Spray Height Control System John Deere 4700, 4710, 4720 Active Roll Installation Manual 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+JD7A-INST Rev S (John Deere 4700, 4710, 4720 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... 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 Valve Mounting... 22 4.7.3 Hydraulic Plumbing... 24 4.8 ELECTRICAL INSTALLATION... 30 4.9 COMPLETING THE INSTALLATION... 35 4.10 SYSTEM MAINTENANCE... 36 5 ELECTRICAL REFERENCE CABLE DRAWINGS... 37 5.1 ITEM C01: 44662B-40 CABLE SENSOR TRUNK... 37 5.2 ITEM C02: 44668 CABLE SENSOR BRANCH... 37 5.3 ITEM C03: 44656D CABLE VALVE VARIABLE RATE DT... 38 5.4 ITEM C04: 44651 CABLE VALVE EXTENSION... 39 5.5 ITEM C10: 44650-14 CABLE UC4 POWER BOOM CONTROL JOHN DEERE... 40 5.6 ITEM C12: 44658-01 CABLE UC4 VALVE BC JD... 41 5.7 ITEM C70: 44658-08D CABLE UC4 ROLL BIAS VALVE DT... 42 5.8 ITEM C71: 44647 CABLE UC4 SENSOR ROLL BIAS... 43 6 APPENDIX A - INTERFACE CABLE MODIFICATION PROCEDURE... 44
1 INTRODUCTION Congratulations on your purchase of the NORAC UC4+ Spray Height Control System. 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. 1
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 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. 2
3 PARTS LISTS The parts that come with your UC4+ Spray Height Control 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 4720 Active Roll Spray Height 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 B09 44695-10 BRACKET SPRAYER FRAME TARGET ROLL BIAS CYLINDER REV C 1 B12 44741 MOUNTING BRACKET ROLL SENSOR TARGET UC4 1 B14 44740 MOUNTING BRACKET MAIN LIFT SENSOR UC4 PLUS 1 B16 105415 CLAMP EXHAUST 2IN PLATED 4 B18 44695-18 PIN ACTIVE ROLL CYLINDER UPPER JD 20MM ZINC 1 B20 44971 SENSOR MOUNTING BRACKET LOW PROFILE 16GA 2 B21 44973 SENSOR MOUNTING BRACKET LOW PROFILE 16 GA LARGE FLANGE 1 C01 44662B-40 CABLE UC4 SENSOR TRUNK AMPF TO AMPF BLACK STANDARD 40FEET 1 C02 44668 CABLE UC4 SENSOR BRANCH 1 AMP RECEPT 3 AMP PLUG BC 1 C03 44656D CABLE VALVE VARIABLE RATE DT 1 C04 44651 CABLE VALVE EXTENSION 1 C10 44650-14 CABLE POWER UC4 BOOM CONTROL JOHN DEERE 1 C12 44658-01 CABLE UC4 VALVE BC JD 1 C70 44658-08D CABLE UC4 VALVE ROLL BIAS DT 1 C71 44674 CABLE UC4 SENSOR ROLL BIAS 2 E01 4461BC+ UC4 PLUS BOOM CONTROL PANEL 1 E02 44631 UC4 ULTRASOUND SENSOR 4 E03 45000* UC4 PLUS ROLL SENSOR W TEMPERATURE PROBE VER. 2 1 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 44865-19 HYDRAULICS FITTING KIT - JD7 1 H21 44865-38 HYDRAULICS FITTING KIT - ACTIVE ROLL 1 H70 44864-04 HOSE ASSEMBLY 122R2-08 168 IN L 6FORX 12FORX 1 3
H71 44864-03 HOSE ASSEMBLY 122R2-08 166 IN L 6FORX 6FORX 1 H75 105480 HYD CYLINDER ROLL BIAS 1.75IN BORE X 7.125IN STROKE REV C 1 H76 44862-11 HOSE ASSEMBLY 122R2-04 60 IN L 4FORX 4FORX 2 M01 446BC+MAN7 OPERATOR MANUAL UC4+ SPRAY HEIGHT CONTROL 1 M10 UC4+BC+JD7A-INST MANUAL INSTALLATION UC4+ JOHN DEERE 4720 ACTIVE ROLL 1 M70 100660 BOLT HEX NC GR5 PLTD 1/4X1 1 M71 100871 NUT LOCK NYLON NC PLT ¼ IN 1 V01 44960D VALVE BLOCK ASSEMBLY 3 STATION CC/LS PROP DT 4 BOLT 1 * For systems purchased BEFORE October 1, 2011, the roll sensor part number is 44641. 4
Table 2: 44865-19 - JD7 Hydraulics Fittings Kit Details Item Part Number Name Quantity Picture F02 104691 TEE ADAPTER - 4FORXR 4MORT 1 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 F07 44916 MALE ADAPTER - 6MB-4MOR MACHINED ORB 4 F08 44928 ORIFICE INSERT.047 IN ONE WAY 4 F09 103381 PLUG - 4MBP 4 F15 105500 SETSCREW 1/4X3/8 1 5
Table 3: 44865-38 - 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 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 Fitting Name Example: SIZE IN 1/16TH'S GENDER: MALE OR FEMALE 6 M B - 6 M OR X 90 TYPE: B - ORB J - JIC OR - FLAT FACE P - PIPE 90 ANGLE SWIVEL TYPE GENDER SIZE 6
Table 4: Additional Parts Item Part Number Packed with: Name Quantity Picture M13 104557 44650-14 (C10) RUBBER GROMMET 1 M14 104302 44658-01 (C12) 6 WAY SHROUD (KEYED B&F) 1 M15 104303 44658-01 (C12) 6 WAY TOWER (KEYED B&F) 1 M16 104302 44651 (C04) 6 WAY SHROUD 1 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. 7
The parts that come with your UC4+ Spray Height Control System are shown below in their general installation configuration. Figure 2: UC4+ Spray Height Control Components 8
9 Figure 3: Hydraulic Plumbing Schematic
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. 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 FOLD IN BOOM LEFT MAIN RIGHT ROLL* N/A N/A FOLD OUT UP DOWN * 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. 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 installed for comparison and troubleshooting purposes. 2. Set your sprayer at field working RPM on the throttle and mark this value in Table 6. 10
Table 6: Boom Test Record (WITHOUT UC4+ Spray Height Control) 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) 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 11
4.3 WING SENSOR INSTALLATION 1. Mount the Low Profile Sensor Mounting Brackets (B20) onto the boom as show in Figure 4 and Figure 5 with the mounting base in front of the tube. 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. 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. Figure 4: Low Profile Bracket Mounting Please refer to the UC4+ system warranty at the end of the UC4+ Sprayer Boom Control Operator s Manual (M01) for implications. 2. Mount the NORAC UC4+ ultrasonic sensors (E02) into the sensor brackets. The sensors should be oriented forward (ahead) of the boom. Front Figure 5: Low Profile Bracket Mounted on Boom 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). 3. Sensor cables should run either through hole in the back or through the side cut-out and behind the bracket. Ensure the cable is clear of moving parts and will not be damaged during folding. Cable-tie the connector in place. The cable must not hang below the boom 12
Exhaust clamps (B16) can be used if mounting the sensor brackets to a portion of the boom with round tubing. General Mounting Rules for UC4+ Ultrasonic Sensors: a) In its lowest position, the sensor must be 9 inches (23 cm) or more from the ground. b) Ensure that there are no obstructions within a 12-inch diameter circle projected directly below the center of the sensor. c) The sensor should be approximately vertical at normal operating heights. Front Figure 6: Low Profile Bracket Mounted with Exhaust Clamps General Mounting Rules for Low Profile Brackets: a) Minimize the distance between the bolts to prevent bending the bracket and prevent the bracket from loosening over time. b) Ensure the bracket is mounted tight against the bottom of the boom, minimizing the distance between the boom structure and the angled flange. Figure 8: Sensor Mounting Guidelines Figure 7: Bracket Mounting Guidelines 13
Apply a light coating of the supplied Permatex Anti-seize grease to all threaded parts upon installation. Figure 9: Sensor Serial Number Installation Location 14
4.4 MAIN LIFT SENSOR INSTALLATION 1. Mount the bracket onto the lowest frame member on the center section of the sprayer. (Figure 11 and Figure 12). Figure 10: Main Lift Sensor Bracket Mounting Figure 12: Main Lift Sensor Bracket Mounting Position (Side View) The General Mounting Rules for Low Profile Brackets and the General Mounting Rules for UC4+ Ultrasonic Sensors, from the previous section, must be followed. 2. Mount the sensor into the bracket. Figure 11: Main Lift Sensor Bracket Mounting Position (Top View) 15
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 13: 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 14: UC4+ Valve Block with Temperature Probe Installed 16
4.6 TARGET INSTALLATION AND ALIGNMENT NOTE: It is very important that the rods be installed on the right hand side of the sprayer. 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. Sensor Bracket Roll Sensor 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. Roll Control Frame Bumper Spring Target Boom Centre Frame Frame Target Sprayer Parallel Lift Frame Figure 15: Roll Control Items Remove the Rubber Bumper Sensor Bracket (B14) Spring Target (B12) Frame Target (B09) Figure 16: Typical Roll Control Install 17
2. Remove the rubber bumpers on both ends of the roll frame (Figure 16). 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 15 and Figure 16. 4. The frame target should be 41 (104cm) from the bottom of the sensor as shown in Figure 18. The frame target (B09) should be mounted to a frame member that does NOT rotate with the boom. 5. Install the spring target (B12) onto the boom center section 16 (41cm) down from the bottom of the sensor as shown in Figure 17. The spring target (B12) must be mounted to a frame member that does move with the boom. Mount Frame Target as close to the vertical member as possible. 6. Assemble the roll sensor mounting bracket as shown in Figure 18. Figure 17: Target Location the wheel in a position that will not interfere with folding. 7. Install the roll sensor bracket on the T- shaped black intermediate frame, as shown in (Figure 17). 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 sensor should not be behind the wheel. Figure 18: Roll Sensor Mounting Bracket 18
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 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 17. 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. Spring Rod trimmed 1 past edge of sensor. Figure 19: 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 19. Spring Rod trimmed just past edge of sensor Figure 20: Sensor and Rod Alignment as Viewed From Above 19
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. 2. Install the roll cylinder (H75) in place of the link arm (Figure 22). When doing this the top pin in the link arm must be replaced with the supplied pin (B18). The snap ring on the existing pin can be used. 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. 5. When the cylinder is installed the bottom bolt must be tightened to 266 ft-lbs (350 Nm) and there should be no slop or free-play on the bottom bolt or the top pin. Any free movement will drastically reduce the active roll performance. Link Arm Position Figure 21: John Deere Link Arm Location 20
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 22: Installed Roll Cylinder Figure 24: Roll Cylinder Installed with Hoses Figure 23: Roll Cylinder Mount Weld Locations 21
4.7.2 Valve Mounting 1. On a clean surface remove all plastic plugs from the NORAC hydraulic Valve (V01). 2. Install the 6MB-6MOR fittings (F05) on the "P" and "T" ports and tighten to 18 ft-lbs. 3. Install the 4MOR-4MB (F06) into the "S" port and tighten to 11 ft-lbs. Figure 26: Valve Block Assembly 9. Mount the 6MB-4MOR fittings (F12) into the A and B ports on the NORAC 3 rd station block. Figure 25: NORAC Valve Block 4. Install two orifices (F08) into the "B" ports with the notch facing outward as shown in Figure 26. 5. Install the remaining orifices (F08) into the "A" ports with the notch facing inward as shown in Figure 26. 6. Install the 6MB-4MOR fittings (F07) into the "A" and "B" ports and tighten to 18 ft-lbs. 7. Insert the 0.047 orifice (F07A) into the B port of the 3 rd station of the block with the notch facing in (Figure 27). 8. Insert the 0.042 orifice (F07B) into the A port of the 3 rd station of the block with the notch facing in (Figure 27). Figure 27: Orifice Orientation 4. Remove the plug from the Sense Line Bleed port. Location is shown in Figure 28. Gently tap the plug with a hammer to loosen it before attempting to remove it. To access bleed orifice, remove the valve coil that is covering it, by unscrewing the nut on the coil. Remove the Sense Line Bleed Orifice and discard. 22
5. Install the setscrew (F11) into the Sense Line Bleed Orifice location. Ensure the setscrew is threaded entirely into the hole and tightened to 35-40 in-lbs to ensure a tight seal. Reinstall the plug and tighten to 35-40 in-lbs. Remove this coil 16. 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 30). Figure 28: Load Sense Bleed Orifice Location on Top of Block You must ensure no hydraulic components will interfere with any sprayer parts or be pulled tight at any time. 10. Mount the NORAC valve (V01) on the sprayer using the valve mounting bracket (B10). 11. Thread a nut onto the short threads of each of the threaded studs. 12. As shown in Figure 29, 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. Figure 29: Valve Mounting Location 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. Figure 30: Valve Mounting Example 23
4.7.3 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. 2. Tee hose H70 into the port on the priority valve labeled EF. This is located on the left hand side, under the rear corner of the cab outside the frame. Use the 12FORXOR- 12MORT Tee fitting (F11) (Figure 31). 6. Tee hose H71 into the inlet on the sprayer s hydraulic in-line filter using a 6FORXR- 6MORT tee fitting (F10). (Figure 32) Tee Fitting (F10) Hose H71 In-line Filter Figure 31: Secondary Pressure Line (H70) (teed into the priority valve EF port) 3. Route hose H70 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 (H70) to the 6FORXR-6MORT tee fitting (F10) in the P port on the NORAC valve block. Figure 32: Secondary Tank Line (H71) (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 (H71). In Figure 33, 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. 24
A B C Figure 33: Secondary Tank Line Install (Load Sense = LS, Tank Line = TL) 7. Route the other end of hose H71 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. 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). The P and T lines are located on the left side of the John Deere valve block. 9. Connect the free end of hose H02, installed at the JD P port, to the tee on the P port of the NORAC valve block. 10. Connect the free end of hose H02 installed on the T port of the JD block to the tee (F10) installed in the T port of the NORAC block. 11. Connect hose H74 to the Load Sense ( S ) port on the valve block. 12. Connect one end of the hydraulic hoses (H76) to the Norac 3 rd station valve block s A and B ports. 13. Route the other end of the hoses to the roll cylinder previously installed. 14. Attach the hose connected to the B port of the valve block to the rod end of the cylinder. 15. Connect the hose connected to the A port of the valve block to the cap end of the cylinder. 16. The existing hoses that run to the boom tilt cylinders should be disconnected from the sprayer valve block and reconnected to the NORAC valve block. a) The raise lines must be connected to the "B" ports of the NORAC valve block. The ports on the sprayer block must then be capped with 4MBP plugs (F09). b) The "A" ports of the NORAC block must be connected to the lower lines of the cylinders. The ports on the sprayer block must then be capped with F09. Most John Deere Sprayers have orifices in the "A" and "B" lines of the boom tilt cylinders. To remove the orifices you must remove the 25
fitting from the cylinder. The orifice is directly beneath the fitting. 17. Tee the Load Sense line (H06) directly in to the port S of the shuttle valve manifold using fitting F03 as shown in Figure 34, Figure 35 or Figure 36. There are multiple versions of JD load sense blocks on sprayers. Choose the picture that most closely resembles your sprayer valve block and tee in accordingly. On some installs the Load sense hose (H06) may be too long and the excess hose must be coiled and secured where it will not interfere with other components. F03 H06 Rear of Sprayer Figure 34: Looking towards the rear of the sprayer on a JD4700, JD4710 26
Rear of Sprayer Front view of block H06 F03 Figure 35: Load Sense Plumbing on some JD4710 27
Rear of Sprayer F03 H06 Figure 36: Load Sense Line Connection to John Deere Combination Valve Block 28
H06 F03 Figure 37: 2003+ Load Sense Line Connection 29
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 (ROP). Four pilot holes for the screws provided need to be drilled to facilitate the control panel mounting. ROP ROP 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 38: Control Panel Mounting Figure 39: JD Control Panel Mounting 30
Figure 40: Cable Configurations: C10, C01, C04 and C70 2. Connect the UC4+ power cable (C10) and sensor trunk cable (C01) to the UC4+ Control Panel (E01) (see Figure 40). 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 C10 into the cab s power bar. 4. Route the free ends of C10 and C01 along the side of the cab post and under the floor mat. 6. Plug in the 6-pin Tower on C10 to the 6-pin Shroud on the valve extension cable (C04). C04 and C70 come with one connector unassembled to allow the cables to be run through a hole in the floor under the steering column. To assemble these connectors, refer to the drawings in Section 5.4 and 5.7. The pins require a special tool to remove if an error is made. The cables may also be routed through the rear window of the cab. 7. Route the free ends of C01, C04 and C70 to the rear of the sprayer near the sprayer valve block. Run the cables along the sprayer frame with the JD harness. Figure 41: Hole under Floor Mat 5. Plug the 2 pin tower on C10 into the 2 pin shroud on the roll bias cable (C70). 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 (M13) for the hole if one does not exist. 31
Figure 42: Cable Configurations: C12, C03, C04 and C70 8. Connect the 6-pin Shroud on C04 to 6-pin Tower on the junction cable (C12) (Figure 42). 9. Connect the 6-pin Tower on the valve cable (C03) to 6-pin Shroud on C12. 10. C12 and C70 have screw terminals. They must be connected to the frame of the sprayer Scrape any paint off the frame where the terminal is mounted. A good location is the bolt holding the JD wiring harness next to the large connector at the rear of the sprayer frame. The terminal must be attached directly to the sprayer frame NOT the parallel linkage. An improper ground can cause UC4+ Spray Height Control malfunctions. 11. Insert the connectors labeled Main Up and Main Down on C12 into the main lift connectors on the John Deere solenoids (Figure 43). 12. Insert the other connectors on C12 into the tilt connectors on the John Deere solenoids (Figure 43). There is one set of different connectors (M14 and M15) included with the interface cable (C12). Some John Deere sprayers use this connector on the left down function. If your sprayer has this connector, remove the existing NORAC connectors using the included pin removal tool. Insert the wires into the new connector and ensure they are in the same position as they were in the previous connector. 32
Front of Sprayer Rear of Sprayer Figure 43: John Deere Boom Valve Block (top view) with Connectors Labeled Some older model John Deere sprayers (4700 and 4710) may have a different style boom valve block that has different connector arrangements. The NORAC interface cable (C12) 44658-01 will require modification. See Appendix A for modification procedure. 33
13. Connect the 4-pin square connector on the roll control cable (C70) to the roll connector on the JD harness (Figure 44). 4-pin Roll Connector Figure 44: JD Roll Connector 14. Install the 2-pin connectors from C03 onto each NORAC valve as shown in Figure 45. 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. 15. Connect the 2-pin connectors on C70 to the 3 rd station of the valve block. The 2-pin connector labeled BIAS UP connects to the same side of the valve block as the hoses. 16. Connect temperature sensor cable (C71) as shown in Figure 46. 17. Connect the Sensor Roll Bias cable (C71) to the trunk cable (C01). Route cable C71 to the roll sensor. 18. Connect the sensor branch cable (C02) to the free connector on cable C71 (Figure 46). 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. Figure 45: Valve Cable Connections IMPORTANT: Provide enough slack in all cables to account for the movement of the main section, parallel lift, and FOLDING boom movement. Figure 46: Cable Configurations: C01, C71 and C02 34
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. Again 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. If the roll direction is opposite to your preference when pressing the switches, you may reverse the direction by swapping the connectors on the 3 rd station block. 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 installed. Record the results for comparison in Table 7. 5. The procedure for the installation of the UC4+ Spray Height Control is now complete. Begin the AUTOMATIC SYSTEM SETUP procedure as described in the UC4+ Spray Height Control Operator s Manual (M01). 35
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: 1. 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. 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. 2. Check that the pin in the top of the cylinder is not loose and does not have any free movement or slop. The bottom cylinder mounting bolt torque must be checked regularly. The bolt must be tightened to 260 ft-lbs (350 Nm). Figure 48: Upper Front Sliding Pad 3. 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 49: Lower Front and Rear Sliding Pads Figure 47: Sliding Pad Locations 36
5 ELECTRICAL REFERENCE CABLE DRAWINGS 5.1 ITEM C01: 44662B-40 CABLE SENSOR TRUNK 5.2 ITEM C02: 44668 CABLE SENSOR BRANCH 37
5.3 ITEM C03: 44656D CABLE VALVE VARIABLE RATE DT 38
5.4 ITEM C04: 44651 CABLE VALVE EXTENSION 39
5.5 ITEM C10: 44650-14 CABLE UC4 POWER BOOM CONTROL JOHN DEERE 40
5.6 ITEM C12: 44658-01 CABLE UC4 VALVE BC JD 41
5.7 ITEM C70: 44658-08D CABLE UC4 ROLL BIAS VALVE DT * Connector S2 is shipped unassembled so that it can be passed through a hole in the floor of the cab. Insert the Red wire into the A cavity and the Black wire into the B cavity of the included connector. The pins require a special tool to remove if an error is made. 42
5.8 ITEM C71: 44647 CABLE UC4 SENSOR ROLL BIAS 43
6 APPENDIX A - INTERFACE CABLE MODIFICATION PROCEDURE Some earlier models of John Deere sprayers (4700 and 4710) may use a different style of boom valve block with a different arrangement of the connectors. As a result, the NORAC 44658-01 interface cable (C12) will need to be modified according to the following instructions (See Figure 50 and Figure 51 for before and after schematics): 1. Using the supplied GP Weatherpack pin tool, locate and carefully remove the blue/black wire tee (Main Down) from the A-position of the 4-pin flat connector tee (S4B & T4B). The blue wire is attached to a black wire that goes across the tee connection (remove both ends of this tee). 2. Locate and remove the brown wire (Left Down) from the A-position of the 6-pin flat shroud (S6A). 3. Insert blue/black wire tee from step 1 into the A-position of the 6-pin flat connector tee (S6A & T6A). Remove the cavity plug from the A-position of the 6-pin tower (T6A). square tee with the red wire (Right Up) in the C-position (S4C & T4C). Insert the green wire (Left Up) from step 5 into the A- position of the 4-pin shroud (S4C). Seal the A-position on the 4-pin tower (T4C) with the cavity plug removed in step 3. 8. Remove the black wire that goes across the connection in the A-position of the 4-pin flat tee with the white wire (Right Down) in the C-position (S4D & T4D). Insert the brown wire (Left Down) from step 2 into the A- position of the 4-pin shroud (S4D). Seal the A-position on the 4-pin tower (T4D) with the cavity plug removed in step 6. 9. The cable modifications are complete. There should be 2 black wires, an incomplete 4-pin square tee and an incomplete 4-pin flat tee left over. 10. Connect the modified harness to the sprayer as indicated in Figure 52. 4. Locate and remove the black wire (Main Up) from the A-position of the 4-pin square connector tee (S4A & T4A). This black wire is attached to a black tee wire similar to the wire described in step 1. 5. Locate and remove the green wire (Left Up) from the A-position of the 6-pin flat shroud (S6B). 6. Insert black wire tee from step 4 into the A- position of the 6-pin flat connector tee (S6B & T6B). Remove the cavity plug from the A- position of the 6-pin tower (T6B). 7. Remove the black wire that goes across the connection in the A-position of the 4-pin 44
45 Figure 50: Cable C12 (44658-01) BEFORE Modification
Figure 51: Cable C12 (44658-01) AFTER Modification 46
Figure 52: Early-Model John Deere Boom Valve Block (top view) with Connectors Labelled. (Valve may be different than illustrated.) 47
www.norac.ca 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 (952)224-4142 SHIPPING ADDRESS: 6667 West Old Shakopee Road, Suite 111 Bloomington, MN 55438 Europe NORAC Europe sarl (+33) (0)4 26 47 04 42 SHIPPING ADDRESS: Rue de l hermitage 01090 Guereins France