Topcon NORAC UC4.5 User manual

A
ctive Roll ControlTM Option
Installation Manual

Printed in Canada
Copyright 2016 by NORAC Systems International Inc.
Reorder P/N: 4567BC-INST Rev H (Active Roll Control Option)
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Kit Parts ...................................................................................................................... 2
3Position Sensor Installation ...................................................................................... 6
4Hydraulic Installation ................................................................................................ 9
5Electrical Installation ............................................................................................... 15
6Software Setup......................................................................................................... 16
7System Maintenance................................................................................................ 17
8Cable Drawings ........................................................................................................ 18

1
1Introduction
Congratulations on your purchase of the NORAC UC4.5 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.
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
2Kit Parts
2.1 Kit Overview
Figure 1: Roll Control Parts

3
2.2 Hydraulic Plumbing
Figure 2: Roll Control Hydraulic Plumbing

4
2.3 List of Parts
This kit is to be used when installing the Active Roll Control option with existing John Deere
installations.
Item Part Number Name Quantity
B09 45032-1 BRACKET UC5 POSITION SENSOR MOUNT V1 2
B10 44695-21 PIN ACTIVE ROLL JD UPPER MOUNTING KIT 1
C04 43220-0.5 CABLE UC5 NETWORK 14 AWG 0.5M 1
C70 44658-46D CABLE UC4 VALVE DT ROLL WITH PIGTAIL 1
E06 45030 UC5 POSITION SENSOR NF W/O HARDWARE 1
E12 43764 UC5 NETWORK COUPLER 2-WAY 1
H74 44862-11 HOSE ASSEMBLY 122R2-04 60 IN L 4FORX 4FORX 2
H75 44695-22 HYD CYLINDER AR 1.75IN W/INTERNAL SENSOR 1
H80 44865-38 HYDRAULICS FITTING KIT - ACTIVE ROLL 1
M02 4567BC-INST MANUAL INSTALLATION ACTIVE ROLL CONTROL OPTION 1
M10 106548 DRILL BIT 3/8" HSS STD JOBBER 1
V70 44962D VALVE ASSEMBLY EXPANSION DPOC PROP DT 4 BOLT 1

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2.4 Active Roll Hydraulic Fittings Kit Details (P/N: 44865-38)
Item Part Number Name Quantity Picture
F10 104586 TEE ADAPTER - 6FORXR 6MORT 3
F11 105338 TEE ADAPTER - 12FORXOR 12MORT 1
F12 44916 MALE ADAPTER - 6MB-4MOR MACHINED ORB 4
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
Not all fittings are used for this installation.
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

6
3Position Sensor Installation
1. Remove the rubber bumpers on both ends of the roll frame (Figure 3).
Figure 3: Rubber Bumper Location
2. The position sensor (E06) should be mounted such that the largest amount of travel of the
sensor can be utilized without exceeding the travel limit. The sensor install length is 17”
(430mm) center to center with ±3.5” (±90mm) travel recommended. It should be mounted
in a location where the sensor will mount without binding or contacting and that is
perpendicular to the direction of travel. Roll the boom fully in each direction and take
measurements to ensure the travel limit is not exceeded.
3. Measure 12-3/4” (325mm) from the centerline of the intermediate frame and boom center
frame towards the left side of the sprayer (when looking from the rear of the sprayer).
Figure 4: Measurement from Centerline of Intermediate Frame (Looking from the Rear)
12-3/4”
(325mm)
Bumpe
r

7
4. Mount the brackets (B09) as shown in Figure 5. Install two (2) cable ties per bracket.
Figure 5: Bracket Mounting (Looking from the Rear)
5. Install the base end of the position sensor with the cable facing the center of the sprayer in
the lowest hole of the bracket possible without making contact with the boom frame. Use
the mounting hardware as shown in Figure 6.
Figure 6: Mounting Hardware
6. Install the linear sensor mounting bolt in the hole of the upper bracket that closest aligns
the end of the sleeve with the center of travel mark (black mark) on the sensor (Figure 7).
If the mark is missing, the distance from the end of the sleeve to the top of the base should
be 4” (100mm). The collar (Figure 6) clamps the sensor and prevents the rubber
grommet from sitting on the bolt threads. Tighten the mounting hardware.
Colla
r
Bolt Nut Nut

8
Figure 7: Center Mark Location
Centerline
Mark
4”
(100mm)

9
4Hydraulic 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. The hydraulic installation may be performed
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
UC4.5 system warranty. It is recommended that a qualified technician perform the
hydraulic installation.
4.1 Valve Assembly
1. On a clean surface remove the plastic plugs from the block.
2. Install the .047 orifice (F07A) into the “B” port of the expansion block with the notch facing
in. Install the 6MB-4MOR (F12) fitting into the “B” port. Tighten to 18 ft-lbs (24 Nm).
3. Install the .042 orifice (F07B) into the “A” port of the expansion block with the notch facing
in. Install the 6MB-4MOR (F12) fitting into the “A” port. Tighten to 18 ft-lbs (24 Nm).
Figure 8: Expansion Block Orifice Orientation

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4.2 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 four 4MBP plugs from the 2 station valve block.
3. Coat the four o-rings in hydraulic oil and install them into the expansion block. Ensure the
o-rings are seated properly.
4. Attach the expansion block to the 2 station block using the included spring washers and
bolts.
5. Tighten the bolts to 31 ft-lbs (42 Nm).
Figure 9: NORAC Expansion Block Assembly

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4.3 Roll Cylinder Installation
1. Remove the link arm (black square tube) connected between the parallel lift frame and roll
frame. See Figure 10 for the link arm location.
Figure 10: John Deere Link Arm Location (looking towards rear of sprayer)
2. Remove the lower link bolt and nut.
3. Roll the intermediate frame (where the link is still attached) counterclockwise until the
upper link pin can be accessed. It may be helpful to use a jack or strap between the boom
frame and the intermediate frame. Remove the snap-ring from the link pin. Remove the
pin and link.
4. Install the cylinder (H75) into the lower mount so that the cylinder ports face the front of
the sprayer. Ensure the pivot sleeve is installed into the cylinder. Install the bolt through
the cylinder and sleeve and torque to 250 ft-lbs (339 Nm).
Figure 11: Lower Bolt Installation
Link Arm
Position

12
5. Loosen the plastic port plugs and extend the cylinder to line up the hole in the intermediate
frame and the cylinder.
6. Install B10 from the rear of the sprayer through the intermediate frame and the cylinder
adding a mounting plate between both sides of the cylinder and the frame. Add the final
plate to the front side of the intermediate frame.
Figure 12: Upper Pin Installation
7. Using the 3/8” drill bit (M10), center the rear plate and pin on the intermediate frame. Drill
through the frame plate from the rear. Clamp the plate in place if desired.
8. After drilling through the first flange of the intermediate frame, align the mounting plates
and slide the drill through all 3 plates to guide and drill through the second flange.
Figure 13: Drilling the Flanges
9. Deburr the holes. Install the mounting bolts into the holes and snug. Drill the second set of
holes and install the mounting bolts. Torque the bolts to 20 ft-lbs (27 Nm).
Figure 14: Upper Pin Installed

13
10. In some cases, the bracket has failed at the weld shown in Figure 15. 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 15: Roll Cylinder Mount Weld Locations
11. Install the 6MB-4MOR (F12) fittings into the cylinder.
12. Install the 4MOR-4FORX90 (F14) fitting onto the cylinder fitting at the cap end of the
cylinder.
Figure 16: Roll Cylinder Installed with Hoses

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4.4 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 2.
2. Install hoses H74 to the roll cylinder that was previously installed. Route the hoses to the
NORAC valve block.
3. Connect the hose attached to the rod end of the cylinder to the “B” port of the expansion
block.
4. Connect the hose attached to the cap end of the cylinder to the “A” port of the expansion
block.

15
5Electrical Installation
Figure 17: Electrical Installation
Only the components shown in black are included in this kit.
1. Plug the 3-pin tower on C70 to the 3-pin shroud on the valve extension cable (C11). Route
C70 to the rear of the sprayer. Use cable ties to secure in place.
2. Connect the 2-pin connectors on C70 to the 3rd station expansion block. The connector
labeled Roll CW goes on the side of the valve block with the hydraulic hoses.
Figure 18: JD Roll Connector
3. Connect the position sensor (E06) to the 8-way coupler. Connect the active roll cylinder
(H75) to the 8-way coupler (E11) using cable C04 and a 2-way coupler (E12).
4-pin Roll
Connector

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6Software Setup
1. Start up the sprayer and test the sprayer’s functionality. The NORAC Control Panel does
not need to be powered on for the original boom function switches to operate. Unfold the
booms and raise/lower each boom and the main section.
Confirm that the cabling and 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 the roll direction is opposite to the operator’s preference when pressing the
switches, reverse the direction by swapping the connectors on the 3rd station
expansion block.
3. Turn on the power for the UC4.5 Control Panel using the switch on the side of its chassis.
4. The procedure for the installation of the UC4.5 Spray Height Control system is now
complete. Begin the AUTOMATIC SYSTEM SETUP procedure as described in the UC4.5
Spray Height Control Operator’s Manual.

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7System 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:
1. 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. 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.
2. Check that the pin in the top of the cylinder is not loose and does not have any free
movement or slop. The bottom cylinder mounting bolt torque must be checked regularly.
The bolt must be tightened to 260 ft-lbs (350 Nm).
3. 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 19: Sliding Pad Locations
Figure 20: Upper Front Sliding Pad Figure 21: Lower Front and Rear Sliding Pads