Note: Indented items indicate parts included in an assembly listed above Part Name/Description Part Number Quantity DirectCommand Kit 4100800 1 Cable Installation Kit 2000901-1 1 Dielectric Grease 2002872 1 Installation Instructions 2005953 1 Y-Splice 4000137 1 Terminator Plug 4000141 1 CAN Bus Line 1 ft 4000218-1 1 Liquid Product Control Module 4000394 1 CAN Bus Stub 8 in. 4000450-1 1 Implement Plug 4000495-1 1 Hagie STS Adapter Cable 4000519-2 1 Quick Reference Card- Liquid 2002831-38 1 Hagie 10 Section Switch Cable 4002038-5 1 Boost Module Replacement Cable 4001314-1 1 PWM 12-Volt Pump Switch 4001566-5 1 Hagie 10 Section Input Cable 4001711 1 Cable- Power (Guidance) Deutsch 2-pin 4002093-14 1 RAM Rail Mount Kit 4100101 1 RAM 201U 5 Arm 4000279 1 RAM 2461U Monitor Mount 4000280 1 RAM 235U Base, Double U-Bolt 4000281 1 Auxiliary Input Module Kit 4100506 1 Can Bus Stub 1 ft. 4000219-1 1 Y-Splice 4000137 1 Dust Plug 12-pin 2002899-12N 1 Auxiliary Input Module 4000437 1 Pump Switch Kit 4100553 1 Switch Box Assembly 2000743 1 Mounting Arm Pump Switch 4001125-9 1 Cab Box Kit 4100513 1 Barbed Locking Retainer 2002267 1 Dome Plug 2002268 1 Cab Box 4000598 1 Cab Box Lid 4000599 1 1/4 in. Hex Nut 2002051-25 4 1/4 in. Flat Washer 2002071-25 4 PN: 2005953 Rev. E December 2013 Page 1 of 15
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 x 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 Hagie STS10, STS12, STS14 and STS16 Self Propelled Sprayers, Model Years 2010-2011 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 Component and Cable Layout 4 Safety Notices 5 Installing the Display 6 Installing the Control Modules 8 Installing the Pump Switch Cables 9 Installing the Display Cable and CAN Bus 10 Installing the Hagie Adapter Cables 11 Installing the Boost Module Replacement Cable 13 Setting Up the Display 14 Page 2 of 15 December 2013 PN: 2005953 Rev. E
Common Components This section contains illustrations of components common to all DirectCommand installations. Their purpose is to ensure proper identification and installation in the sections that follow. Brown Seal Blue Seal CAN Bus connectors 1. Terminator PN: 4000141 2. Plug PN: 4000136 Not all applications 3. Y Splice PN: 4000137 1. Auxiliary Input Module 2. Liquid Product Control Module PN: 2005953 Rev. E December 2013 Page 3 of 15
DirectCommand Installation Component and Cable Layout Page 4 of 15 December 2013 PN: 2005953 Rev. E
Safety Notices CAUTION: Sprayer booms should be lowered to ground or on mechanical safety stops before starting work. Do not work under sprayer booms supported by hydraulic system only. Turn off sprayer and wait for all machine 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 hoses, wiring, controls, etc. that could be damaged when drilling any mounting 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 the Null Modem Cable PN: 2000819, included in the Display kit, to prevent damage to the Display or the GPS receiver. IMPORTANT: Use the 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: 2005953 Rev. E December 2013 Page 5 of 15
DirectCommand Installation Installing the Display Parts required for procedure: (1) Ag Leader INTEGRA Display Or (1) EDGE Display Or (1) InSight Display (1) RAM Rail Mount Kit PN: 4002000 PN: 4001500 PN: 4001000 PN: 4100101 From Pump Switch Kit: (1) Mounting Arm PN: 40001121 (1) Switch Box Assembly PN: 2000743 (2) Hex Nut #10-24 PN: 2002051-10 (2) Flat Washer #10 PN: 2002071-10 (1) Screw #10-24 PN: 2002075-10038 Step-by-step instructions for installing the Display 1. Turn on the current rate control console, if equipped with one, and copy down the boom section widths and flow meter calibration numbers. 2. Run the machine 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 Raven flow meter calibration is in pulses per 10 gallons, the Ag Leader Display requires pulses per gallon for calibration. To calculate the appropriate values, divide the Raven calibration number by 10 before entering it into the Ag Leader Display. NOTE: Raven boom section widths are in inches, the Ag Leader Display requires boom widths in feet. Divide the widths by 12 before entering into the Ag Leader Display. 3. Disconnect the cable from the back of the console and remove the console from the sprayer. 4. Cut the cable ties holding the console cable to the mounting arm and route the cable towards the rear of the cab and below the armrest. Page 6 of 15 December 2013 PN: 2005953 Rev. E
NOTE: An external Pump Switch is necessary to prevent damage to the product pump. This switch can be installed using the mounting brackets provided, or mounted in the sprayer console. Console mounting will have to be installer fabricated. 5. Using the following picture, assemble the Pump Switch Box, PN: 2000743 to the Pump Switch Mounting Bracket, PN: 4001121 using the hardware provided. The Pump Switch will mount to the left side of the display. Assembled Pump Switch Bracket 6. Lay the Display face down on a stable surface and align the four holes in the RAM Mount Base, PN: 4000280 and Pump Switch Bracket with the mounting holes on the back of the Display. Using the four Phillips pan head screws and lock washers, secure brackets to the Display. 7. 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 on the arm where the previous console was mounted. 8. Mount the Display in a convenient place for operation on the cab rail, but out of the operator s line of sight while operating the sprayer. PN: 2005953 Rev. E December 2013 Page 7 of 15
DirectCommand Installation Installing the Control Modules Parts required for procedure: From DirectCommand Kit: (1) Liquid Product Control Module PN: 4000394 (1) Implement Plug PN: 4000495-1 From Auxiliary Input Module Kit: (1) Auxiliary Input Module (1) Deutsch Dust Plug PN: 4000437 PN: 2002899-12N From Cab Box Kit (1) Cab Box (1) Dome Plug (2) Barbed Locking Retainer (4) ¼-in. Hex Nuts (4) ¼-in. Flat Washers PN: 4000598 PN: 2002268 PN: 2000267 PN: 2002051-25 PN: 2002071-25 Step-by-step instructions for installing the Control Modules 1. Position the Cab Box on the floor, underneath the right hand console. Make sure to leave room for cabling. 2. Decide which access hole to route the cables through. Install the corrugated cable protector in the chosen hole and plug the other hole with the Dome Plug, PN: 2002268. IMPORTANT: Make sure to keep the Cab Box out of the operator s area preventing module damage and a hazard to the operator. NOTE: The Cab Box may be secured to the cab floor mat using the included retainers; Steps 3 and 4 are for that purpose. At the operator s discretion, the Cab Box may be left unsecured for easier transport from vehicle to vehicle. 3. Mark the location of the holes in the bottom of the box on the floor mat. Remove the box and cut a half-inch slot in the floor mat on the marked locations. Page 8 of 15 December 2013 PN: 2005953 Rev. E
Arrows show holes for securing the Cab Box 4. Use the white nylon barbed locking retainers to secure the Cab Box to the floor by pressing them through the holes of the Cab Box and into the rubber floor mat below. 5. Mount the Liquid Product Control Module, PN: 4000394, and the Auxiliary Input Module, PN: 4000437 inside the Cab Box. Use the hardware provided to secure the modules inside the Cab Box. 6. Connect the Implement Plug, PN: 4000495-1 to the black 12-pin Deutsch receptacle on the Liquid Product Control Module marked AUXILIARY. NOTE: The red jumper wire must be plugged into the black 3-pin Weatherpack connector of the Implement Plug for Liquid Product Control Module to enable product application. Installing the Pump Switch Cables Parts required for procedure: From Direct Command Kit: (1) Pump Switch PN: 4001566-5 From Pump Switch Kit: (1) Pump Switch Cable PN: 4001125-9 PN: 2005953 Rev. E December 2013 Page 9 of 15
DirectCommand Installation Step-by-step instructions for installing the Pump Switch Cables 1. Insert the 3-pin Weatherpack plug and 3-pin Deutsch receptacle on the Pump Switch Cable, PN: 4001125-9 through the front of the Switch Box Housing, or an empty switch position in the console. 2. As the Pump Switch Cable is fed all the way through the hole, with the switch indicator light on top, gently push the switch until it clicks into place. 3. Connect the gray 8-pin Deutsch plug on the Pump Switch, PN: 4001566-5 into the gray 8-pin receptacle marked CHANNEL 1 on the Liquid Product Control Module. 4. Connect the 3-pin Weatherpack plug and the 3-pin Deutsch receptacle on the Pump Switch Cable, PN: 4001125-9 to the mating connectors of the Pump Switch. Installing the Display Cable and CAN Bus Parts required for procedure: From the DirectCommand Kit (1) Y-Splice PN: 4000137 (1) Terminator PN: 4000141 (1) CAN Bus Line 1 ft PN: 4000218-1 (1) CAN Bus Stub 8 in. PN: 4000450-1 From Auxiliary Input Module Kit: (1) CAN Bus Stub 1 ft. PN: 4000219-1 (1) Y-Splice PN: 4000137 From the 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 Display Cable and CAN Bus 1. Connect the round 28-pin connector on the Display Cable, PN: 4001608-12, 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 connectors at the opposite end of the Display Cable into the Cab Box. 3. 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. Page 10 of 15 December 2013 PN: 2005953 Rev. E
NOTE: To properly connect the CAN Bus terminals, firmly pinch the metal clip against the plastic connection and then mate the ends. 4. Connect the single end of the first CAN Y-Splice, PN: 4000137 to the mating connector on the Display Cable. 5. Plug the CAN Bus Stub 1 ft. PN: 4000219-1 into the gray connector of the Y-Splice. 6. Plug the opposite end of the CAN Bus Stub into the mating receptacle labeled CAN BUS on the Auxiliary Input Module. 7. Connect one end of the CAN Bus Line 1 ft. PN: 4000218-1 to the black side of the Y-Splice. 8. Plug the single end of the second Y-splice into the opposite end of the CAN Bus Line. 9. Insert the CAN Bus Terminator, PN: 4000141 into the black side of the second Y-Splice. 10. Plug the CAN Bus Stub 8 in. PN: 4000450-1 into the gray side of the second Y-Splice. 11. Connect the opposite end of the 8 in. CAN Bus stub into the mating connector labeled CAN BUS on the Liquid Product Control Module. Installing the Hagie Adapter Cables Parts required for procedure: From DirectCommand Kit: (1) Hagie STS Adapter Cable PN: 4000519-2 (1) Hagie 10 Section Switch Cable PN: 4002038-5 (1) Hagie 10 Section Input Cable PN: 4001711 From Cab Box Kit: (1) Cab Box Lid PN: 4000599 PN: 2005953 Rev. E December 2013 Page 11 of 15
DirectCommand Installation Step-by-step instructions for installing the Hagie Adapter Cables 1. Plug the round Amp Connector of the Hagie STS Adapter Cable, PN: 4000519-2 into the connector previously connected to the back of the original control console. Line up the connectors properly and tighten the lock collar on the control harness. 2. Plug the 3-pin Weatherpack connector on the Hagie STS Adapter Cable into the 3-pin Weatherpack shroud on the Display Cable. 3. Connect the gray 2-pin Deutsch plug to the gray 2-pin Deutsch receptacle on the red and black wires coming from the Liquid Product Control Module. 4. Connect the gray 8-pin Deustch plug into the mating receptacle of the Pump Switch Cable, PN: 4001566-5. 5. Plug the gray 6-pin Deutsch connector into the gray 6-pin receptacle marked RADAR on the Auxiliary Input Module. 6. Raise the right side switch console by lifting the front edge of the console. Locate the gray 12-pin Deutsch connector marked CHI- 4. Separate the connectors and plug the 10 Section Switch Cable, PN: 4002038-5 inline with the Hagie Factory Cable. 7. Locate the 10mm Ring Terminal on the same end of the 10 Section Switch Cable referred to in step 6. Connect this Ring Terminal to one of the chassis grounding points in the right side switch console. Connector CHI-4 in Console Page 12 of 15 December 2013 PN: 2005953 Rev. E
8. Route the opposite end of the cable down through the bottom of the armrest. Connect the Green 12-pin plug into the 12-pin receptacle on the Switch Input Cable, PN: 4001711. 9. Connect the Green 12-pin plug on the opposite end of the Switch Input Cable, PN: 4001711 into the mating receptacle marked Switch A in the Auxiliary Input Module. 10. Connect the Brown 12-pin plug on the Switch Input Cable into the mating receptacle marked Switch B in the Auxiliary Input Module. 11. Connect the Gray 12-pin plug on the 10 Section Switch Cable, PN: 4002038-5 into the receptacle marked BOOM on the Liquid Product Control Module. 12. Bundle all cables and secure them in the Cab Box. Retain the Cab Box Lid, PN: 4000599 with the 1/4-turn Thumb Screws. 13. Replace any panels removed during installation. Installing the Hagie Boost Module Replacement Cable Step-by-step instructions for Installing the Hagie Boost Module Replacement Cable Parts required for procedure: From DirectCommand Kit: (1) Hagie Boost Module Replacement PN: 4001314-1 1. Locate the factory installed Boost Module, PN: 063-0172-686 that is connected to the PWM solenoid valve on the right side of the sprayer. PN: 2005953 Rev. E December 2013 Page 13 of 15
DirectCommand Installation Factory installed Boost Module 2. Install the Boost Module Replacement Cable, PN: 4001314-1 where the Boost Module was previously installed. IMPORTANT: Failure to remove the boost module may result in damage to electrical components and poor flow control performance. 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 charts for initial sprayer set up. NOTE: If it becomes necessary to change one of these default settings make changes to one value at a time so that changes can be evaluated accurately. Page 14 of 15 December 2013 PN: 2005953 Rev. E
Setting Name Control Valve Configuration PWM Frequency Default Value PWM 12 Volt 122 Description Rate Control is achieved through speed changes of 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. This setting is the frequency that the PWM control valve is pulsed at Gain* 350 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. Zero Flow Offset Allowable Error Flow Meter Cal** 20 2% See Note 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 information tag on the flow meter. PN: 2005953 Rev. E December 2013 Page 15 of 15