Norac UC4+ User manual

Apache 859, 790 (2000+)
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+AP1-INST Rev A (Apache 859/790)
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
1INTRODUCTION .................................................................................................................................. 1
2GENERAL SYSTEM DESCRIPTION .................................................................................................. 2
3PARTS LISTS ...................................................................................................................................... 3
4INSTALLATION 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 ................................................................................................ 12
4.5 ROLL SENSOR INSTALLATION ....................................................................................................... 13
4.5.1 Boom Frame Roll Sensor Mounting ...................................................................................... 14
4.5.2 Chassis Roll Sensor Mounting .............................................................................................. 15
4.6 HYDRAULIC INSTALLATION ........................................................................................................... 16
4.6.1 Valve Assembly ..................................................................................................................... 16
4.6.2 Valve Mounting...................................................................................................................... 16
4.6.3 Hydraulic Plumbing ............................................................................................................... 17
4.7 ELECTRICAL INSTALLATION .......................................................................................................... 18
4.8 COMPLETING THE INSTALLATION .................................................................................................. 21
5ELECTRICAL REFERENCE – CABLE DRAWINGS ........................................................................ 22
5.1 ITEM C1: 44662B-40 –SENSOR TRUNK CABLE ........................................................................... 22
5.2 ITEM C2: 44668 –SENSOR BRANCH CABLE ................................................................................. 22
5.3 ITEM C02B: 44664 –CABLE UC4 CAN NODE DUAL .................................................................. 23
5.4 ITEM C10: 44650-12 –POWER CABLE VERSION 12...................................................................... 23
5.5 ITEM C11: 44658-07 –WIRING HARNESS UC3 BOOM CONTROL PIGTAIL TO SHROUD ................... 24
5.6 ITEM C12: 44659 –VALVE CASE/PATRIOT/APACHE ..................................................................... 25

1
1INTRODUCTION
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 via
the information given below:
Phone: [phone] Canada (Toll Free)
1-866-306-6722 United States (Toll Free)
0-800-404-8389 United Kingdom (Toll Free)
1-306-664-6711 all other regions
E-mail: [email protected]
Website: www.norac.ca

2
2GENERAL 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
3PARTS 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 859, 790 UC4+ Spray Height Controller System Parts (Rev A)
Item Part Number Name Quantity
B05 44706-01 KIT CABLE TIE BLACK 10 PCS 21 IN 150 PCS 7.5 IN 1
B10 44700-06 BRACKET VALVE MOUNTING STD 1
B11 44743 MOUNTING BRACKET MAIN LIFT SENSOR UC4 PLUS 1
B13 44728 MOUNTING BRACKET COMPLETE UC4 BREAKAWAY EXTENDED 2
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
C02B 44664 CABLE UC4 CAN NODE DUAL 1
C10 44650-12 CABLE POWER UC3 BOOM CONTROL CASE IH 4260 1
C11 44658-07 WIRING HARNESS UC3 BOOM CONTROL PIGTAIL TO SHROUD 1
C12 44659 CABLE VALVE PATRIOT/CASE IH 4260 2
E01 4461BC+ UC4 PLUS BOOM CONTROL PANEL 1
E02 44631 UC4 ULTRASOUND SENSOR 3
E03 44641 UC4 PLUS ROLL SENSOR W TEMPERATURE PROBE 1
E04 44642 UC4 PLUS ROLL SENSOR 1
H02 44863-37 HOSE ASSEMBLY 122R2-06 24 IN L 6FJX90 6FJX 2
H20 44865-02 HYDRAULICS FITTING KIT - AP1 1
M01A 446BC+MAN6-1 MANUAL UC4+ BOOM CONTROL 2008 OPERATORS SMALL BOOKLET 1
M01B 446BC+MAN6-2 MANUAL UC4+ BOOM CONTROL 2008 QUICK REFERENCE SMALL BOOKLET 1
M10 UC4+BC+AP1-INST MANUAL INSTALLATION UC4+ APACHE 2001-2004 1
V01 44933S VALVE BLOCK ASSEM UC4-BC 2-STATION CC/LS VARIABLE RATE 1

4
Table 2 - 44865-02 (Rev A) - Hydraulics Fittings Kit Details
Item Part Number Name Quantity
Picture
F02 104369 PLUG - 6MBP 4
F03 104634 CAP - 6FJCN NO 6 FEMALE JIC 2
F04 103839 JIC T COUPLER - 6FJXR 6MJT 2
F05 103312 MALE ADAPTER - 6MB 6MJ 4
F08 44928 ORIFICE INSERT .047 IN ONE WAY 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:

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
4INSTALLATION 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 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 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]
Avg 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]
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 (B11) 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).
It is advised to avoid mounting the
sensor bracket to a breakaway
portion of the boom because a
breakaway action can cause the
UC4+ Spray Height Control
system to force a boom close to the
ground.
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 9).

10
5. Sensor cables should run through the
mounting bracket tube and then behind
the 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 wing 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 Guidlines
AB
B
D
C
Ultrasonic
Acoustic Cone

11
Figure 9 – Sensor Serial Number Installation Location
3 SENSOR SYSTEM
5 SENSOR SYSTEM

12
4.4 MAIN LIFT SENSOR INSTALLATION
1. Assemble the main lift sensor bracket
(B11) as shown in Figure 10.
Figure 10 – 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 11 and Figure 12).
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 11 – Main Lift Sensor Bracket
Mounting Position
3. Mount the sensor onto the sensor
mounting collar (Figure 11).
Figure 12 – Main Lift Sensor Mounted in
the Correct Location
Bracket Tube
Sensor
Mounting Tab
Sensor Mounting
Colla
r
Bracket Base

13
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 13.
The roll sensors must be mounted
tightly to the brackets.
Figure 13 – Mounting the Roll Sensor to
the Roll Sensor Mounting Bracket
When mounting the roll sensors, use the
following guidelines and refer to Figure 14.
a) The smaller the distance between Aand
Bin Figure 14, the better the
performance will be.
b) Ensure the roll sensors are sitting
relatively level when the sprayer chassis
and boom are level.
c) Both 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 14 – General Roll Sensor Mounting Location on a Trapeze Style Boom
Connectors towards
Right-hand Wing Æ

14
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 15.
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 15).
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 had wing (when looking from
the rear of the sprayer).
Figure 15 – 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.

15
4.5.2 Chassis Roll Sensor Mounting
1. It is often best to cable tie the chassis
roll sensor in place. When mounting the
chassis roll sensor follow the guidelines
and refer to Figure 16.
The chassis 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 14).
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.
d) Make sure the temperature probe is
able to reach the side of the valve
block.
Figure 16 – Chassis 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 17 – Temperature Probe Attached
to the UC4+ Valve Block

16
4.6 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.
4.6.1 Valve Assembly
1. On a clean surface remove all plastic
plugs from the NORAC hydraulic Valve
(V01) (Figure 18).
Figure 18 – NORAC Valve Block
2. Install the 6MB-6MJ (F05) fittings on
the “P” and “T” ports and tighten to 18
ft-lbs.
3. Install the orifices (F08) into the "B"
ports with the notch facing outward as
shown in Figure 19.
4. Install the 6MB-6MJ fittings (F05) into
the “B” ports and tighten to 18 ft-lbs.
5. Install the 6MBP plugs (F02) into the
“A” ports and tighten to 18 ft-lbs.
Figure 19 – Valve Block Assembly
4.6.2 Valve Mounting
1. Mount the NORAC valve (V01) on the
sprayer using the valve mounting
bracket (B10).
2. As shown in Figure 20, screw short side
of the threaded rods into the bottom of
the valve block at least 3/8". The valve
mounting holes are drilled and tapped
3/8 NC-1" deep.
3. Tighten the Hex nuts to hold the rods.
4. Put the mounting bracket on the other
side of the tube and tighten with the
spring washers and the Hex nuts.
5. Cut excess off of the rods, if necessary.

17
If using 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.
You must ensure no hydraulic
components will interfere with any
sprayer parts or be pulled tight at
any time.
Figure 20 – Valve Mounting Location
4.6.3 Hydraulic Plumbing
WARNING!
From this point in the installation the
booms will be inoperative until the
electronics are fully installed.
You must ensure there are no
other orifices present in the circuit
between the NORAC valve block
and the boom cylinders.
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. Connect the 90 degree fitting on hose
H02 to the Pressure (P) and Tank (T)
ports on the NORAC valve block using
F04.
3. Tee in the P and T hoses to the ports on
the sprayer valve block with the JIC T
coupler (F04).
4. The existing hoses that run to the boom
tilt cylinders should be removed from
the sprayer’s 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 (H04).
b. The "A" ports of the NORAC block
must be plugged using the 6MBP
plug (F02).