john deere 4700, 4710, 4720 active roll …bc+jd7a...reorder p/n: uc4+bc+jd7a-inst rev n (john deere...

John Deere 4700, 4710, 4720 Active Roll Installation Manual

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+JD7A-INST Rev N (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 C1: 44662B-40 – SENSOR TRUNK CABLE ............................................................................................. 37 5.2 ITEM C2: 44668 – SENSOR BRANCH CABLE .................................................................................................. 37 5.3 ITEM C3: 44656D – CABLE VALVE VARIABLE RATE DT ............................................................................... 38 5.4 ITEM C4: 44651 – VALVE EXTENSION CABLE ............................................................................................... 39 5.5 ITEM C10: 44650-14 – POWER CABLE .......................................................................................................... 39 5.6 ITEM C12: 44658-01 – UC4 JD JUNCTION CABLE ........................................................................................ 40 5.7 ITEM C70: 44658-08D – UC4 ROLL BIAS VALVE CABLE DT ....................................................................... 41 5.8 ITEM C71: 44647 – CABLE UC3 SENSOR ROLL BIAS ................................................................................... 42

6 APPENDIX A - INTERFACE CABLE MODIFICATION PROCEDURE ........................................................ 43

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 issues or have suggestions regarding the parts list or the installation procedure, please don’t hesitate to contact us.

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 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+ 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 Sprayer Boom 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

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 44674 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

C01 44662B-40 CABLE UC3 SENSOR TRUNK AMPF TO AMPF BLACK STANDARD 40FEET 1

C02 44668 CABLE UC3 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 UC3 BOOM CONTROL JOHN DEERE 1

C12 44658-01 UC3 CABLE VALVE BC JD REV-A 1

C70 44658-08D CABLE VALVE ROLL BIAS DT 1

C71 44674 CABLE UC3 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


H20 44865-19 HYDRAULICS FITTING KIT - JD7 1

H21 44865-38 HYDRAULICS FITTING KIT - ACTIVE ROLL 1



4

H75 105480 HYD CYLINDER ROLL BIAS 1.75IN BORE X 7.125IN STROKE REV C 1


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 numbers is 44641.

5

Table 2 – 44865-19 - JD7 Hydraulics Fittings Kit Details

Item Part Number Name Quantity Picture

F02 104691 TEE ADAPTER - 4FORXR 4MORT 1


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


F08 44928 ORIFICE INSERT .047 IN ONE WAY 4

F09 103381 PLUG - 4MBP 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 - Active Roll Fittings Kit Details

These fittings are only used when installing the active roll option.

Item Part Number Name Quantity Picture


F11 105338 TEE ADAPTER - 12FORXOR 12MORT 1


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

7

Table 4 – Additional Parts

Item Part Number Packed with: Name Quantity Picture

M13 104557 44650-14 (C10) RUBBER GROMMET 1

M14 104314 44658-01 (C12) 6 WAY SHROUD (KEYED A&F) 1

M15 104315 44658-01 (C12) 6 WAY TOWER (KEYED A&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.

8

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

9

Figure 3 – Hydraulic Plumbing Schematic

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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

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 6.

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.

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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

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4.3 WING SENSOR INSTALLATION

1. Assemble the Breakaway Sensor Mounting Brackets (B13) 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

2. Mount the sensor bracket onto the boom.

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.

3. The sensor mounting brackets can be installed with the mounting base behind (Figure 8) or in front of the tube (Figure 6).

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.

4. 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).

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 10).

5. Sensor cables should run through the mounting bracket tube and then behind the

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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

Figure 9 - Wing Sensor Mounting

A B B

D

C

Ultrasonic Acoustic Cone

14

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

Figure 10 – Sensor Serial Number Installation Location

3 SENSOR SYSTEM

5 SENSOR SYSTEM

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4.4 MAIN LIFT SENSOR INSTALLATION

1. Assemble the main lift sensor bracket (B14) as shown in Figure 11.

Figure 11 – 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 12 and Figure 13).

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 12 – Main Lift Sensor Bracket

Mounting Position

3. Mount the sensor onto the sensor mounting collar (Figure 12).

Figure 13 – 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 14. If desired, the tube part of the bracket can be cut to a shorter length.

Figure 14 - Mounting Location of Main Lift

Sensor

Bracket Tube

Sensor Mounting Tab

Sensor Mounting Collar

Bracket Base

16

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 15 – 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 16 – UC4+ Valve Block with

Temperature Probe Installed

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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.

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 17 – Roll Control Items

Figure 18 – Typical Roll Control Install

Bumper

Frame Target

Roll Control Frame

Sprayer Parallel Lift Frame

Sensor Bracket

Roll Sensor

Spring Target

Boom Centre Frame

Frame Target (B07)

Spring Target (B12)

Sensor Bracket (B11)

Remove the Rubber Bumper

18

2. Remove the rubber bumpers on both ends of the roll frame (Figure 18).

3. Install the frame target (B07) onto the parallel lift frame. The mounting bolt should be close to the vertical member of the frame facing forwards. See Figure 17 and Figure 18.

4. The frame target should be 41” (104cm) from the bottom of the sensor as shown in Figure 18.

The frame target (B07) 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 19.

The spring target (B12) must be mounted to a frame member that does move with the boom.

Figure 19 – Target Location

6. Assemble the roll sensor mounting bracket as shown in Figure 20.

7. Install the roll sensor bracket on the T-shaped black intermediate frame, as shown in (Figure 19). 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 wheel in a position that will not interfere with folding.

The sensor should not be behind the wheel.

Figure 20 – Roll Sensor Mounting

Bracket

Mount Frame Target as close to the vertical member as possible.

19

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 19.

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.

Figure 21 – 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 21.

Figure 22 - Sensor and Rod Alignment as

Viewed From Above

Spring Rod trimmed 1” past edge of sensor

Spring Rod trimmed just past edge of sensor

20

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 23 for the link arm location.

2. Install the roll cylinder (H75) in place of the link arm (Figure 24). 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.

Figure 23 – John Deere Link Arm Location

Link Arm Position

21

Figure 24 – 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 25. 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 25 – Roll Cylinder Mount Weld

Locations

Figure 26 – Roll Cylinder Installed with

Hoses

Roll Cylinder

22

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 27 – NORAC Valve Block

4. Install two orifices (F08) into the "B" ports with the notch facing outward as shown in Figure 28.

5. Install the remaining orifices (F08) into the "A" ports with the notch facing inward as shown in Figure 28.

6. Install the 6MB-4MOR fittings (F07) into the "A" and "B" ports and tighten to 18 ft-lbs.

Figure 28 – Valve Block Assembly

7. Insert the 0.047” orifice (F07A) into the “B” port of the 3rd station of the block with the notch facing in (Figure 29).

8. Insert the 0.042” orifice (F07B) into the “A” port of the 3rd station of the block with the notch facing in (Figure 29).

9. Mount the 6MB-4MOR fittings (F12) into the “A” and “B” ports on the NORAC 3rd station block.

Figure 29 - Orifice Orientation

23

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 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.

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.

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 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

24

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 32).

Figure 32 - 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.

6. Tee hose H71 into the inlet on the sprayer’s hydraulic in-line filter using a 6FORXR-6MORT tee fitting (F10). (Figure 33)

Figure 33 - 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 34, 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.

Tee Fitting (F10)

Hose H71

In-line Filter

25

A B C

Figure 34 – 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 3rd 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 fitting from the cylinder. The orifice is directly beneath the fitting.

26

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 35, Figure 36 or Figure 37.

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.

Figure 35 - Looking towards the rear of the sprayer on a JD4700, JD4710

Rear of Sprayer

F03

H06

27

Figure 36 - Load Sense Plumbing on some JD4710

Rear of Sprayer

Front view of block

H06

F03

28

Figure 37 – Load Sense Line Connection to John Deere Combination Valve Block

H06

F03

Rear of Sprayer

29

Figure 38 – 2003+ Load Sense Line Connection

H06

F03

30

ROP

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.

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 39 – Control Panel Mounting

Figure 40 – JD Control Panel Mounting

ROP

31

Figure 41 – Cable Configurations: C10, C1, C4 and C70

2. Connect the UC4+ power cable (C10) and sensor trunk cable (C01) to the UC4+ Control Panel (E01) (see Figure 41).

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.

Figure 42 – Hole under Floor Mat

5. Plug the 2 pin tower on C10 into the 2 pin shroud on the roll bias cable (C70).

6. Plug in the 6-pin Tower on C10 to the 6-pin Shroud on the valve extension cable (C04).

C04 comes with one connector (M16) unassembled to allow the cable to be run through a hole in the floor under the steering column. To assemble this connector (M16), refer to the drawing in Section 5.4. The pins require a special tool to remove them if you make an error.

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.

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.

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Figure 43 – 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 43).

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 44).

12. Insert the other connectors on C12 into the tilt connectors on the John Deere solenoids (Figure 44).

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.

33

Figure 44 - 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.

Rear of Sprayer

Front of Sprayer

34

13. Connect the 4-pin square connector on the roll control cable (C70) to the roll connector on the JD harness (Figure 45).

Figure 45 – JD Roll Connector

14. Install the 2-pin connectors from C03 onto each NORAC valve as shown in Figure 46. 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.

Figure 46 – Valve Cable Connections

15. Connect the 2-pin connectors on C70 to the 3rd 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 47.

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 47).

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.

Figure 47 – Cable Configurations: C01, C71 and C02

4-pin Roll Connecto

35

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 3rd 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).

36

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:

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 48 - Sliding Pad Locations

Figure 49 - Upper Front Sliding Pad

Figure 50 - Lower Front and Rear Sliding

Pads

37

5 ELECTRICAL REFERENCE – CABLE DRAWINGS

5.1 ITEM C1: 44662B-40 – SENSOR TRUNK CABLE

5.2 ITEM C2: 44668 – SENSOR BRANCH CABLE

38

5.3 ITEM C3: 44656D – CABLE VALVE VARIABLE RATE DT

39

5.4 ITEM C4: 44651 – VALVE EXTENSION CABLE

5.5 ITEM C10: 44650-14 – POWER CABLE

40

5.6 ITEM C12: 44658-01 – UC4 JD JUNCTION CABLE

41

5.7 ITEM C70: 44658-08D – UC4 ROLL BIAS VALVE CABLE DT

42

5.8 ITEM C71: 44647 – CABLE UC3 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 51 and Figure 52 for before and after schematics):

1. Using the supplied GP Weatherpack pin tool, 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. Insert blue/black wire tee from step 1 into the A-position of the 6-pin flat connectors, M14 and M15 (S6C & T6C), that are supplied in the zip lock bag with the cable (these connectors are keyed on the A and F position).

3. Locate and remove the green wire (Left Up) from the A-position of the 6-pin flat shroud (S6B). Also remove the 5 black wires from this tee (S6B & T6B). Use these 5 wires to tee the remaining positions of the two 6-pin connectors (S6C & T6C) used in step 2 together (BB, CC., DD… etc). Remove the cavity plug from the A-position of T6B for use in step 4. After this step, there will be 2 unused 6-pin flat connectors.

4. Remove the black wire that goes across the connection in the A-position of the 4-pin square tee with the red wire (Right Up) in the C-position (S4C & T4C). Insert the green wire (Left Up) from step 3 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.

5. Locate and remove the brown wire (Left Down) from the A-position of the 6-pin flat shroud (S6A). 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) into the A-position of the 4-pin shroud (S4D). A cavity plug will be removed in step 6 that may be used to seal the empty cavity created when removing the black wire from the 4-pin flat tower (T4D).

6. Locate and remove the black wire (Main Up) from 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. Insert black wire into the A-position of the 6-pin flat assembly removed in step 5 (S6A & T6A). This will require removing the cavity plug installed in the A-position of the 6-pin tower (T6A). The cavity plug can then be used to seal the empty socket created in step 5.

7. The cable modifications are complete. There should be 2 unused 6-pin flat connectors, 2 black wires, an incomplete 4-pin square tee and an incomplete 4-pin flat tee left over.

8. Connect the modified harness to the sprayer as indicated in Figure 53.

44

Figure 51 – Cable C12 (44658-01) BEFORE Modification

45

Figure 52 - Cable C12 (44658-01) AFTER Modification

46

Figure 53 - Early-Model John Deere Boom Valve Block (top view) with Connectors

Labelled. (Valve may be different than illustrated.)

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

www.norac.ca

john deere 4700, 4710, 4720 active roll …bc+jd7a...reorder p/n: uc4+bc+jd7a-inst rev n (john deere...

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