Spray Height Control System Active Roll ControlTM Installation Manual (4-Bolt) Improving the competitiveness of Industry and Agriculture through Precision Measurement
Printed in Canada Copyright 2010 by NORAC Systems International Inc. Reorder P/N: 4467BC+4B-INST Rev D (Active Roll Control – 44962D) 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..........................................................................................................................................................
1 INTRODUCTION This kit provides the necessary hydraulic and electrical parts that will allow your sprayer to provide ACTIVE boom roll control. These parts integrate into your existing NORAC UC4+ Sprayer Height Control System for minimal setup of this feature. Every standard UC4+ Sprayer Height Control System ships with a Main Roll Sensor in the center of the booms. With your roll control option installed, this sensor will now do double-duty and be able to detect the pivot position of your booms.
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.
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 2: 44865-38 - Active Roll Fittings Kit Details Item Part Number Name 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 .
The parts that come with your Active Roll Control kit are shown below in their general installation configuration.
Figure 3: Hydraulic Plumbing Schematic 6
4 INSTALLATION PROCEDURE 4.1 TARGET INSTALLATION AND ALIGNMENT NOTE: It is very important that the rods be installed on the right hand side of the sprayer. 1. If your sprayer had roll sensors mounted on it, the roll sensors and roll sensor cable must be removed. 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. 2.
Remove Bumper the Rubber Sensor Bracket (B11) Spring Target (B12) Frame Target (B09) Figure 5: Typical Roll Control Install 3. Remove the rubber bumpers on both ends of the roll frame (Figure 5). 4. 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 4 and Figure 5. 5. The frame target should be 41” (104cm) from the bottom of the sensor as shown in Figure 6.
7. Assemble the roll sensor mounting bracket as shown in Figure 7. 8. Install the roll sensor bracket on the Tshaped black intermediate frame, as shown in (Figure 6). 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 9. 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.
Spring Rod trimmed 1” past edge of sensor. Figure 8: Target Rod Alignment (Side View) 11. 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. Viewed From Above Some adjustment of the Sensor Roll Bracket may be necessary to achieve proper alignment. 12.
4.2 HYDRAULIC INSTALLATION IMPORTANT: 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. Component failure due to oil contamination is not covered under the UC4+ Spray Height Control warranty. It is recommended that a qualified technician does the hydraulic installation. 4.2.1 Roll Cylinder Installation 1.
Roll Cylinder Figure 11: 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 12. 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.
4.2.2 Valve Mounting 1. Remove the four 4MBP plugs from the two station valve block. This valve block may already be installed on the sprayer. 6. Attach the expansion block to the 2 station block using the included spring washers and bolts. 2. Insert the 0.047” orifice (F07A) into the “B” port of the expansion block with the notch facing in (Figure 14). 7. Tighten the bolts to 31 ft-lbs Torque. 3. Insert the 0.
4.2.3 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 H71 into the sprayer’s main hydraulic supply located on the left hand side, under the rear corner of the cab outside the frame.
3. Route hose H71 to the NORAC valve block, following existing hoses. 4. Attach the 6FORXR-6MORT tee fittings (F10) to the “P” and “T” ports on the NORAC Valve block. 15 5. Attach hose (H71) to the 6FORXR6MORT tee fitting (F10) in the “P” port on the NORAC valve block. 6. Tee hose H78 into the inlet on the sprayer’s hydraulic in-line filter using a 6FORXR-6MORT tee fitting (F10) (Figure 18).
Hose H78 Tee Fitting (F10) In-line Filter Figure 18: Secondary Tank Line (H78) (teed into the tank return near the in-line filter) (H78). In Figure 19, illustration A The load-sense return line (also shows the original plumbing of teed into the in-line filter) has an the load sense return and orifice. orifice between the fittings. B and C show two options for Ensure the orifice is located in a installation of the tee fitting.
7. Route the other end of hose H78 to the NORAC valve block, following existing hoses. Connect it to the 6FORXR-6MORT tee fitting (F10) in the “T” port of the NORAC valve block. 8. Connect the disconnected “P” and “T” lines to the tees (F10) installed in the “P” and “T” ports on the NORAC valve block. 9. Connect one end of the hydraulic hoses (H74) to the NORAC 3rd station expansion valve block’s “A” and “B” ports. 10. Route the other end of the hoses to the roll cylinder previously installed. 11.
4.3 ELECTRICAL INSTALLATION Ensure the Trunk Cable that is routed to your Main Roll Sensor has enough slack for the movement of the center section and roll frame. The cable must be routed up the center of the roll frame and out to the sensor. 1. Route the Roll Control Valve Cable (C70) from the Power Cable (44650-14 (C10), see standard installation manual) in the cab to the rear of the sprayer. Follow the previously installed valve cable and trunk cable, and use cable ties to secure in place.
9. Cable tie all cables to existing hoses or cables. IMPORTANT: Provide enough slack in all cables to account for the movement of the main section, parallel lift and FOLDING boom movement.
4.4 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.
4.5 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.
5 ELECTRICAL REFERENCE – CABLE DRAWINGS 5.1 ITEM C70: 44658-08D – CABLE UC4 VALVE ROLL BIAS 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.
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