MY2007 sprayers 2. Connect the gray 2-pin Deustch Receptacle to the mating connector on the Power Cable. PN: 2005890 Rev. H December 2013 Page 13 of 17
DirectCommand Installation 3. Connect the round 4-pin CAN Connector into the black side of the Y-Splice installed on the Display Cable. 4. Connect the Implement Cable, PN: 4000726-12 to the mating connector on the Can/High Power Cable. 5. Route the opposite end of the Implement Cable along the right side of the sprayer towards the back of the machine. 6. Decide on where the Liquid Control Module, PN: 4000394 will be mounted. The suggested location is underneath the catwalk on the right hand side of the machine, approximately even with the back edge of the product tank. NOTE: The module should be mounted so it is protected from impact and field debris and within reach of the implement cable. 7. Using a 9/32 drill, use the Module as a layout template. Locate and drill the first hole, secure the module with the hardware from the Large Module Hardware Kit. Drill the remaining holes and secure the module with the hardware provided. IMPORTANT: Do not drill holes in the sprayer mainframe. Due to high stress loads on the mainframe, cracking may occur from drilled holes. 8. Connect the round 4-pin CAN Connector of the 1 ft. CAN Bus Stub, PN: 4000219-1 into the gray side of the Y-Splice on the Implement Cable. 9. Plug the 4-pin gray plug on the opposite end of the CAN Bus Stub into the mating receptacle on the Liquid Control Module marked CAN BUS. 10. Connect the one of the 2 pin gray plugs from the Implement Cable into the mating receptacle, on the red and black wires coming from the Liquid Control Module. 11. Install the Implement Plug, PN: 4000495-1 into the black receptacle on the Liquid Control Module marked AUXILIARY. NOTE: The red jumper wire must be plugged into the black 3-pin Weatherpack connector of the Implement Plug for the Liquid Control Module to enable product application. Page 14 of 17 December 2013 PN: 2005890 Rev. H
12. Locate the RoGator Boom Valve 31-pin connector at the rear of the sprayer. Twist the locking ring and disconnect the boom cable. Boom Valve Connection 13. Connect the Boom Section Control Cable, PN: 4000870-5 in line with the RoGator Cable. 14. Route the opposite end of the Boom Section Control Cable towards the Liquid Control Module, and plug the 12-pin Gray Plug into the mating receptacle marked BOOM. 15. Connect the gray 8-pin plug from the Flow Control Cable, PN: 4000868-17 into the mating receptacle on the Liquid Control Module marked CHANNEL 1. 16. Route the gray 3-pin plug on the Flow Control Cable towards the back of the machine below the boom valve control box. IMPORTANT: The AgChem flow control cables are configured for +12V flow meter power. Please verify your flow meter specs prior to cable connection to prevent potential flow meter damage. 17. Locate the flow meter below the boom valve control box, and disconnect the gray 3-pin Deutsch plug from the flow meter. Connect the gray plug from the Flow Control Cable into the flow meter. 18. Route the gray 6-pin receptacle towards the front of the machine. PN: 2005890 Rev. H December 2013 Page 15 of 17
DirectCommand Installation 19. Locate the gray 6-pin Deutsch connector between the cab and product tank. The cable will be marked RATE CONTROL. Separate the connection and plug the sprayer cable into the gray 6-pin receptacle on the Flow Control Cable. 20. Secure all cables with zip ties, avoiding sharp edges and pinch points that could damage cables. 21. Reinstall any panels removed during installation. Page 16 of 17 December 2013 PN: 2005890 Rev. H
Setting Up the Display Setting Name Control Valve Configuration PWM Frequency 1. Refer to the Quick Reference Guide, PN: 2002831-38 for setting up the Display. 2. Enter the default settings from the chart on the next page for the initial sprayer setup. Default Value PWM Ground 122 Gain* 600 Zero Flow Offset Allowable Error Flowmeter Cal** 30 2% See Note Description Rate control is achieved through speed changes to the solution pump. The PWM pump setting is programmed to control an electric solenoid valve used to adjust the hydraulic flow to the pump. This valve adjusts the application rate indirectly. A constant 12V+ power source is supplied to the electric solenoid valve and a variable 12-Volt Ground PWM signal is provided by the Liquid Control Module to provide rate control This setting is the frequency that the PWM control valve is pulsed at This setting determines how aggressively the control valve responds when making rate change adjustments. The higher the value, the more aggressive the system response is. NOTE: Leaving all other valve control settings at the default value and making a small adjustment to the Gain is usually all that is required to fine-tune the control system. This setting represents the maximum duty cycle that is sent to the control valve without producing any hydraulic flow from the PWM valve. Using too high of a Zero Flow Offset value can cause the product control system to not properly shut off. 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. Note: Raven flow meter calibration numbers are in pulses per 10 gallons of product flow. To calculate the appropriate values, divide the Raven calibration number by 10 before entering into the Ag Leader Display. *InSight Displays must have firmware upgraded to version 5.0 or above and the Liquid Product Control Module must be upgraded to firmware version 1.8.00 or above for proper flow control operation using PWM Flow Control. Any firmware version on EDGE or Ag Leader INTEGRA Displays will work with Liquid Control Module 1.8.00 firmware. **Verify that the flow meter calibration number is correct by checking the information tag on the flow meter. PN: 2005890 Rev. H December 2013 Page 17 of 17