Norac Active Roll Control UC5 Series User manual

UC5 Active Roll ControlTM
JD 4930, 4940 (44952D)
Installation Manual
5467BC-3B-
J
D10

Printed in Canada
Copyright 2010 by NORAC Systems International Inc.
Reorder P/N: 5467BC-3B-JD10-INST Rev C (UC5 Active Roll Control–JD 4930,4940 44952D))
NOTICE: NORAC Systems International Inc. reserves the right to improve products and their specifications without notice and
without the requirement to update products sold previously. Every effort has been made to ensure the accuracy of the information
contained in this manual. The technical information in this manual was reviewed at the time of approval for publication.

Contents
1Introduction................................................................................................................ 1
2Technical Specifications ............................................................................................ 2
3General UC5 System Layout.................................................................................... 3
4Kit Parts ...................................................................................................................... 4
5Linear Roll Cylinder Installation............................................................................... 8
6Hydraulic Installation .............................................................................................. 13
7Electrical Installation ............................................................................................... 16
8Software Setup......................................................................................................... 18
9Cable Drawings ........................................................................................................ 19

1
1Introduction
Congratulations on your purchase of the NORAC UC5 Spray Height Control System. This
system is manufactured with top quality components and is engineered using the latest
technology to provide operating reliability unmatched for years to come.
When properly used the system can provide protection from sprayer boom damage, improve
sprayer efficiency, and ensure chemicals are applied correctly.
Please take the time to read this manual completely before attempting to install the system. A
thorough understanding of this manual will ensure that you receive the maximum benefit from
the system.
Your input can help make us better! If you find issues or have suggestions regarding the parts
list or the installation procedure, please don’t hesitate to contact us.
Note: Spring compression tool (John Deere part number: JDG10394) is required
for installation and is available from your John Deere dealer.
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.

2
2Technical Specifications
CAN ICES-3(A)/NMB-3(A)
This device complies with part 15 of the FCC Rules. Operation is subject to the following two
conditions: (1) This device may not cause harmful interference, and (2) this device must accept
any interference received, including interference that may cause undesired operation.
This equipment has been tested and found to comply with the limits for a Class A digital device,
pursuant to part 15 of the FCC Rules. These limits are designed to provide reasonable
protection against harmful interference when the equipment is operated in a commercial
environment. This equipment generates, uses, and can radiate radio frequency energy and, if not
installed and used in accordance with the instruction manual, may cause harmful interference to
radio communications. Operation of this equipment in a residential area is likely to cause
harmful interference in which case the user will be required to correct the interference at their
own expense.
This Class A digital apparatus complies with Canadian ICES-003.
Pursuant to EMC Directive – Article 9, this product is not intended for residential use.
Table 1: System Specifications
Supply Voltage (rated) 12VDC
Supply Current (rated) 10
A
Hydraulic Pressure (maximum) 3300 psi
Baud Rate 250 kbps
Clock Frequency (maximum) 96 MHz
Solenoid Valve PWM Frequency 300 Hz
Ultrasonic Sensor Transmit Frequency 50 kHz
Operating Temperature Range 0°C to 80°C

3
3General UC5 System Layout
Figure 1 illustrates the general layout of the UC5 system components:
Figure 1: General UC5 System Layout

4
4Kit Parts
4.1 Kit Overview
Figure 2: UC5 Roll Control Parts

5
4.2 Hydraulic Plumbing
Figure 3: UC5 Roll Control Hydraulic Plumbing

6
4.3 List of Parts
This kit is to be used when installing the Active Roll Control option with existing John Deere
4930 and 4940 installations that have a valve block that was purchased before December of
2010. These valve blocks require a 3-bolt expansion block.
Item Part Number Name Quantity
B25 44760 BRACKET MOUNTING LINEAR ROLL JD 4920 1
C03 43220-03 CABLE UC5 NETWORK 14 AWG 3M 1
C10 43230-04 CABLE UC5 VALVE 2PIN DT TO 2PIN DT 2
E05 43750 UC5 ULTRASONIC SENSOR 1
E12 43764 UC5 NETWORK COUPLER 2-WAY 1
H02 44863-31 HOSE ASSEMBLY 122R2-06 106 IN L 6FORX 6FORX 2
H12 44865-66 HYDRAULICS FITTING KIT - JD10A 1
H20 44752-C2 LINEAR ROLL CYLINDER 8IN 1
M02
5467BC-3B-JD10-INST MANUAL INSTALLATION UC5 ACTIVE ROLL CONTROL - JD 4930, 4940 (44952D)
1
P03 105882 UC5 NETWORK 6 PIN PLUG 1
V02 44952D VALVE ASSEMBLY EXPANSION DPOC PROP DT 1

7
4.4 Hydraulic Fitting Kit Details (P/N: 44865-65)
Item Part Number Name Quantity
Picture
F10 44927 ORIFICE INSERT .031 IN ONE WAY 1
F11 44975 ORIFICE INSERT .036 IN ONE WAY 1
F12 104590 90 DEGREE ADAPTER - 6MOR 6FORX90 2
F13 44917 MALE TO MALE ADAPTER - 6MB 6MOR 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:
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.

8
5Linear Roll Cylinder Installation
5.1 Removing the Rubber Bumpers, Springs and Dampers
The springs are under compression and must be retained during disassembly.
Failure to ensure the spring forces are removed safely may result in injury or
damage to the equipment.
1. Remove the rubber bumpers (Figure 4) from each side of the sprayer boom.
Figure 4: Rubber Bumpers
2. The springs to be removed are located on the bottom rear of the sprayer boom (Figure
5). Spring compression tools are needed to remove the springs (John Deere part number:
JDG10394). Please reference John Deere TM113619 – 4940 Self-Propelled Sprayer Repair
for instructions on removing the springs.
Figure 5: Spring Location

9
When all the boom suspension components (springs, dampers and bumpers) are
removed, the boom may roll to one side or move unexpectedly.
3. Remove the upper and lower mounting bolts and remove the damper from each side of the
sprayer boom (Figure 6).
Figure 6: Dampers to be Removed

10
5.2 Active Roll Mounting Bracket Installation
1. Install the mounting bracket as shown in Figure 7. Ensure the stop on the lower mount is
outside the frame.
2. Tighten the mounting bolts 50-70 ft-lbs.
Figure 7: Linear Roll Mounting Bracket Assembly
Figure 8: Lower Linear Roll Mounting Bracket
Figure 9: Upper Linear Roll Mounting Bracket

11
5.3 Linear Roll Cylinder Assembly
The linear roll cylinder must be mounted on the right hand side of sprayer.
1. In the linear roll cylinder crate is the linear roll cylinder, boom target, spring target and
sensor bracket.
Figure 10: Linear Roll Cylinder Assembly
2. Using the supplied 9/16 inch bolt, 5/8 inch lock washer and 9/16 inch washer, install the
damper end (one port) of the linear roll cylinder onto the top mounting bracket. (Figure
9)
3. Using the 1 inch bolt, 1 inch lock washer and 1 inch nut, attach the cylinder end of the
linear roll cylinder to the bottom mount. (Figure 8) Be careful not to move the shaft of
the cylinder because doing so will push oil out and suck air in.
4. Install the spring target and align by rotating the metal casing around the linear roll cylinder.
5. Install a sensor onto the sensor mounting bracket.
6. Mount the sensor bracket to the damper end (the end with no hoses). A straight edge can
be used to line up the spring target with the center of the hole on the sensor mounting
bracket. The mount should be facing as far forward as possible, but be sure it will not
contact the catwalk when the boom is raised to the top.
7. Mount the cylinder target to the cylinder end (the end with hoses).
8. Align the cylinder target (bottom rod) so that it is 5/8” to the side of the spring target
(Figure 11).

12
Figure 11: Linear Roll Cylinder Target Alignment
Top View
Side View
Sensor
Mount
Spring
Target
Cylinder
Target

13
6Hydraulic Installation
Ensure all pressure has been bled from the system before disconnecting any lines
or fittings. Hydraulic pressure will exist on the wing tilt circuits unless the wings
are being supported by other means. You may wish to perform the hydraulic
installation 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 UC5
system warranty. It is recommended that a qualified technician perform the
hydraulic installation.
6.1 Valve Assembly
1. On a clean surface remove all plastic plugs from the block.
2. Install the orifice (F10) into the “A” port of the expansion block with the notch facing in.
3. Install the orifice (F11) into the “B” port of the expansion block with the notch facing in.
4. Install the 6MB-6MOR (F13) fittings into the “A” and “B” ports of the expansion block.
Tighten to 18 ft-lbs (24 Nm).
Figure 12: Expansion Block Orifice Orientation

14
6.2 Expansion Block Assembly
1. Loosen the existing 2 station valve block so that it can be moved and/or twisted for the
installation of the expansion block.
2. Remove the three 4MBP plugs from the 2 station valve block.
3. Coat the three o-rings in hydraulic oil and install them into the expansion block. Ensure the
o-rings are seated properly.
4. Thread the 4.5” studs into the existing 2 station valve block.
5. Attach the expansion block to the 2 station block using the included spring washers and
nuts.
6. Tighten the nuts on the studs to 31 ft-lbs.
Figure 13: NORAC Expansion Block Assembly

15
6.3 Hydraulic Plumbing
From this point on in the installation the booms will be inoperative until the
hydraulics are fully installed.
1. After the NORAC valve is mounted, the hydraulic hoses and fittings can be plumbed. The
plumbing for the hydraulic circuit is shown schematically in Figure 3.
2. Connect hoses H02 to the “A” and “B” ports of the NORAC expansion block and route to
the roll cylinder.
3. Connect the hose from the “A” port to the port on the rod end of the cylinder using a
6MOR-6FORX90 (F12) fitting and a 6MB-6MOR (F13) fitting.
4. Connect the hose from the “B” port to the port on the barrel of the cylinder using a
6MOR-6FORX90 (F12) fitting and a 6MB-6MOR (F13) fitting.

16
7Electrical Installation
1. Locate the valve module installed on the NORAC valve block. Remove the plugs installed
in positions 7 and 8.
2. Connect the 2 pin connector on cables C10 into positions 7 and 8 on the valve module.
Connect the other end of cables C10 to the 2 pin connectors on the NORAC expansion
block (V02).
3. Disconnect and remove the two NORAC roll sensors (small rectangular box with a cable
running from it). See Figure 14 for locations.
Figure 14: Roll Sensor Locations
4. Connect the active roll sensor (E05) to the 8-way coupler (E11) where one of the roll
sensors was connected using cable C03 and a 2-way coupler (E12). Plug the unused
connector where the second roll sensor was connected using the 6-pin plug.

17
Figure 15: Valve Module Connections
Figure 16: Electrical Installation
Only the components shown in black are included in this kit.
Output Numbe
r
Normal Function
1 Left Up
2 Left Down
3 Right Up
4 Right Down
5 Option 1
6 Option 2
7 Roll CW
8 Roll CCW