OPERATOR’S MANUAL - DICKEY-john Master.compressed.pdf · 2019-02-08 · OPERATOR’S MANUAL Flex4 Control System 11001-1576B-201608 INTRODUCTION / 3 INTRODUCTION The DICKEY-john

OPERATOR’S MANUAL

Flex4 Control System11001-1576B-201608

/ I

Safety Notices ..................................................................................................... 1Disclaimer ......................................................................................................................... 1

Introduction ......................................................................................................... 3Features ............................................................................................................................ 3Requirements .................................................................................................................... 3

Component Overview ......................................................................................... 5Flex4 Terminal .................................................................................................................. 5

Terminal Buttons .............................................................................................................................. 6Terminal Connections ...................................................................................................................... 6

Operator Remote Switch Module....................................................................................... 7Switch Module Functions ................................................................................................................. 7

Rate Control Module ......................................................................................................... 8Output Module ................................................................................................................. 10Miscellaneous Components ............................................................................................ 12

Keyboard ........................................................................................................................................ 12Ground Speed Sensor ................................................................................................................... 12Road Temperature Adapter (Optional) ........................................................................................... 12Feedback/Application Rate Sensor (Optional) ............................................................................... 13Gate Height Sensors (Optional) ..................................................................................................... 13Hydraulic Pressure Sensors (Optional) .......................................................................................... 13Flow Meters .................................................................................................................................... 13Valve Control Output ...................................................................................................................... 13Harnesses ...................................................................................................................................... 13Hopper Level Sensor (Optional) ..................................................................................................... 13GPS Receiver (Optional) ................................................................................................................ 13Video Camera (Optional) ............................................................................................................... 13

Installation ......................................................................................................... 15Switch Module Mount ...................................................................................................... 15

Switch Module Bracket Assembly .................................................................................................. 15RAM Mount Bracket Installation ...................................................................................... 16

Cab Terminal Bracket Assembly .................................................................................................... 17Remote Switch Module Bracket Kit ................................................................................. 18System Harness Connections.......................................................................................... 19

Cab Harness .................................................................................................................................. 21Rate Control Module Harness ........................................................................................................ 21Roadwatch Temperature Adapter and Flex4 Interface Cable ........................................................ 23Extension Harness ......................................................................................................................... 23Output Module Harness ................................................................................................................. 24Electric Motor Driver Harness ........................................................................................................ 24

Operate Screen ................................................................................................. 25(1) Control Channels ...................................................................................................................... 25(2) Display Function Buttons .......................................................................................................... 26(3) Spread Width Bar ..................................................................................................................... 26(3) Rad/Air Temperature Sensors .................................................................................................. 26(3) Boom Sections .......................................................................................................................... 26(3) Conveyor .................................................................................................................................. 26(3) Alarms ....................................................................................................................................... 26(4) Accessory Sensors/Alarms ....................................................................................................... 26(5) Ground Speed/Time/Date ......................................................................................................... 26

Display Settings (Camera/Display/Alarms) ..................................................................... 27

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II /

Operation .......................................................................................................... 29Pre-operating Checklist .................................................................................................. 29Spreading Material ......................................................................................................... 29Blast ................................................................................................................................ 30Pause ............................................................................................................................. 31Material Selection ........................................................................................................... 32

Turn Off an Active Channel ............................................................................................................ 33Unload Material .............................................................................................................. 33Manual Ground Speed Override ..................................................................................... 35Automatic Manual Control Channel Override ................................................................. 36Driver Login .................................................................................................................... 37Route Selection .............................................................................................................. 37Boom Section Control ..................................................................................................... 38Anti-Ice Feature .............................................................................................................. 39Accessory Sensors ......................................................................................................... 39

Output Module Accessories ............................................................................................................ 39Hydraulic Accessory Tool Operation .............................................................................. 41Current and Season Run Totals ..................................................................................... 41

Flex4 Programming .......................................................................................... 43Passcode Restrictions .................................................................................................... 43Using the Keyboard ........................................................................................................ 44Keyboard Functions ........................................................................................................ 44

Text Entries .................................................................................................................................... 45Label Entries ................................................................................................................................... 46Number Entries ............................................................................................................................... 47

System Programming ...................................................................................... 49Operate Mode (F1) ......................................................................................................... 49Anti-Ice Button Mode Feature ......................................................................................... 49Granular Channel Setup (F2) ......................................................................................... 51Granular Rate Setup ....................................................................................................... 52

Material Label ................................................................................................................................. 52Units ............................................................................................................................................... 52Spreader Constant ......................................................................................................................... 52Calibration Gate Height .................................................................................................................. 52Application Rate Method ................................................................................................................ 53Blast Rate ....................................................................................................................................... 54

Granular Configuration (F2) ............................................................................................ 55Drive Frequency ............................................................................................................................. 56PWM Offset .................................................................................................................................... 56PWM Saturation ............................................................................................................................. 56System Response .......................................................................................................................... 56Valve Boost .................................................................................................................................... 56AFILT .............................................................................................................................................. 56Material ........................................................................................................................................... 56Sensor Constant ............................................................................................................................. 56Spreader Constant ......................................................................................................................... 56Calibration Gate Height .................................................................................................................. 57

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/ III

System Programming cont ................................................................................58Liquid Channel Setup (F3) .............................................................................................. 58Liquid Rate Setup ........................................................................................................... 59

Material Label ................................................................................................................................. 60Units ............................................................................................................................................... 60Application Rate Method ................................................................................................................ 60Target Rate .................................................................................................................................... 61Minimum/Maximum Rate ............................................................................................................... 61Inc/Dec Step ................................................................................................................................... 61Blast Rate ....................................................................................................................................... 61

Boom Configuration (Liquid/Anti-Ice) .............................................................................. 62Function ......................................................................................................................................... 63Active Level .................................................................................................................................... 63

Auxiliary S (F4) ................................................................................................................ 64Assign ‘Auxiliary S’ as Spinner ....................................................................................................... 64Spinner Units .................................................................................................................................. 65Unload ............................................................................................................................................ 65Drive Frequency ............................................................................................................................. 65No Ground Speed .......................................................................................................................... 65Blast Rate ....................................................................................................................................... 65Pulse Feedback ............................................................................................................................. 66Spinner Constant ........................................................................................................................... 66PWM Offset .................................................................................................................................... 66PWM Saturation ............................................................................................................................. 66System Response .......................................................................................................................... 66Valve Boost .................................................................................................................................... 66AFILT ............................................................................................................................................. 66Ground Speed Related (GSRS) ..................................................................................................... 66GSRS Slope ................................................................................................................................... 66Maximum GSRS ............................................................................................................................ 66

Auxiliary Control Channel Configuration (F5) ................................................................. 67Accessory Sensors (F9) .................................................................................................. 68

Gate Height Sensor ........................................................................................................................ 69Road Temperature Sensor ............................................................................................................. 70Air Temperature Sensor ................................................................................................................. 72Tank Level Sensor Configuration ................................................................................................... 73Down Pressure ............................................................................................................................... 74Bed Height ..................................................................................................................................... 75Digital Accessories ......................................................................................................................... 76Joystick Labels ............................................................................................................................... 79

System Setup (F10) ........................................................................................................ 80Blast Setup ...................................................................................................................... 80

Blast Timer ..................................................................................................................................... 81Blast Speed .................................................................................................................................... 81

Date and Time ................................................................................................................ 81Units and Language ........................................................................................................ 82Service ............................................................................................................................ 83

Software Version ............................................................................................................................ 83System Reset ................................................................................................................................. 84Service Keyboard Mode ................................................................................................................. 84

Troubleshooting .............................................................................................................. 85GPS Sensor ................................................................................................................................... 86

Output Module Setup (F11) ............................................................................................ 87Front/Rear Conveyor ...................................................................................................................... 87Left/Right Conveyor ....................................................................................................................... 87Gate Height Control ....................................................................................................................... 88

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Data Logging (F12) ......................................................................................................... 89Alarm History .................................................................................................................................. 89Truck ID .......................................................................................................................................... 90

Driver Setup .................................................................................................................... 91Driver ID Configuration ................................................................................................................... 91Configuration Setup ........................................................................................................................ 93Route Configuration ........................................................................................................................ 94Operational Totals .......................................................................................................................... 95Lifetime Totals ................................................................................................................................ 97

Calibrations ....................................................................................................... 99Material and Spinner System Response Calibrations (F6) ............................................. 99

Granular Response Calibration ...................................................................................................... 99Recording Calibration Data .......................................................................................... 100Maintaining Calibration Accuracy ................................................................................. 101

System Response Adjustments .................................................................................................... 101System Response Constant ......................................................................................................... 101Valve Boost .................................................................................................................................. 101AFILT ............................................................................................................................................ 102

Granular Drop Test Calibration ..................................................................................... 102Drop Test Preparation .................................................................................................................. 102Performing a Granular Drop Test ................................................................................................. 102Granular Calibration Adjustments ................................................................................................. 105

Liquid Drop Test Calibration (F6) ................................................................................. 105Drop test Preparation ................................................................................................................... 105Performing a Liquid Drop Test ...................................................................................................... 105Liquid Calibration Adjustments ..................................................................................................... 107

Auxiliary System Response and Drop Test .................................................................. 108Spinner System Response Calibration ......................................................................... 108

Spinner Spread Width .................................................................................................................. 110Ground Speed Configuration (F8) ................................................................................. 112

Ground Speed Source .................................................................................................................. 112Maximum Control Speed .............................................................................................................. 112Manual Speed On ......................................................................................................................... 112Manual Speed Access .................................................................................................................. 112Maximum Manual Speed .............................................................................................................. 113Manual Speed .............................................................................................................................. 113Control Startup Speed .................................................................................................................. 113Control Shutoff Speed .................................................................................................................. 113Ground Speed Constant ............................................................................................................... 113

Ground Speed Calibration (F8) ..................................................................................... 114

Import/Export Data Files ................................................................................ 117Passcode Enabled ........................................................................................................ 117Export Configuration Files ............................................................................................ 117Export Log Data Files ................................................................................................... 118Import Configuration Files ............................................................................................ 121

Diagnostics ..................................................................................................... 123Perform a Diagnostics Check ....................................................................................... 123Terminal ........................................................................................................................ 125Control Module ............................................................................................................. 125

Material ......................................................................................................................................... 126Spinner ......................................................................................................................................... 127

Output Module .............................................................................................................. 129

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Troubleshooting .............................................................................................. 131

Appendix A Converting Constants ............................................................... 137Fine Tuning Application ................................................................................................ 137Calculating Spreader Constants ................................................................................... 138

Warranty ............................................................................................................139

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SAFETY NOTICES / 1

SAFETY NOTICES

Safety notices are one of the primary ways to call attention to potential hazards. An absence of specific alerts does not mean that there are no safety risks involved.

This Safety Alert Symbol identifies important safety messages in this manual. When you see this symbol, carefully read the message that follows. Be alert to the possibility of personal injury or death.

Use of the word WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

Use of the word CAUTION with the Safety Alert Symbol indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.

Use of the word CAUTION without the safety alert symbol indicates a potentially hazardous situation which, if not avoided, may result in equipment damage.

DISCLAIMERDICKEY-john reserves the right to make engineering refinements or procedural changes that may not be reflected in this manual. Material included in this manual is for informational purposes and is subject to change without notice.

OPERATOR’S MANUAL


SAFETY NOTICES / 2

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INTRODUCTION / 3

INTRODUCTION

The DICKEY-john Flex4 system can simultaneously control both granular and liquid snow and ice removal materials. Separate channels for granular and liquid precisely controls and maintains the desired applications.

The flow of material varies automatically in proportion to the changes in ground speed so the application rate remains uniform. When Automatic mode is enabled, spreading automatically starts when the truck begins to move and automatically stops when the truck stops.

The operator interface consists of a:

• Console• Switch Module

Desired material application rates are entered on the Setup screens by attaching a keyboard.

Figure 1Flex4 Console and Remote Operator’s Switch Module

FEATURES• 7 inch color display• 4 channel closed-loop control of granular, liquid, auxiliary (liquid or

granular), and spinner functions• Summer mode feature for roadside spraying, burming, and operation

of hydraulic tools• Day/night mode• Optional camera to view rear of truck to monitor material dispensing

and to avoid potential accidents• Optional vehicle and fleet data management packages

REQUIREMENTSThe Flex4 system requires the following components for operation:

• Flex4 terminal• Operator’s remote switch module• Working set master module• Keyboard (programming only)

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4 / INTRODUCTION

• Application rate sensor on salt spreader and flow meter on prewet system

• Application rate ECU to drive hydraulic valve and electric pumps to regulate material application

• Valve control devices• Harnesses to connect system devices• Ground speed sensor (from speedometer)• GPS receiver (if vehicle tracking and data transfer is required)

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COMPONENT OVERVIEW / 5

COMPONENT OVERVIEW

Components included with the Flex4 system:

• Flex4 terminal• Flex4 terminal mounting bracket and hardware• Rate control module• Remote switch module• Remote switch module mounting bracket and hardware• Cab power harness• Rate control module harness

Optional components:

• 10’ CAN extension harness• Output module and harness• Solenoid driver• Electric motor/pump driver• Camera 4.3mm lens• Flex4 camera adapter• 20’ camera extension• Feedback sensors

NOTE: Contact DICKEY-john Technical Support to order optional components at 1-800-637-3302.

FLEX4 TERMINAL The Flex4 terminal is a 7” color display that provides simultaneous viewing of:

• Rates• Spread width• Vehicle speed• Spread direction• Road temperature• Joystick selection• Accessory input monitoring

Figure 2Flex4 Terminal

TerminalButtons

1-6

TerminalButtons7-12

Home button returns to Operate screen oradjusts Operate screen layout

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6 / COMPONENT OVERVIEW

TERMINAL BUTTONS• Twelve buttons are located on the left and right side of the terminal that

correspond with screen text to provide screen navigation and quick adjustment to system settings

• Home button returns to Operate screen from any screen• Home button adjusts Operate screen layout

TERMINAL CONNECTIONS1. Video camera connection2. Terminal harness connection3. USB RS232 port for data download and keyboard connection. The

USB port can be used for the following purposes:– Transmission of current operation information and logged data for

export to external hardware.– Accepts a USB memory device for exporting logged spread data for

transfer to a laptop computer.– Import of system firmware updates to display terminal and master

control module from USB memory device.– Imports system configuration files to program each display terminal

and master control module with system calibration values.4. Rotary button for scrolling through display menu items

Figure 3Flex4 Terminal Side and Back View

1 2

3

4

OPERATOR’S MANUAL



OPERATOR REMOTE SWITCH MODULEThe Operator’s Remote Switch Module consists of buttons that control material application rate and spread width knob to adjust spinner speed and regulate spreading of material. The module is backlit for visibility during night operation and is mounted next to the display, driver seat arm rest, or on side of the electronic joystick hydraulic controller.

Figure 4Operator Switch Module

SWITCH MODULE FUNCTIONSAUTO ON/OFFThe Auto On/Off button regulates the amount of material applied in relation to the ground speed and turns the application of product on or off.

PAUSEPause button stops applying material but continues to calculate the total miles driven. Auto mode must be active for the Pause feature to operate.

BLASTThe Blast button applies material at a pre-programmed dispersal rate in Auto mode and manual override with Auto Switch in ON or OFF position.

RATE (-)The Rate (-) button decreases the amount of pre-programmed material with each button press in Auto mode and manual override.

RATE (+)The Rate (+) button increases the amount of pre-programmed material with each button press in Auto mode and manual override.

SPREAD WIDTH KNOBSpread Width Knob adjusts the spinner speed to regulate material spread width. The spread width percentage displays on the console. Pressing the spread width knob also selects a channel to adjust.

SpreadWidthKnob

OPERATOR’S MANUAL



RATE CONTROL MODULEThe Rate Control Module houses the system’s primary interface device. All system parameters, constants, and memory are stored in the module and controls material application by interfacing with valves and feedback sensors.

1. Select an area on the vehicle chassis to mount the Rate Control Module that allows for easy hookup and access.

2. Use the enclosure as a template to mark the location of the mounting holes.

3. Drill four 9/32 inch diameter holes where marked.

Figure 5Rate Control Module

IMPORTANT: Do not use the enclosure as a guide when drilling. Do not overtighten nuts as this may damage the mounting tabs of the enclosure.

The module can be mounted in any of the following orientations:

Figure 6Acceptable Orientation

Do not install the module in any orientation other than shown in (Figure 6). The connection wires must not be mounted upward as moisture can collect inside the unit and damage the circuits.

6.80”

7.0”

7.45”

3.93”

PREFERRED ACCEPTABLE ACCEPTABLE

OPERATOR’S MANUAL



4. Mount with the label side of module facing out. Do not mount with the connector facing up (see Caution).

Connect any additional adapter harnesses to the module harness.

The Rate Control module harness can accept an extension harnesses or the output harness.

The Rate Control harness controls and provides connection to the following inputs:

– 1 granular control channel– 1 liquid control channel (prewet or anti-ice)– 1 auxiliary/spinner control channel (liquid or granular)– 1 auxiliary channel (liquid or granular channel)– 2 application rate sensors– 4 hydraulic valves (PWM)– 1 down pressure sensor– 1 control valve (Servo)– 2 flow meters– 1 gate height sensor– 1 ground speed sensor– 1 remote on/off– 2 digital sensors– 1 hopper level sensor– 1 tank level sensor– 2 6-pin Servo connectors– 1 road/air temperature sensor adapter (optional)

5. Install sensors, valves, etc. per the instructions included with the items.6. Install PWM valve assembly and feedback sensor for each control loop

and connect the devices to their respective inputs on the harness making certain to match PWM 1/Servo 1 with FB1, PWM2/Servo 2 with FB2, etc.

7. Secure any unused and excess cable lengths where necessary.

OPERATOR’S MANUAL



OUTPUT MODULEThe Output Module is an auxiliary to the Rate Control Module to drive additional accessories installed on the vehicle such as boom section shutoff valves, open and close V-Box gates, switching valves for front/rear conveyors, switching valves for left/right discharge cross conveyors, and accessory 12 volt switched output.

1. Select an area on the vehicle chassis to mount the module that allows for easy hookup and access. Extensions may be used to reach members installed on remote areas of the vehicle.

2. The module can be mounted in the same orientations as the rate control module as illustrated in (Figure 6).

Figure 7Output Module

Do not install the module in any orientation other than illustrated in (Figure 6). The connection wires must not be mounted upward as moisture can collect inside the unit and damage the circuits. Ensure that module connectors do not face upward.

3. Mount with the label side of the module facing out.4. To bolt the member to a frame:

– Use the enclosure as a template to mark the location of the mounting holes.

– Drill two 9/32 inch diameter holes where marked. – Attach to frame using 1/4 x 20 bolts or other fastening devices as

illustrated in Figure 8.

Do not use the enclosure as a guide when drilling. Do not overtighten nuts as this may damage the mounting tabs on the enclosure.

4.00

.2912 HOLES

4.63

4.68 1.37

0.630

2.365.24

OPERATOR’S MANUAL



Figure 8Securing Member with Bolts

5. To tie strap the module to a frame:– Use one long tie strap to loop around the member body and

through both mounting holes as illustrated in Figure 9. – If necessary, drill mounting holes following the procedure described

above. – Securely tighten tie strap. – Install a second tie strap toward the label end of the enclosure for

additional support.

1/4 x 20 BOLT

1/4 FLAT WASHER

1/4 SPLITLOCKWASHER

1/4 NUT

TRUCKFRAMEOR BEDSUPPORT

1/4 x 20THREADED "U"BOLT OROTHERFASTENINGDEVICE

1/4 FLAT WASHER

1/4 SPLIT LOCKWASHER

1/4 NUT

TRUCKFRAME ORBED SUPPORT

OPERATOR’S MANUAL



Figure 9Securing Member with Tie Straps

6. Connect an output module harness to the output module and connect the output module harness to the Power/CAN backbone, refer to (Figure 16).

7. Connect each module harness to its module inserting both connectors until the connector locking tabs engage.

8. Lay out the boom shutoff harness along the boom frame to each of the shutoff outputs.

9. Route wires in locations where they will not be damaged. 10. Secure the harness with tie straps.

NOTE: The last module harness in the system must have a CAN terminator installed for proper system operation.

IMPORTANT: Ensure the locking tabs engage when inserting the connectors. The connection is sealed only when the locking tabs have fully engaged.

MISCELLANEOUS COMPONENTS

KEYBOARDA keyboard is required to program and calibrate the system. The keyboard has been environmentally hardened for use in the ice control field. After programming and calibration, the keyboard is disconnected and stored.

GROUND SPEED SENSORThe ground speed sensor generates vehicle speed information for the console. Sensor electrical pulses proportional to the vehicle ground speed are vital to system operation because true vehicle ground speed is necessary for accurate product application. The system can function with a variety of electronic and mechanical speedometer sensors, such as hall effect and reluctance sensors.

ROAD TEMPERATURE ADAPTER (OPTIONAL)Temperature sensors allow for direct readout of road temperature and ambient air temperature.

TRUCKFRAMEORBEDSUPPORT

OPERATOR’S MANUAL



FEEDBACK/APPLICATION RATE SENSOR (OPTIONAL)Feedback sensors send product flow information to the console for accurate product application. Both granular and spinner channels require pulsed electrical sensors having an output proportional to the mechanism speed. The liquid channel accepts either electrical-pulsed sensors or analog sensors with outputs proportional to material flow (pulsed). A liquid prewetting system only accepts pulsed feedback while higher capactiy anti-icing systems accept either pulsed or analog.

GATE HEIGHT SENSORS (OPTIONAL)Measures gate height setting in inches and automatically adjusts conveyor speed to compensate for gate height changes and maintain application rate.

HYDRAULIC PRESSURE SENSORS (OPTIONAL)Hydraulic pressure sensors measure the amount of down pressure applied on the underbody scraper.

FLOW METERSFlow meter measures the flow rate of material being applied.

VALVE CONTROL OUTPUTFlex4 rate controllers control PWM hydraulic and Servo valve electric motors that regulate material flow for accurate control of product application rates. Granular and spinner channels regulate the hydraulic oil flow rate to a motor. Liquid channels use various different configurations such as servo ball valves and electric pumps.

HARNESSESHarnesses are included that are required for communication between the console and components. Optional extension harnesses are available for the Rate Control Module harness and output module harness when mounted in areas where additional harnessing is required. Electric motor driver harness is also available.

HOPPER LEVEL SENSOR (OPTIONAL)A hopper level sensor can be used to trigger an alarm when material falls below the sensor mounting level.

GPS RECEIVER (OPTIONAL)A GPS receiver for vehicle tracking.

VIDEO CAMERA (OPTIONAL)A video camera installed on the rear of truck allows viewing of material dispensing and aids in backing the vehicle.

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INSTALLATION / 15

INSTALLATION

The Switch Module can be mounted next to the terminal with provided hardware or to the armrest using an optional remote switch module mount bracket.

The standard hardware kit includes the following components:

• Ram Mount Kit (attaches terminal to vehicle dash)• Switch Module Mount (attaches switch module to terminal)

Optional remote switch module mounting hardware can be ordered separate that mounts the switch module to the armrest.

SWITCH MODULE MOUNTThe switch module mounting bracket attaches the remote switch module to the terminal and includes the following components:

• Main switch module mounting bracket• Bracket shroud• 3 Hex nuts• 4 washers

SWITCH MODULE BRACKET ASSEMBLYAttach Shroud and Module to Bracket:

1. Align shroud to the bracket (4) stud bolts. 2. Secure shroud to bracket with (4) washers.3. Align switch module so the connectors insert through the module

bracket connector opening and the (3) switch module stud bolts insert through the bolt holes of the bracket assembly.

4. Secure switch module to the bracket using (3) hex nuts.

Figure 10Switch Module/Terminal Bracket

1

2

3

4 Shroud

Hex Nut (3)Washer (4)

Switch ModuleBracket

Switch ModuleStud bolts (3)

Connectoropening

BracketStud Bolts (4)

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16 / INSTALLATION

Attach Terminal to Switch Module Bracket:1. Loosen wing bolt of the RAM mount bracket and remove ball mount

attachment.2. Align the (4) holes on the switch module bracket to the terminal.3. Align RAM ball mount with switch module bracket holes.4. Secure terminal to bracket using (4) lock washers and (4) metric

screws (included with RAM mount bracket).5. Re-attach ball mount to RAM mount bracket and tighten wing bolt to

secure.

Figure 11Attach Terminal

RAM MOUNT BRACKET INSTALLATIONThe RAM mount bracket secures the terminal to the vehicle dashboard or other surface suitable for operator viewing using a RAM mount bracket.

• Ball mount at top and bottom of bracket allows for orientation in many different positions.

• Wing bolt in middle of bracket tightens and secures the terminal to the desired position.

The terminal mounting kit includes the following:

• 1 RAM mount bracket• 4 metric screws• 4 SAE screws• 4 hex nuts• 4 washers #10• 4 washers 1/4

RAM BallMount

Loosen wing bolt

Removeball mountattachment

RAM MountBracket

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INSTALLATION / 17

CAB TERMINAL BRACKET ASSEMBLY1. Secure bracket to truck cab using 4 SAE screws (included).2. Adjust terminal for ideal viewing by loosening/tightening the wing nut.

Figure 12Cab Terminal Mount

Position terminal so that operator view is not obstructed and does not interfere with tractor operation.

Secure Ram mountbracket (4) SAE Screws

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18 / INSTALLATION

REMOTE SWITCH MODULE BRACKET KITThe optional Remote Switch Module bracket kit allows mounting the switch module to the armrest. This kit is available separately and can be ordered by contacting the DICKEY-john Technical Support Group at 1-800-637-3302.

To install Bracket:1. Place the rubber washer between the bracket base opening and the

side bracket opening aligning with the 1/4-20 nut.2. Place bolt through the side bracket and washer to secure to the

bracket base.3. Remove (2) screws from the flat surface of the armrest.4. Align bracket base to the armrest holes and secure to the armrest with

the (2) screws.5. Attach switch module to bracket as illustrated in (Figure 10).

Figure 13Remote Switch Module Bracket Installation

RubberWasher

Securebolt

Remove armrestscrews, insertbracket, re-attachscrews

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INSTALLATION / 19

SYSTEM HARNESS CONNECTIONSThe Flex4 control system connects to the truck cab harness and is powered on and off when the ignition switch is powered on and off.

System harnessing connections include:

• Cab harness• Rate control module harness• Output module harness• Optional extension harness• Optional electric motor/pump driver harness• Optional Road Watch Adapter and Flex4 interface cable

Figure 14System Architecture with Electric Motor / Pump Driver and Optional Output Module Harness

Outputmodule466492101

Boom ShutoffValve

GPSReceiver(optional)

OptionalVideo Camera

CabHarness466495051

Battery

CANTerminator

Rate Control Module467985410S1

DownPressure

HydraulicValve

Flow Meter

Application Rate

ControlValve

Rate ControlModule Harness466495071

Flex4 Terminal467980507

Extension Harness466495060

Switch Module466495210

Electric Motor/Pump Driver466495430

connects to Rate Control Module harness

OutputModuleHarness466495081

RoadWatchAdapter

Wireless Module(future release)

Gate Height Sensor

Flex4Interface

Cable466495072

TemperatureSensor

GroundSpeed

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20 / INSTALLATION

Figure 15System Architecture with Electric Motor/Pump Driver Harness

GPSReceiver(optional)

Wireless Module(future release)

OptionalVideo Camera

CabHarness466495051

Battery

CANTerminator

Rate Control Module467985410S1

Gate Height Sensor

DownPressure

HydraulicValve

Flow Meter

Application Rate

ControlValve

Rate ControlModule Harness466495071

Flex4 Terminal467980507

Extension Harness466495060

Switch Module466495210

Electric Motor/Pump Driver466495430

Connects to Rate Control Module Harness

RoadWatchAdapter

Flex4 InterfaceCable 466495072

TemperatureSensor

Ground Speed

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INSTALLATION / 21

CAB HARNESS

NOTE: The ignition lead must be connected to switched +12VDC for the system to power up and down properly.

1. Connect the power leads directly to the battery. 2. Connect the ignition wire to a switched +12VDC. 3. Connect the chassis ground lead to a bare point of the cab frame that

offers a good chassis ground connection. 4. Connect the CAN terminator, wireless module, switch module,

RoadWatch, and GPS, to their respective connectors on the cab harness.

Figure 16Cab Harness

RATE CONTROL MODULE HARNESS1. Connect the Rate Control Module harness to the mating connector of

the cab harness (use an extension harness if additional length is needed).

2. Secure harness as needed.3. Connect the module harness to the mating connectors of the CAN/

power backbone, if used. The Rate Control Module uses a 30 and 18-way connector with a jackscrew to secure the connector to the module. The output module uses a pair of 12-pin connectors.

4. Secure module harness as needed.

Ignition

Battery

GPSReceiver

WirelessModule(futurerelease)

SwitchModule

CANTerminator

ToTerminal

To Extension Harnessor Rate Control Module Harness

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22 / INSTALLATION

Figure 17Rate Control Module Harness

Digital 1 SensorDigital 2 Sensor

Hopper Level Sensor

Remote Blast

Ch2 Pressure/Bed Height (Analog 1)

Down Pressure Sensor (Analog 4)Gate Height Sensor (Analog 3)

Tank Level Sensor (Analog 2)

Boom Section

Servo 2Auxiliary

Servo 1Liquid

JoystickScraper

Remote On/Off

Ground SpeedCH3 Granular Feedback

CH2 Auxiliary Feedback

CH1 Liquid Feedback

PWM Ch 4 Aux S/SpinnerPWM Ch 3 Granular

PWM Ch 2 AuxiliaryPWM Ch 1 Liquid

CH4 Spinner Feedback

Terminator

Rate ControlModule

Electric PumpDriver Harness, Extension Harness,or Output ModuleHarness

Cab or ExtensionHarness

Flex4 Interface cable attaches to any of the

analog 1-4 connectors. RoadWatch Temperature

Sensor Adapter connects to the Flex4 Interface cable.

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INSTALLATION / 23

ROADWATCH TEMPERATURE ADAPTER AND FLEX4 INTERFACE CABLEThe Flex4 Interface cable connects to any of the Rate Control Module Harness analog 1-4 connectors. The RoadWatch Temperature Adapter connects to the Flex4 Interface cable.

The analog position must then be identified at the (F9) Accessory Sensor screen to identify what function is connected to the analog 1, 2, 3, or 4 connector.

Figure 18RoadWatch Temperature Adapter and Flex4 Interface Cable

EXTENSION HARNESSExtension harness (10 ft) is optional and used when extra length is required to connect with the Rate Control Module harness and the Output Module harness.

Figure 19Extension Harness

RoadWatchAdapter

TemperatureSensor

Connectsto Rate ControlModuleHarnessvia Analog 1,2, 3, or 4connectors

Flex4 Interface Cable

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24 / INSTALLATION

OUTPUT MODULE HARNESSOptional output harness controls boom section shutoff.

1. Connect the output harness to the mating connector of the Rate Control Module harness.

2. Use extension harness, if required.3. Connect output module and boom shutoff modules to the mating

connectors of the CAN/Power backbone.4. Connect electric motor/pump driver harness, if used.

Figure 20Output Module Harness

ELECTRIC MOTOR DRIVER HARNESSDrives electric pumps or motors that draw high current (greater than 2 amps).

Figure 21Electric Motor Driver Harness

Reverse Auger

Conveyor Left

Conveyor Right

+12V Switch Out

Gate HeightOutput 6

Output 1

Output 2

Output 3

Output 4

Output 5

Boom ShutoffValves

Rate ControlModule Harnessor ExtensionHarness

Electric MotorPump DriverHarness

Output Module

To PWM channel(liquid or auxiliary)

Rate ControlModule Harness,

Extension Harness,d l

To electric pump

OPERATOR’S MANUAL


OPERATE SCREEN / 25

OPERATE SCREEN

The Operate screen has five main structured areas to display button selections and operation functions that include:

1. Control channel application rate windows displays up to 4 channels when assigned as materials (non spinner)

2. Display function buttons on left and right side of display3. Main operator window displaying alarms, temperature readings,

spread width status bar, and optional video 4. Accessory/alarm status windows5. Ground speed, time, and date information

NOTE: Large font on the Operate screen indicates the control is active. Small font indicates the control is not active.

Figure 22Operate Screen Layout

(1) CONTROL CHANNELSFour control channels monitor granular and liquid applications and also controls spinner speed.

Control channel windows display target application rates (APR) when the vehicle is stationary and the actual application rate when spreading material for granular and liquid materials.

– Application of granular material (pounds/kilogram) per mile (km) or area based (pounds per sq ft/grams per sq/meter) (lbs/acre)

– Application of liquid material gallon (liters) per ton based on the granular applications rate or gallons (liters) per mile (km) and gallons (liters) per sq yard (meter) (gal/acre)

An auxiliary channel window allows selection of another granular or liquid channel with the same units available as channel one and two.

Target rates of product control channels can be changed by pressing the respective Rate Increase/Decrease button on the switch module. An audible beep indicates a rate adjustment change.

1

2 2

4

3

5

OPERATOR’S MANUAL


26 / OPERATE SCREEN

Channels are turned on and off by pressing the respective CH ON or CH OFF function buttons. The channel window reads “OFF” when the channel is selected to be off and returns to the rate when turned on again. Channel must be selected using spread width knob.

(2) DISPLAY FUNCTION BUTTONSTwelve buttons are located on the left and right side of the terminal that correspond with screen text to provide screen navigation and quick adjustment to system settings.

NOTE: Interchange Spread Width Bar window with the Channel (Rate) window by pressing the terminal Home button.

(3) SPREAD WIDTH BARSpread width bar indicates spinner operation and spread width in percent. Value is adjusted using the spread width knob on the switch module. Rotating the spread width knob on the switch module changes the rotational speed of the spinner and indicates the percentage on the spread width bar display. The bar is at the 100% position when the knob is clockwise corresponding to maximum spinner speed. Pressing the spinner left and right arrows positioned on the sides of the spread width bar indicates the selected spinner to be changed. Both can be adjusted simultaneously.

(3) ROAD/AIR TEMPERATURE SENSORSWhen enabled, the current road/air temperature displays on the Operate screen with current readings and triggers an audible alarm when outside of defined parameters.

(3) BOOM SECTIONSBoom nozzle graphics appear on screen, when enabled, to indicate boom section on/off status.

(3) CONVEYORWhen enabled, a left/right conveyor symbol and a front/rear conveyor symbol provides current position and can be changed by pressing the respective buttons.

(3) ALARMSAlarm text appears in this window when user-defined parameters are outside of limits set.

(4) ACCESSORY SENSORS/ALARMS• Digital and analog accessory sensors enabled will display sensor

status in the lower display window. • Accessory alarms will display in this area with a one beep audible

alarm. The sensor status remains in red until issue is resolved.

(5) GROUND SPEED/TIME/DATE• Ground speed is independent of product application and displays

actual ground speed in the lower display window. A manual ground speed setting also appears in this location, when enabled.

OPERATOR’S MANUAL


OPERATE SCREEN / 27

• Current time and date displays below the ground speed window.

DISPLAY SETTINGS (CAMERA/DISPLAY/ALARMS)Display settings adjust the characteristics of appearance and volume of the terminal:

• Camera settings (appearance of the camera window display on the terminal)

• Display brightness (lightness/darkness of screen)• Alarm volume (high/low adjustment of audible alarm when error

occurs)

To change a Display Setting:1. At the Operate screen, press the Display Settings button. 2. To modify a display setting, press the Camera, Display Brightness, or

Alarm Volume button. 3. Press the Increase button or Decrease button to adjust the bar graph.

Each time the button is pressed the setting changes and is visible on the screen with a percent adjustment.

NOTE: Pressing the Back button returns to previous menu.

Camera settings, display brightness, and alarm volume values are adjusted in bar graph form.

– The Camera Settings bar graph indicates the appearance of the camera window on the display allowing adjustment to brightness, contrast, saturation, hue, and rotation.

– The Display Brightness bar graph indicates the brightness level of the display. A full bar graph indicates the most brightness. The brightness changes each time the Increase/Decrease buttons are pressed.

– The Alarm Volume bar graph indicates the volume level for the audible alarm. An empty bar graph indicates the lowest volume; a full bar graph indicates the highest volume. The volume level will sound each time the increase/decrease arrows are pressed.

OPERATOR’S MANUAL


28 / OPERATE SCREEN

Figure 23Display Settings Screen

DAY AND NIGHT MODEDay and Night mode adjusts the terminal screen colors for better visibility to sunlight or while operating at night. The default screen setting is night mode.

To change Day/Night Mode:1. Press the Day Mode On button (item 3) to change to the Day Mode

setting. Press again to return to the night mode setting.

Figure 24Day and Night Mode Screens

1

2

3

4

5

6

7

8

9

10

11

Camera Window

Current Display Settings

A

A

B

C

B

C

A B CAdjustment

Buttons

Day/NightMode

Adjustment50%

Day Mode Night Mode

OPERATOR’S MANUAL


OPERATION / 29

OPERATION

The Flex4 system powers on when the ignition switch is turned on. A DICKEY-john startup screen and Flex4 screen displays for up to 60 seconds before the Operate screen appears and the system is operational.

The console automatically closes all system actuators and performs self tests including system configuration and application data during startup. If an error occurs at power up or during operation, an error message displays with recovery information.

IMPORTANT: The system should be programmed and calibrated before spreading material.

Figure 25Powerup Screens

PRE-OPERATING CHECKLISTThe following procedures must be performed for effective operation:

• Perform System Response procedure for all granular, liquid, and auxiliary channels

• Calibration of ground speed sensor• Material application rates entered for each product to be applied

NOTE: Channel and spread width windows can be interchanged on the Operate screen by pressing the Home button located on the lower right side of the terminal.

SPREADING MATERIALTo begin Spreading Material:

1. Press the Auto On/Off button to engage Automatic mode. AUTO appears on the display when the system is stationary.

2. As the vehicle starts moving, AUTO is replaced with the material application rate relative to the ground speed. When the vehicle stops, material application will stop.

OPERATOR’S MANUAL


30 / OPERATION

To increase/decrease a rate:1. Select the channel/material to change by pushing in the Spread Width

knob on the switch module The selected channel is highlighted in yellow.

2. With the selected channel highlighted, press either the Rate (-) or Rate (+) until the desired rate displays.

NOTE: System setup is only accessible when the system is stationary with no ground speed.

Figure 26Operate Screen

NOTE: Application rate appears in small font when the control is not active. Rate appears in a larger font when the control is active.

BLASTThe Blast function is operable for both stationary and moving vehicle conditions to increase the amount of material spread by a predefined rate. Blast can be used in Auto mode, manual control channel override, and manual ground speed.

To activate Blast:1. Press the Blast button. An alarm sounds indicating Blast is activated

and Blast appears on the display. A Blast rate automatically shuts off if a time interval has been defined at the Blast Setup screen.

If a predefined time interval has not been set, Blast is turned off manually by pressing the Blast button.

Auto enabledwith 0ground speed

Applicationof materialrelative toground speed

DRIVERLOGIN

DRIVERDRIVERLOGIN

SPINNER

ANTI-ICE

SPINNER

ANTI-ICE

OPERATOR’S MANUAL


OPERATION / 31

Figure 27Blast Feature Enabled

PAUSEThe Pause feature stops applying material while operating in Auto mode but continues to calculate miles driven. Pause can be used in Auto mode, manual control channel override, and manual ground speed.

To activate Pause:1. To enable, press the Pause button. An alarm sounds indicating Pause

is activated and Pause will appear on the display. 2. To disable, press the Pause button again. An alarm sounds indicating

Pause is disabled and will disappear on the display.

Figure 28Pause Feature Enabled

BLAST BLAST

SPINNER

ANTI-ICE

DRIVERLOGIN

CH

ROUTESELECT

DRIVERDRIVERLOGIN

CH

ROUTESELECT

SPINNER

ANTI-ICE

OPERATOR’S MANUAL


32 / OPERATION

MATERIAL SELECTIONOne granular, one liquid, and two auxiliary (liquid or granular) materials can display simultaneously on the console display.

To Change a Material:1. With the vehicle stopped and ground speed at 0, press the Material

Select button.2. At the Material Selection screen, press either the Granular or the

Liquid button.3. Press the Select Arrow button to choose the desired material.

Selected material displays in yellow. 4. When selected, press the Back button to return to the Operate screen.

Figure 29Material Selection

GRANULAR LIQUID

AUX

DRIVERLOGIN

USERHELP

CH

ROUTE SELECT

CH

SPINNER

ANTI-ICE

AUX S

OPERATOR’S MANUAL


OPERATION / 33

TURN OFF AN ACTIVE CHANNELA channel can be turned off while in Auto mode.

1. Push in the spreader width knob on the switch module to highlight the desired channel/material. To select the liquid channel, an additional press is required.

2. Press the CH OFF button. If a granular channel is turned off, any active material spreading in gallons/ton will also turn off simultaneously. A liquid channel can be independently turned off and the granular channel will stay active.

3. Press the CH ON button to re-activate the channel.

Figure 30Turning a Channel Off

UNLOAD MATERIALThe Unload feature quickly removes remaining material from the vehicle. Vehicle must be stationary for operation to begin.

To Unload Material:1. Position vehicle to appropriate location with ground speed at 0.2. At the Operate screen, press the Unload button.3. At the Material Select screen, choose materials by pressing the

corresponding button. Selected materials for removal will display at center of screen, i.e. “Salt Selected”.

4. Press the Start button to begin unload.5. Press the Stop button when unload is complete.

Liquid channel

DRIVERLOGIN

DRIVERLOGIN

SPINNER

ANTI-ICE

ROUTESELECT

SPINNER

ANTI-ICE

ROUTESELECT

CH ON

CH OFF

OPERATOR’S MANUAL


34 / OPERATION

Figure 31Unloading a Material

Ensure the area is clear prior to unloading to avoid possible injury.

START

STOP

X

X

OPERATOR’S MANUAL


OPERATION / 35

MANUAL GROUND SPEED OVERRIDEManual ground speed override is a manual override feature used when the ground speed sensor has failed. A manual speed can be entered in setup mode forcing the system to operate in manual speed mode and to spread material at the specified rate.

To operate in Manual Override:1. At the Operate screen, press the Material Select button.2. At the Material Select screen, press the Manual Speed button.

Continue pressing the Manual Speed button until Enable Manual Speed is highlighted.

3. Press the Select Arrow buttons to increase/decrease manual speed.

Figure 32Manual Override

4. Press the Back button to return to the Operate screen. Manual Speed is now enabled and displays on the Operate screen.

When operating in manual mode, the system is turned on and off using the Auto On/Off button.

IMPORTANT: The Pause button is functional in manual mode however miles driven during Pause mode will not be added to total miles driven while operating with manual ground speed enabled.

O.OO.O

Increase/decreasemanualspeed

CH

ROUTESELECT

DRIVERLOGIN

ANTI-ICE

SPINNER

OPERATOR’S MANUAL


36 / OPERATION

NOTE: If manual mode is not accessible, manual speed access has been set to off in the program mode.

Figure 33Operate Screen with Manual Mode Enabled

AUTOMATIC MANUAL CONTROL CHANNEL OVERRIDEWhen an application rate sensor or flow meter failure occurs, the system reverts to automatic manual override and continues to operate the control channel in a manual override state. Manual override allows material to be spread at the same programmed rate without interruption. When a failure occurs, the rate decreases to “0” and “Manual” replaces the material name. Rate returns from “0” back to target rate while manual override is enabled.

NOTE: Accuracy of material application rates will be affected due to the loss of a rate feedback sensor.

Figure 34Manual Control Channel Override

ManualOverrideEnabled

DRIVERLOGIN

CH

ROUTESELECT

SPINNER

ANTI-ICE

MANUAL MANUAL

0.0 0.0

MANUAL MANUAL

550 13.0

SPINNER

ANTI-ICE

LOGINSPINNER

ANTI-ICE

CH

ROUTESELECT

SPINNER

ANTI-ICE

CH

ROUTESELECT

DRIVERLOGIN

OPERATOR’S MANUAL


OPERATION / 37

DRIVER LOGINThe Driver Login screen displays a list of up to 20 drivers created by an authorized user. The Driver Login screen automatically displays if a login is required when the system is powered on. The Operate screen displays after the passcode is entered.

NOTE: If it is important to log data by driver, verify that the Driver Login function is enabled at the (F12) Data Logging screen.

To Login:1. At the Driver Login screen, select the respective number for the driver

operating vehicle.2. Enter the passcode for the driver.

– Use the Back button to correct an incorrect passcode entry.3. Press the Enter button to accept the passcode and display the

Operate screen.

Figure 35Driver Login Screen

To Logout:1. At the Operate screen, press the Logout button. The driver is

automatically logged out and displays the Driver Login screen for the next driver.

NOTE: If the Route Selection button does not appear on the Operate screen, it has not been enabled at the (F12) Data Logging screen.

ROUTE SELECTIONThe Route Selection screen lists up to 20 routes created by an authorized user in setup mode. A route can be selected from the list and will appear on the Operate screen.

NOTE: Miles, hours, and spread totals are logged by route and viewable at the Totals screen.

To Select a Route:1. At the Operate screen, press the Route Select button to display the

Route Select screen.2. Select the desired route by pressing the respective Route (1-20)

button. The only routes that appear are those created at the Data Logging screen. Once the route is selected, the screen automatically returns to the Operate screen with route name listed.

3. To remove the route from the Operate screen, return to the Route Select screen and press the No Route button.

OPERATOR’S MANUAL


38 / OPERATION

Figure 36Route Selection Screen

BOOM SECTION CONTROLBoom section control buttons appear on the Operate screen when ground speed is greater than zero. Button state indicates action to occur when pressed.

To enable Boom Section Control:• Press the Section ON button(s) to turn on. When a section is turned

on, the button changes to a Section OFF button.• Each section can be turned on and off independently. • Spray nozzle graphics indicate active state. Any nozzle that is active

displays in green and a nozzle that is inactive displays in red.

NOTE: Refer to page 62 to enable boom section control feature.

Figure 37Boom Section Control

Button indicatesaction to occurwhen pressed

OPERATOR’S MANUAL


OPERATION / 39

ANTI-ICE FEATUREAn Anti-Ice button appears on the Operate screen when a channel is enabled for anti-ice material. Activating the anti-ice feature automatically turns granular and liquid channels off to spread anti-ice material. Deactivating anti-ice stops spreading anti-ice material and automatically turns the granular and liquid channels on again.

To activate Anti-Ice:1. At the Operate screen, press the Anti-Ice On button. 2. Press the Anti-Ice Off button to deactivate.

IMPORTANT: To enable the Anti-Ice Button mode at the Operate screen, refer to “System Programming-Anti-Ice Button Mode Feature” section for proper setup.

Figure 38Anti-Ice On/Off Feature

ACCESSORY SENSORSA dedicated accessory window at screen bottom of the Operate screen displays the enabled accessory sensors. When operating within normal ranges, the sensor status appears in green text. When the pre-defined limits exceed the normal ranges, an audible alarm beeps with an alarm message and the sensor status flashes in red. Operation can continue when a sensor is in an alarm state and the sensor status remains in red until normal ranges are met.

OUTPUT MODULE ACCESSORIESAn accessory connected to an output module and enabled at the (F11) Output Module screen can be monitored and controlled at the Operate screen.

Front/Rear Conveyor• The Front/Rear Conveyor button toggles between front and rear

operation. A graphic indicates the current active state.

Granular and Liquidchannels are ON Anti-Ice

OFF

Granular and Liquidchannels are OFF Anti-Ice

ON

OPERATOR’S MANUAL


40 / OPERATION

Figure 39Front/Rear Conveyor Button and Graphics

Gate Increase/Decrease• If gate height is increased, the conveyor speed decreases.• If gate height is decreased, the conveyor speed increases.

Figure 40Gate Increase/Decrease Buttons

Left/Right Spinner• Left/Right Spinner button toggles between activating the left spinner,

right spinner, or both left and right spinner.

Figure 41Left/Right Spinner

REAR

LEFT RIGHT

OPERATOR’S MANUAL


OPERATION / 41

HYDRAULIC ACCESSORY TOOL OPERATIONTo control an accessory tool during operation, press the Rate Increase/Decrease buttons on the switch control module to increase and decrease the hydraulic flow. The PWM signal percentage sent to the hydraulic valve displays in the channel window.

Accessory tools shut off when:

– Ground speed reaches zero – or the Auto On/Off switch is turned off.

An increase in ground speed activates the tool to the previous PWM percentage.

The control channel is set to Manual without Feedback for this feature. Refer to Granular Configuration Setup (F2).

Figure 42Operate Screen with Manual Percentage Reading

CURRENT AND SEASON RUN TOTALSThe Totals screen provides accumulated material usage, miles, and hours driven using Auto mode, Blast, and Pause functions. Total operating data can be viewed in current run totals, season run totals, or by route.

NOTE: Totals by driver are viewable only by exporting the data file to a report software tool program.

Run totals are logged and recorded in the following ways:

• Total Miles (km), tons (metric/English), and gallons (liters) spread while in automatic control mode for each control channel and product spread.

• Miles (km), tons (metric/English), and gallons (liters) spread while in Blast mode for each product spread.

• Total vehicle miles (km) driven• Liquid gallons (liters) sprayed during prewetting and anti-icing

application• Total time spent spreading granular, spraying liquid, and blasting• Miles (km), tons (metric/English), and gallons (liters) spread while in

Pause mode• Trip Log indicates total miles driven in Operate mode

ControlChannelSalt set forManual w/oFeedback

OPERATOR’S MANUAL


42 / OPERATION

To view Totals:At the Operate screen, press the Totals button.

1. Current, Season, and Route button toggles between Current, Season, and Route run total screens.

2. Material Type Select button toggles between granular and liquid materials.

3. Material Select button scrolls through and displays totals for each material.

4. To reset totals, press the Reset Current Material button.5. Reset Trip Log button clears accumulated miles to zero.6. Route Select button toggles and displays totals for each route.7. Back button returns to previous screen.

IMPORTANT: Season totals are cleared at the F12 Data Logging/Operational Totals screen. Current and Route totals are clearable at this screen, if the capability is enabled at F12 Operational Totals.

Figure 43Total Screen

1

2

3

4

5

6

7

OPERATOR’S MANUAL


FLEX4 PROGRAMMING / 43

FLEX4 PROGRAMMING

A keyboard is required to program and calibrate the system. The keyboard is removed after programming is complete. System will not allow entry of setup menus, calibration, or configuration without a keyboard attached.

Function keys (F1 through F12) located at the top of the keyboard are used to display 12 menu screens that define desired system settings. Configuration parameters can be changed on menu screens by using the up and down arrow keys on the keyboard.

Access to menus using keyboard function keys include:• F1 Operate screen• F2 Granular Channel Setup• F3 Liquid Channel Setup• F4 Auxiliary S Granular/Liquid/Spinner Channel Setup• F5 Auxiliary Granular/Liquid Channel Setup• F6 Calibration• F7 Diagnostics• F8 Ground Speed Setup• F9 Accessory Sensor Setup• F10 System Setup• F11 Output Module Setup• F12 Data Logging

PASSCODE RESTRICTIONSTwo types of passcodes are optional and can be enabled to require a driver/supervisor to--

• Login with a passcode before driver operation is allowed• Login to gain access and change configuration setup values with a

keyboard

The system passcode settings are shipped as disabled. Passcodes can be enabled at the (F10) System screen (Driver Login Setup).

Once passcode settings are enabled, the codes will be required before a driver begins operation or configuration setup screens are accessed. Passcodes can be any combination of numbers up to 10 digits.

OPERATOR’S MANUAL


44 / FLEX4 PROGRAMMING

USING THE KEYBOARDProgramming is performed when the truck is stationary and the system is off.

1. Attach keyboard to terminal at the USB connection on the side of the terminal.

Figure 44USB Port

KEYBOARD FUNCTIONS(1) Function labels identify each function button

(2) Function button displays menus for respective functions

(3) Number buttons are used to select parameters from menu list and to insert values

(4) Alpha buttons are used to create text labels and to make selections

(5) Enter button accepts an entry and opens a window for text fields if more than one selection is available for a parameter

(6) Escape button returns to the previous menu

NOTE: A value on the screen is changed by using the up/down arrow keys on the keyboard to highlight a function box.

Figure 45Keyboard Layout and Functions

USBport

P

Esc F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 F11 F12 NumLock

PrtScSysRc

ScrollLock

PauseBreak

1!

2 3 4 5 6 7 7 8 8 9 9 0

@ # $ % ^ & *

*

( ) _ + BackSpace Home- =

Q W E R T Y U I O { } |4 5 6 _ [ ] \

A S D F G H J K L : "Enter

EnterCapsLock 1 2 3 +

PgDn

ShiftZ X C V B N M < > ?

Shift, . / /0End

Alt Ins DelFn Ctrl Alt ~`

OPERATE GRANULAR LIQUID AUXAUX S CAL. DIAG. GROUNDSPEED

ACC.SENSORS

OUTPUTMODULESYSTEM DATA

LOGGING

TM

1

23

4 5

6

OPERATOR’S MANUAL



TEXT ENTRIES1. Press Enter to open a text window on the screen to display all possible

selections.2. Use the Up/Down Arrow buttons to highlight and select the desired

parameter.3. Press Enter to accept.

Figure 46Open a Text Window

Press ‘Enter’to opentextwindow

OPERATOR’S MANUAL



LABEL ENTRIES1. To create label names, such as a Material Name, highlight the field and

begin typing the name. A virtual keyboard displays onscreen and the name as entered appears at top of the virtual keyboard.

2. Press the Enter button to accept the label entry.

NOTE: The Enter button will not select a text field.

Figure 47Virtual Keyboard

MaterialLabel

Using the keyboardup/down arrowbuttons select andhighlight a parameter

OPERATOR’S MANUAL



NUMBER ENTRIES1. To enter a number value, highlight the field and begin typing numbers

from the keyboard. A virtual keypad display onscreen and the number, as entered, appears at top of the virtual keypad.

2. Press the Enter button to accept the label entry.

Figure 48Virtual Keypad

2500.0

NumberKeypad

OPERATOR’S MANUAL



OPERATOR’S MANUAL


SYSTEM PROGRAMMING / 49

SYSTEM PROGRAMMING

The Flex4 Ice Control system has configuration screens to enter user-defined rates, limits, and parameters for regulating system product application. A keyboard is required for programming.

Four channels are available for material and spinner control:

• (1) dedicated granular channel (F2)• (1) dedicated liquid channel (F3)• (1) auxiliary channel for granular/liquid or spinner control (F4)• (1) auxiliary channel for liquid or granular (F5)

Additional setup for proper system operation includes performing:

• System Calibration (F6)• Diagnostics (F7)• Ground Speed Setup (F8)• Accessory Sensor Setup (F9)• System Setup (F10)• Output Module Setup (F11)• Data Logging (F12)

IMPORTANT: System programming MUST be conducted before performing a system calibration. Accurate system calibration constants are determined through regular calibration routines. Known constants can be entered reducing the calibration procedures required. Calibration corrections can be performed anytime to fine-tune accuracy.

OPERATE MODE (F1)The Operate screen can be accessed at anytime during programming by pressing the F1 function key. No programming functions are available at this screen but can be used to verify active selections.

The Operate screen shows programmed values for spreading material and provides access to the following functions:

• Material Selection screen• Unloading Material screen• Virtual Terminal Display settings• Current Totals screen

Refer to the Operation section for detailed function descriptions.

ANTI-ICE BUTTON MODE FEATUREA special mode is available in those situations where toggling between turning on anti-ice and turning off liquid/granular happens simultaneously by pressing an Anti-Ice button on the Operate screen.To get the Anti-Ice button to appear on the Operate screen, the following channels must be set per the following steps.

OPERATOR’S MANUAL


50 / SYSTEM PROGRAMMING

To Enable the Anti-Ice Button on the Operate screen:1. Press the (F2) Granular button to verify the granular channel is

enabled.2. Press the (F3) Liquid button and set the channel to prewet.3. Press the (F5) Auxiliary button and set the channel to Anti-Ice.4. Press the (F1) Operate button, the Anti-Ice button displays onscreen.

Figure 49Activating the Anti-Ice Key

Granular and Liquidchannels are ON Anti-Ice

OFF

Granular and Liquidchannels are OFF Anti-Ice

ON

OPERATOR’S MANUAL



GRANULAR CHANNEL SETUP (F2)Granular channel setup screen defines the set of values of four material application rates, min/max limits, and blast rates as well as the configuration parameters for hydraulic valves and sensors.

Granular channel parameters include:

• Material Label• Units• Spreader Constant• Calibration Gate Height• Application Rate Method (Step or Rate)• Blast Rate

The channel’s current status displays as Enabled or Disabled.

To Change the Channel’s Status:1. Use the Up or Down arrow keys on the keyboard to select and

highlight the function box.2. Press the Enter key and select the desired function status as either

Enable or Disable.3. Press the Enter key to accept.4. To define material rates, press the respective item number (1 - 4) using

the keyboard to display the Granular Rates screen.5. Press the Enter key to open a menu selection box to display and

select the appropriate parameters.

NOTE: Calibration Gate Height only appears on this screen when enabled and configured at the Accessory Sensors (F9) screen.

Figure 50Granular Channel Setup

STEP METHOD RATE METHOD

OPERATOR’S MANUAL



GRANULAR RATE SETUP

MATERIAL LABELA user-defined material name entered (10 characters maximum) that identifies the material configured for a channel on the Operate screen.

UNITSUnit of measure for granular material are available in the following parameters:

– lbs (kilograms) per mile (km)– lb/mift (g/Km-m)– lbs per sq ft/grams per sq meter– lbs per sq yd/meter– lbs/kft2 (Kg/m2)– lbs per acre (Kg/Ha)

SPREADER CONSTANTRepresents the number of pulses generated by the application rate sensor per pound of material (P/LB or P/KG) discharged from the spreader. The spreader constant varies for each granular material, spreader vehicle, and gate height setting (if optional gate height sensor is installed and enabled).

If the spreader constant is known, the value can be manually entered via a keyboard with no granular calibration required. For unknown spreader constant values, a granular calibration should be performed.

CALIBRATION GATE HEIGHTCalibration Gate Height displays only if the gate height sensor is enabled at the Accessory Sensor screen (F9). If enabled, the calibration gate height value displayed is the setting of the gate height (inches) as a result of a performed spreader calibration.

IMPORTANT: The Gate Height must be enabled before a spreader calibration is performed. Refer to the Spreader Calibration procedure.

The original calibrated gate setting can be changed to provide a more accurate granular material application by adjusting the conveyor speed.

– An increased gate height decreases conveyor speed– A decreased gate height increases conveyor speed

If the sensor voltage is outside the range between the Closed and Open position values, the display states Gate Low or Gate High. If Gate Low displays, the signal from the sensor is exceeding the open voltage. In either case, an alarm activates. The Gate Height should be checked and set at the granular calibration it was ran for on that granular channel.

OPERATOR’S MANUAL



APPLICATION RATE METHOD Two methods are available to control the application of material:

• Step Method• Rate Method

Step MethodAllows rates to be changed by a fixed increment using the Rate Increase/Decrease buttons on the switch module.

NOTE: Rate changes only occur when the material is selected/highlighted on the Operate screen.

To select the Step Method:Maximum Rate establishes the maximum application rate in lbs/mile or g/Km-m that the control allows. Target Rate cannot be incremented to a value greater than this established Max Rate.

1. Highlight the Step method selection box and press the Enter key on the keyboard.

2. Select Yes and press the Enter key again. 3. Enter the desired target rate (lbs/mile) for material application to be

controlled by this channel.4. Enter a minimum application rate limit for this channel. Minimum rate

establishes the minimum application rate that the control allows. Target rate cannot be decremented to a value lower than this established Min Rate.

5. Enter a maximum application rate limit for this channel. Maximum rate establishes the maximum application rate that the control allows. Target rate cannot be incremented to a value greater than this established Max Rate.

6. Enter an Increase/Decrease Step value that sets the increase/decrease rate. The increment/decrement percent rate establishes the percentage of change of the entered target rate that is applied each time the Rate Increase/Decrease button is pressed.

NOTE: The maximum or minimum rates may not be reached if the % increase or decrease, based off the target rate, exceeds the maximum or minimum rate limits set.

7. Enter a desired blast rate that applies a higher-than-normal, spot application when the Blast button is pressed during operation.

Figure 51Step Method Screen

OPERATOR’S MANUAL



To select the Rate Method:Rate Method allows ten user-defined application rates to be entered. Rates can be adjusted during operation using the Rate Increase/Decrease buttons on the switch module.


2. Select No and press the Enter key again.3. Enter desired rates (Rates 1-10). If less than 10 rates are desired,

enter a zero (0) for each rate following the last programmed rate. The initial rate displayed during operation is Rate 1. Other rates are selected by pressing the Rate Increase/Decrease button on the switch module.


Figure 52Step Method Screen

BLAST RATEA Blast Rate (lbs per mile) defines a higher than normal spot-application rate that is applied when the Blast button is pressed. A time and speed to simulate the length of time and ground speed to apply material when the vehicle is stationary can be entered at the (F10) System Setup screen. When the Blast Speed is set to zero, blasting cannot be initiated when the vehicle is stopped.

OPERATOR’S MANUAL



GRANULAR CONFIGURATION (F2)Configuration parameters defined for each channel correlate with the types of hydraulic valves and sensors installed and related performance specifications. These values should not change unless system hardware is modified or related calibration routines are performed.

IMPORTANT: A calibration should be performed for each channel prior to operating to ensure accurate material application.

To enter Configuration Values:1. At the F2 Granular Setup screen, press 5 on the keyboard.2. At the Granular Configuration screen, highlight the control mode

selection box and press the Enter key to select Auto or Manual with Feedback.

3. Press the Enter key to confirm the selection.4. Use the keyboard arrow keys to scroll to each constant’s selection box.

Figure 53Granular Configuration Screen

CONTROL MODEMANUAL WITH FEEDBACKOverrides the current system when not operating properly. Using the Rate Increase/Decrease buttons during operation sets the RPM rate for the control channel. Actual RPM rate displays based on actual ground speed and spreader constants entered.

MANUAL WITHOUT FEEDBACKTypically used when operating with an accessory tool, such as a front sweeper, using a PWM signal to open and close the valve. The Increase/Decrease buttons are used to increase/decrease the hydraulic flow to the accessory tool and a PWM percentage on the Operate screen indicates the PWM signal sent to the hydraulic valve.

OPERATOR’S MANUAL



AUTOControl channel calculates application rates based on ground speed and signal feedback from the application rate sensor (closed loop control) under normal operating conditions.

DRIVE FREQUENCYDrive Frequency specifies the frequency for the proportional valve. The recommended setting is defined by the specific valve manufacturer.

PWM OFFSETPWM Offset identifies the minimum amount of PWM valve drive required to start the granular mechanism.

PWM SATURATIONPWM Saturation identifies the amount of drive the granular valve system requires to operate a PWM valve at full speed.

SYSTEM RESPONSEAdjusts the control system response time to the hydraulic and mechanical systems of the granular control channel on each particular spreader vehicle.

VALVE BOOSTIncreases the amount of system response initially applied to the granular control to reach final operating speed as quickly as possible.

AFILTFilters the feedback signal to minimize the effect of electrical noise and mechanical vibrations. The smaller the number, the greater degree of filtering.

MATERIALSelection of the four materials that are configurable for the channel.

SENSOR CONSTANTSensor Constant establishes the number of pulses for one revolution of the application rate sensor. If a standard DICKEY-john application rate sensor is used, the value should be set to 360.0.

SPREADER CONSTANTThe Spreader Constant displayed value is viewable only and indicates the current setting. This value automatically adjusts when a granular calibration is performed.

OPERATOR’S MANUAL



CALIBRATION GATE HEIGHTCalibration Gate Height only displays if enabled as an accessory sensor at the (F9) Accessory Sensor screen. This value is viewable only and indicates the current setting. The value automatically adjusts when a granular calibration is performed.

OPERATOR’S MANUAL



LIQUID CHANNEL SETUP (F3)Liquid channel setup allows configuration of up to four different liquid materials, entry of the material parameters, and to identify the performance specifications of the installed actuators and sensors. Each material can be set with different parameters.

The liquid channel can be set as either Prewet (gal/ton) (spraying with a pre-wet spray bar), Anti-ice (gal/mile) (used with anti-icing boom), or Liquid (gal/area).

Liquid channel parameters include:

• Material Label• Units• K Factor• Application Rate Method (Step or Rate)• Blast Rate

The channel’s current status is displayed as Enabled or Disabled.

To Change the Channel’s Status Function:1. Use the Up or Down Arrow keys on the keyboard to select and

highlight the Function box.2. Press the Enter key and select the desired function status as either

Prewet, Liquid, or Disable.3. Press the Enter key to accept.4. To setup material parameters for Materials 5-8, select items 1-4 using

the keyboard.

Figure 54Liquid Channel Setup Screen

Boom selectiononly displays

when a channelis set for liquid

or anti-iceapplication.

LIQ 1LIQ 2LIQ 3LIQ 4

OPERATOR’S MANUAL



LIQUID RATE SETUPEach material assigned to the liquid channel requires entry of material parameters.

Figure 55Liquid Application

ANTI-ICE RATES

gal/mileA-ICE 1

PREWET 1

gal/ton29981.75

gal/tongal/tongal/tongal/tongal/ton

5.000.500

25.50.500

50.0

PREWET 1

LIQ 1gal/ac

gal/acgal/acgal/acgal/acgal/ac

20.60.825

42.10.825

57.8

OPERATOR’S MANUAL



MATERIAL LABELA user-defined material name entered (10 characters maximum) that identifies the material configured for a channel on the Operate screen.

UNITSThe unit type selected displays material application rate as follows:

gal/mile - Gallons per mile

gal/mift - Foot traveled per mile

gal/ft2 - Square feet per gallon

gal/yd2 - Square yards per gallon

gal/kft2 - Thousand square feet

gal/ac - Gallons per acre

K FACTORK Factor represents the number of flow meter pulses generated by the sensor per gallon/liter of dispersed liquid for pre-wet and anti-icing liquids through the flow meter.

The K Factor number stamped on the flow meter body is sufficiently accurate for keyboard entry if the viscosity of the liquid is near that of water.

If the flow meter constant is unknown, the actual value will adjust to the correct constant during the liquid calibration.

APPLICATION RATE METHOD Two methods are available to control the application of material:

• STEP Method• Rate Method

STEP MethodSTEP Method allows rates to be changed by a fixed increment using the Rate Increase/Decrease buttons on the switch module. STEP method requires a Target Rate, Min/Max Rate, and Inc/Dec Step defined.

To select the STEP Method:Maximum Rate establishes the maximum application rate in gallons per mile (L/km) that the control will allow. Target Rate cannot be incremented to a value greater than this established Max Rate.


2. Select Yes and press the Enter key again. 3. Enter the desired target rate for material application to be controlled by

this channel.4. Enter a minimum application rate limit for this channel. 5. Enter a maximum application rate limit for this channel. 6. Enter an Increase/Decrease Step value that sets the increase/

decrease rate.

OPERATOR’S MANUAL



IMPORTANT: The maximum or minimum rates may not be reached if the % increase or decrease, based off the target rate, exceeds the maximum or minimum rate limits set.


Figure 56STEP Method Enabled

TARGET RATETarget rate establishes the desired amount of material to be applied in gallons/mile by a control channel.

MINIMUM/MAXIMUM RATEThe minimum and maximum rates establish the minimum and maximum application rates that the control will allow. Target rate cannot be decremented to a value lower than this established minimum and maximum rates.

INC/DEC STEPThe increment/decrement rate establishes the amount of change of the entered target rate that is applied each time the Rate Increase/Decrease button is pressed.

BLAST RATEBlast Rate defines a higher than normal, spot-application rate applied when the Blast button is pressed.

Rate Method:Rate Method allows ten user-defined application rates to be entered. Rates can be adjusted during operation using the Rate Increase/Decrease buttons on the switch module.

To select the Rate Method:1. Highlight the Step method selection box and press the Enter key on

the keyboard.2. Select No and press the Enter key again.

OPERATOR’S MANUAL



3. Enter desired rates (Rates 1-10). If less than 10 rates are desired, enter a zero (0) for each rate following the last programmed rate. The initial rate displayed during operation is Rate 1. Other rates are selected by pressing the Rate Increase/Decrease button on the switch module.


Figure 57Rate Method Enabled

BOOM CONFIGURATION (LIQUID/ANTI-ICE)Boom Configuration screen identifies how the unit is controlling or monitoring boom sections and assigns boom sections to a liquid or auxiliary channel. A total of 6 boom sections can be controlled by the system. A DICKEY-john output module must be installed to support boom control.

To assign Boom Sections:1. At the (F3) Liquid Menu screen, select 6 on the keyboard to display

the Boom Configuration screen.1. Select the function type as either Control or Sense.2. Select the active level output signal as either Ground or 12V.3. To change the default name for each boom label, press the respective

number (1-6) and type the new label name in the virtual keypad.4. Add the width of each boom section.5. Select the channel type that controls each boom label.

OPERATOR’S MANUAL



NOTE: Anti-ice and pre-wet channel types do not require a width entry and the width column will not appear in those instances.

Figure 58Boom Configuration Screen

FUNCTION

NOTE: Contact DICKEY-john Technical Support at 1-800-637-3302 to order a DICKEY-john output module.

ControlBoom sections are controlled by a DICKEY-john output module allowing sections to be turned on and off at the Operate screen with assigned section buttons.

SenseBoom sections are controlled by a separate switch box. Boom sections are only sensed by the unit and displays on or off status on the Operate screen.

ACTIVE LEVELActive level sets the output signal as either ground or 12V for a valve driver to control a boom shutoff delay.

OPERATOR’S MANUAL



AUXILIARY S (F4)The Auxiliary control channel has programming flexibility as a Liquid, Granular, Prewet, Anti-Ice channel or for spinner control.

Four materials are possible and assigned as materials 9-12.

Configuration and boom setup for an auxiliary channel must be enabled at this screen for the channel to be in an active state. Refer to the Granular Configuration (F2) and Liquid Configuration (F3) sections for parameter definition and setup instructions.

Refer to Assign ‘Auxiliary S’ as Spinner to configure channel for spinner control.

Press the Calibration (F6) key to initiate channel calibration.

Figure 59Aux S Screen

ASSIGN ‘AUXILIARY S’ AS SPINNERSpinner constants set the parameters and performance specifications for installed actuators and sensors. These values do not change unless the system hardware changes or the related calibration routines are re-run.

To enter Spinner Configuration Values:1. At the F4 Aux S screen, use the Up or Down Arrow keys on the

keyboard to select and highlight ”Spinner”.2. Press “1” to enter parameter values per below definition.

OPERATOR’S MANUAL



Figure 60Spinner Configuration Screen

SPINNER UNITSSpinner units set the spread width bar graph to display in percent, feet, or RPM. Pulse Feedback must be set to YES for the spinner units to be selected as RPM. If a spinner spread width calibration is required, spinner units must be selected as feet to perform the calibration.

UNLOADEnable the Unload feature by selecting Yes to activate the spinner during unloading. Select No to disable during the unload process.

DRIVE FREQUENCYDrive Frequency specifies the frequency for the installed proportional valve. The recommended setting for this option should be specified from the valve manufacturer.

NO GROUND SPEEDSelect Yes to allow the spinner to continue running when there is no ground speed. Select No for the spinner to stop running when there is no ground speed.

BLAST RATEA Blast Rate percentage greater than zero percent sets the maximum spinner speed when Blast is pressed regardless of any adjustment to the spread width knob. A Blast Rate percentage set at zero places no constraints on the maximum spinner speed when using the spread width knob.

OPERATOR’S MANUAL



PULSE FEEDBACKEnable Pulse Feedback by selecting YES for closed-loop control. Disable Pulse Feedback by selecting NO for open-loop control.

SPINNER CONSTANTSpinner Constant establishes the number of pulses for one revolution of the spinner. Spinner Constant appears only when Pulse Feedback is YES.

PWM OFFSETPWM Offset identifies the minimum amount of PWM valve drive required to start the liquid mechanism.

PWM SATURATIONPWM Saturation identifies the amount of drive the liquid valve system requires to operate a PWM valve at full speed.

SYSTEM RESPONSEAdjusts the control system response time to the hydraulic and mechanical systems of the liquid control channel on each particular spreader vehicle.

VALVE BOOSTIncreases the amount of system response initially applied to the liquid control to reach final operating speed as quickly as possible.

AFILTFilters the feedback signal to minimize the effect of electrical noise and mechanical vibrations. The smaller the number the greater degree of filtering.

GROUND SPEED RELATED (GSRS)Regulate the spinner speed related to ground speed and running closed loop. Enable by selecting Yes. Controlling the spinner according to ground speed allows the material to disperse at zero velocity. Displays only if Pulse Feedback is YES.

GSRS SLOPEWhen GSRS is enabled, GSRS Slope indicates the spinner revolutions per mph/kmh on the Operate screen. Displays only if Ground Speed Related is YES.

MAXIMUM GSRSWhen GSRS is enabled, Max GSRS determines the scaling of the spinner bar graph on the Operate screen. A full bar graph indicates that the maximum GSRS speed has been exceeded in mph/kph. No alarm is associated with this constant. Displays only if Ground Speed Related is YES.

OPERATOR’S MANUAL



AUXILIARY CONTROL CHANNEL CONFIGURATION (F5)The Auxiliary control channel has the flexibility to be programmed as a Liquid, Granular, Prewet, or Anti-Ice channel with the same parameter setup available as channels one and two.

Four materials are possible and assigned as materials 5-8.

Configuration and boom setup for an auxiliary channel must be enabled at this screen for the channel to be in an active state. Refer to the Granular Configuration (F2) and Liquid Configuration (F3) sections for parameter definition and setup instructions.

Press the Calibration (F6) key to initiate channel calibration.

Figure 61Auxiliary Control Channel Screen

OPERATOR’S MANUAL



ACCESSORY SENSORS (F9)Accessory sensor screen sets the parameters for installed sensors that can be monitored, when enabled, on the Operate screen. All accessory sensors are set to disabled and must be enabled and may require calibration.

Up to four analog sensors can be enabled at one time. Analog sensor types include:

• Gate height• Bed height• Road/Air temperature (requires the Flex4 interface cable and

RoadWatch temperature adapter that connects to any of the analog 1-4 positions on the rate control module harness.

• Tank level• Down pressure

Two digital accessory sensors can be enabled at one time.

In addition to configuring accessory sensors, an installed DICKEY-john joystick’s active position can be viewed on the Operate screen when enabled at this screen.

To enable Accessory Sensors:1. At the (F9) Accessory menu screen, highlight the Analog Acc Sensor

input box and press the Enter key to open the sensor drop down list.2. Select the sensor and press Enter.3. To open the Sensor Configuration screen of the selected sensor, press

the corresponding key (1 - 6) to select a menu item. Refer to (Figure 62).

IMPORTANT: The RoadWatch Sensor adapter must be connected to an additional adapter cable that connects to the Rate Control Module harness. The adapter cable must be connected to the connectors labeled as Analog 1, 2, 3 or 4 . The connection point for the road temperature and air temperature must be identified at the F9 Accessory Sensor screen.

Figure 62Accessory Sensors Screen

Press 1-7 on keyboardto enable and

configure respectivesensors.

OPERATOR’S MANUAL



GATE HEIGHT SENSORA gate height sensor compensates for changes from the original calibrated gate setting by adjusting the conveyor speed for a more accurate granular material application. If the gate height is increased, conveyor speed decreases and a decreased gate height increases the conveyor speed.

Gate Height status appears on the Operate screen as GATE 0.0 IN (cm).

Figure 63Gate Height Sensor

GATE HEIGHT CALIBRATIONGate height calibration captures the voltage range of seven gate height positions from the closed to open positions that are used when spreading material.

To perform a Gate Height Calibration:1. Select YES to enable gate height.2. Highlight the Closed Inches (cm) column.3. Set the gate to the closed position.4. Measure the height at the closed position and enter that amount in

inches (cm) in the Closed input field.5. Press “C” to capture the current gate height voltage at the closed

setting. The voltage automatically is calculated and entered at each position.

6. Repeat steps 3 through 5 for each position. The gate should be at the full open height to measure at the Open position.

If the sensor voltage is outside the range between the closed and open position values, the display will state Gate Low or Gate High and an alarm activates. The gate height should be checked and set at the granular calibration it was ran for on that granular channel.

If the gate height is enabled and calibrated, all of the desired granular materials that are enabled must be recalibrated through a material drop test. If enabled materials are not calibrated, the system will alarm.

PRESS C TO CAPTURE VOLTAGE

OPERATOR’S MANUAL



ROAD TEMPERATURE SENSORA road temperature sensor monitors road temperature changes. When enabled, an alarm on the Operate screen identifies when defined road temperature changes occur.

IMPORTANT: The RoadWatch Sensor adapter must be connected to the Flex4 Interface cable that connects to the Rate Control Module harness. The Interface cable must be connected to the connectors labeled as Analog 1, 2, 3 or 4. The connection point for the road temperature and air temperature must be identified at the F9 Accessory Sensor screen.

Road Temperature status appears on Operate screen as:

To enable Road Temperature Values:1. At the Road/Air Temperature Menu screen, select the corresponding

number.2. Select Yes at the Temperature Enabled input box.3. Enter the alarm temperature in degrees F to alert of road temperature

changes to indicate when application rate or material changes are required. Temperatures must be entered in descending order with Alarm Temp 1 the highest setting and Alarm Temp 3 the lowest setting.

4. Enter the temperature hysteresis that will clear the temperature alarm when a positive temperature change has occurred. If Alarm Temp 1 is 20 degrees F and the Temperature Hysteresis is set at 5 degrees F, the alarm activates when the temperature drops below 20 degrees F and clears when the temperature reaches 25 degrees F.

5. The High and Low Calibration values should not be changed and should be created from the calibration routine.

6. After values are entered, press C to begin the calibration procedure. Calibration lasts approximately 10-20 seconds.

7. Press “D” when done.

67F ROAD TEMPERATURE AIR 75F

OPERATOR’S MANUAL



Figure 64Road Temperature Sensor

IMPORTANT: The Road WatchTM temperature sensor or Surface PatrolTM temperature sensor must be disconnected and the Flex4 Interface cable and the DICKEY-john temperature sensor adapter connected to the main harness for successful calibration. If the interface cable and the DICKEY-john temperature sensor adapter is disconnected when the calibration is performed, an error screen displays.

NOTE: Road WatchTM is a registered trademark of Commercial Vehicle Group TM. Surface Patrol Technology is a registered trademark of Control Products Inc.

Figure 65Road Temperature Sensor Calibration

OPERATOR’S MANUAL



AIR TEMPERATURE SENSORAn air temperature sensor monitors air temperature changes. When enabled, an alarm on the Operate screen identifies when defined air temperature changes occur. Refer to Road Temperature section for display appearance on Operate screen.

To enable Air Temperature Sensor Values:1. Air temperature sensor input values and calibration procedures are

similar to road temperature sensors. Refer to Road Temperature Sensor section for entering values.

NOTE: The Road WatchTM temperature sensor or Surface PatrolTM temperature sensor must be disconnected and the DICKEY-john temperature sensor adapter connected to the main harness for successful calibration. If the DICKEY-john temperature sensor adapter is disconnected when calibration is performed, an error screen displays.

Figure 66Air Temperature Sensor Screens

IMPORTANT: The Road WatchTM sensor adapter must be connected to the Flex4 interface cable that connects to the rate control module harness. The interface cable must be connected to the rate control module connectors labeled as Analog 1, 2, 3 or 4. The connection point for the road temperature and air temperature must be identified at the F9 Accessory Sensor screen.

OPERATOR’S MANUAL



TANK LEVEL SENSOR CONFIGURATIONThe tank level sensor monitors the liquid level for pre-wet or anti-ice systems.

To enable the Tank Level Sensor:1. At the Tank Level Menu screen, select Yes at the Tank Level Enabled

input box.2. Tank level status can display in a bargraph format (Yes) or percentage

of approximate material remaining (No).3. Highlight the Empty Voltage input box. The tank must be empty before

performing the Empty Voltage calibration. 4. Press “C” to capture the empty voltage reading.5. Fill tank to appropriate level. Highlight the Full Voltage input box. The

tank must be full before performing the Full Voltage calibration.6. Press “C” to capture the full voltage reading.

IMPORTANT: It is recommended that voltages are automatically captured but manual entry of voltages can be entered.

7. Enter a tank level alarm percentage to warn when the tank level has reached the alarm limit. The value has a 5% hysteresis tolerance to prevent random alarming due to varying tank levels while driving.

EXAMPLE: If the tank alarm is set for 10%, the alarm activates when the level drops below 10% but will not clear until the level reaches 15%. If the tank alarm is set for 100 gallons on a 1000 gallon capacity, the alarm activates when the level drops below 100 gallons but does not clear until the level reaches 150 gallons.The alarm sounds for the first five seconds and text will flash until the condition is cleared or another alarm sounds.

Figure 67Tank Level Sensor

PRESS C TO CAPTURE VOLTAGE

OPERATOR’S MANUAL



DOWN PRESSUREA down pressure sensor monitors the relative pressure applied to the under body belly scraper.

Down Pressure status appears on the Operate screen as:

To enable the Down Pressure Sensor:1. At the Down Pressure Menu screen, select Yes at the Down Pressure

Enabled input box.2. Highlight the Minimum Pressure input box. 3. Elevate the scraper before performing the minimum pressure reading

calibration. 4. Press “C” to capture the minimum pressure reading.5. Highlight the maximum pressure input box. 6. Position the scraper downward until road contact occurs and the

desired normal road contact pressure is reached. This will set the 100% down pressure maximum value (next step).

7. Press “C” to capture the maximum voltage reading.

IMPORTANT: It is recommended that voltages are automatically captured through the calibration but manual entry of voltages can be entered.

8. Enter a down pressure alarm percentage to warn when the down pressure is within the specified percentage of reaching the maximum down pressure limit.

Figure 68Down Pressure

DWN PRES100%

OPERATOR’S MANUAL



BED HEIGHTA bed height sensor activates when the bed has exceeded the recommended operating height.

All mechanical linkages should be inspected and maintained on a regularly scheduled interval to ensure proper operation of the bed height alarm. Visual inspection of the bed height must be maintained as the primary indicator of safe bed height operation. The alarm should only be used as a secondary convenience indicator. The operator assumes all risk in using this feature. DICKEY-john assumes no responsibility for alarm failure to indicate an unsafe operating height.

Bed Height status appears on Operate screen as:

To enable a Bed Height Sensor:1. At the Bed Height Menu screen, select Yes at the Bed Height Enabled

input box.2. Highlight the Bed Down input box. The dump bed must be completely

down and the sensor installed before performing the calibration. 3. Press “C” to capture the bed down reading.4. Bed Alarm indicates the voltage when the bed has exceeded normal

operating height and can be entered manually or automatically. 5. Highlight the Bed Alarm input box. The dump bed must must be near

the maximum operating height and the sensor installed before automatic entry can occur. Press “C” to automatically capture sensor voltage. For manual entry, select the bed alarm text and enter the voltage when the bed exceeds the normal operating height.

Figure 69Bed Height Sensor Screen

BED 113%

OPERATOR’S MANUAL



DIGITAL ACCESSORIESTwo digital sensors can be installed to monitor critical operation parameters on the vehicle.

To enable a Digital Accessory Sensor:1. At the F9 Accessory screen, press 6 or 7 to open a Digital Accessory

screen.2. Select Yes at the Digital Acc Enabled input box.3. At the Sensor Type input box, select the appropriate sensor as digital,

frequency, or camera. Sensor type determines what parameters appear on the screen.

4. Select the Active Level power supply as either 12V or ground.5. Enter an appropriate active and inactive label that identifies the sensor

type and status on the Operate screen.6. Select the Alarm Mode as either Never, Auto, or Always.

Figure 70Digital Accessory Screens

SENSOR TYPEDIGITAL and FREQUENCY - Select the sensor type as digital or frequency.

CAMERA - Select camera to automatically view camera video on the display screen when it senses a 12V input. Typically used when the truck is placed in reverse and 12V is sensed; the camera automatically appears on the display.

ACTIVE LEVEL (Digital or Camera)Active level sets the sensor output signal as either Ground or 12V to sense the sensor as on or off.

OPERATOR’S MANUAL



ACTIVE LABELA user-defined name that identifies the sensor type or function that displays on the Operate screen providing sensor status, i.e. active label name (HOPPER FULL).

INACTIVE LABELA user-defined name that identifies the sensor type or function that displays on the Operate screen providing sensor status, i.e., inactive label name (HOPPER LOW).

ALARM MODE NEVER - Alarms are turned off and will not trigger an alarm condition during operation.

AUTO - Alarm occurs after the defined alarm delay only when the system is active and controlling.

ALWAYS - Alarm occurs after the defined alarm delay during operate mode and shutdown mode.

ALARM DELAYAmount of time delay in seconds that occurs before an alarm is triggered based on user-defined sensor parameters.

SYSTEM SHUTDOWNSelect Enabled to shutdown the system from operating anytime an alarm is triggered.

Figure 71Accessory Sensor Screen (Frequency)

LABEL (Frequency)A user-defined name that identifies sensor type and displays on the Operate screen providing sensor status (7 character maximum).

CONSTANT (Frequency)Constant establishes the number of pulses for one revolution of the application rate sensor.

OPERATOR’S MANUAL



OFFSET (Frequency)The Offset determines the units of which the constant is converting the frequency into.

ALARM MODENEVER - Alarms are turned off and will not trigger an alarm condition during operation.

AUTO - Alarm occurs after the defined alarm delay only when the system is active and controlling.

ALWAYS - Alarm occurs after the defined alarm delay during operate mode and shutdown mode.

HIGH/LOW ALARM LIMIT (Frequency)The High and Low Alarm limit values determine when an alarm is triggered to warn when a certain condition is met that is set by user-defined parameters.

ALARM DELAYAmount of time delay in seconds that occurs before an alarm is triggered based on user-defined sensor parameters.

HIGH/LOW SHUTDOWN (Frequency)The system shutdowns automatically when High and Low Shutdown is enabled and the alarm condition is met as defined in High and Low Alarm Limits. Both High and Low Shutdown functionality is independent of each other.

OPERATOR’S MANUAL



JOYSTICK LABELSWhen a DICKEY-john joystick is installed, joystick labels can be created to indicate functions that are enabled or active.

Joystick function appears on Operate screen as:

To create Joystick Control Names:1. At the (F9) Accessory menu screen, press 7 on the keyboard to display

the Joystick Labels screen.1. Select Yes at the Joystick Sense Enabled input box to indicate a

DICKEY-john joystick is installed.2. At each label input box, enter a user-defined name that correlates with

the joystick function.

Figure 72Joystick Labels Screen

SCRAPER

OPERATOR’S MANUAL



SYSTEM SETUP (F10)System setup defines the following parameters:

• Blast Setup• Date and Time• Units and Language• Service• Troubleshooting• GPS Sensor• Wireless Configuration (not currently functional)

To access the System Setup Screen:1. Press the F10 key to display the System menu screen.2. At the System Setup screen, press the respective item number to open

a menu item.

Figure 73System Setup Screen

BLAST SETUP1. Press 1 on the keyboard to select Blast Setup.

Figure 74Blast Setup Screen

OPERATOR’S MANUAL



BLAST TIMER Enter number of seconds for the length of the Blast cycle. When set to zero (0), the blast cycle lasts only as long as the Blast button is pressed.

BLAST SPEEDEstablishes an artificial vehicle ground speed when vehicle is at standstill or moving slowly to compute the rate material dispenses during a blast cycle.

– For speeds faster than this value, the actual vehicle ground speed determines the spread rate.

– If Blast speed is set to zero, the screen will show a BLAST but no material will fall.

DATE AND TIMEThe date and time of the unit is factory set to Central Standard Time. The time can be re-set to the appropriate time zone by entering in either 12 hour or 24 hour time.

To set Date and Time:1. At the F10 System menu screen, press the 2 key to display the Date

and Time screen.2. Select ‘Yes’ in the 24 Hour input box for a 24 hour clock setting. Select

‘No’ in the 24 Hour input box for a 12 hour (am/pm) setting.3. At the Current Time input box, highlight the digits to change and type in

the time.4. At the Current Date input box, highlight the digits to change and type in

the date.

Figure 75Date and Time Screen

OPERATOR’S MANUAL



UNITS AND LANGUAGEThe system is equipped with a set of various languages that display the user screens in the language selected. Language default is English (US).

Available Languages:

• English• Additional languages may be available on future releases. Contact

Technical Support at 1-800-637-3302 for available languages.

Units of measurement available:

• US• Metric

To enter Units and Language:1. At the (F10) System menu screen, press the 3 key to display the Units

and Language screen.2. Select Yes to enable metric as the unit of measurement. Default is set

to English. 3. The current language setting of English cannot be adjusted.

Figure 76Units and Language Screen

OPERATOR’S MANUAL



SERVICEThe Service menu is typically used by authorized personnel to incorporate product enhancements, troubleshoot, and identify the system’s current software version.

1. Press 4 on the keyboard to select the Service menu screen.

SOFTWARE VERSION1. Press 1 at the Service screen to display the system’s installed software

version.

Figure 77Software Version Screen

OPERATOR’S MANUAL



SYSTEM RESET1. Press 2 at the Service menu screen to reset system parameters to

default factory values. 2. A confirmation screen prompts a Yes or No selection before the system

reset occurs.

Figure 78System Reset Screen

SERVICE KEYBOARD MODE1. Press 3 at the Service menu screen to enable service keyboard mode

that allows keyboard use when the ground speed is above 0 AND the ground speed is OFF.

Figure 79Service Keyboard Mode Screen

OPERATOR’S MANUAL



TROUBLESHOOTING Troubleshooting screens provide access to System Response screens relating to spinner and material channels.

IMPORTANT: It is recommended that these parameters not be modified as any changes could affect performance. Contact DICKEY-john Technical Support at 1-800-637-3302 for assistance.

1. At the (F10) System menu screen, press 5 on the keyboard to display the Troubleshooting screen.

2. Select the corresponding number to view the material or spinner channel system parameters.

Figure 80Troubleshooting Screen

OPERATOR’S MANUAL



GPS SENSORIf a GPS sensor is installed, it must be enabled at the GPS Sensor screen.

GPS coordinates with a time and date recording of the following events are stored in the terminal:

• When truck was started and turned off, type of material spread, and application rates selected by operator

• When control system was operating in an error condition, such as application error, manual override, or loss of feedback sensor

• When the control system exceeded the vehicle maximum speed alarm set point

• When control was in automatic mode of control versus off• When blast and pause function was activated• GPS coordinates of location by time and date

Log GPS Position per Event This feature must be enabled to log events with GPS position and coordinates in the data log file. GPS coordinates are stored in the log data file for use in an data management software reporting package for vehicle tracking.

If this feature is disabled, a sequence of events, miles driven, distance, and speed are recorded with no GPS coordinates.

To enable GPS Sensor:1. At the (F10) System menu screen, press 6 on the keyboard to display

the GPS Sensor screen.2. Select Yes to indicate a GPS sensor is installed.3. Select Yes to log GPS position and coordinates by event.

Figure 81GPS Sensor Screen

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OUTPUT MODULE SETUP (F11)An optional output module connects to the master control module via a CAN BUS to control additional installed accessories. A 10 foot accessory harness extension is available that connects the output module harness to the rate control harness, if required.

Accessory functions include:

• Boom section shutoff valves• Open and close V-Box gates• Switching valves for front/rear conveyors• Switching valves for left/right discharge cross conveyors

To enter Output Module Setup:1. Press F11 to display the Output Module screen.2. Select Yes to Enable.3. Select Yes if a 12V output signal is used.4. Select Yes to control the front and rear conveyor.5. Select Yes to control material application from the left and right side of

the truck at the Operate screen6. Select Yes to control raising and lowering the gate height from the cab.7. Enter the increase/decrease PWM% that determines how fast the gate

opens and closes.8. Enter the increase/decrease time that affects the speed of opening and

closing the gate.

Figure 82Output Module Setup Screen

FRONT/REAR CONVEYORSelect Yes to control the front and rear conveyor position during operation by selecting the front and rear conveyor buttons available on the Operate screen. Current conveyor position is displayed on the Operate screen.

LEFT/RIGHT CONVEYORSelect Yes to control material application from the left and right side of the truck at the Operate screen. Spinner direction can be left, right, or both can be on at the same time. The active position of the conveyor displays on the Operate screen.

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GATE HEIGHT CONTROLSelect Yes to control raising and lowering the gate height from the cab.

INC/DEC PWMThe PWM percentage entered determines the PWM signal level that is sent to the electric actuated cylinder when the gate increase or decrease button is pressed from the main Flex4 terminal Operate screen. The higher the PWM signal is set, the faster the gate opens or closes.

INC/DEC TIMEThe time entered determines how long the PWM signal is sent to the electric actuated signal each time the gate increase or decrease button is pressed from the Flex4 terminal Operate screen. The higher the time is set, the longer the gate continues to open or close upon a single press of the gate increase/decrease button.

Example: PWM percentage set at 40 and time set at 2 seconds. Pressing the Gate Increase button sends a 40% PWM signal to the electric actuated cylinder for 2 seconds.

OPERATOR’S MANUAL



DATA LOGGING (F12)The Data Logging menu screen includes those items that are stored to data files for transfer to a reporting software.

To view Data Logging Screens:1. Press F12 to display the Data Logging menu screen.2. Press the respective item number to open a menu item.

Figure 83Data Logging Screen

ALARM HISTORYVarious alarm conditions can occur whenever the system encounters an abnormal condition or detects a specific alarm. Alarms are presented in either a full screen display or as an audible alarm. Full screen alarms provide an alarm description and may give instructions on how to resolve the issue. Each alarm type has an associated alarm number that can be cross-referenced in the Troubleshooting and Alarms section.

Some alarms require a specific action before the alarm condition will cease. In these cases, instructions are indicated on the alarm display.

Alarms can be acknowledged by pressing the Alarm Cancel button.

To view Alarm History:1. At the Data Logging screen, press 1 to access the Alarm History

screen.– The number of the alarm, data, time the condition occurred, along

with the alarm description displays. – Up to 275 alarms can be recalled.– Each alarm occurrence can have up to 6 occurrences of the alarm

tagged with a date and time stamp.

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NOTE: Press the Page Up or Page Down buttons to view screen 2 alarms.

Figure 84Alarm History Screen

TRUCK IDAn identifying name for a truck which can be changed at anytime. A Truck ID is used as part of the file name during import/export of configuration and data downloading to correlate the truck with the appropriate data files.

1. At the Data Logging screen, press 2 to access the Truck ID screen and enter desired ID.

Figure 85Truck ID Screen

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DRIVER SETUPDriver logins require a passcode to perform certain system functions.

1. Driver ID Configuration (tracking of routes/roads/driver)2. Configuration Setup (entry of configuration settings)

To customize Driver Details:1. At the Data Logging screen, press 3 to display the Driver Details

screen.2. At the Driver Details screen, press the corresponding number to

display the desired configuration screen.

Figure 86Driver Details Screen

DRIVER ID CONFIGURATIONA driver login and passcode can be enabled to allow each driver to login and logout when the unit is powered on or when users change so that tracking of routes and roads with materials spread, miles driven, and route spread can be recorded for an individual driver. The default language is English but a specific language can be chosen so that during logon the system automatically changes to the user-defined language for the driver.

Up to 20 different driver names and passcodes can be entered. An additional screen to add names and passcodes is selected by pressing the More button.

IMPORTANT: If a driver login on power up is mandatory, make sure to select Configuration Setup at the Driver Details screen (Figure 86) and set Driver Login Required as YES. If Driver Login is set at NO and a driver passcode is entered at the Driver ID Configuration screen, login is available but will not automatically display on power up.

OPERATOR’S MANUAL



To enable a Driver Passcode:1. At the Driver Details screen, press 1 to display the Driver ID

Configuration screen.2. Highlight the Driver Name input box and type in a user name.3. At the passcode input box, enter a passcode for each user. To ensure

that individual driver’s data is recorded separately a different passcode should be used for each driver name.

4. Select the appropriate language, if available.– To remove a driver’s name and passcode, highlight the

corresponding delete input box located next to the user. – Use the + or - key to enter a checkmark to select. Upon exit of this

screen, the selected driver and passcode will be removed.

Figure 87Driver ID Configuration and Login Screen

After Driver ID Configuration is setup, the Driver Login/Logout screen appears requiring the driver’s personal passcode before gaining access to the Operate screen. Refer to the Operation section for additional information.

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CONFIGURATION SETUP

NOTE: A keyboard is required to enter configuration setup screens.

Enabling the Configuration Passcode will require a user to enter a passcode independent of the driver ID passcode to enter, view, or change any of the Configuration Setup screens.

Setting a passcode at the Configuration Setup screen restricts system settings to only be changed by authorized users with the created passcode. Once a passcode is enabled, it must be entered to gain entry into the configuration screens.

NOTE: The unit is shipped with driver and system passcode settings disabled.

To modify Configuration Setup:1. At the Driver Details screen, press 2 to display the Configuration Setup

screen.2. Highlight the Configuration Passcode input box and select Enabled.3. At the Passcode input box, enter a passcode using numbers only. A

passcode can be entered at this screen or by an attached keyboard.4. Retype the passcode again in the Confirm Passcode input box.5. At the Driver Login Required input box, select YES to require a driver

to enter a driver passcode as well as the system configuration passcode. Select NO if a driver login personal passcode is not required and only the configuration passcode is desired.

NOTE: Passcodes can only be entered as numbers not as alpha characters or symbols.

Figure 88Configuration Setup and Configuration Passcode Screens

After a configuration passcode is created, the Configuration Passcode screen appears to gain entry into any configuration setup screens. Returning to the Operate screen completes that setup session and requires re-entry of the passcode again to enter setup screens.

Disabling the passcode setting resets the system allowing full access to configuration screens.

DATA IMPORTDONE

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DATA IMPORTDONE

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DATA IMPORTDONE

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REBOOTTERMINAL

YOU MUST REBOOT THE TERMINAL TO SAVEALL IMPORTED DATA

ENTER CONFIGURATION PASSCODE

ENTER

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ROUTE CONFIGURATIONTwenty (20) pre-defined route names can be entered for selection on the Operate screen so that data specific to that route; rates, material, total quantity, miles driven,etc., is logged and recorded. Route specific data can also be viewed at the Operational Totals screen.

To enter Route Names:1. At the Data Logging screen, press 4 to access the Route Configuration

screen.2. Highlight the Route Name input box and type in the desired name. A

maximum of 12 digits is accepted.– To remove a route name, highlight the corresponding delete input

box located next to the user. Use the + or - key to enter a checkmark to select. Upon exit of this screen, the selected route will be removed.

After Routes are setup, a Route button is enabled at the Operate screen to access the Route Selection screen. Refer to the Operation section for additional information.

Figure 89Route Configuration and Selection Screens

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OPERATIONAL TOTALSGranular and liquid totals are logged individually and viewable on the Totals screen by:

• Current run totals• Season totals• Route

To view Operational Totals:1. At the (F12) Data Logging screen, press 5 to access the Operational

Totals menu screen.2. At the Operational Totals screen-Reset Totals Enable selection, select

Yes for operator access to clear totals from the Operate screen. Select No for no operator access to clear totals. The Trip Log on the Totals screen can be cleared with a Yes or No selection.

3. Select the corresponding number key to view granular, liquid, anti-ice, prewet, or active material totals. Active Materials screen displays and clears only the current materials displayed on the Operate screen.– Press More button to view additional materials.

4. At the Material menu screen, select the corresponding number key to view material totals.

5. At the Totals screen, press C to clear current totals and S to clear season totals.

Material totals are reported in tons, miles, and hours for current and season totals for the following modes:

AUTOMATIC MODE- total miles driven is logged in miles (km), tons (metric/English), and gallons (liters) for each control channel and product spread.

BLAST MODE- total miles driven in Blast mode is logged in miles (km), tons (metric/English) and gallons (liters) spread for each product.

PAUSE MODE- total miles driven in Pause mode is logged in miles (km), tons (metric/English), and gallons (liters) spread for each product.

OPERATOR’S MANUAL



NOTE: Season totals can only be cleared using the keyboard at the Operational Totals screen.

Figure 90Operational Totals Screen

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LIFETIME TOTALSAccumulated totals display in miles and hours for Automatic, Blast, and Pause modes. These totals are informational only and cannot be changed or cleared.

To view Lifetime Totals:1. At the (F12) Data Logging screen, press 6 on the keyboard to access

the Lifetime Totals screen.

Figure 91Lifetime Totals Screen

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CALIBRATIONS

Spreader trucks have a variety of material delivery systems and various combinations of hydraulic/liquid pumps, valves, and motors. It is important that calibrations of the system and control channels are performed to define configuration characteristics and ensure optimum performance.

Two calibration types are recommended prior to operation:

1. Material and Spinner System Response Calibrations2. Drop Test Calibration

IMPORTANT: Performing the following procedures in the order outlined ensures the greatest accuracy.

MATERIAL AND SPINNER SYSTEM RESPONSE CALIBRATIONS (F6)A system response calibration adjusts the response time of the system to the installed hydraulic and mechanical systems. Performing this calibration determines the system response and related constants, such as Valve Boost, PWM Offset, and AFILT, for each of the control channels.

Constants may vary slightly each time a system response calibration is performed. Manual fine tuning for optimum performance is acceptable.

IMPORTANT: During calibrations, the truck must be running and the RPM’s should be within the truck’s normal operating range.

GRANULAR RESPONSE CALIBRATIONDuring calibration, a set of values for System Response, Valve Boost, PWM Offset, and AFILT automatically calculate, store, and display on the Granular Configuration screens for all granular materials.

NOTE: Liquid pre-wet and liquid anti-ice channel setup follows same steps as granular. Refer to page 94 for Drop Test and Calibration procedures.

To perform a Granular System Response Calibration:1. At the System Calibration screen (F6), select (1) Granular System

Response. A warning screen indicates this test activates the channel and material will dispense.

2. Press “R” to begin test. A series of steps display on the screen during calculations. When finished, the System Response Done screen displays.

3. When the calibration is complete the results automatically record in the proper locations. Press “C” to automatically begin drop test or press “D” to return to the Calibration screen.

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100 / CALIBRATIONS

Figure 92System Response Calibration Screens

NOTE: Liquid pre-wet and anti-ice channels have similar calibration steps as granular.

RECORDING CALIBRATION DATAAfter performing each calibration, record the calibration constants on the Calibration Data Record sheets included with this manual. If console replacement is necessary, export system files to a USB memory device for import to another system.

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CALIBRATIONS / 101

MAINTAINING CALIBRATION ACCURACYCalibration accuracy can be affected by various conditions and to retain optimum performance a system calibration should be performed for the following conditions:

• If a new material is added and the spreader, nozzle, or flow meter constant is not accurately known, perform a granular or liquid calibration routine.

• If wear of the conveyor/auger mechanism, actuator valves, flow meter, nozzles, or other system components is suspected, perform a new catch test (granular or liquid calibration) to re-establish APR accuracy.

• Perform a ground speed calibration after installing new or different tires.

• Each known physical (mechanical) change in the system should be followed immediately by a system response calibration on the related control channel (granular, liquid pre-wet, liquid anti-ice, or spinner).

• A periodic system recalibration when repair or replacement has occurred on any system components, including hydraulic hoses, fluid changes, and normal wear.

• A yearly system calibration of all control channels at the beginning of each spreader season.

SYSTEM RESPONSE ADJUSTMENTSAdjustments after a system calibration can be made so the system responds faster or slower than calculated by the automatic calibration routines.

Automatic calibration routines should always be performed prior to modification to establish basic values.

System performance can be improved by adjusting the following functions:

SYSTEM RESPONSE CONSTANT• Control system responds slowly in speed and is slow to start

– Increase the system response value• System oscillates around the target APR

– Decrease the system response value

Excessive oscillation should be limited to +/-5% of the target APR to minimize wear on the PWM valve. Most systems can be tuned by altering only this value.

VALVE BOOSTValve Boost increases system response only at startup to quickly start system spreading. The value does not affect stability when operating at the target APR and does not normally require adjustment.

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102 / CALIBRATIONS

AFILTNoisy feedback sensors cause the APR’s to randomly jump. AFILT value indicates the amount of feedback noise rejection. The smaller the number, the greater the filtering. Decreasing the AFILT can reduce the problem but also can cause the system to become more sluggish. Typically this value does not require adjustment.

GRANULAR DROP TEST CALIBRATION The Drop Test determines the spreader constant for a given granular material. The spreader constant is the number of pulses generated by the application rate sensor per pound of granular material discharged. A separate calibration routine must be run for each granular material used.

During a calibration the control system runs the conveyor/auger mechanism dispensing material while the vehicle is stationary. When a sufficient amount of material has been discharged, the operator stops the spreader mechanism, weighs the material discharged, and enters the amount at the Calibration screen. The system then calculates, stores, and displays the spreader constant.

DROP TEST PREPARATION1. Load the vehicle hopper with the desired material and verify the gate

height is adjusted to the proper setting on the V-Box spreader. If tailgate spreads are in use, ensure auger is full.

2. Load enough material to provide a uniform flow throughout the calibration procedure.

3. Position a suitable container or drop cloth to catch all dispensed material from the conveyor/auger. The container must be large enough to obtain a good, representative sample. The larger the sample weighed, the better the accuracy. Alternatively, if a vehicle scale is available, weigh the truck before and after dispensing material.

4. System is ready for calibration drop test.

PERFORMING A GRANULAR DROP TEST

NOTE: Steps 1 and 2 are performed when a granular drop test is initiated from the F6 Calibration screen.

1. At the System Calibration screen (F6), select the Granular Drop Test and follow the onscreen instructions.

2. At the Granular Calibration screen, select and press the corresponding number (1-4) of the appropriate material.

A warning message indicates material will dispense when the procedure is started. Ensure all personnel are clear before starting the next step.

IMPORTANT: If a gate height sensor is installed, verify the gate height sensor selection is enabled at the (F9) Accessory Sensor screen before performing the drop test.

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CALIBRATIONS / 103

NOTE: Calibration Data Sheets are available in back of this manual to record constants.

3. With the vehicle stationary, engage the hydraulic system. 4. Increase engine RPMs to normal operating range.5. Press “R” to begin test and to run the conveyor/auger. Several steps

display during calculations before the System Response Done screen appears. The number in the middle of the screen shows the counts accumulating from the APR sensor. If a count is not recorded and stays on “0”, stop the test and check the application rate sensor.

6. When a sufficient amount of material has dispensed, press “S” to stop the system. A screen appears indicating the previous spreader constant and the sensor counts accumulated during the current run.

7. Perform the next step while the screen waits for the results.8. If using a vehicle scale, reweigh the truck and calculate the amount of

material dispensed in pounds.9. Enter that number into the console and press “D” when finished. The

new spreader constant is now stored and displayed on the calibration screen and on the appropriate configuration screen for this material.

10. For maximum accuracy, repeat the entire procedure at least three times.

11. Average the results and enter the average as the final spreader constant.

12. Record the material’s spreader constants on the Calibration Data Records sheets at the rear of this manual.

13. Repeat this procedure for each granular material used.

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Figure 93Granular Drop Test Procedure

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CALIBRATIONS / 105

NOTE: Pressing “S” stops the calibration and values default to the original settings.

GRANULAR CALIBRATION ADJUSTMENTSIf small but consistent application rate errors are observed over a period of time, the spreader constant can be modified to improve application accuracy. Refer to Appendix A for steps to re-calculate a new spreader constant. This constant can be manually entered on the Granular Configuration screen. A granular calibration routine can also be repeated to correct this type of APR error.

LIQUID DROP TEST CALIBRATION (F6)A Liquid Drop Test Calibration determines a flow meter constant (K Factor) for each liquid material used. The K Factor represents the number of pulses generated by the flow meter per gallon of liquid dispensed. The nozzle constant is a measure of flow rate through the nozzle at a standard pressure. Separate calibrations are necessary for each liquid material because of viscosity differences.

The liquid drop test routine causes the control system to run the liquid pump dispensing material while the vehicle is stationary. When a sufficient amount of liquid has been discharged, the system is stopped and the discharged liquid weighed, and the amount entered at the Calibration screen. The system then calculates, stores, and displays the K Factor.

DROP TEST PREPARATION1. Load vehicle tank with material.2. Position a suitable container to catch all the material dispensed

through the liquid pump. The container must be large enough to obtain a good, representative sample. The larger the sample weighed, the higher degree of accuracy. When calibrating a pre-wet liquid material, the pre-wet bar can be removed from its mounting and placed inside the catch container. Alternatively, especially for flow meter and anti-ice liquid materials, temporarily disconnect an appropriate hose and place inside the catch container.

3. System is ready for calibration drop test.4.

NOTE: Calibration Data Sheets are available in back of this manual to record constants.

A warning message indicates material will dispense when procedure is started. Ensure all personnel are clear before starting the next step.

PERFORMING A LIQUID DROP TEST

NOTE: Steps 1 and 2 are performed when a granular drop test is initiated from the F6 Calibration screen.

1. At the System Calibration screen (F6), select the Liquid Drop Test and follow the onscreen instructions.

2. At the Liquid Calibration screen, select and press the corresponding number (1-4) of the appropriate material.– For pressure-based anti-ice systems, a target pressure must be

entered. This should be the nozzle manufacturer’s rating pressure typically 40 psi (2.75 bar).

– If running pressure, ensure booms are drained prior to running Offset

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106 / CALIBRATIONS

A warning message displays indicating that material will dispense when channel is activated. Ensure all personnel are clear before starting the next step.

3. When ONLY the liquid channel is propelled by the hydraulic system, start the engine keeping the vehicle stationary.

4. Engage the hydraulic system and increase the engine RPMs to normal operating range.

5. Press “R” to run the liquid pump and start the calibration routine. For flow meter based systems, use the Rate Increase/Decrease buttons on the switch module to obtain an adequate discharge rate. The number displayed indicates the accumulating count from the APR sensor.

6. When a sufficient amount of liquid has dispensed, press “S” to stop. – For a flow meter-based system, a screen appears showing the

previous K Factor and the sensor counts accumulated during the current run.

– For a pressure-based system, the previous nozzle constant and collection time display. The screen asks for an entry of gallons before proceeding.

7. Perform the next step while the screen waits for the results.8. Weigh the material caught and calculate the amount dispensed in

gallons.9. Enter the number into the console and press Enter.

IMPORTANT: The amount dispensed value must be entered to adjust the K Factor value; otherwise the K Factor will remain at the current setting.

10. Press “D” when finished. The flow meter constant is now stored and displayed on this screen and on the Liquid Configuration screen for this material.

11. For maximum accuracy, repeat the entire procedure at least three times.

12. Average the results and enter the average as the final K Factor constant.

13. Record the material’s K Factor constants on the Calibration Data Records sheets at the rear of this manual.

14. Repeat this procedure for each liquid material used.

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Figure 94Liquid Drop Test Calibration Procedure

LIQUID CALIBRATION ADJUSTMENTSIf small but consistent application rate errors are observed, the values can be manually adjusted to improve application accuracy. Refer to Appendix A for steps to re-calculate a new flow meter constant. This constant can be manually entered on the Liquid Configuration screen. A liquid calibration routine can also be repeated to correct this type of APR error.

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AUXILIARY SYSTEM RESPONSE AND DROP TESTAdditional auxiliary channels 3 and 4 are available for granular or liquid rate control. Channel Setup screens require the same configuration parameters, calibration, and drop test requirements as channels 1 and 2. Refer to the Granular and Liquid Configuration sections for additional information.

SPINNER SYSTEM RESPONSE CALIBRATIONWhen “F4 Aux S” is assigned as Spinner, performing a Spinner System Response determines PWM Offset and PWM Saturation values when using a proportional valve with no feedback sensor to drive the spinner channel. Spinner calibration allows for open loop or closed loop operation of the spinner to coordinate spread width knob position with a specific spread width for lane mile material application.

To perform a Spinner System Response Test:1. At the System Calibration screen (F6), select Spinner System

Response and follow the onscreen instructions. 2. At the Spinner System Response screen, press “R” to begin test.3. Spinner will be set to off when the calibration starts. Slowly rotate the

knob clockwise until the minimum spinner speed is achieved. 4. Press R to run.5. When the desired offset is achieved, press C to capture the offset.6. Rotate the spinner knob clockwise until the maximum spinner speed is

achieved.7. Press C to capture the saturation.8. Spinner calibration is complete. Press D to exit.9. libration drop test.

NOTE: Calibration Data Sheets are available in the back of this manual to record constants.

A warning message indicates material will dispense when procedure is started. Ensure all personnel are clear before starting the next step.

Figure 95Spinner System Response Screens

3. SPINNER SYSTEM RESPONSE

1. AUX S SYSTEM RESPONSE2. AUX S DROP TEST

(LIQUID/GRANULAR 5-8)




4. SPINNER SPREAD WIDTH

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CALIBRATIONS / 109

Figure 96Spinner System Response Screens

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110 / CALIBRATIONS

SPINNER SPREAD WIDTHA spinner spread width calibration adjusts to the spinner configuration settings defined at the Spinner Calibration screen and correlates these settings to the increase and decrease adjustment of the spread width knob automatically adjusting the amount of material applied. A spread width bar graph displays on the Operate screen to indicate spread width percentage.

IMPORTANT: A spinner spread width calibration can only be performed when spinner units are selected as feet on the Spinner Configuration (F4) screen.

To perform a Spinner System Response Calibration:1. Load vehicle with material.2. At the F6 Calibration menu, select Spinner Spread Width and follow

onscreen instructions.3. Position a suitable container to catch all granular material dispensed

from the conveyor/auger. The larger the sample weighed, the better the accuracy. The container must be large enough to obtain a good representative sample.

4. Press C to proceed to further calibration instruction.5. Press S to to start calibration.

Figure 97Spinner Spread Width

6. When a sufficient amount of material has dispensed, press “C” to pause the calibration.

7. Measure the material dispensed and enter the spread width amount in inches into the Spread Width popup window. This process is required an additional 4 times to calculate an average that appears on the screen each time another calibration is ran.

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CALIBRATIONS / 111

8. After the final calibration, a calibration complete screen appears. Press “D” to return to the main Calibration screen.

Figure 98Spinner Spread Width

Enter measured spreadwidth into popupwindow

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GROUND SPEED CONFIGURATION (F8)Ground speed configuration sets the parameters for ground speed type and performs a calibration.

Figure 99Ground Speed Configuration

GROUND SPEED SOURCECAN Used when ground speed is provided by a radar/digital (3-wire) type sensor connected to the cab harness or if radar/forward ground speed is communicated on the CAN bus.

DIGITALUsed when ground speed is provided by a radar/digital (3-wire) type sensor connected to the actuator harness.

RELUCTANCEUsed when ground speed is provided by a reluctance (2-wire) type sensor connected to the actuator harness through an adapter harness.

MAXIMUM CONTROL SPEEDIndicates the allowed maximum speed in AUTO mode before a Maximum Speed Exceeded warning occurs. The value entered is based on the highest speed for acceptable system performance. If a zero is entered, the function is disabled.

MANUAL SPEED ONManual Speed On overrides the current system when the ground speed sensor is not operating properly. An internally-generated ground speed signal allows for continued operation and can also be used for testing, troubleshooting, or calibrating the vehicle while stationary.

MANUAL SPEED ACCESSAllows the operator to activate the manual speed mode when necessary. Manual speed can be enabled and disabled at the Material Selection screen.

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MAXIMUM MANUAL SPEEDSets the maximum manual ground speed allowed to spread the target APR.

MANUAL SPEEDRepresents the ground speed in miles per hour with an artificial, internally-generated signal. Vehicle speed should run close to the maximum manual speed to ensure materials are spread to the target APR.

CONTROL STARTUP SPEEDThe speed the system begins to operate when ground speed sensor pulses start. Until this threshold is crossed, the startup ground speed signal is used.

CONTROL SHUTOFF SPEEDMinimum ground speed allowed before the system stops operation. It is recommended that shutoff speed be set at 0.0 unless speed appears from a mechanical sensor.

GROUND SPEED CONSTANTDetermines the number of pulses received from the ground speed sensor per mile of travel. If unknown, the value automatically calculates during a ground speed calibration.

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GROUND SPEED CALIBRATION (F8)Ground speed calibration establishes a ground speed constant(s) for the vehicle. The constant is determined by counting the number of ground speed sensor pulses generated in a distance of one mile.

Figure 100Ground Speed Calibration Screens

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To establish a Ground Speed Constant:1. Accurately measure one mile marking the start and finish points.

Markers should be visible from the cab while driving past. Alternatively, two highway mileage markers can be used.

2. At the Ground Speed Calibration screen (F8), press C to begin calibration.

3. Drive to the start of the course at a minimum speed of 5 mph (8Km/hr). 4. When even with the start marker, press S on the keyboard. The

calibration begins as the vehicle is moving.5. Drive at normal operating speed.

NOTE: For better accuracy, it is recommended to slow down at the second marker so reaction time is better when pressing “S” to stop.

6. At the finish marker, press C to complete the calibration.7. Press S to save the value, press R to restart the calibration or press

Esc to abort the calibration.8. To ensure accuracy, repeat the calibration procedure three times and

average the results. Enter the average value.9. Record the ground speed constant on the Calibration Data Records

sheets at the rear of this manual.

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IMPORT/EXPORT DATA FILES

Two separate functions can be performed with the Import/Export button.

• Import/export of system configuration settings to a USB memory device to import to other terminals

• Export of logged data files for reporting purposes

PASSCODE ENABLEDIf a driver passcode is enabled at the Configuration Setup screen, this passcode is required before importing or exporting files can occur. The code can be entered on the Passcode screen or by using an attached keyboard. The Passcode screen appears after pressing the Import/Export button.

Enter the passcode and press the Enter button to proceed.

Figure 101Passcode Screen

NOTE: USB memory device must be inserted into the terminal before the Import/Export button appears.

EXPORT CONFIGURATION FILESTo export Configuration Files:

1. Insert USB memory device into side of terminal.2. At the Operate screen, an Import/Export button appears after the

USB memory device is inserted.3. Press the Import/Export button.4. At the Import Export screen, select Config USB Export button. The

Export to USB confirmation screen displays the file name that contains the configuration files.

5. Press the Export Now button.6. A Data Export Done screen indicates file transfer is complete.

DATA IMPORTDONE

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DATA IMPORTDONE

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DATA IMPORTDONE

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ENTER CONFIGURATION PASSCODE

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Figure 102Exporting Configuration Files

EXPORT LOG DATA FILESLog data files are exported following the same procedure as exporting configuration files. Log data files can be imported to a reporting software tool to create truck fleet reports.

To export Log Data Files:1. Insert USB memory device into side of terminal.2. Press the Import/Export button.

CONFIGURATION

EXPORT TO USB

EXPORTNOW

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DATA EXPORTDONE

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CONFIGURATION

IMPORT/EXPORT

LOGGED DATA

CONFIGUSB

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DATAUSB

EXPORT

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CONFIGUSB

IMPORT

FILE NAME:Flex4_Truck ID_2016-07-29.

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3. At the Import Export screen, select Data USB Export button. The Export to USB confirmation screen displays the file name that contains the configuration files.

4. Select the type of export to perform.– Export Now- Exports files– Export and Clear Totals- Exports files and clears all current totals

in lieu of individually clearing each material total at the Totals screen.

5. A Data Export Done screen indicates file transfer is complete.

Figure 103Export Log Data Files

LOGGED DATA

EXPORT TO USB

EXPORTNOW

BACK

DATA EXPORTDONE

BACK

CONFIGURATION

IMPORT/EXPORT

LOGGED DATA

CONFIGUSB

EXPORT

DATAUSB

EXPORT

BACK

CONFIGUSB

IMPORT

FILE NAME:Flex4_Truck ID_2016-07-29.

Logged Data Files Export in Progress

EXPORT &CLEARTOTALS

PLEASE REMOVE STORAGE DEVICE AND CHECK THATDATA WAS EXPORTED CORRECTLY

WOULD YOU LIKE TO CLEAR CURRENT TOTALS?PRESS BACK TO EXIT AND PRESERVE TOTALS

OPERATOR’S MANUAL



EXPORT FILE STRUCTUREThe export file structure when exporting configuration and log data files to a USB memory device is formatted as follows:

• A folder is created that Flex4 data is stored (Flex4_DataFolder)• Each time an export occurs the file name is saved with the Flex4 name

identifier, the Truck ID, date of the download, and time of the download

FILE STRUCTURE: Flex4_DataFolder/Flex4_TruckID_Date_Time

EXAMPLE: Flex4_DataFolder/Flex4_42067_2011-09-14_15-00-39

OPERATOR’S MANUAL



IMPORT CONFIGURATION FILESTo import Configuration Files:

1. Insert USB memory device into side of terminal.2. At the Operate screen an Import/Export button appears after the USB

memory device is inserted.3. At the Import/Export screen, select Config USB Import button. This

button only appears if files exist on the USB memory device.4. Select the desired file to import and press the Import File button.5. Select the desired file types to import and press the Import Now

button. Use the terminal keys to select the choices.– A Data Import screen indicates file(s) are uploaded to terminal.

Figure 104Importing Configuration Files

SELECT FILE FROM BELOW LIST

IMPORT FROM USB

IMPORTFILE

BACK

CONFIGURATION

IMPORT/EXPORT

LOGGED DATA

CONFIGUSB

EXPORT

DATAUSB

EXPORT

BACK

CONFIGUSB

IMPORT

Dj_Flex4_Settings_42067.xml

SELECT DATA TO BE IMPORTED

IMPORT SETTINGS

BACKUSE TERMINAL KEYS TO SELECT DATA

CONFIGURATIONS

ROUTE NAMES

DRIVER NAMES

PASSCODES IMPORTnow

OPERATOR’S MANUAL



6. Press the Reboot Terminal button to turn the system off and on again to accept imported data.

Figure 105Reboot Terminal

DATA IMPORTDONE

BACK

DATA IMPORTDONE

BACK

DATA IMPORTDONE

BACK

REBOOTTERMINAL


OPERATOR’S MANUAL


DIAGNOSTICS / 123

DIAGNOSTICS

Diagnostic screens (F7) can be used to check system performance by displaying sensor input readings that connect to the terminal, control module, and output module that could indicate potential issues.

Three Diagnostic screens are available and selected based on where the sensor is connected:

• Terminal (joystick inputs)• Control module (control channels, spinner, auxiliary sensors)• Output module (added accessories)

PERFORM A DIAGNOSTICS CHECKTo perform a diagnostics check, vehicle ground speed must be zero and manual ground speed must be enabled at the appropriate ground speed setting. Actual readings will display on the Diagnostics screen at the defined rate and the manual ground speed entered when the switch module Auto On button is enabled.

Enable Manual Ground Speed:1. Enable manual ground speed with the vehicle stopped and the switch

module Auto On/Off button in Off mode.2. At the Operate screen, press the Material Select button to display the

Material Selection screen.3. Press the Manual Speed button to select Enable Manual Speed.4. Press the Select button to enter the appropriate ground speed to

perform test.5. Press the Back button to return to the Operate screen. Verify that the

manual speed is active on the screen.6. Connect the keyboard to access the Diagnostics screen and press the

F7 button on the keyboard to display the Diagnostics screen.

OPERATOR’S MANUAL


124 / DIAGNOSTICS

Figure 106Enable Manual Ground Speed

To Perform a Diagnostics Check:1. Press the appropriate number on the keyboard to select the terminal,

control module, or output module screens.2. At the selected Diagnostics screen, press the switch module Auto On/

Off button to On to display system readings.

Figure 107Main Diagnostic Screen

O.OO.O

Increase/decreasemanualspeed

OPERATOR’S MANUAL


DIAGNOSTICS / 125

TERMINALThe Terminal screen indicates the current state of the joystick inputs connected to the terminal as either ON or OFF. Pressing the appropriate joystick function while on this screen indicates if the joystick is functioning properly.

– An incorrect state on the screen that doesn’t correspond with the actual joystick function could indicate the joystick is not wired correctly or a defective joystick.

Figure 108Terminal Diagnostics Screen

CONTROL MODULEThe Control Module Diagnostics screen provides sensor readings for control channels, auxiliary channel, spinner, and accessory sensors. Any misreadings could indicate a control module problem, a faulty sensor, or bad sensor connection.

1. At the Main Diagnostics screen, press 2 on the keyboard to display the Control Module Diagnostics screen.

2. Select the appropriate material (Granular, Liquid, Aux, Aux S), spinner, or accessory sensor to perform the relevant diagnostic check.

Figure 109Control Module Diagnostics Screen

OPERATOR’S MANUAL


126 / DIAGNOSTICS

MATERIALTarget RateTarget Rate displays the defined application rate set at the configuration screen and the rate the Diagnostics screen will perform the test.

– Target rate can be adjusted at the Operate screen by pressing the Increase/Decrease Rate buttons on the switch module to achieve the desired target rate.

Actual RateActual rate is the rate that is being applied during the test. The Actual Rate should match or run closely to the Target Rate.

– A wrong actual rate could indicate that a system response should be performed or a faulty feedback sensor.

Set PointSet Point, displayed in hertz, is the pulses per second required for the feedback sensor to achieve the target rate at the manual ground speed set.

– No set point could indicate a configuration issue or faulty master module.

Filtered FeedbackFiltered Feedback is the actual pulses per second of the feedback sensor and indicates the PWM signal being sent to the hydraulic control valve.

– No filtered feedback could indicate a faulty feedback sensor.

Pulse CountPulse Count reading indicates pulses sent from the feedback sensor to the rate control module.

Output PWMOutput PWM indicates the current PWM signal and continues to increase until the desired target rate is reached and then should remain steady when achieved.

RPMRPM indicates the revolutions per minute of the conveyor/auger.

Ground Speed FrequencyGround Speed Frequency identifies the pulses per second coming into the control module and could indicate a potential problem with the module, not reading a signal from the sensor, or a speed sensor failure.

Voltage readings from the truck battery are displayed for the following:

– Solenoid Power– Solenoid Ground– ECU Power– ECU Ground

OPERATOR’S MANUAL


DIAGNOSTICS / 127

SPINNERThe Spinner Diagnostics screen provides readings related to the rotary spinner knob on the operator switch module and corresponding PWM signal being sent to the coil controlling oil flow to the spinner motor.

Any misreadings could indicate a faulty switch module or rate control module.

Figure 110Spinner Diagnostics

Target Rate Only applicable if spinner is set for RPM control or GSRS mode.

Output PWMOutput PWM indicates the current PWM signal and continues to increase until the desired target rate is reached and then should remain steady when achieved.


Voltage ReadingsVoltage readings from the truck battery are displayed for the following:

– Solenoid Power (voltage from battery to solenoid relays)– Solenoid Ground (voltage from battery to solenoid relays)– ECU Power (voltage present at rate controller module)– ECU Ground (voltage present at rate controller module)

AUX 2

OPERATOR’S MANUAL


128 / DIAGNOSTICS

Accessory SensorsVoltage readings of accessory sensors relate to voltage feedback from specific sensors in their current position. When sensor position changes, the voltage reading changes.

– A zero (0) voltage reading indicates a faulty sensor or bad connection.


Voltage ReadingsVoltage readings from the truck battery are displayed for the following:

– Solenoid Power (voltage from battery to solenoid relays)– Solenoid Ground (voltage from battery to solenoid relays)– ECU Power (voltage present at rate controller module)– ECU Ground (voltage present at rate controller module)

Figure 111Accessory Sensor Diagnostics

AUX S

AUX S

OPERATOR’S MANUAL


DIAGNOSTICS / 129

OUTPUT MODULEOutput Module Diagnostics screen indicates the current state of attached accessories such as boom section shutoff valves, V-Box gate, front/rear conveyor valves, left/right discharge cross conveyors valves, and the accessory 12 volt switched output.

Press the appropriate Accessory button to verify correct position. An incorrect state on the screen that doesn’t correspond with the physical state of the attached accessory could indicate a communication issue with the Output Module.

Figure 112Output Module Diagnostics Screen

AccessoryButtons

OPERATOR’S MANUAL


130 / DIAGNOSTICS

OPERATOR’S MANUAL


TROUBLESHOOTING / 131

TROUBLESHOOTING

Error messages display when an abnormal event occurs. For any failure that persists, contact DICKEY-john Technical Support at 1-800-637-3302.

OPERATOR’S MANUAL


132 / TROUBLESHOOTING

ERROR CODE ERROR PROBABLE CAUSE CORRECTIVE ACTION

10 Rate Controller Stack Alarm Internal system software error. Cycle system power off and on.

11 Rate Controller System Stack Alarm

Internal system software error. Cycle system power off and on.

50 Rate Controller Offline Alarm Communication to the rate controller has been lost. 1. Verify rate control module has a good connection.2. Inspect CAN harness for damage.3. Inspect ECU harness and fuse for damage.4. Inspect ECU for damage.

51 Rate Controller Intermittent Alarm

Communication to the rate controller was lost but has been re-established.

Check for intermittent connections.1. Verify rate control module has a good connection.2. Inspect CAN harness for damage.3. Inspect ECU harness and fuse for damage.4. Inspect ECU for damage.

52 Remote Operator Controller Offline Alarm

Communication to the switch module has been lost. 1. Verify switch module is connected properly.2. Inspect CAN harness for damage.3. Inspect ECU harness and fuse for damage.4. Inspect ECU for damage

53 Output Module Offline Alarm Output member module is no longer online. 1. Verify output module is connected properly.2. Inspect CAN harness for damage.3. Inspect ECU harness and fuse for damage.4. Inspect ECU for damage

54 Output Module Intermittent Alarm

Communication to the output module was lost but has been re-established.

Verify output module is connected properly.2. Inspect CAN harness for damage.3. Inspect ECU harness and fuse for damage.4. Inspect ECU for damage

200 Auto has been turned off alarm

Master switch was left on (auto) and is now in a state that does not allow the system to run.

Turn Auto off before entering setup mode with keyboard. Check connections to feedback sensors.

222 Valve Calibration Abort Alarm Control channel valve calibration has been aborted due to an error.

Try calibration again.

206 “Channel” Auto Open (In Manual Control)

A manual override state occurs when an application rate sensor or flow meter fails. Manual override allows material to be spread at the same programmed rate without interruption. When a failure occurs, the rate decreases to “0” and “Manual” replaces the material name. Rate returns from “0” back to target rate while manual override is enabled. Material may be over or under applied in this mode.

Check feedback sensors, i.e., application rate sensors and flow meters.

208 “Channel” Application Rate error (granular)

A fully open valve is indicated but the target APR cannot be achieved.

1. Reduce the truck ground speed to allow the system to catch up and the error to clear.2. Shift to a lower gear to increase engine RPM and hydraulic pump rotation.3. Check hydraulic disconnects and filter.4. Ensure correct spreader constant is programmed into console. Check original setting or run a granular calibration.5. Incorrect PWM SAT setting (See Granular Configuration screen). Compare against original setting or run system response on the granular channel setting. 6. Check for insufficient hydraulic oil flow at normal engine RPM. 7. Check spreader valve, electrical connections to the valve coil, resistance of the coils (See manufacturers specifications), and verify voltage from control console.

OPERATOR’S MANUAL



208 “Channel” Application Rate Error (liquid)

A fully open valve is indicated but the target APR cannot be achieved.

1. Check to see if the liquid tanks are low, shutoff valves are partially closed, bypass valves are open too far, or an obstruction is in the liquid tank outlet. 2. Check filters between the liquid tank and suction side of the liquid pump for blockage.3. Check for plugged nozzles or nozzles that are too small to supply sufficient gallons per minute.4. If using a electric liquid pump, check that the nozzle pressure (spray bar pressure) does not exceed 40 psi. Some electric pumps have an internal pressure switch to shut pump off high back pressure conditions.5. Ensure a correct K-FACTOR is programmed. Compare it against the number stamped on the flowmeter body or recorded on the Calibration Data Record Sheet. If original settings are not available, run a liquid calibration.6. Observe the PWM SAT under the Liquid Configuration screen. Compare against original setting. If not available, run a system response on the liquid channel.

250 Prewet Channel Disabled Prewet is not linked to a granular channel. The system cannot run as configured. 1. Setup a granular channel to use as a reference for the prewet application.2. Or change the prewet channel type.

300 Invalid Gate Height Sensor Configuration

The calibration points of the gate height are incorrect. Most likely, the values do not follow an increasing or decreasing only pattern.

1. Check calibration numbers and re-run calibration.2. or accept default values and continue calibration.

301 Invalid Gate Height Open Calibration

The open calibration point is near zero. A zero full open position is not valid.

1. Check calibration numbers and re-run calibration.2. or accept default values and continue calibration.

302 Invalid Temperature Calibration

Temperature calibration did not complete. 1. Verify temperature sensor adapter is connected and the temperature sensor is disconnected. With adapter connected and sensor unplugged, the signal should toggle between 0.7V and 2.7V.

400 GPS Signal Low Poor GPS signal 1. Verify GPS is enabled at the F10 screen.2. GPS signal may be blocked. Move to a clear area.3. Check that receiver connection is secure.

401 Data Memory Near Full Memory for storing operation data is running low. 1. Export data to a USB memory device.

402 Data Log Memory Full Memory for operation is full and no additional data can be saved.

1. Export data to a USB memory device.

403 Invalid Task Data A task controller device error may occur on systems with previous software versions when loading new software.

1. Acknowledge alarm and follow onscreen instructions2. Insert a USB memory device.3. Export files.

500 Gate High Gate is above the open or highest calibrated point. 1. Check sensor and calibrations.

501 Gate Low Gate is below the closed or lowest calibrated point. 1. Check sensor and calibrations.

502 Bed Height Too High Bed is above the alarm value. 1. Lower bed or check sensor.

503 Down Pressure Too High Down pressure has exceeded the alarm threshold. 1. Reduce down pressure or check sensor.

504 Tank Pressure Low Tank level has dropped below alarm level. 1. Fill Tank.2. Adjust alarm level setting.3. Check sensor.

505 Air Temp Below Alarm Value 1

Temperature has dropped below alarm threshold. 1. Adjust alarm setting.2. Check sensor.






OPERATOR’S MANUAL



508 Road Temp Below Alarm Value 1






511 Digital Accessory 1 Active 1. Adjust alarm setting.2. Check sensor.

512 Digital Accessory 1 High Sensor has reached the defined high alarm limit value.

1. Adjust alarm setting.2. Check sensor.

513 Digital Accessory 1 Low Sensor has reached the defined low alarm limit value.


514 Digital Accessory 1 Shutdown

Digital accessory sensor has reached the defined alarm limit and the control has been shutdown to protect the system.


515 Digital Accessory High Shutdown

Sensor has reached the defined high alarm shutdown limit and the control has been shutdown to protect the system.


516 Digital Accessory Low Shutdown

Sensor has reached the defined low alarm shutdown limit and the control has been shutdown to protect the system.


517 Digital Accessory 2 Active 1. Adjust alarm setting.2. Check sensor.

518 Digital Accessory 2 High Sensor has reached the defined high alarm limit value.


519 Digital Accessory 2 Low Sensor has reached the defined low alarm limit value.


520 Digital Accessory 2 Shutdown

Digital accessory sensor has reached the defined alarm limit and the control has been shutdown to protect the system.


521 Digital Accessory High Shutdown

Sensor has reached the defined high alarm shutdown limit and the control has been shutdown to protect the system.


522 Digital Accessory Low Shutdown

Sensor has reached the defined low alarm shutdown limit and the control has been shutdown to protect the system.


523 Hopper Low Hopper level is low. 1. Fill hopper.2. Check sensor.

604 ECU Low Voltage 1. Damaged CAN or module harness.2. Defective module

1. Inspect CAN/module harness of the module for damage.2. Inspect module for damage and replace, if necessary.

605 ECU High Voltage 1. Damaged CAN or module harness.2. Defective module

1. Inspect CAN/module harness of the module for damage.2. Inspect module for damage and replace, if necessary.

606 Solenoid Low Voltage 1. Damaged CAN or module harness.2. Blow module harness fuse.3. Defective module.

1. Inspect CAN/module harness of the module for damage.2. Inspect module harness fuse and replace, if necessary.3. Inspect module for damage and replace if necessary.

607 Solenoid Voltage with Control Shutdown

Solenoid voltage is too high and the control system has shutdown.

1. Voltage issue must be corrected before control can resume.

608 Ground Low Voltage 1. Damaged/shorted actuator harness2. Defective PWM valve driver or Servo valve driver.3. Defective module.

1. Inspect actuator harness for damage around the PWM and Servo valve connections. Repair or replace harness.2. Inspect PWM or Servo valve drivers for damage and replace if necessary.3. Inspect module for damage and replace if necessary.

609 Ground High Voltage Ground offset has drifted high. 1. Check vehicle grounding.


OPERATOR’S MANUAL



701 Service Keyboard Mode A mode that allows keyboard use when ground speed is above 0 and the master switch is OFF.

1. Service Keyboard Mode is enabled at the F10 System screen. Warning continues to displays until the function is disabled.


OPERATOR’S MANUAL



OPERATOR’S MANUAL


APPENDIX A CONVERTING CONSTANTS / 137

APPENDIX A CONVERTING CONSTANTS

FINE TUNING APPLICATION

Adjusting Granular ConstantsIf small (less than 10%) but consistent granular APR errors (either high or low) are observed over a period of time, fine tuning of the system can be performed by adjusting the value of the spreader constant by the same percentage as follows:

EXAMPLE: If SPR CON is 100 and Target APR is 300 LBS/MILE but Actual APR is known to be 315 LBS/MILE, adjust SPR CON using the above formula:

NOTE: Keyboard enter the new SPR CON on the appropriate (Granular) configuration screen.

Adjusting Liquid ConstantsIn a manner similar to that for granular (shown above,), liquid APR errors can be corrected by fine tuning the flowmeter constant (K-FACTOR) as follows:

EXAMPLE: If K-FACTOR is 1,000 and Target APR is 10 GAL/MILE, but Actual APR is known to be 9.5 GAL/MILE, adjust K-FACTOR using the above formula:

New SPR CON = Old SPR CON x Target APRActual APR

New SPR CON = 100 x = 95.2 300315

New K-FACTOR = Old K-FACTOR x Target APRActual APR

New K-FACTOR = 1000 x = 1053 109.5

OPERATOR’S MANUAL


138 / APPENDIX A CONVERTING CONSTANTS

CALCULATING SPREADER CONSTANTSThe spreader constant can be calculated if the following is known:

A = Number of pulses per revolution of the sensor shaft.B = Turns of the sensor shaft for each turn of the final shaft.C = Pounds of material discharged per revolution of the final shaft.

EXAMPLE:

A = 360 pulses per revolution (for Dj sensor p/n 46436-017X).B = 25 turns of the sensor shaft for each turn of the final shaft.C = 50 pounds of material discharged per revolution of final shaft.

NOTES:

1. V-Box spreaders have a different SPR CON for each gate setting.2. The number of pulses per revolution for several Dj shaft sensors are:

360 for p/n 46436-017X (standard DICKEY-john shaft sensor).60 for p/n 10844-000X180 for p/n 464361500S1

SPR CON = Pulses Per PoundA x BC

SPR CON = = 180 P/LB 360 x 2550

Dealers have the responsibility of calling to the attention of their customers the following warranty prior to acceptance of an order from their customer for any DICKEY-john product.

DICKEY-john® WARRANTY DICKEY-john warrants to the original purchaser for use that, if any part of the product

proves to be defective in material or workmanship within one year from date of original

installation, and is returned to DICKEY-john within 30 days after such defect is discovered,

DICKEY-john will (at our option) either replace or repair said part. This warranty does not apply

to damage resulting from misuse, neglect, accident, or improper installation or maintenance; any

expenses or liability for repairs made by outside parties without DICKEY-john’s written consent;

damage to any associated equipment; or lost profits or special damages. Said part will not be

considered defective if it substantially fulfills the performance expectations. THE FOREGOING

WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES OF

MERCHANTABILITY, FITNESS FOR PURPOSE, AND OF ANY OTHER TYPE, WHETHER

EXPRESS OR IMPLIED. DICKEY-john neither assumes nor authorizes anyone to assume for it

any other obligation or liability in connection with said part and will not be liable for

consequential damages. Purchaser accepts these terms and warranty limitations unless the

product is returned within fifteen days for full refund of purchase price.

For DICKEY- john Service Department, call

1-800-637-3302 in either the U.S.A. or Canada

Headquarters: 5200 Dickey-john Road, Auburn, IL USA 62615 TEL: 217 438 3371, FAX: 217 438 6012, WEB: www.dickey-john.com

Europe: DICKEY-john Europe S.A.S, 165, boulevard de Valmy, 92706 – Colombes – France TEL: 33 (0) 1 41 19 21 80, FAX: 33 (0) 1 47 86 00 07 WEB: www.dickey-john.com

Copyright 2016 DICKEY-john Corporation Specifications subject to change without notice.

http://www.dickey-john.com/

http://www.dickey-john.com/

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OPERATOR’S MANUAL - DICKEY-john Master.compressed.pdf · 2019-02-08 · OPERATOR’S MANUAL Flex4 Control System 11001-1576B-201608 INTRODUCTION / 3 INTRODUCTION The DICKEY-john