john deere 4830 and 4730 with active rollbc+jd8a-insth.pdf · c16 44658-54 cable uc4 interface c16...
TRANSCRIPT
John Deere 4830 and 4730 with
Active Roll
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 H (John Deere 4830 and 4730 Active Roll)
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 ............................. .............................................................................. 9
4.1 EXISTING SYSTEM CHECK ............................................................................................................... 9 4.2 BOOM SPEED TEST........................................................................................................................ 9 4.3 WING SENSOR INSTALLATION ....................................................................................................... 11 4.4 MAIN LIFT SENSOR INSTALLATION....................................... ............................................... 14 4.5 TARGET INSTALLATION AND ALIGNMENT ....................................................................................... 15 4.6 HYDRAULIC INSTALLATION ........................................................................................................... 18
4.6.1 Roll Cylinder Installation........................................................................................................ 18 4.6.2 Valve Mounting...................................................................................................................... 19 4.6.3 Hydraulic Plumbing ............................................................................................................... 21
4.7 ELECTRICAL INSTALLATION .......................................................................................................... 25 4.8 COMPLETING THE INSTALLATION .................................................................................................. 31 4.9 SYSTEM MAINTENANCE ................................................................................................................ 32
5 ELECTRICAL REFERENCE – CABLE DRAWINGS.............. .......................................................... 33
5.1 ITEM C2: 44668 – SENSOR BRANCH CABLE ................................................................................. 33 5.2 ITEM C3: 44656 – VALVE CABLE (VARIABLE RATE)...................................................................... 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 C70: 44658-46 – ROLL CABLE WITH PIGTAIL ...................................................................... 39 5.9 ITEM C71: 44674 – CABLE UC3 SENSOR ROLL BIAS .................................................................. 40
6 APPENDIX A – VALVE BLOCK CONNECTOR CHANGE.......... ..................................................... 41
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 is sues 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)
0-800-404-8389 United Kingdom (Toll Free)
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 (Rev B)
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
B10 44700-06 BRACKET VALVE MOUNTING STD 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
C02 44668 CABLE UC3 SENSOR BRANCH 1 AMP RECEPT 3 AMP PLUG BC 1
C03 44656 CABLE VALVE VARIABLE RATE 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
C70 44658-46 CABLE VALVE UC4 BC C5 ROLL WITH PIGTAIL 1
C71 44674 CABLE UC3 SENSOR ROLL BIAS 1
E01 4461BC+ UC4 PLUS BOOM CONTROL PANEL 1
E02 44631 UC4 ULTRASOUND SENSOR 4
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 2
H06 44862-05 HOSE ASSEMBLY 122R2-04 144 IN L 4FORX 4FORX 1
H20 44865-36 HYDRAULICS FITTING KIT - JD8 1
H70 44865-38 HYDRAULICS FITTING KIT - ACTIVE ROLL 1
H71 44864-02 HOSE ASSEMBLY 122R2-08 168 IN L 6FJX 12FORX 1
4
Item Part Number Name Quantity
H72 44862-11 HOSE ASSEMBLY 122R2-04 60 IN L 4FORX 4FORX 2
H75 105480 HYD CYLINDER ROLL BIAS 1.75IN BORE X 7.125IN STROKE (6 SAE PORTS) REV C 1
H78 44864-01 HOSE ASSEMBLY 122R2-08 166 IN L 6FJX 6FJX 1
M01A 446BC+MAN6-1 MANUAL UC4+ BOOM CONTROL 2008 OPERATORS LARGE BOOKLET 1
M01B 446BC+MAN6-2 MANUAL UC4+ BOOM CONTROL 2008 QUICK REFERENCE SMALL BOOKLET 1
M10 UC4+BC+JD8A-INST MANUAL INSTALLATION UC4+ JOHN DEERE 30 SERIES WITH ACTIVE ROLL 1
M70 100660 BOLT HEX NC GR5 PLTD 1/4X1 1
M71 100871 NUT LOCK NYLON NC PLTD 1/4 IN 1
V01 44933D VALVE BLOCK ASSEM UC5-BC 2-STATION CC/LS VARIABLE RATE DT CONNECTORS 1
V70 44952d VALVE ASSEMBLY EXPANSION DPC PROP DT 1
5
Table 2 – 44865-36 - Hydraulics Fittings Kit Details
Item Part Number Name Quantity Picture
F02 104691 TEE ADAPTER - 4FORXR 4MORT 5
F03 104586 TEE ADAPTER - 6FORXR 6MORT 3
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° ANGLESWIVELTYPEGENDERSIZE
TYPE:B - ORBJ - JICOR - FLAT FACEP - PIPE
Fitting Name Example:
6
Table 3 – 44865-38 (Rev E) - Active Roll Fittings Kit Details
These fittings are only used when installing the active roll option.
Item Part Number Name Quantity Picture
F10 104586 TEE ADAPTER - 6FORXR 6MORT 3
F11 105338 TEE ADAPTER - 12FORXOR 12MORT 1
F12 44916 MALE ADAPTER - 6MB-4MOR MACHINED ORB 4
F13 104907 MALE TO FEMALE ADAPTER - 6MJ 6FORX 2
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
Uc4+bc+jd
7
The parts that come with your UC4 System are shown below in their general installation configuration.
Figure 2 – UC4+ Spray Height Control System Components
*If your valves or cables appear different than shown, see Appendix A for more details.
8
Figure 3 – Hydraulic Plumbing Schematic
9
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 4.
It is necessary to test the boom functions in all directions
Table 4 – Hydraulic System Function Check Sheet
BOOMFOLD
INFOLD OUT UP DOWN
LEFTMAINRIGHTROLL* 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 5.
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 5, “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 5, 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 5
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 5.
8. These “Average Times” now represent how quickly your system can react to manual control. In Section 4.8, this procedure is repeated with the UC4+ Spray Height Control system installed for comparison and troubleshooting purposes.
10
Table 5 – 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 6 – 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
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4.3 WING SENSOR INSTALLATION
1. Assemble the Breakaway Sensor Mounting Brackets (B11) 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).
It is advised to avoid mounting the sensor bracket to a breakaway portion of the boom because a breakaway action can cause the UC4+ Spray Height Control system to force a boom close to the ground.
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.
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).
12
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
13
Figure 9 – Sensor Serial Number Installation Location
3 SENSOR SYSTEM
5 SENSOR SYSTEM
14
4.4 MAIN LIFT SENSOR INSTALLATION
1. Assemble the main lift sensor bracket (B14) 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
15
4.5 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 14 - Roll Control Items
Figure 15 - Typical Roll Control Install
2. Remove the rubber bumpers on both ends of the roll frame (Figure 14).
3. Install the frame target (B09) onto the parallel lift frame. The mounting bolt should be close to the vertical member of the frame facing forwards. See Figure 14 and Figure 15.
The frame target (B09) should be mounted to a frame member that does NOT rotate with the boom.
4. Install the spring target (B12) onto the boom center section 8-11/16" down from the top tube as shown in Figure 16.
Frame Target (B09)
Spring Target (B12)
Sensor Bracket (B11)
Remove the Rubber Bumper
16
The spring target (B12) must be mounted to a frame member that does move with the boom.
Figure 16 – Target Location
5. Assemble the roll sensor mounting bracket as shown in Figure 17.
6. Install the roll sensor bracket on the T-shaped black intermediate frame, as shown in (Figure 16). 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 7.
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 17 – Roll Sensor Mounting
Bracket
7. 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.
8. 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 16.
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.
17
Figure 18 – Target Rod Alignment (Side View)
9. 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.
10. Once alignment is correct, trim the top rod so it is 1 inch past the edge of the sensor, as shown above in Figure 18.
Figure 19 – Using a Plastic Tube to Help Align the Spring Target
Spring Rod trimmed 1” past edge of sensor (once alignment is complete)
18
4.6 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.
4.6.1 Roll Cylinder Installation
1. Remove the link arm (black square tube) connected between the parallel lift frame and roll frame. See Figure 20 for the link arm location.
Figure 20 – John Deere Link Arm Location
2. Install the roll cylinder (H75) in place of the link arm (Figure 21).
3. Install the 6MB-6MOR (F12) fittings into the cylinder.
4. Install the 4MOR-4FORX90 fitting onto the cylinder fitting at the cap end of the cylinder.
Figure 21 – 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 22. 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.
Link Arm
Roll Cylinder
19
Figure 22 – Roll Cylinder Mount Weld Locations
5. Install the 6MB-4MOR fittings (F12) into the cylinder.
4.6.2 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 23).
2. Install the 6MB-6MOR fittings (F05) on the "P" and "T" ports and tighten to 18 ft-lbs.
3. Install the 4MOR-4MB fittings (F06) into the "S" port and tighten to 11 ft-lbs.
Figure 23 – NORAC Valve Block
4. Install the 6MB-4MOR fittings (F09) into the "A" and "B" ports and tighten to 18 ft-lbs.
5. Remove the three 4MBP plugs from the UC4+ two station valve block (V01) (Figure 24).
Figure 24 – 2 Station valve block plug removal
6. Coat the three o-rings in hydraulic oil and install them into the expansion block.
Make sure the o-rings are properly seated.
Figure 25 – Expansion valve O-ring placement
7. If this is the only expansion block attached to the two station valve block, thread the 4.5” studs into the UC4+ block.
Bolts (3.5”) may be included in your kit as a substitution for the studs.
Remove these plugs
20
Figure 26 – Expansion valve stud insertion
8. If two expansion blocks are installed, 7” long studs are provided.
Bolts (6”) may be included in your kit as a substitution for the studs.
Figure 27 –Attaching two expansion valves
9. Attach the expansion block to the UC4+ block using the included spring washers and nuts.
10. Tighten the nuts on the studs to 31 ft-lbs Torque.
Figure 28 – Expansion valve final assembly
4. Insert the 0.047” orifice (F07A) into the “B” port of the expansion block with the notch facing in (Figure 29).
5. Insert the 0.042” orifice (F07B) into the “A” port of the expansion block with the notch facing in (Figure 29).
6. Mount the 6MB-4MOR fittings (F12) into the “A” and “B” ports on the NORAC expansion block.
Figure 29 - Expansion block orifice orientation
21
7. Mount the NORAC valve (V01 and V70) on the sprayer using the valve mounting bracket (B10).
8. Thread a nut onto the short threads of each of the threaded studs.
9. As shown in Figure 30, 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.
10. Place the valve block onto a frame member, with the studs extending to the other side of the member.
11. 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.
12. Tighten the two nuts so the valve block is held on tight and cannot move.
13. Cut excess off of the rods, if necessary.
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 31).
You must ensure no hydraulic components will interfere with any sprayer parts or be pulled tight at any time.
Figure 30 – Valve Mounting Location
Figure 31 – Valve Mounting Example
4.6.3 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.
22
2. Tee hose H71 into the sprayer’s main hydraulic supply located on the right hand side, under the rear corner of the cab outside the frame. Use the 12FORXR-12MORT Tee fitting (F11) (Figure 32).
Figure 32 – Secondary Pressure Line Connection
3. Route hose H71 to the NORAC valve block, following existing hoses. Attach the 6MJ-6FORX fitting (F13) to the end of the hose.
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. Use a 6FORXR-6MORT tee fitting (F11) and the 6MJ-6FORX adapter fitting (F13) (Figure 33).
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).
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.
A B C
Figure 33 – Secondary Tank Line Install
(Load Sense = LS, NORAC Secondary Tank Line = TL)
23
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, using a 6MJ-6FORX adapter fitting (F13).
8. Connect the Norac supplied hoses (H01) to the 6MB-6MOR fittings on the Norac valve block (V01) A and B ports.
9. Tee the hoses, H01 (A and B lines), into the ports on the sprayer valve block with 6FORXR-6MORT fittings (F03).
a) The “raise” lines must be connected to the "B" ports of the NORAC valve block.
b) The "A" ports of the NORAC block must be connected to the “lower” lines of the cylinders.
10. Connect one end of the hydraulic hoses (H72) to the Norac 3rd station expansion valve block’s “A” and “B” ports.
11. Route the other end of the hoses to the roll cylinder previously installed.
12. Attach the hose connected to the “B” port of the valve block to the rod end of the cylinder.
13. Connect the hose connected to the “A” port of the valve block to the cap end of the cylinder.
14. Connect the NORAC supplied hose H06 to the Load Sense (S) port on the NORAC valve block.
15. Route the Load Sense Line (H06) to the shuttle valve manifold located underneath the sprayer (Figure 34).
16. Tee the Load Sense line (H06) directly in to the port SB of the shuttle valve manifold as shown in Figure 34.
24
Figure 34 – Load Sense Line Connection
H06 or
H06A
F03
25
ROP 4.7 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 35 – Control Panel Mounting
Figure 36 – JD Control Panel Mounting
ROP
26
Figure 37 – 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) (see Figure 37).
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 38 – Hole under floor mat
7. Route the free end (R16) of C10 out the hole under the floor mat (Figure 38).
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.
27
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 39).
Figure 39 - Alternate cab exit for cabling
8. Attach the valve extension cable (C11) to C10 (Figure 37).
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.
Cab Exit
28
Figure 40 – Cable Configurations: C70, C11, C16 and C03
10. Connect the variable rate valve cable (C03) to the valve extension cable (C11) (Figure 40).
11. Install the square DIN connectors from C03 onto each NORAC valve as shown in Figure 41. The connectors are marked RIGHT UP , LEFT UP, RIGHT PORT and LEFT PORT . Cables labeled with PORT go on the side as the hydraulic hoses. Fasten with the included rubber seals and screws.
12. Connect the roll control cable (C11) to S3 on the valve extension cable.
13. Install the square DIN connectors from C70 onto the NORAC expansion block as shown in Figure 41.
The two free wires on C17 should be trimmed and sealed with heatshrink or silicone so they do not short together or get tangled in other components.
Figure 41 – Valve Cable Connections
14. Connect S3 on cable C16 to the valve extension cable C11.
15. Route the free end of C16 under the sprayer to the shuttle valve manifold. Unplug the load sense jam valve connector (Figure 42) and plug in the tower connector from C16. Connect the load sense jam valve connector to the free connector on C16.
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Figure 42 – Load Sense Jam Valve Connector
16. Connect the Sensor Roll Bias cable (C71) to the valve extension cable (C11).
17. Route cable C71 to the roll sensor.
18. Connect the sensor branch cable (C02) the free connector on cable C17 (Figure 43).
Figure 43 – Cable Configurations: C11 and C02
19. 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
20. 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.
Connector Location
Connector
30
31
4.8 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 6.
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 (M01A).
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4.9 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 44 – Sliding Pad Locations
Figure 45 – Upper Front Sliding Pad
Figure 46 – Lower Front and Rear Sliding Pads
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5 ELECTRICAL REFERENCE – CABLE DRAWINGS
5.1 ITEM C2: 44668 – SENSOR BRANCH CABLE
34
5.2 ITEM C3: 44656 – VALVE CABLE (VARIABLE RATE)
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
5.8 ITEM C70: 44658-46 – ROLL CABLE WITH PIGTAIL
40
5.9 ITEM C71: 44674 – CABLE UC3 SENSOR ROLL BIAS
41
6 APPENDIX A – VALVE BLOCK CONNECTOR CHANGE
Starting in January 2009, NORAC is changing the connectors on the boom height control valve block. The new style valve block will have 2-pin Deutsch connectors on the coils. The previous models had Hirschman style connectors as shown in Figure 2. The new style valve blocks and cabling look similar to Figure 47 and Figure 48. Your system may ship with either style valve block, both are functionally equivalent. The system will operate properly with either style of connector.
Figure 47: New two station valves and cabling with Deutsch connectors
Figure 48: New expansion block and cabling with Deutsch connectors
Displayed valve block 44933D replaces valve 44933S
Displayed valve block 44952D replaces valves 44952 and 44947
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
www.norac.ca