Norac UC4+ Apache 1010 2005+ User manual

Apache 1010 (2005+) Enhanced Stability
Installation Manual
Spray Height Control System
Improving the competitiveness of Industry and Agriculture
throu
g
h Precision Measurement

Printed in Canada
Copyright 2005-08 by NORAC Systems International Inc.
Reorder P/N: UC4+BC+AP2-INST Rev H (Apache 1010 (2005+) Enhanced Stability)
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...........................................................................................................7
4.1EXISTING SYSTEM CHECK ..............................................................................................................7
4.2BOOM SPEED TEST........................................................................................................................7
4.3WING SENSOR INSTALLATION.........................................................................................................9
4.4MAIN LIFT SENSOR INSTALLATION..................................................................................................13
4.5ROLL SENSOR INSTALLATION.......................................................................................................14
4.5.1Boom Frame Roll Sensor Mounting......................................................................................15
4.5.2Intermediate Frame Roll Sensor Mounting ...........................................................................16
4.5.3Reference Frame Roll Sensor Mounting...............................................................................17
4.6HYDRAULIC INSTALLATION ...........................................................................................................18
4.6.1Valve Assembly.....................................................................................................................18
4.6.2Valve Mounting......................................................................................................................19
4.6.3Hydraulic Plumbing ...............................................................................................................19
4.7ELECTRICAL INSTALLATION..........................................................................................................20
4.8COMPLETING THE INSTALLATION ..................................................................................................23
5ELECTRICAL REFERENCE – CABLE DRAWINGS........................................................................24
5.1ITEM C02: 44668 –CABLE SENSOR BRANCH...............................................................................24
5.2ITEM C02B: 44664 –CABLE UC4 CAN NODE DUAL....................................................................25
5.3ITEM C03: 44656D –CABLE VALVE VARIABLE RATE DT..............................................................26
5.4ITEM C05: 44674 –CABLE UC4 SENSOR ROLL BIAS ...................................................................27
5.5ITEM C10: 44650-39 –CABLE POWER GENERIC SELF-PROPELLED ..............................................28
5.6ITEM C11: 44651-03 –CABLE VALVE EXTENSION GENERIC.........................................................29
5.7ITEM C12: 44658-18 –CABLE UC4 VALVE AP2 MAIN .................................................................30
5.8ITEM C13: 44658-17 –CABLE UC4 SENSE AP2.........................................................................31
5.9ITEM C14: 44658-99 –CABLE UC4 INTERFACE POWER PIGTAIL FUSED .......................................32

1
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.

2
2 GENERAL SYSTEM DESCRIPTION
Figure 1 depicts the general system layout of the UC4+ Sprayer Boom 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 system 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: Apache 1010 (2005+) Enhanced Stability 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
B17 44972 SENSOR MOUNTING BRACKET LOW PROFILE RAINFLAP 16GA 2
B20 44971 SENSOR MOUNTING BRACKET LOW PROFILE 16GA 2
B21 44973 SENSOR MOUNTING BRACKET LOW PROFILE 16 GA LARGE FLANGE 1
C02 44668 CABLE UC4 SENSOR BRANCH 1 AMP RECEPT 3 AMP PLUG BC 1
C02B 44664 CABLE UC4 CAN NODE DUAL 1
C03 44656D CABLE VALVE VARIABLE RATE DT 1
C05 44674 CABLE UC4 SENSOR ROLL BIAS 1
C10 44650-39 CABLE POWER GENERIC SELF-PROPELLED 1
C11 44651-03 CABLE EXTENSION VALVE GENERIC 1
C12 44658-18 CABLE UC4 VALVE AP2 MAIN 1
C13 44658-17 CABLE UC4 SENSE AP2 1
C14 44658-99 CABLE UC4 POWER PIGTAIL FUSED
1
E01 4461BC+ UC4 PLUS BOOM CONTROL PANEL 1
E02 44631 UC4 ULTRASOUND SENSOR 3
E03 45000* UC4 PLUS ROLL SENSOR W TEMPERATURE PROBE VER. 2 1
E04 45001* UC4 PLUS ROLL SENSOR VER. 2 2
H02 44863-37 HOSE ASSEMBLY 122R2-06 24 IN L 6FJX90 6FJX 3
H04 44863-17 HOSE ASSEMBLY 122R2-06 32 IN L 6FJX90 8FJX 1
H20 44865-03 HYDRAULICS FITTING KIT - AP2 1
M01 446BC+MAN7 OPERATOR MANUAL UC4+ SPRAY HEIGHT CONTROL 1
M10 UC4+BC+AP2-INST MANUAL INSTALLATION UC4+ APACHE 1010 (2005+) ENHANCED STABILITY 1
V01 44963D VALVE BLOCK ASSEMBLY 2 STATION CC/LS PROP DT 4 BOLT 1
* For systems purchased BEFORE October 1, 2011, the roll sensor part numbers are 44641 and 44642.

4
Table 2: 44865-03 - Hydraulics Fittings Kit Detail
Item Part Number Name Quantity
Picture
F04 103839 T ADAPTER - 6FJXR 6MJT 3
F05 103312 MALE ADAPTER - 6MB 6MJ 4
F07 104632 T ADAPTER - 8FJXR 8MJT 1
F08 44928 ORIFICE INSERT .047 IN ONE WAY 2
F09 104369 PLUG - 6MBP 2
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:
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.

5
The parts that come with your UC4+ System are shown below in their general installation
configuration.
Figure 2: UC4+ Spray Height Control System Components

6
Figure 3: Hydraulic Plumbing Schematic

7
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 system.
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 3.
It is necessary to test the boom
functions in all directions
Table 3: Hydraulic System Function
Check Sheet
BOOM FOLD IN FOLD OUT UP DOWN
LEFT
MAIN
RIGHT
ROLL* 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 4.
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 4,“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 4,
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 4
6. Repeat Steps 1through 5for 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 4.
8. These “Average Times” now represent
how quickly your system can react to
manual control. In Section 4.8, this
procedure is repeated with the UC4+
Spray Height Control system installed
for comparison and troubleshooting
purposes.

8
Table 4: Boom Test Record (WITHOUT UC4+ Spray Height Control system)
Working RPM:
Boom Trial #1
[Sec]
Trial #2
[Sec]
Trial #3
[Sec]
A
vg Time
[Sec]
Left UP
Left DOWN
Right UP
Right Down
Main UP
Main DOWN
Roll CW
Roll CCW
Table 5: Boom Test Record (WITH UC4+ Spray Height Control system)
Working RPM:
Boom Trial #1
[Sec]
Trial #2
[Sec]
Trial #3
[Sec]
A
vg Time
[Sec]
Left UP
Left DOWN
Right UP
Right Down
Main UP
Main DOWN
Roll CW
Roll CCW

9
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.
Figure 4: Low Profile Bracket Mounting
Figure 5: Low Profile Bracket Mounted on
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.
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.
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.
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 12).
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.
Front

10
Rainflaps are only installed in the
wing sensor brackets.
4. Insert one side of the rainflap rod into the
pre-bent hinge tab on the sensor bracket.
(Figure 6)
Figure 6: Rainflap Rod in Pre-Bent Hinge
Tab
5. Align the other side of the rainflap rod with
the unbent hinge tab. (Figure 7)
Figure 7: Align Rainflap Rod
6. 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 8)
Figure 8: Bend Rainflap Hinge Tab
7. 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).
Figure 9: Bracket Mounting Example

11
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 10: Bracket Mounting Guidelines
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.
Figure 11: Sensor Mounting Guidelines

12
Apply a light coating of the supplied Permatex Anti-seize grease to all threaded
parts upon installation.
Figure 12: Sensor Serial Number Installation Location

13
4.4 MAIN LIFT SENSOR INSTALLATION
1. Mount the bracket onto the lowest
frame member on the center section of
the sprayer. (Figure 14 and Figure
15).
Figure 13: Main Lift Sensor Bracket
Mounting
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 14: Main Lift Sensor Bracket
Mounting Position (Top View)
Figure 15: Main Lift Sensor Bracket
Mounting Position (Side View)

14
4.5 ROLL SENSOR INSTALLATION
Mount the roll sensors to the included roll
sensor brackets using the machine screws
and nylon lock nuts, as illustrated in Figure
16.
The roll sensors must be
mounted tightly to the brackets.
Figure 16: Mounting the Roll Sensor
to the Roll Sensor Mounting Bracket
When mounting the roll sensors, use the
following guidelines and refer to Figure 17.
a) The intermediate frame roll sensor
must have the lowest serial number and
the chassis roll sensor must have the
highest serial number.
b) The smaller the distance between Aand
Bin Figure 17, the better the
performance will be.
c) Ensure the roll sensors are sitting
relatively level when the sprayer chassis
and boom are level.
d) All roll sensors must be mounted with
the circular AMP connector facing
towards the Right-Hand Wing (when
looking from the rear of the sprayer).
Figure 17: General Roll Sensor Mounting Location on a Trapeze Style Boom
Connectors towards
Right-hand Wing 

15
4.5.1 Boom Frame Roll Sensor
Mounting
1. Use the supplied hardware to mount
the boom frame roll sensor (E04) as
shown in Figure 18.
When mounting the boom frame roll
sensor follow these guidelines:
a) To prevent bending the bracket,
ensure bolts are placed as close
together as possible (minimize Cin
Figure 18).
b) Be sure to use the roll sensor
without the temperature probe
(E04).
c) When the boom is centered (not
rolled over) the roll sensor should
be level with respect to the sprayer
chassis.
d) It is best to mount the roll sensor to
the left hand trapeze link (when
looking from the rear of the
sprayer).
e) The roll sensor AMP (circular)
connector MUST exit towards
the right hand wing (when
looking from the rear of the
sprayer).
Figure 18: Boom Frame Roll Sensor
Mounted to a Trapeze Link
2. Cable-tie the sensor connector to the
frame with enough slack to allow the
link to rotate.
Make sure the bracket does not
collide with any parts of the
sprayer when the boom rotates.
Also ensure there is enough slack
to allow the roll sensor to rotate.

16
4.5.2 Intermediate Frame Roll Sensor Mounting
The intermediate frame roll
sensor has the temperature
probe on it.
1. It is often best to cable tie the
intermediate frame roll sensor in place.
When mounting the intermediate frame
roll sensor follow the guidelines and
refer to Figure 19.
The intermediate frame roll
sensor must be mounted on a
portion of the sprayer that does
not pivot and is as close to the
boom frame roll sensor as
possible (Figure 17).
a) Make sure you are using the roll
sensor with the temperature probe
(E03).
b) Ensure the roll sensor is level with
respect to the chassis.
c) The AMP (circular) connector
MUST exit towards the right
hand wing (when looking from the
rear of the sprayer).
d) Make sure the temperature probe is
able to reach the side of the valve
block.
Figure 19: Intermediate Roll Sensor
Mounting
2. Fasten the temperature probe to the
UC4+ valve block, using the supplied
3/8”x1/2” bolt as shown in Figure 17.
3. Cable-tie the temperature probe cable
and AMP (circular) connector securely
to a frame member.
Check that the roll sensors and
cables will not interfere with, or
come into contact with any parts
of the sprayer.
Figure 20: Temperature Probe
Attached to the UC4+ Valve Block

17
4.5.3 Reference Frame Roll Sensor
Mounting
The reference frame roll sensor
should be the highest serial
number.
1. The reference frame (chassis) roll sensor
mounts on the left side of the rear axle
below the main up/down coils (Figure
21). The AMP (circular) connector
MUST exit towards the right hand
wing.
2. Ensure the sensor is mounted adequately
and that the cable provides enough slack.
Figure 21: Reference Frame Roll Sensor Mounting