upgrade uc4+ active roll installation manual€¦ · h75 44695‐22 hyd cylinder ar 1.75in...

UC4.5 Upgrade from UC4+ Active Roll

Installation Manual

Printed in Canada

Copyright 2016 by NORAC Systems International Inc. Reorder P/N: 4590BC‐AR‐INST Rev B (UC4.5 Upgrade from UC4+ (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.

Contents

1 Introduction .................................................................................................................... 1

2 Parts Overview ................................................................................................................ 2

3 Component Removal ....................................................................................................... 4

4 Installation ...................................................................................................................... 6

5 Main Lift Sensor Installation .......................................................................................... 12

6 Roll Sensor Installation .................................................................................................. 13

7 Position Sensor Installation ........................................................................................... 14

8 Roll Cylinder Installation ................................................................................................ 17

9 Software Setup .............................................................................................................. 20

10 Cable Schematics ........................................................................................................... 21

1

1 Introduction

Congratulations on your purchase of the NORAC Spray Height Control System. This system is manufactured with top quality components and is engineered using the latest technology to provide operating 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.

Every effort has been made to ensure the accuracy of the information contained in this manual. All parts supplied are selected to specially 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.

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2 Parts Overview

2.1 General UC4.5 System Overview

Figure 1: General UC4.5 System Layout

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

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2.2 List of Parts (4590BC‐AR1)

Item Part Number Name Quantity

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

B09 45032‐1 BRACKET UC5 POSITION SENSOR MOUNT V1 2

B10 44695‐21 PIN ACTIVE ROLL JD UPPER MOUNTING KIT 1

C05 43210‐20 CABLE NETWORK 18 AWG 20M 2


C09 44644‐08 CABLE BUSMONITOR (DT FEMALE TO AMP MALE) 1

E03 43742 UC5 ROLL SENSOR W TEMPERATURE PROBE 1

E05 43750 ULTRASONIC SENSOR 3

E06 45030 UC5 POSITION SENSOR NF W/O HARDWARE 1

E11 43765 NETWORK COUPLER 8‐WAY 1


E20 43764T NETWORK COUPLER 2‐WAY WITH TERMINATOR REV‐B 2

H75 44695‐22 HYD CYLINDER AR 1.75IN W/INTERNAL SENSOR REV A 1

M01 UC4.5‐BC‐MANUAL‐OPERATOR

OPERATOR MANUAL UC4.5 SPRAY HEIGHT CONTROL 1

M02 4590BC‐AR‐INST MANUAL INSTALLATION UC4.5 UPGRADE FROM UC4+ (ACTIVE ROLL) 1

M06 45015 ANTI‐SEIZE LUBRICANT KIT 1

M07 106548 DRILL BIT 3/8" HSS STD JOBBER 1

P03 105882 NETWORK 6 PIN PLUG 1

2.3 List of Parts (4590BC‐AR2)

Item Part Number Name Quantity

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

B09 45032‐1 BRACKET UC5 POSITION SENSOR MOUNT V1 2

B10 44695‐21 PIN ACTIVE ROLL JD UPPER MOUNTING KIT 1



C09 44644‐08 CABLE BUSMONITOR (DT FEMALE TO AMP MALE) 1

E03 43742 UC5 ROLL SENSOR W TEMPERATURE PROBE 1

E05 43750 ULTRASONIC SENSOR 5

E06 45030 UC5 POSITION SENSOR NF W/O HARDWARE 1




E20 43764T NETWORK COUPLER 2‐WAY WITH TERMINATOR REV‐B 2

H75 44695‐22 HYD CYLINDER AR 1.75IN W/INTERNAL SENSOR REV A 1

M01 UC4.5‐BC‐MANUAL‐OPERATOR

OPERATOR MANUAL UC4.5 SPRAY HEIGHT CONTROL 1

M02 4590BC‐AR‐INST MANUAL INSTALLATION UC4.5 UPGRADE FROM UC4+ (ACTIVE ROLL) 1

M06 45015 ANTI‐SEIZE LUBRICANT KIT 1

M07 106548 DRILL BIT 3/8" HSS STD JOBBER 1

P03 105882 NETWORK 6 PIN PLUG 1

4

3 Component Removal

All ultrasonic sensor mounting brackets must remain on the machine.

3.1 4590BC‐AR1

1. Prior to installing the new components, remove the components listed in Table 1 from the boom (Figure 2).

Table 1: Parts to Remove – 4590BC‐AR1

Designator Quantity Part Number Description

C02 1 44668 Branch Cable

C71* 2 44674 Sensor Cables

B09 1 44695‐10 Sprayer Frame Bracket

B12 1 44741 Target Rod

H75 1 105480 Hydraulic Cylinder

B14** 1 44740 Mounting Bracket

* If applicable.

** If there is NOT a separate main lift sensor, relocate this bracket to be used for the main lift height sensor as shown in Section 5.

Figure 2: Active Roll ‐ Three Sensor System Layout

5

3.2 4590BC‐AR2

1. Prior to installing the new components, remove the components listed in Table 2 from the boom (Figure 3).

Table 2: Parts to Remove – 4590BC‐AR2

Designator Quantity Part Number Description

C02 1 44668 Branch Cable

C71* 2 44674 Sensor Cables

B09 1 44695‐10 Sprayer Frame Bracket

B12 1 44741 Target Rod

H75 1 105480 Hydraulic Cylinder

B14** 1 44740 Mounting Bracket

C02B 1 44669 Severe Terrain Cable

* If applicable.

** If there is NOT a separate main lift sensor, relocate this bracket to be used for the main lift height sensor as shown in Section 5.

Figure 3: Active Roll ‐ Five Sensor System Layout

6

4 Installation

4.1 Ultrasonic Sensor Serial Number Arrangement

When installing the ultrasonic sensors, start with the smallest serial number on the left‐hand side, and proceed to the largest serial number on the right hand side. Each ultrasonic sensor has a serial number stamped on the sensor housing.

Apply a light coating of the supplied Permatex Anti‐seize grease to all threaded parts upon installation.

A problem can arise if a sensor is not mounted correctly. This may only become apparent once the control system is switched from soil to crop mode.

7

4.2 UC4+ to UC4.5 Cabling Connection

1. Connect R4 of cable 44644‐08 (C09) to P4 (Figure 4) of the existing 44651‐03 cable (C11).

Figure 4: P4 on Cable 44651‐03 (C11)

2. Secure the 8‐way coupler (E11) to the center section of the boom using large zip ties.

3. Connect cable 44644‐08 (C09) to the 8‐way coupler (E11).

Figure 5: C11, C09, and E11 Connection

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4.3 4590BC‐AR1

Figure 6: 4590BC‐AR1 Layout

1. Route two 43210‐20 (C05) network cables to the outer sensor location on each boom tip from the 8‐way coupler (E11). Follow existing lines when routing these cables to avoid pinching or rubbing.

2. Mount an ultrasonic sensor in each outer wing bracket.

3. At the sensor brackets, attach a 2‐way coupler with terminator (E20) to the sprayer boom. The 2‐way coupler with terminator is the white two way coupler. Plug the sensor and the CANbus cable (C05) into the 2‐way coupler.

4. Mount an ultrasonic sensor in the main lift bracket. Connect to the 8‐way coupler (E11) using cable C07 and a 2‐way coupler (E12).

5. Mount the 43742 roll sensor (E03) using the guidelines in Section 6. Connect to the 8‐way coupler (E11).

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6. Mount the 45030 position sensor (E06) using the guidelines in Section 7. Connect to the 8‐way coupler (E11).

7. Mount the 44695‐22 hydraulic cylinder w/ internal position sensor (H75) using the guidelines in Section 8. Connect to the 8‐way coupler (E11) using cable C07 and a 2‐way coupler (E12).

8. Install the 6‐pin plug (P03) into the remaining open connections of the 8‐way coupler (E11).

9. Complete the hydraulic installation using the guidelines in Section 8.

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4.4 4590BC‐AR2

Figure 7: 4590BC‐AR2 Layout

1. Route two 43210‐10 (C05) network cables to the inner sensor location on each boom tip from the 8‐way coupler (E11). Follow existing lines when routing these cables to avoid pinching or rubbing.

2. Mount an ultrasonic sensor in each inner wing bracket.

3. At the sensor brackets, attach a 3‐way coupler (E10) to the sprayer boom. Plug the sensor and the CANbus cable (C05) into the 3‐way coupler.

4. Route two 43210‐10 (C05) network cables to the outer sensor location on each boom tip from the 3‐way coupler (E10). Follow existing lines when routing these cables to avoid pinching or rubbing.

5. Mount an ultrasonic sensor in each outer wing bracket.

6. At the sensor brackets, attach a 2‐way coupler with terminator (E20) to the sprayer boom. The 2‐way coupler with terminator is the white two way coupler. Plug the sensor and the CANbus cable (C05) into the 2‐way coupler.

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7. Mount an ultrasonic sensor in the main lift bracket. Connect to the 8‐way coupler (E11) using cable C07 and a 2‐way coupler (E12).

8. Mount the 43742 roll sensor (E03) using the guidelines in Section 6. Connect to the 8‐way coupler (E11).

9. Mount the 45030 position sensor (E06) using the guidelines in Section 7. Connect to the 8‐way coupler (E11).

10. Mount the 44695‐22 hydraulic cylinder w/ internal position sensor (H75) using the guidelines in Section 8. Connect to the 8‐way coupler (E11) using cable C07 and a 2‐way coupler (E12).

11. Install the 6‐pin plugs (P03) into the remaining open connections of the 8‐way coupler (E11).

12. Complete the hydraulic installation using the guidelines in Section 8.

12

5 Main Lift Sensor Installation

1. Assemble the main lift sensor bracket (B11) as shown in Figure 8.

Figure 8: Main Lift Bracket Assembly

2. There are a variety of ways to mount the main lift bracket on most sprayers. The bracket should position the sensor approximately in the center of the sprayer, forward of the boom. An example of this mounting is illustrated in Figure 9.

3. Mount the ultrasonic sensor to the main lift bracket. Run the sensor cable down the center of the main lift bracket tube.

Figure 9: Example Mounting of the Main Lift Bracket

Avoid mounting the main lift sensor over or near a wheel‐track. Measurements from the wheel‐track do not provide an accurate crop height and will cause measurement and control error.

Ensure the bracket does not collide with any other part of the sprayer throughout the full range of main lift motion.

13

6 Roll Sensor Installation

For this installation, the roll sensor is only being used for temperature compensation.

1. Securely mount the roll sensor to the included roll sensor bracket using the #6 machine screws. Tighten screws to 10 in‐lbs. (1.1 Nm)

2. Attach the roll sensor and roll sensor bracket to the boom, near the NORAC valve block using the provided cable ties.

3. Fasten the temperature probe from E03 to the NORAC valve block using the included 3/8x1/2” bolt as illustrated in Figure 11.

Figure 10: Mounting Roll Sensor to Bracket

Figure 11: NORAC Valve Block with Temperature Probe Installed

14

7 Position Sensor Installation

1. Remove the rubber bumpers on both ends of the roll frame if they have not been previously removed (Figure 12).

Figure 12: Rubber Bumper Location

2. The position sensor (E06) should be mounted such that the largest amount of travel of the sensor can be utilized without exceeding the travel limit. The sensor install length is 17” (430mm) center to center with ±3.5” (±90mm) travel recommended. It should be mounted in a location where the sensor will mount without binding or contacting and that is perpendicular to the direction of travel. Roll the boom fully in each direction and take measurements to ensure the travel limit is not exceeded.

3. Measure 12‐3/4” (325mm) from the centerline of the intermediate frame and boom center frame towards the left side of the sprayer (when looking from the rear of the sprayer).

Figure 13: Measurement from Centerline of Intermediate Frame (Looking from the rear)

Bumper

12‐3/4” (325mm)

15

4. Mount the brackets (B09) as shown in Figure 14, Figure 15 and Figure 16. Install two (2) cable ties per bracket.

Figure 14: Bottom Bracket Mounting

Figure 15: Top Bracket Mounting

Figure 16: Bracket Mounting (Looking from the Rear)

5. Install the base end of the position sensor with the cable facing the center of the sprayer in the lowest hole of the bracket possible without making contact with the boom frame. Use the mounting hardware as shown in Figure 17.

Figure 17: Mounting Hardware

Collar Bolt Nut Nut

16

6. Install the linear sensor mounting bolt in the hole of the upper bracket that closest aligns the end of the sleeve with the center of travel mark (black mark) on the sensor (Figure 18). If the mark is missing, the distance from the end of the sleeve to the top of the base should be 4” (100mm). The collar (Figure 17) clamps the sensor and prevents the rubber grommet from sitting on the bolt threads. Tighten the mounting hardware.

Figure 18: Center Mark Location

Centerline Mark

4” (100mm)

17

8 Roll Cylinder Installation

1. Remove the existing Active Roll cylinder connected between the parallel lift frame and roll frame. See Figure 19 for the cylinder location.

Figure 19: Active Roll Cylinder Location (looking towards rear of sprayer)

2. Remove the lower link bolt and nut

3. Roll the intermediate frame (where the cylinder is still attached) counterclockwise until the upper pin can be accessed. It may be helpful to use a jack or strap between the boom frame and the intermediate frame. Remove the snap‐ring from the pin. Remove the pin and cylinder.

4. Install the cylinder (H75) into the lower mount so that the cylinder ports face the front of the sprayer. Ensure the pivot sleeve is installed into the cylinder. Install the bolt through the cylinder and sleeve and torque to 250 ft‐lbs (339 Nm).

Figure 20: Lower Bolt Installation

Cylinder Position

18

5. Loosen the plastic port plugs and extend the cylinder to line up the hole in the intermediate frame and the cylinder.

6. Install B10 from the rear of the sprayer through the intermediate frame and the cylinder adding a mounting plate between both sides of the cylinder and the frame. Add the final plate to the front side of the intermediate frame.

Figure 21: Upper Pin Installation

7. Using the 3/8” drill bit (M10), center the rear plate and pin on the intermediate frame. Drill through the frame plate from the rear. Clamp the plate in place if desired.

8. After drilling through the first flange of the intermediate frame, align the mounting plates and slide the drill through all 3 plates to guide and drill through the second flange.

Figure 22: Drilling the Flanges

9. Deburr the holes. Install the mounting bolts into the holes and snug. Drill the second set of holes and install the mounting bolts. Torque the bolts to 20 ft‐lbs (27 Nm).

Note: Apply a small amount of Anti‐seize to each bolt prior to installing.

Figure 23: Upper Pin Installed

19

10. 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 24. 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 24: Roll Cylinder Mount Weld Locations

11. Install the 6MB‐6MOR fittings into the cylinder.

12. Install the 4MOR‐4FORX90 fitting onto the cylinder fitting at the cap end of the cylinder.

Figure 25: Roll Cylinder Installed with Hoses

20

9 Software Setup

1. Start up the sprayer and test the sprayer’s functionality. The display terminal does not need to be powered on for the original boom function switches to operate. Unfold the booms and raise/lower each boom and the main section.

Confirm that the cabling and hoses do not pinch, stretch or bind over the entire range of motion.

2. Turn on the power for the display terminal using the switch on the side.

3. The procedure for the installation of the UC4.5 Spray Height Control system is now complete. Begin the AUTOMATIC SYSTEM SETUP procedure as described in the UC4.5 Spray Height Control Operator’s Manual (M01).

21

10 Cable Schematics

10.1 Item C05: 43220‐10 ‐ Cable Network 14 AWG – 10m 43210‐20 – Cable Network 18AWG – 20m

22

10.2 Item C07: 43220‐01 ‐ Cable Network 14 AWG – 1m

23

10.3 Item C09: 44644‐08 ‐ Cable Busmonitor (DT Female to AMP Male)

CanadaNORAC Systems International Inc.

Phone: (+1) 306 664 6711 Toll Free: 1 800 667 3921

Shipping Address: 3702 Kinnear Place

Saskatoon, SK S7P 0A6

United States NORAC, Inc.

Phone: (+1) 952 224 4142 Toll Free: 1 866 306 6722

Shipping Address: 6667 West Old Shakopee Road, Suite 111

Bloomington, MN 55438

Europe NORAC Europe

Phone: (+33) (0)4 26 47 04 42 Shipping Address: Rue de l’hermitage 01090 GUEREINS

France

www.norac.ca

upgrade uc4+ active roll installation manual€¦ · h75 44695‐22 hyd cylinder ar 1.75in...

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