spray height controller - norac systemsbc+jd8a-instm.pdf · once the hydraulics have been...

John Deere 4830 and 4730 with

Active Roll and Proportional Main Lift

Installation Manual

Spray Height Controller

Improving the competitiveness of Industry and

Agriculture through Precision Measurement

Printed in Canada

Copyright 2005-08 by NORAC Systems International Inc.

Reorder P/N: UC4+BC+JD8A-INST Rev M (John Deere 4830 and 4730 with Active Roll and

Proportional Main Lift)

NOTICE NORAC Systems International Inc. reserves the right to improve products and their specifications without notice and without the

requirement to update products sold previously. Every effort has been made to ensure the accuracy of the information contained in this manual. The technical information in this manual was reviewed at the time of approval for publication.

TABLE OF CONTENTS

1 INTRODUCTION.................................................................................................................................. 1

2 GENERAL SYSTEM DESCRIPTION .................................................................................................. 2

3 PARTS LISTS ...................................................................................................................................... 3

4 INSTALLATION PROCEDURE ......................................................................................................... 10

4.1 EXISTING SYSTEM CHECK ............................................................................................................. 10 4.2 BOOM SPEED TEST...................................................................................................................... 10 4.3 WING SENSOR INSTALLATION....................................................................................................... 12 4.4 MAIN LIFT SENSOR INSTALLATION...................................................................................... 15 4.5 ROLL SENSOR INSTALLATION ....................................................................................................... 16 4.6 TARGET INSTALLATION AND ALIGNMENT....................................................................................... 17 4.7 HYDRAULIC INSTALLATION ........................................................................................................... 20 4.7.1 Roll Cylinder Installation........................................................................................................ 20 4.7.2 Expansion Block Assembly ................................................................................................... 21 4.7.3 Valve Mounting...................................................................................................................... 22 4.7.4 Hydraulic Plumbing ............................................................................................................... 24

4.8 ELECTRICAL INSTALLATION .......................................................................................................... 27 4.9 COMPLETING THE INSTALLATION .................................................................................................. 31 4.10 SYSTEM MAINTENANCE ................................................................................................................ 32

5 ELECTRICAL REFERENCE – CABLE DRAWINGS........................................................................ 33

5.1 ITEM C2: 44668 – SENSOR BRANCH CABLE ................................................................................. 33 5.2 ITEM C3: 44656D – CABLE VALVE VARIABLE RATE DT................................................................ 34 5.3 ITEM C10: 44650-39 – GENERIC SELF PROPELLED POWER CABLE............................................... 35 5.4 ITEM C11: 44651-03 – GENERIC VALVE EXTENSION CABLE ......................................................... 36 5.5 ITEM C14: 44658-30 – JD POWER INTERFACE CABLE.................................................................. 37 5.6 ITEM C15: 44602-01 – REMOTE HAND CONTROL BOX VER.1 RMR............................................... 38 5.7 ITEM C16: 44658-54 – INTERFACE CABLE ................................................................................... 39 5.8 ITEM C17: 44658-45D – UC4 MAIN LIFT CABLE DT..................................................................... 40 5.9 ITEM C70: 44658-08D – UC4 ROLL BIAS VALVE CABLE DT ....................................................... 41 5.10 ITEM C71: 44674 – CABLE UC3 SENSOR ROLL BIAS .................................................................. 42

1

1 INTRODUCTION

Congratulations on your purchase of the NORAC UC4+ Spray Height Controller. This system is

manufactured with top quality components and is engineered using the latest technology to

provide operating features and reliability unmatched for years to come.

When properly used the system can provide protection from sprayer boom damage, improve

sprayer efficiency, and ensure chemicals are applied correctly.

Please take the time to read this manual completely before attempting to install the system. A

thorough understanding of this manual will ensure that you receive the maximum benefit from

the system.

YOUR INPUT CAN HELP MAKE US BETTER! If you find issues or have suggestions

regarding the parts list or the installation procedure, please don’t hesitate to contact us via

the information given below:

Phone: 1-800-667-3921 Canada (Toll Free)

1-866-306-6722 United States (Toll Free)

(+33) 06 03 87 80 78 Europe

1-306-664-6711 all other regions

E-mail: [email protected]

Website: www.norac.ca

2

2 GENERAL SYSTEM DESCRIPTION

Figure 1 depicts the general system layout of the UC4+ Spray Height Control system.

Figure 1 – System Components and General Location

NOTICE:

Every effort has been made to ensure the

accuracy of the information contained in this

manual. All parts supplied are selected

specially to fit the sprayer to facilitate a

complete installation. However, NORAC

cannot guarantee all parts fit as intended due

to the variations of the sprayer by the

manufacturer. Please read this manual in

its entirety before attempting installation.

ATTENTION:

When installing the UC4+ Spray Height

Control system please be aware that at a

point in the installation your sprayer booms

will be inoperative until the installation is

complete. Any installation procedure

requiring boom movement will need to be

done first. Once the hydraulics have been

disconnected you must complete the

electrical installation before the booms

become operative.

3

3 PARTS LISTS

The parts that come with your UC4+ Sprayer Boom System are listed in Table 1. The item

number on the left side of this table references each part. Please ensure that all parts in your

kit are present before proceeding with your installation.

Table 1 – John Deere 30 Series Sprayer Boom Control system Parts

Item Part Number Name Quantity

B05 44706-01 KIT CABLE TIE BLACK 10 PCS 21 IN 150 PCS 7.5 IN 1

B07 44695-10 BRACKET SPRAYER FRAME TARGET ROLL BIAS CYLINDER REV C 1

B11 44740 MOUNTING BRACKET ROLL SENSOR UC4 1

B12 44741 MOUNTING BRACKET ROLL SENSOR TARGET UC4 1

B13 44728 MOUNTING BRACKET COMPLETE UC4 BREAKAWAY EXTENDED 2

B14 44743 MOUNTING BRACKET MAIN LIFT SENSOR UC4 PLUS 1

B15 105415 CLAMP EXHAUST 2IN PLATED 4

B16 105416 CLAMP EXHAUST 1-1/4 IN PLATED 4

B20 44700-10 MOUNTING KIT VALVE EXPANSION - 4 X 6IN STUDS 1

C02 44668 CABLE UC3 SENSOR BRANCH 1 AMP RECEPT 3 AMP PLUG BC 1

C03 44656D CABLE VALVE VARIABLE RATE DT 1

C10 44650-39 CABLE POWER GENERIC SELF-PROPELLED 1

C11 44651-03 CABLE EXTENSION VALVE GENERIC 1

C14 44658-30 CABLE INTERFACE UC4 BC C14 POWER JD 1

C15 44602-01 BOX SWITCH UC4 REMOTE HAND CONTROL VER.1 RMR 1

C16 44658-54 CABLE UC4 INTERFACE C16 MP2 RMAN LONG 1

C17 44658-45D CABLE VALVE UC4 BC MAIN DT 1

C70 44658-46D CABLE VALVE UC4 BC C5 ROLL DT WITH PIGTAIL 1

C71 44674 CABLE UC3 SENSOR ROLL BIAS 2

E01 4461BC+ UC4 PLUS BOOM CONTROL PANEL 1

E02 44631 UC4 ULTRASOUND SENSOR 4

E03 44641 UC4 PLUS ROLL SENSOR W TEMPERATURE PROBE 1

H01 44862-13 HOSE ASSEMBLY 122R2-04 36 IN L 4FORX 4FORX90 4

H02 44863-23 HOSE ASSEMBLY 122R2-06 32 IN L 6FORX 6FORX 3


H20 44865-36 HYDRAULICS FITTING KIT - JD8 1

H21 44865-37 HYDRAULICS FITTING KIT - JD9 1

H70 44865-38 HYDRAULICS FITTING KIT - ACTIVE ROLL 1

4

Item Part Number Name Quantity



H75 105480 HYD CYLINDER ROLL BIAS 1.75IN BORE X 7.125IN STROKE (6 SAE PORTS) REV C 1


M01 446BC+MAN7 OPERATOR MANUAL UC4+ SPRAY HEIGHT CONTROL 1

M10 UC4+BC+JD8A-INST MANUAL INSTALLATION UC4+ JOHN DEERE 30 SERIES W ACTIVE ROLL AND PROP ML 1

M70 100660 BOLT HEX NC GR5 PLTD 1/4X1 1

M71 100871 NUT LOCK NYLON NC PLTD 1/4 IN 1

V01 44963D VALVE BLOCK ASSEMBLY 2 STATION CC/LS PROP DT 4 BOLT 1

V70 44962D VALVE BLOCK ASSEMBLY EXPANSION DPOC PROP DT 4 BOLT 2

5

Table 2 – 44865-36 - Hydraulics Fittings Kit Details

Item Part Number Name Quantity Picture

F02 104691 TEE ADAPTER - 4FORXR 4MORT 5


F04 105226 MALE TO FEMALE ADAPTER - 4MOR 6FORX 1

F05 44917 MALE ADAPTER - 6MB-6MOR MACHINED ORB 4

F06 104693 MALE ADAPTER - 4MOR 4MB 1

F09 44916 MALE ADAPTER - 6MB 4MOR MACHINED ORB 4

6 M B - 6 M OR X 90SIZE IN

1/16TH'S

GENDER: MALE

OR FEMALE

90° ANGLESWIVEL

TYPE

GENDER

SIZE

TYPE:

B - ORB

J - JIC

OR - FLAT

FACE

P - PIPE

Fitting Name

Example:

The use of dielectric grease is not recommended on any NORAC electrical connections.

To ensure all stainless steel hardware does not gall or seize apply a light coating of the

supplied Permatex Anti-seize grease to all threaded parts upon installation. Permatex Anti-

seize lubricant is preferred, but other similar anti-seize products may be used.

6

Table 3 – 44865-38 - Active Roll Fittings Kit Details

These fittings are only used when installing the active roll option.



F11 105338 TEE ADAPTER - 12FORXOR 12MORT 1

F12 44916 MALE ADAPTER - 6MB-4MOR MACHINED ORB 4

F14 104694 MALE ADAPTER 4MOR 4FORX90 1

F07A 44928 ORIFICE INSERT .047 IN ONE WAY 1

F07B 44935 ORIFICE INSERT .042 IN ONE WAY 1

*NOTE: Fitting F14 may not be used for this installation

7

Table 4 - 44865-37 - Hydraulics Fittings Kit Details


*F03 104586 TEE ADAPTER - 6FORXR 6MORT 1

*F05 44917 MALE ADAPTER - 6MB 6MOR 1

*F08 44926 ORIFICE INSERT 3/64" 1

*F09 104369 PLUG - 6MBP 1

6 M B - 6 M OR X 90SIZE IN

1/16TH'S

GENDER: MALE

OR FEMALE

90° ANGLESWIVEL

TYPE

GENDER

SIZE

TYPE:

B - ORB

J - JIC

OR - FLAT

FACE

P - PIPE

Fitting Name

Example:

8

The parts that come with your UC4+ System are shown below in their general installation

configuration.

Figure 2 – UC4+ Spray Height Control System Components

9

Figure 3 – Hydraulic Plumbing Schematic

10

4 INSTALLATION PROCEDURE

4.1 EXISTING SYSTEM CHECK

It is necessary to check the existing system’s

functionality before installing the UC4+

Spray Height Control system.

1. Drive your sprayer onto a flat piece of

land, with unobstructed boom movement

(e.g. no power lines).

2. Test that all boom functions operate

correctly. As you test each function

check it off in Table 5.

It is necessary to test the boom

functions in all directions

Table 5 – Hydraulic System Function

Check Sheet

BOOM

FOLD

IN

FOLD

OUT UP DOWN

LEFT

MAIN

RIGHT

ROLL* N/A N/A

* Some sprayers may not have this function.

4.2 BOOM SPEED TEST

IMPORTANT:

Raise/lower all boom sections several

times to warm up the hydraulic system.

Grease all moving parts for consistent

results.

1. Lower each boom and main section as

close to the ground as possible.

2. Set your sprayer at field working RPM

on the throttle and mark this value in

Table 6.

You will need a stopwatch or a

watch that displays “seconds” for

the next step.

3. Raise the LEFT boom from its extreme

LOW position to the very TOP of its

travel. Record the time this takes in

Table 6, “Trial #1” for “Left UP”.

4. Lower the LEFT boom from its extreme

HIGH position to the BOTTOM of its

travel. Record this time in Table 6,

Trial #1 for “Left DOWN”.

Be careful when lowering the

booms so they don’t hit the

ground.

5. Similarly, record two more time trials

(Trial #2 & #3) for the LEFT boom and

record in Table 6.

6. Repeat Steps 1 through 5 for the RIGHT,

MAIN and ROLL functions.

Your sprayer may not have a roll

feature.

7. Average the three trials recorded for

each boom movement and record this

calculation in the “Average Time” slot in

Table 6.

8. These “Average Times” now represent

how quickly your system can react to

manual control. In Section 4.9, this

procedure is repeated with the UC4+

Spray Height Control system installed

for comparison and troubleshooting

purposes.

11

Table 6 – Boom Test Record (WITHOUT UC4+ Spray Height Control system)

Working RPM:

Boom Trial #1

[Sec]

Trial #2

[Sec]

Trial #3

[Sec]

Avg Time

[Sec]

Left UP

Left DOWN

Right UP

Right Down

Main UP

Main DOWN

Roll CW

Roll CCW

Table 7 – Boom Test Record (WITH UC4+ Spray Height Control system)

Working RPM:

Boom Trial #1

[Sec]

Trial #2

[Sec]

Trial #3

[Sec]

Avg Time

[Sec]

Left UP

Left DOWN

Right UP

Right Down

Main UP

Main DOWN

Roll CW

Roll CCW

12

4.3 WING SENSOR INSTALLATION

1. Assemble the Breakaway Sensor

Mounting Brackets (B13) as show in

Figure 4 and Figure 5.

Figure 4 – Breakaway Sensor Bracket

Exploded View

Figure 5 – Breakaway Sensor Mounting

Bracket Assembly

To assemble the breakaway sensor

bracket:

a) Assemble the bolt and nut into the

collar.

b) Grease the bottom edge of the collar

and the angled tube of the base.

c) Place the collar onto the angled tube

of the mounting base.

d) Install the spring between the collar

and the upper ring of the base.

e) Insert tube through assembly and

tighten the collar

If possible, mount the sensor

brackets while the booms are in

their folded position to ensure that

they will not interfere with

anything when the boom is folded

for transport.

2. The sensor mounting brackets can be

installed with the mounting base behind

(Figure 8) or in front of the tube (Figure

6).

Mounting the sensor bracket to

the break-away section of the

boom may cause the boom to drop

suddenly as a break-away occurs.

This will occur on break-away

sections which lift as they break

away.

For optimal boom tip protection, it

is recommended that the sensor be

mounted within approximately

two feet (60cm) of the boom tip.

Exhaust clamps (B15 and B16) can

be used if mounting the sensor

brackets to a portion of the boom

with round tubing.

Please refer to the UC4+ Spray Height

Control system warranty at the end of

the UC4+ Spray Height Control

system Operator’s Manual (M01) for

implications.

13

3. Mount the NORAC UC4+ ultrasonic

sensor (E02) into the sensor brackets.

The sensors should be oriented forward

(ahead) of the boom (see Figure 6 and

Figure 8).

When installing the UC4+ sensors

(E02), start with the smallest serial

number on the left hand side

proceeding to the largest serial

number on the right hand side

(Figure 9).

4. Sensor cables should run through the

mounting bracket tube and then behind

the member the bracket is mounted onto.

Cable-tie the connector in place. The

cable must not be allowed to hang below

the boom (Figure 6).

Figure 6 – Another Acceptable Mounting

Avoid mounting sensors in

locations where they may read

from parts of the boom as shown

in Figure 7.

Figure 7 – Poor Mounting

(Sensor Reading off Boom)

General mounting rules for UC4+

ultrasonic sensors:

a) In its lowest position, the sensor

mouth must be 9 inches or more

from the ground.

b) The bottom of the sensor must be at

least 9 inches in front of the spray

nozzles.

c) The bottom of the sensor must be at

least 9 inches above the spray

nozzles.

d) Ensure that there are no obstructions

within a 12-inch diameter circle

projected directly below the center of

the sensor.

e) The sensor should be approximately

vertical at normal operating heights.

Figure 8 – Sensor Mounting Guidelines

A B

B

D

C

Ultrasonic

Acoustic Cone

14

Figure 9 – Sensor Serial Number Installation Location

3 SENSOR SYSTEM

5 SENSOR SYSTEM

15

4.4 MAIN LIFT SENSOR INSTALLATION

1. Assemble the main lift sensor bracket

(B11) as shown in Figure 10.

Figure 10 – Main Lift Sensor Bracket

2. The bracket can then be mounted to the

lowest frame member on the center

section of the sprayer. The bracket

should be mounted so the sensor

mounting collar is in approximately the

center of the sprayer and ahead of the

boom (Figure 11 and Figure 12).

The sensor mounting collar must

not be behind the sprayer’s wheel.

The General Mounting Rules for

UC4+ Ultrasonic Sensors, from the

previous section, must be followed.

Figure 11 – Main Lift Sensor Bracket

Mounting Position

3. Mount the sensor onto the sensor

mounting collar (Figure 11).

Figure 12 – Main Lift Sensor Mounted in

the Correct Location

A common mounting location for the main

lift sensor on a John Deere sprayer is shown

in Figure 13. If desired, the tube part of the

bracket can be cut to a shorter length.

Figure 13 - Mounting Location of Main

Lift Sensor

Bracket Tube

Sensor

Mounting Tab

Sensor Mounting

Collar

Bracket Base

16

4.5 ROLL SENSOR INSTALLATION

For this installation, the roll sensor

is only being used for temperature

compensation.

1. Mount the roll sensor to the provided roll

sensor bracket.

Figure 14 – Mounting the Roll Sensor to

the Roll Sensor Mounting Bracket

2. Attach the roll sensor and roll sensor

bracket to the boom, near the NORAC

valve block using the provided cable ties.

3. Attach the temperature probe on the roll

sensor to the side of the NORAC valve

block, using the provided 3/8” bolt.

Figure 15 – UC4+ Valve Block with

Temperature Probe Installed

17

4.6 TARGET INSTALLATION AND ALIGNMENT

The sprayer must be level when

installing the UC4+ Roll Control

System. The sprayer booms

should be level as well, parallel to

the sprayer’s lift frame.

1. To ease the installation of the UC4+ Roll

Control system, unfold the sprayer on a

level area and lower the center section to

three or four feet above the ground. A

ladder or step will also be required to

complete the installation.

Figure 16 - Roll Control Items

Figure 17 - Typical Roll Control Install

2. Remove the rubber bumpers on both

ends of the roll frame (Figure 16).

3. Install the frame target (B07) onto the

parallel lift frame. The mounting bolt

should be close to the vertical member

of the frame facing forwards. See Figure

16 and Figure 17.

4. The frame target should be 41” (104cm)

from the bottom of the sensor as shown

in Figure 18.

The frame target (B07) should be

mounted to a frame member that

does NOT rotate with the boom.

Frame Target (B07)

Spring Target (B12)

Sensor Bracket (B11)

Remove the Rubber

Bumper

18

5. Install the spring target (B12) onto the

boom center section 16” (41cm) down

from the bottom of the sensor as shown

in Figure 18.

The spring target (B12) must be

mounted to a frame member that

does move with the boom.

Figure 18 – Target Location

6. Assemble the roll sensor mounting

bracket as shown in Figure 19.

7. Install the roll sensor bracket on the T-

shaped black intermediate frame, as

shown in (Figure 18). The required

mounting hardware is included with the

bracket.

The bracket rod is designed to

slide in the bracket collar to allow

for sensor alignment required in

Step 8.

The sensor should be mounted

between the parallel lift arms and

the wheel in a position that will not

interfere with folding.

The sensor should not be behind

the wheel.

Figure 19 – Roll Sensor Mounting

Bracket

8. Adjust the targets and sensor bracket

using a 4-foot level or a plumb line. The

goal of this step is to have the sensor

bracket and both targets in the proper

locations. The proper location of the

targets are as follows:

i) Spring target on the centerline of the

sensor.

ii) Frame target ½" to the left

(passenger) side of the centerline.

Ensure the sprayer is level AND

the booms are level when installing

the roll targets.

9. Hang a plumb line down the center of

the sensor mounting hole of the sensor

bracket. Check each target and compare

them to the proper location. See Figure

18.

i) Ensure that both the roll and spring

targets are perpendicular to the

sensor.

ii) If both targets are to one side of the

plumb line, adjust the location of the

spring target bracket using the

adjustable ball and socket mount.

iii) The frame target can be adjusted by

sliding the bracket along the parallel

lift frame. This target should be

located ½" off the centerline.

19

Figure 20 – Target Rod Alignment (Side View)

10. When the target positions are correct

ensure all mounting bolts are tight, then

double-check the target locations to

ensure that they haven’t drifted out of

position.

Some adjustment of the Sensor

Roll Bracket may be necessary to

achieve proper alignment.

11. Once alignment is correct, trim the top

rod so it is 1 inch past the edge of the

sensor, as shown above in Figure 20.

Spring Rod trimmed 1” past

edge of sensor (once

alignment is complete)

20

4.7 HYDRAULIC INSTALLATION

WARNING!

The hydraulic system creates very high

pressure. Before disconnecting any

hydraulic lines ensure all pressure has

been bled from the system. When

changing the boom hydraulic hoses leave

the booms in TRANSPORT POSITION.

IMPORTANT:

Component failure due to oil

contamination is not covered under the

UC4+ Spray Height Control system

warranty. It is recommended that a

qualified technician does the hydraulic

installation.

4.7.1 Roll Cylinder Installation

1. Remove the link arm (black square tube)

connected between the parallel lift frame

and roll frame. See Figure 21 for the

link arm location.

Figure 21 – John Deere Link Arm

Location

2. Install the roll cylinder (H75) in place of

the link arm (Figure 22).

3. Install the 6MB-6MOR (F12) fittings

into the cylinder.

4. Install the 4MOR-4FORX90 (F14)

fitting onto the cylinder fitting at the cap

end of the cylinder.

Figure 22 – Installed Roll Cylinder

In several cases, the lower cylinder

mount on the roll control

hydraulic cylinder has failed. In

the documented cases, the bracket

has failed at the weld shown in

Figure 23. It is recommended that

all sprayers with roll control add

weld to the existing bracket to

prevent failure.

Some sprayers from 2005 and

newer already have gussets added

at the factory.

Figure 23 – Roll Cylinder Mount Weld

Locations

5. Install the 6MB-4MOR fittings (F12)

into the cylinder.

Link Arm

Roll Cylinder

21

4.7.2 Expansion Block Assembly

1. Remove the four 4MBP plugs from the 3

station valve block (Figure 24).

2. Coat the four o-rings in hydraulic oil and

install them into the expansion block.

Ensure the o-rings are seated properly.

3. Thread the 6” studs into the 2 station

valve block.

4. Attach the expansion blocks to the 2

station block using the included spring

washers and nuts. Tighten the nuts to 31

ft-lbs.

Figure 24 - NORAC Expansion Block Assembly

22

4.7.3 Valve Mounting

Orifices are not installed in the

NORAC two station valve block

for this sprayer because the John

Deere orifices in the wing cylinders

are used.

1. On a clean surface remove all plastic

plugs from the NORAC hydraulic Valve

(V01) (Figure 25).

2. Install the 6MB-6MOR fittings (F05) on

the "P" and "T" ports and tighten to 18

ft-lbs.

3. Install the 4MOR-4MB fitting (F06) into

the "S" port and tighten to 11 ft-lbs.

Figure 25 – NORAC Valve Block

4. Install the 6MB-4MOR fittings (F09)

into the "A" and "B" ports and tighten to

18 ft-lbs.

5. Install the orifice (*F08) and the 6MB

6MOR fitting (*F05) into the “B” port

of the first expansion block.

6. Install the 6MBP plug (*F09) into the

“A” port of the first expansion block.

7. Install the .047 orifice (F07A) into the

“B” port of the second expansion block

with the notch facing in. Install the

6MB-4MOR (F12) fitting into the “B”

port. Tighten to 18 ft-lbs (24 Nm).

8. Install the .042 orifice (F07B) into the

“A” port of the second expansion block

with the notch facing in. Install the

6MB-4MOR (F12) fitting into the “A”

port. Tighten to 18 ft-lbs (24 Nm).

10. Mount the NORAC valve (V01 and

V70) on the sprayer using the valve

mounting bracket.

11. Thread a nut onto the short threads of

each of the threaded studs.

12. Screw the short side of the threaded rods

into the bottom of the valve block and

tighten the hex nuts tight to the valve

block.

13. Place the valve block onto a frame

member, with the studs extending to the

other side of the member.

14. Slide the flat bar from the bracket over

the studs and install a spring washer and

nut onto each of the studs to hold the

bracket in place.

15. Tighten the two nuts so the valve block

is held on tight and cannot move.

16. Cut excess off of the rods, if necessary.

23

If you wish to use bolts, the bolts

should thread into the valve block

at least 3/8". The valve mounting

holes are drilled and tapped 3/8

NC-1" deep. The rule of thumb for

bolt length is 1-1/2" longer than

the tube size.

The recommended location for the

valve is on the angled cross tube of

the parallel linkage on the sprayer.

Orient the valve block so the "A"

and "B" ports face towards the

boom (Figure 27).

You must ensure no hydraulic

components will interfere with any

sprayer parts or be pulled tight at

any time.

Figure 26 – Valve Mounting Location

Figure 27 – Valve Mounting Example

24

4.7.4 Hydraulic Plumbing

WARNING!

From this point in the installation the

booms will be inoperative until the

electronics are fully installed.

1. After the NORAC valves are mounted,

the hydraulic hoses and fittings can be

plumbed. The plumbing for the

hydraulic circuit is shown schematically

in Figure 3.

2. Tee hose H71 into the sprayer’s main

hydraulic supply located on the left hand

side, under the rear corner of the cab

outside the frame. Be sure to connect

the tee fitting into the “EF” port of the

priority valve. Use the 12FORXR-

12MORT Tee fitting (F11) (Figure 28).

Figure 28 – Secondary Pressure Line

Connection

3. Route hose H71 to the NORAC valve

block, following existing hoses.

4. Attach the 6FORXR-6MORT tee fittings

(F10) to the P and T ports on the

NORAC Valve block.

5. Attach hose (H71) to the 6FORXR-

6MORT tee fitting (F10) in the P port on

the NORAC valve block.

6. Tee hose H78 into the inlet on the

sprayer’s hydraulic in-line filter using a

6FORXR-6MORT tee fitting (F10)

(Figure 29).

Figure 29 - Secondary Tank Line (H78)

(teed into the tank return near the in-line

filter)

The load-sense return line (also teed

into the in-line filter) has an orifice

between the fittings. Ensure the

orifice is located in a manner that it

will not restrict the flow of the new

tank line (H78). In Figure 30,

illustration A shows the original

plumbing of the load sense return and

orifice. B and C show two options for

installation of the tee fitting.

Tee Fitting

(F10)

Hose H78

In-line Filter

25

A B C

Figure 30 – Secondary Tank Line Install

(Load Sense = LS, NORAC Secondary Tank Line = TL)

7. Route the other end of hose H78 to the

NORAC valve block, following existing

hoses. Connect it to the 6FORXR-

6MORT tee fitting (F10) in the T port of

the NORAC valve block.

8. Connect the NORAC supplied hoses

(H02) to the Pressure (P) and Tank (T)

ports on the NORAC valve block.

9. Tee the hoses, H02 (P and T lines), into

the ports on the sprayer valve block with

6FORXR-6MORT fittings (F03) and

6MB-6MOR fittings (F05). The elbow

fittings currently in place must be

replaced by the 6MB-6MOR fitting

(F05).

10. The existing hoses that run to the boom

tilt cylinders should be disconnected

from the sprayer valve block. Place the

4FORXR 4MORT fittings (F02) in line

with the JD valve block and the existing

boom tilt cylinders.

11. Attach the 90 degree fitting from hose

H01 to the 4FORXR 4MORT fittings

(F02).

12. Attach the other end of the hoses H01 to

the NORAC valve block “A” and “B”

ports.

13. The “raise” lines must be connected to

the "B" ports of the NORAC valve

block.

14. The "A" ports of the NORAC block

must be connected to the “lower” lines

of the cylinders.

15. Connect one end of the hydraulic hoses

(H72) to the second NORAC expansion

valve block’s “A” and “B” ports.

16. Route the other end of the hoses to the

roll cylinder previously installed.

17. Attach the hose connected to the “B”

port of the second expansion block to the

rod end of the cylinder.

18. Connect the hose connected to the “A”

port of the second expansion block to the

cap end of the cylinder.

19. Connect the NORAC supplied hose H06

to the Load Sense (S) port on the

NORAC valve block.

20. Route the Load Sense Line (H06) to the

shuttle valve manifold located

underneath the sprayer (Figure 33).

21. Tee the Load Sense line (H06) directly

in to the S port of the shuttle valve

26

manifold using fittings F03 and F04 as

shown in Figure 3. The shuttle valve is

located on the bottom of the sprayer as

shown in Figure 33.

22. Attach hose H02 to port B on the first

expansion block. Route the free end of

the hose (H02) to the John Deere main

lift tee, which is located on the right

hand end of the John Deere valve block

(Figure 31).

Figure 31 - Main Lift Tee Location

23. Disconnect the John Deere main lift tee

and insert the supplied 6FORXR

6MORT tee fitting (*F03). Attach the

hose (H02) to the 6FORXR 6MORT tee

fitting (*F03). (Figure 32)

You must ensure no hydraulic

components will interfere with any

sprayer parts or be pulled tight at any

time.

Figure 32 - Main Lift Tee Fitting Installed

Figure 33 – JD Shuttle Valve Location

Main Lift Tee

*F03 H02

H06

F03

27

ROP 4.8 ELECTRICAL INSTALLATION

1. Install the UC4+ Control Panel (E01) in

the cab of the sprayer. Mount the panel

where it will be clearly visible and

within easy reach of the operator.

A good spot to mount the UC4+ control

panel is on the right hand side of the cab

to the Roll Over Protection Bar. Four

pilot holes for the screws provided need

to be drilled to facilitate the control

panel mounting.

If desired, a mounting bracket (part

#A53255) can be purchased from your

local John Deere dealer to allow the

UC4+ control panel to be mounted to the

existing John Deere terminal mount.

Another option is to purchase an adapter

for the flexible panel mount that has a

3/8" NC threaded stud on the end to bolt

through the existing JD mount. You can

find these at your local outdoor store as a

RAM mount part number RAM-B-236.

(See http://www.ram-mount.com/)

Figure 34 – Control Panel Mounting

Figure 35 – JD Control Panel Mounting

ROP

28

Figure 36 – Cable Configurations: C10, C11, C14 and C15

2. Connect R10 and P4 on the UC4+

power cable (C10) to the mating

connectors on the UC4+ Control Panel

(E01) (Figure 36).

Ensure the UC4+ Control Panel’s

power is OFF for the remaining

installation. (Bottom of switch

pressed IN).

3. Plug the 3-pin connector on C14 into the

cab’s power bar.

4. Find a suitable location to mount the

hand control (C15) in the cab where it is

easily accessible.

The cable on C15 must be able to

reach to the mating cable (P16B)

on the UC4+ power cable.

5. Attach connector R16B on the hand

control cable (C15) to connector P16B

on the UC4+ power cable (C15).

6. Route the free ends of C10 along the

side of the cab post and under the floor

mat.

Figure 37 – Hole under Floor Mat

7. Route the free end (R16) of C10 out the

hole under the floor mat (Figure 37).

The hole in the floor may be

covered by a plate, or a grommet

may be installed in the hole. They

can be reinstalled after the wiring

is complete. NORAC supplies a

grommet for the hole if one does

not exist.

The hold in the floor may be too

small for the connector. In this

situation the cable can be routed

out the back of the cab through an

opening close to the bottom of the

rear, right window (Figure 38).

29

Figure 38 - Alternate Cab Exit for

Cabling

8. Attach the valve extension cable (C11)

to C10 (Figure 36).

9. Route the valve extension cable (C11) to

the rear of the sprayer near the sprayer

valve block. Run the cable along the

sprayer frame with the JD harness.

10. Connect the variable rate valve cable

(C03) to the valve extension cable (C11)

(Figure 39).

11. Install the 2-pin connectors from C03

onto each NORAC valve as shown in

Figure 40. The connectors are marked

RIGHT UP, LEFT UP, RIGHT

DOWN and LEFT DOWN. Cables

labeled with UP go on the same side as

the hydraulic hoses.

Figure 39 – Cable Configurations: C70, C17, C11, C16 and C03

12. Connect the six pin shroud (T6B) on

cable C17 to the mating tower on the

valve extension cable (C11).

13. Connect the three pin tower (T3) on

cable C17 to the mating tower on the

valve extension cable (C11).

One connector on C17 will remain

disconnected. It is used when

installing other UC4+ options.

14. Install the two 2-pin connectors on the

end of cable C17 to the first expansion

block.

The connector marked “Main Up”

goes on the same side of the block as

the hoses.

15. Connect the roll control cable (C70) to

S3 on cable C17.

16. Install the 2-pin connectors from C70

onto the second expansion block with

Cab Exit

30

the connector labeled BIAS UP on the

same side of the block as the hoses.

The two free wires on C70 should

be trimmed and sealed with

heatshrink or silicone so they do

not short together or get tangled in

other components.

Figure 40 – Valve Cable Connections

17. Connect S3 on cable C16 to the valve

extension cable C11.

18. Route the free end of C16 under the

sprayer to the shuttle valve manifold.

Unplug the load sense jam valve

connector (Figure 41) and plug in the

tower connector from C16. Connect the

load sense jam valve connector to the

free connector on C16.

19. Connect the Sensor Roll Bias cable

(C71) to the valve extension cable

(C11).

20. Route cable C71 to the roll sensor.

21. Connect the sensor branch cable (C02)

to the free connector on cable C71

(Figure 42).

Figure 41 – Load Sense Jam Valve

Connector

22. Route the sensor branch cable (C02) to

the wing and main sensors. Follow

existing cables and/or hydraulic lines

along the boom.

Route the main lift cable through

the main lift mounting bracket

tube to provide additional cable

protection

23. Cable-tie the installed cables every 12

inches.

IMPORTANT:

Provide enough slack in all cables to

account for the movement of the main

section, parallel lift, and FOLDING boom

movement.

Figure 42 – Cable Configurations: C11, C71 and C02

Connector

Location

Connector

31

4.9 COMPLETING THE INSTALLATION

1. Start up your sprayer and test the

sprayer’s functionality. The NORAC

Control Panel does not need to be

powered up for the original switches to

function. Unfold the booms and

raise/lower each boom and main section.

Confirm that the cabling/hoses are

agreeable to the entire range of

motion.

2. If any functions do not work, review the

hydraulic and electrical portions of this

manual to check for proper installation.

If you still have trouble, contact

NORAC for assistance.

3. Turn on the power for the UC4+ Control

Panel using the switch on the side of its

chassis.

4. Repeat the Boom Speed Test as

described in Section 4.2 Boom Speed

Test with the NORAC UC4+ Spray

Height Control system installed. Record

the results for comparison in Table 7.

5. The procedure for the installation of the

UC4+ Spray Height Control system is

now complete. Begin the AUTOMATIC

SYSTEM SETUP procedure as

described in the UC4+ Spray Height

Control system Operator’s Manual (M01).

32

4.10 SYSTEM MAINTENANCE

For good performance in corners, when

driving over terraces or through ditches at an

angle, or in hard steer situations it is

important to do the following:

a) The Teflon sliding pads on the boom

must not grab in dynamic situations

(corners, terraces etc). See the photos

below for the location of the sliding

pads.

b) Apply grease to the complete surface of

all sliding pads. Manually rotate the

boom (by pushing on the ends) to access

the entire surface of the pads when

greasing.

c) Ensure the sprayer operator continues

this maintenance for proper operation.

It is recommended that the pads be

re-coated with grease every 20

hours of operation.

Figure 43 – Sliding Pad Locations

Figure 44 – Upper Front Sliding Pad

Figure 45 – Lower Front and Rear

Sliding Pads

5 ELECTRICAL REFERENCE – CABLE DRAWINGS

5.1 ITEM C2: 44668 – SENSOR BRANCH CABLE

34

5.2 ITEM C3: 44656D – CABLE VALVE VARIABLE RATE DT

35

5.3 ITEM C10: 44650-39 – GENERIC SELF PROPELLED POWER CABLE

36

5.4 ITEM C11: 44651-03 – GENERIC VALVE EXTENSION CABLE

37

5.5 ITEM C14: 44658-30 – JD POWER INTERFACE CABLE

38

5.6 ITEM C15: 44602-01 – REMOTE HAND CONTROL BOX VER.1 RMR

39

5.7 ITEM C16: 44658-54 – INTERFACE CABLE

40

5.8 ITEM C17: 44658-45D – UC4 MAIN LIFT CABLE DT

41

5.9 ITEM C70: 44658-08D – UC4 ROLL BIAS VALVE CABLE DT

42

5.10 ITEM C71: 44674 – CABLE UC3 SENSOR ROLL BIAS

Canada

NORAC Systems International Inc.

CALL TOLL FREE: 1-800-667-3921

(306)664-6711

SHIPPING ADDRESS:

3702 Kinnear Place

Saskatoon, SK

S7P 0A6

United States

NORAC, Inc.

CALL TOLL FREE: 1-866-306-6722

(763)786-3080

SHIPPING ADDRESS:

1290 Osborne Rd NE, Suite F Fridley, MN

55432-2892

Europe

NORAC Europe sarl

(+33) 06 03 87 80 78

SHIPPING ADDRESS:

Rue de l’hermitage

01090 Guereins

France

www.norac.ca

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