Norac UC4.5 Installation Manual

Copyright  2014 by NORAC Systems International Inc. Reorder P/N: UC4.5-BC-SS1-INST Rev B (Sprayer Specialties 60’, 80’, 90’ Contour Boom) 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.

2 General UC4.5 System Layout ................................................................................. 2 3 Kit Parts ...................................................................................................................... 3 4 Pre-Install Checklist ................................................................................................... 7 5 Ultrasonic Sensor Installation .................................................................................. 8 6 Roll Sensor Installation ............................................................................................ 12 7 Electrical Installation ............................................................................................... 15 8 Hydraulic Installation .............................................................................................. 18 9 Software Setup ......................................................................................................... 22 10  Cable Drawings ........................................................................................................ 23 11  Appendix A – Optional Main Lift Sensor Installation .......................................... 31

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.

Figure 1 illustrates the general layout of the UC4.5 system components: Figure 1: General UC4.5 System Layout Do not use high speed power tools/drills when installing hardware. 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.

Item Part Number Name Quantity B01 44971-05 U-BOLTS WITH HARDWARE FOR LP BRACKET MOUNTING 2 B05 44706-01 KIT CABLE TIE BLACK 10 PCS 21 IN 150 PCS 7.5 IN 1 B17 44972 SENSOR MOUNTING BRACKET LOW PROFILE RAINFLAP 16GA 2 B20 44971 SENSOR MOUNTING BRACKET LOW PROFILE 16GA 2 C03 44656D CABLE VALVE VARIABLE RATE DT 1 C05 43210-15 CABLE UC5 NETWORK 18 AWG 15M 2 C07 43220-01 CABLE UC5 NETWORK 14 AWG 1M 1 C10 44650-50 CABLE UC4.5 POWER SELF-PROPELLED TYPE 1 C11 44651-50 CABLE UC4.5 EXTENSION VALVE GENERIC 1 C12 44658-18 CABLE VALVE UC4 AP2 MAIN 1 C13 44658-34 CABLE UC4 INTERFACE BYPASS GP2 1 C16 44658-111 CABLE INTERFACE UC4 ROLL SENSE GP 1 C30 43250-06 43250-06 CABLE UC5 BATTERY PIGTAIL FUSED - 5A 1 E01 45100 UC4.5 BOOM CONTROL PANEL 1 E03 43742 UC5 ROLL SENSOR W TEMPERATURE PROBE 1 E04 43741 UC5 ROLL SENSOR VER. 2 1 E05 43750 UC5 ULTRASONIC SENSOR 2 E11 43765 UC5 NETWORK COUPLER 8-WAY 1 E12 43764 UC5 NETWORK COUPLER 2-WAY 2 E20 43764T UC5 NETWORK COUPLER 2-WAY WITH TERMINATOR 2 H01 44863-06 HOSE ASSEMBLY 122R2-06 40 IN L 6FJX 6FJX90 2 H02 44863-29 HOSE ASSEMBLY 122R2-06 36 IN L 8FJX90 6FJX 2 H10 44865-74 HYDRAULICS FITTING KIT - SS 1 M01 UC4.5-BC-MANUAL- OPERATOR OPERATOR MANUAL UC4.5 SPRAY HEIGHT CONTROL 1 M02 UC4.5-BC-SS1-INST MANUAL INSTALLATION UC4.5 SPRAYER SPECIALTIES 1 P03 105882 UC5 NETWORK 6 PIN PLUG 3 V01 44963D VALVE BLOCK ASSEMBLY 2 STATION CC/LS PROP DT 4 BOLT 1 3.4 Optional Main Lift Kit An optional main lift sensor kit is available for purchase from NORAC. Part Number Name 4571BC UC4.5 MAIN LIFT OPTION - 44973

Item Part Number Name Quantity Picture F01 44928 ORIFICE INSERT .047 IN ONE WAY 2 F02 104369 PLUG - 6MBP 2 F03 103312 MALE ADAPTER - 6MB 6MJ 4 F04 103839 TEE ADAPTER - 6FJXR 6MJT 2 F05 42997-01 MALE ADAPTER - 8MB 8MJ - 1/32 ORIFICE 2 F06 104632 TEE ADAPTER 8FJXR 8MJT 4 6 M B - 6 M OR X 90 SIZE IN 1/16TH'S GENDER: MALE OR FEMALE 90° ANGLE SWIVEL TYPE GENDER SIZE TYPE: B - ORB J - JIC OR - FLAT FACE P - PIPE Fitting Name Example:

installation. 1. Unfold the sprayer over a flat, unobstructed area (i.e. no power lines…etc.). 2. Ensure all boom-fold operations are functional (place a check mark in boxes below). 3. Bring engine to field-operational RPM and record below. 4. Record the time (seconds) it takes for a full stroke for all boom functions. To ensure repeatable measurements, take the average of 3 trials. 5. Not all sprayers will have the functions listed below in Figure 4. Ensure the boom has sufficient travel so it does not contact the ground during these tests. Figure 4: Pre-Install Boom Speeds

5.1 Ultrasonic Sensor Serial Number Arrangement When installing the 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 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. Figure 5: Sensor Serial Number Arrangement

1. Minimize the distance between the bolts to prevent bending the bracket and prevent the bracket from loosening over time. 2. Ensure the bracket is mounted tight against the bottom of the boom, minimizing the distance between the boom structure and the angled flange. Figure 6: Bracket Mounting Guidelines A problem can arise if a sensor is not mounted correctly. It is possible for the sensor to read off of the boom instead of the ground. This may only become apparent once the control system is switched from soil to crop mode. Also be careful that the sensor bracket does not collide with any other part of the boom when the boom is folded to transport position. If possible, mount the sensor brackets while the booms are folded to ensure they will not cause interference.

1. The sensor bracket should be oriented forward (ahead of the boom). 2. Typically the best mounting location for the wing sensor brackets will be near the end of the boom tips, approximately two feet (60cm) from the end. 3. Depending on the boom design, some breakaway sections will lift upwards as they break back. If the sensor is mounted to this portion of the boom, the system will force the boom downwards towards the ground as the boom folds backwards. 4. Mount the sensor bracket onto the boom using the U-bolts provided (B01). 5. Mount the NORAC ultrasonic sensor into the sensor bracket and run the sensor cable 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. Figure 7: Bracket Mounting Example

120’ booms. 1. Insert one side of the rainflap rod into the pre-bent hinge tab on the sensor bracket. (Figure 8) Figure 8: Rainflap Rod in Pre-Bent Hinge Tab 2. Align the other side of the rainflap rod with the unbent hinge tab. (Figure 9) Figure 9: Align Rainflap Rod 3. Bend the hinge tab inward over the rainflap rod until the hinge tab fits securely in the detent groove on the backside of the sensor bracket. (Figure 10) Figure 10: Bend Rainflap Hinge Tab 4. Ensure the rainflap actuates smoothly when the bracket is turned upside down and returns to the open position when the sensor bracket is returned to its operating position (sensor pointing downwards toward the ground).

6.1 Bracket Assembly 1. Securely mount the roll sensors to the included roll sensor brackets using the #6 machine screws. Tighten screws to 10 in-lbs (1.1 Nm). 2. The orientation of the mounted roll sensor to the roll sensor bracket will depend on the bracket mounting. The roll sensor CANbus connector must be pointing towards the right side of the sprayer (when looking from the rear of the sprayer). Figure 11: Mounting Roll Sensor to Bracket Figure 12: Roll Sensor Orientation - Connector Facing Right Wing

1. When mounting the roll sensors, mount the roll sensor without the temperature probe on the boom frame and the roll sensor with the temperature probe on the chassis. Figure 13: Roll Sensor and 8-Way Coupler Mounting 2. Ensure the roll sensors are relatively level when the sprayer boom and chassis are level. 3. Both roll sensor cables should be pointing towards the right hand wing of the sprayer. 4. Ensure both roll sensors are mounted adequately and that the cables provide enough slack to allow sufficient boom roll. Chassis Roll Sensor With Temperature Probe Boom Frame Roll Sensor 8-Way Coupler

block using the included 3/8x1/2” bolt as illustrated in Figure 14. Figure 14: NORAC Valve Block with Temperature Probe Installed

will be clearly visible and within easy reach of the operator. A good spot to mount the UC4.5 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. 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 an existing mount. These are available at your local outdoor store as a RAM mount part number RAM-B-236. (See http://www.ram- mount.com/) Figure 15: Cable Configurations: C10, C11 and C30 2. Connect the UC4.5 power cable (C10) to the UC4.5 Control Panel in the cab. Ensure that both plugs (P16 and P4) are connected to the panel. Cable tie C10 to the RAM mount to help provide strain relief. 3. Connect cable C30 to P6A of C10 using a 2-way coupler (E12). Connect C30 to an appropriate power supply. Ensure the UC4.5 Control Panel’s power is OFF for the remaining installation. (Bottom of switch pressed IN). 4. Route the P12/P6 of C10 out of the cab. 5. Connect P12/P6 to R12/R6 of the extension cable (C11) outside of the cab. 6. Run cable C11 to the rear of the sprayer, in the vicinity of the valve block.

7. Connect the 3-pin tower (T3) on cable C16 to S3 on C11. 8. Insert the 2-pin tees (S2A-T2A - S2D-T2D) of C16 between the matching valve connections (Left Up, Left Down, Right Up, Right Down) on the sprayer valve block. 9. Connect the 6-pin shroud on cable C12 to T6 on C11. 10. Insert the 2-pin tees (S2A-T2A and S2B-T2B) of C12 between the matching valve connections (Main Up, Main Down) on the sprayer valve block. 11. Connect the 3-pin shroud (S3) on cable C13 to T3 on C11. 12. Insert the 2-pin tee of C13 between the bypass valve connection on the sprayer valve block. Figure 17: Interface Wiring Depiction Bypass Left Up Main Up Right Up Left Down Main Down Right Down

(C11). 14. Connect the 2-pin connectors on the valve interface cable to the NORAC valve block, as shown in Figure 18. 15. The connectors on the valve cable (C03) 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 18: Valve Cable Connections 16. Fasten the 8-way coupler to the boom with cable ties as shown in Figure 13. Connect P6 on C11 to the 8-way coupler. 17. Connect the boom frame roll sensor to the 8-way coupler. 18. Connect the chassis roll sensor (temp. probe) to the 8-way coupler using cable C01 and a 2-way coupler (E12). 19. Connect two cables (C05) to the 8-way coupler and route along the booms to the wing sensors. Follow existing cables and hoses to be sure the cable will not be pinched or stretched. 20. 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 2-way coupler. Plug the sensor and the CANbus cable into the 2-way coupler. 21. Insert the 6-pin plugs (P03) into the remaining connections on the 8-way coupler. IMPORTANT: Provide enough slack in all cables to account for the movement of the main section, parallel lift, and FOLDING boom movement.

or fittings. Hydraulic pressure will exist on the wing tilt circuits unless the wings are being supported by other means. The hydraulic installation may be performed with the wings in transport position, resting on the ground or with the tilt cylinders fully extended. Component failure due to oil contamination is not covered under the NORAC UC4.5 system warranty. It is recommended that a qualified technician perform the hydraulic installation. 8.1 Valve Assembly 1. On a clean surface remove the plastic plugs from the block. 2. Install two 6MB 6MJ fittings (F03) into the “P” and “T” ports on the NORAC block. Tighten to 18 ft-lbs (24 Nm). 3. Insert the orifices (F01) into the “B” ports with the notch facing out. 4. Install the other two 6MB 6MJ fittings (F03) into the “B” ports on the NORAC block. Tighten to 18 ft-lbs (24 Nm). 5. Install the 6MBP plugs (F02) into the “A” ports on the NORAC block and tighten to 18 ft- lbs (24 Nm). Figure 19: NORAC Valve Block Details

Ensure that no hydraulic components will interfere with any sprayer parts or be pulled tight at any time. The recommended mounting location is on the cross beam between the parallel lift arms on the main section. 1. A suitable mounting location for the valve block is illustrated in Figure 20. 2. Insert the threaded rod into the block and use a hex nut to hold the rod. The block holes are 3/8” NC-1” deep. If bolts are used instead of the threaded rod, ensure the bolts thread in at least 3/8”. 3. Use the remaining hardware to secure the block to the sprayer. 4. Cut off excess threaded rod, if necessary. Figure 20: Valve Block Mounting

installed. 1. After the NORAC valves are mounted, the hydraulic hoses and fittings can be plumbed following the schematic in Figure 3. 2. Attach the 90° end of hose H01 to the NORAC valve block pressure port. 3. Route hose H01 to the sprayer valve block. Tee the hose into the sprayer pressure port using a 6FJXR 6MJT fitting (F04). (Figure 21) 4. Attach the 90° end of hose H01 to the NORAC valve block tank port. 5. Route hose H01 to the sprayer valve block. Tee the hose into the sprayer tank port using a 6FJXR 6MJT fitting (F04). (Figure 21) Figure 21: Pressure and Tank Tee Location 6. Remove the existing tees from the accumulators used for the wing tilt functions shown in Figure 22. Pressure Tee Tank Tee

7. Insert the 8MB 8MJ – 1/32 orifice fittings (F05) into each accumulator. Attach two of the 8FJXR 8MJT fittings (F06) in line on each accumulator as shown in Figure 23. Figure 23: Accumulator Hydraulic Fittings 8. Attach the 90° ends of hoses H02 to the tees installed on the accumulators. Route hoses H02 to the NORAC valve block. 9. Connect hoses H02 to the “B” ports on the NORAC valve block. 10. Connect the original hoses from the sprayer valve block and the wing cylinders to the tees installed on the accumulators. 11. Tighten all fittings before restarting the machine and attempting to run hydraulic functions. Right Tilt Accumulator Left Tilt Accumulator

Panel (E01) 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 and 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. 3. Turn on the power for the UC4.5 Control Panel using the switch on the side of its chassis. 4. 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).

10.3 ITEM C07: 43220-01 - CABLE UC5 NETWORK 14 AWG - 1M

For complete instructions for installing the main lift sensor, please refer to the manual included with the main lift kit. When installing the main lift option, the sensor bracket should be mounted as shown in Figure 24. Always follow the sensor mounting guidelines to ensure optimal sensor performance and prevent sensor measurement error. Figure 24: Main Lift Bracket Mounting Location Figure 25: Sensor Serial Number Arrangement with Main Lift Sensor

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