Norac Gregson Maverick 120 Series User manual

Gregson Maverick 120 Series
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+GM1-INST Rev C (Gregson Maverick 120 Series)
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................................................................................................................................................. 2
2GENERAL SYSTEM DESCRIPTION ................................................................................................................. 3
3PARTS LISTS ..................................................................................................................................................... 4
4INSTALLATION PROCEDURE.......................................................................................................................... 8
4.1 EXISTING SYSTEM CHECK .............................................................................................................................. 8
4.2 BOOM SPEED TEST....................................................................................................................................... 8
4.3 WING SENSOR INSTALLATION ..................................................................................................................... 10
4.4 MAIN LIFT SENSOR INSTALLATION............................................................................................................... 13
4.5 ROLL SENSOR INSTALLATION...................................................................................................................... 14
4.6 ROLL SENSOR INSTALLATION (TRAPEZE STYLE BOOMS).............................................................................. 15
4.6.1 Boom Frame Roll Sensor Mounting..................................................................................................... 16
4.6.2 Chassis Roll Sensor Mounting ............................................................................................................. 17
4.7 ROLL SENSOR INSTALLATION (CENTER PIVOT STYLE BOOMS) ..................................................................... 18
4.7.1 Boom Roll Sensor Mounting ................................................................................................................ 19
4.7.2 Chassis Roll Sensor Mounting ............................................................................................................. 19
4.7.3 Inverted Roll Sensor Mounting............................................................................................................. 20
4.7.4 Temperature probe............................................................................................................................... 21
4.8 HYDRAULIC INSTALLATION .......................................................................................................................... 22
4.8.1 Valve Assembly.................................................................................................................................... 22
4.8.2 Valve Mounting..................................................................................................................................... 22
4.8.3 Hydraulic Plumbing .............................................................................................................................. 24
4.9 ELECTRICAL INSTALLATION......................................................................................................................... 25
4.10 COMPLETING THE INSTALLATION ................................................................................................................. 28
5ELECTRICAL REFERENCE – CABLE DRAWINGS....................................................................................... 29
5.1 ITEM C01: 44662B-40 –SENSOR TRUNK CABLE ........................................................................................ 29
5.2 ITEM C02: 44668 –SENSOR BRANCH CABLE.............................................................................................. 29
5.3 ITEM C02B: 44664 –CABLE UC4 CAN NODE DUAL................................................................................... 30
5.4 ITEM C03: 44656 –VALVE CABLE (VARIABLE RATE) .................................................................................. 30
5.5 ITEM C04: 44651 –VALVE EXTENSION CABLE ............................................................................................ 31
5.6 ITEM C10: 44650-11 –POWER CABLE GREGSON MAVERICK....................................................................... 32
6APPENDIX A – VALVE CONNECTOR CHANGE ........................................................................................... 33

2
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 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

3
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
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.

4
3 PARTS LISTS
The parts that come with your UC4+ Sprayer Boom 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 – UC4+ Spray Height 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
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
C03 44656D CABLE VALVE VARIABLE RATE DT 1
C04 44651 CABLE VALVE EXTENSION 1
C10 44650-11 CABLE POWER UC3 BOOM CONTROL GREGSON MAVERICK 1
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
H03 44863-07 HOSE ASSEMBLY 122R2-06 60 IN L 6FJX 6FJX90 2
H04 44862-03 HOSE ASSEMBLY 122R2-04 112 IN L 4FJX90 6FJX 2
H05 44862-02 HOSE ASSEMBLY 122R2-04 70 IN L 4FJX90 6FJX 2
H20 44865-10 HYDRAULICS FITTING KIT - GM1 1
M01 446BC+MAN7 OPERATOR MANUAL UC4+ SPRAY HEIGHT CONTROL 1
M10 UC4+BC+GM1-INST MANUAL INSTALLATION UC4+ GREGSON, MAVERICK 120 1
V01 44933D VALVE BLOCK ASSEM UC5-BC 2-STATION CC/LS VARIABLE RATE DT 1

5
Table 2 – 44865-10: Hydraulics Fittings Kit Details
Item Part Number Name Quantity
Picture
F01 44928 ORIFICE INSERT .047 IN ONE WAY 4
F02 103312 MALE ADAPTER - 6MB 6MJ 6
F03 104369 PLUG - 6MBP 2
F04 104470 MALE ADAPTER - 10MB 6MJ 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:

6
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
*If your valve connectors or cables appear different than shown, refer to Appendix A for
more details.

7
Figure 3 – Hydraulic Components

8
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 4.10, this
procedure is repeated with the UC4+
Spray Height Control system installed
for comparison and troubleshooting
purposes.

9
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
Some sprayers may not have the Roll functions.

10
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.
Please refer to the UC4+ Spray Height
Control system warranty at the end of
the UC4+ Spray Height Control
Operator’s Manual (M01) for
implications.
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).

11
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 Guidelines
AB
B
D
C
Ultrasonic
Acoustic Cone

12
Figure 9 – Sensor Serial Number Installation Location
3 SENSOR SYSTEM
5 SENSOR SYSTEM

13
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

14
4.5 ROLL SENSOR INSTALLATION
Before installing the roll sensors you must determine if your sprayer has a trapeze style or center pivot
style boom. For installation on a trapeze style boom refer to Section 4.6. For installation on a center
pivot boom refer to Section 4.7.
Figure 13 – Trapeze Style Boom
Figure 14 – Center Pivot Boom
Trapeze
Links
Center
Pivot

15
4.6 ROLL SENSOR INSTALLATION (TRAPEZE STYLE BOOMS)
Mount the roll sensors to the included roll
sensor brackets using the machine screws
and nylon lock nuts. (Figure 20)
The roll sensors must be mounted
tightly to the brackets.
Figure 15 – Mounting the Roll Sensor to the
Roll Sensor Mounting Bracket
When mounting the roll sensors, use the
following guidelines and refer to Figure 16.
a) The smaller the distance between Aand
Bin Figure 16, 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 16 – General Roll Sensor Mounting Location on a Trapeze Style Boom
Connectors towards
Right-hand Wing Æ

16
4.6.1 Boom Frame Roll Sensor Mounting
1. Use the supplied hardware to mount the
boom frame roll sensor (E04) as shown in
Figure 17.
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 17).
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 17 – 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.

17
4.6.2 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 18.
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 16).
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 18 – 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 19.
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 19 – Temperature Probe Attached to
the UC4+ Valve Block

18
4.7 ROLL SENSOR INSTALLATION (CENTER PIVOT STYLE BOOMS)
Mount the roll sensors to the included roll
sensor brackets using the machine screws
and nylon lock nuts. (Figure 20)
The roll sensors must be mounted
tightly to the brackets.
Figure 20 – Mounting the Roll Sensor to the
Roll Sensor Mounting Bracket
When mounting the roll sensors use the
following guidelines and refer to Figure 21.
a) The smaller the distance between Aand
Bin Figure 21, the better the
performance will be.
Distance A can not be more than 12”.
b) The roll sensors must not be mounted
below the pivot point.
c) Ensure the roll sensors are sitting
relatively level when the sprayer chassis
and boom are level.
d) 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 21 – Mounting Guidelines for Center Pivot Sprayers
Connectors towards
Right-hand Wing Æ