PRODUCT MANUAL LIGHT VEHICLE ENGINE PROTECTION SYSTEM. Part No. 3206

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1 PRODUCT MANUAL LIGHT VEHICLE ENGINE PROTECTION SYSTEM Part No. 3206

2 DISCLAIMER Copyright Remote Control Technologies Pty Ltd (RCT) All rights reserved. No part of this manual may be reproduced, copied, translated, or transmitted in any form or by any means without the written permission of Remote Control Technologies Pty Ltd. (RCT). Information provided in this manual is intended to be accurate and reliable. However, Remote Control Technologies Pty Ltd (RCT) assumes no responsibility for its use or infringements upon the rights of third parties that may result from its use. All examples and diagrams shown in this manual are intended only as an aid to understanding the text, not to guarantee operation. Remote Control Technologies Pty Ltd (RCT) will accept no responsibility for actual use of the product based on these illustrative examples. Please contact your nearest Remote Control Technologies Pty Ltd (RCT) branch for more information concerning applications in life critical situations or high reliability. Remote Control Technologies Pty Ltd (RCT) reserves the right to make changes to any product herein to improve reliability, function or design. All specifications are subject to change without notice M0140.docx Rev 2.2 Modified on 02/10/2015 Copyright RCT

Contents GENERAL SAFETY WARNINGS 4 PRODUCT OVERVIEW 5 FEATURES AND FUNCTIONS 5 OPERATION AND USE 6 ENGINE COOLANT LEVEL 6 ENGINE TEMPERATURE 6 ENGINE OIL PRESSURE LOW 6 AUDIBLE ALARM OUTPUT 6 IDLE

3 Contents GENERAL SAFETY WARNINGS 4 PRODUCT OVERVIEW 5 FEATURES AND FUNCTIONS 5 OPERATION AND USE 6 ENGINE COOLANT LEVEL 6 ENGINE TEMPERATURE 6 ENGINE OIL PRESSURE LOW 6 AUDIBLE ALARM OUTPUT 6 IDLE OUTPUT (OPTIONAL) NOT USED 6 SHUTDOWN ETR (OPTIONAL) NOT USED 6 INSTALLATION GUIDE 7 WIRING CONNECTIONS 7 ENGINE TEMPERATURE SENSOR 8 ENGINE COOLANT LEVEL SENSOR 8 ENGINE OIL PRESSURE SWITCH 9 AUDIBLE ALARM 9 EXTERNAL WIRING DIAGRAM (049f) 10 CALIBRATION 11 SERVICE INFORMATION 11 SERVICE SCHEDULE 11 SERVICE PROCEDURE 11 Coolant Level Sensor 11 Coolant Temperature Switch 11 Engine Oil Pressure Switch 11 TEST PROCEDURE 12 Coolant Level Sensor 12 Coolant Temperature Switch 12 Engine Oil Pressure Switch 12 PARTS LIST 12 TECHNICAL SPECIFICATIONS 13 COMPLIANCE AND STANDARDS 13 TROUBLESHOOTING 13 GLOSSARY 14 WARRANTY 14 M0140.docx Rev 2.2 Modified on 02/10/2015 Copyright RCT 3 16

4 GENERAL SAFETY WARNINGS PERSONAL SAFETY Everyone is responsible for safety. The installer/service personnel should be trained and authorized to complete the required work. Ensure that the machine is safely isolated during installation and testing to protect all personnel. Complete all required risk assessments and job safety analysis (JSA) before commencing work. Observe all site specific and machine OEM procedures regarding the following: working at heights working in heat working in confined spaces all other site specific occupational health and safety (OH&S) procedures MACHINE Carry out all prestart operations as per site and machine OEM procedures. Ensure the machine is safely isolated during installation and testing to protect the machine and other equipment in the area. Do not operate any machine with a known fault and report all findings to the supervisor in writing. Test and operate machine as per machine OEM and site procedures. Read and understand machine and site specific operational and testing instructions. PRODUCT Before applying power to the equipment, the user/repairer/ installer must read all product instructions. If in doubt, seek assistance. Ensure electrical connections are made as per RCT s recommendations. Test circuits prior to connecting power to any component. The equipment contains no user serviceable parts inside. Return the unit to RCT for repairs. Retain product and installation instructions for future use. Ensure that RCT s recommended service procedures are included in the machine s service routine. Observe all machine, site and RCT product warnings. Follow all machine, site and RCT product operating procedures at all time. The application of safety should not be limited to the above recommendations M0140.docx Rev 2.2 Modified on 02/10/2015 Copyright RCT

PRODUCT OVERVIEW The Muirhead Light Vehicle Engine Protection system, part number 3206, offers engine protection for light commercial vehicles and off road mobile.

This greatly reduces premature engine failure, damage, and costly repairs.

5 PRODUCT OVERVIEW The Muirhead Light Vehicle Engine Protection system, part number 3206, offers engine protection for light commercial vehicles and off road mobile. The system operates by monitoring three critical areas of potential engine failure engine coolant level, engine temperature, and engine oil pressure and alerts the operator when there is an issue. This greatly reduces premature engine failure, damage, and costly repairs. The system provides audible and visual warnings and incorporates additional outputs for return to idle or shutdown modes, this product is compact in design and easy to install. FEATURES AND FUNCTIONS Audio and visual indication on reader Australian made and tested Universal applications Multi-voltage applications Tamper proof User friendly display Customised electronic circuitry Guards against engine failure Reduces costly engine repairs Easy diagnosis of engine problems Optional idle or shutdown function in the event of engine fault Reduces operator responsibility Supply voltage volts DC Environmentally sealed IP32 M0140.docx Rev 2.2 Modified on 02/10/2015 Copyright RCT 5 16

6 OPERATION AND USE When the ignition is switched on, the oil pressure indicator will illuminate along with the engine fault indicator and the audible alarm will sound. Once the engine has started and gained sufficient oil pressure, all alarms will stop. The unit is now monitoring the engine. Once a fault has been detected, the engine fault indicator will flash for ten seconds, along with the indicator of the particular circuit that has caused the fault and the audible alarm will sound. The Muirhead Light Vehicle Engine Protection system, part number 3206 has been designed as a generic engine protection system incorporating three inputs (one designated as a special AC circuit for detecting coolant) and three outputs. The configuration of these inputs and outputs are as follows; ENGINE COOLANT LEVEL (White Wire) This circuit detects low engine coolant. It is configured to have a 5 second delay prior to activating its individual warning indicator and the external audible alarm and optional shutdown process. This circuit activates when the circuit becomes open. ENGINE TEMPERATURE (Yellow Wire) This circuit detects high engine temperature. It is configured to have a 1 second delay prior to activating its corresponding warning indicator and the external audible alarm and optional shutdown process. This circuit activates when the circuit becomes open. ENGINE OIL PRESSURE LOW (Pink Wire) This circuit detects low engine oil pressure. It is configured to have a 1 second delay prior to activating its corresponding warning indicator and the external audible alarm and optional shutdown process. This circuit activates when the circuit becomes open. AUDIBLE ALARM OUTPUT (Green Wire) The audible alarm output circuit switches on as soon as an individual warning indicator has been activated. The alarm will remain on in a constant state until the operator has rectified the individual engine fault that was registered on the control unit. Once the engine fault has been rectified, the fault indicator that was illuminated on the control unit will cease along with the sounding of the alarm. IDLE OUTPUT (OPTIONAL) NOT USED (Brown Wire) This circuit operates as a direct opposite to the audible alarm circuit. It switches off when the audible alarm switches on. This circuit is only used in conjunction with additional control systems that can return the engine to idle on detection of a fault. SHUTDOWN ETR (OPTIONAL) NOT USED (Yellow/Blue Wire) This circuit operates similar to the idle output. However, this time delay is factory set to 10 seconds and therefore allows the vehicle to run for 10 seconds after the detection of a fault and the warning system has become active. The circuit is powered to run. The circuit switches off once a fault has been active for 10 seconds. This circuit also incorporates an override circuit to allow the vehicle to start when no oil pressure is present M0140.docx Rev 2.2 Modified on 02/10/2015 Copyright RCT

It is recommended that the wiring loom be installed alongside the OEM engine wiring ensuring that it is secured at regular intervals; this will provide protection from heat and abrasion, and any

7 INSTALLATION GUIDE 1. Install the control unit in a suitable location in full visibility of the driver, preferably on the instrument panel. 2. Refer to the wiring table below and the wiring diagram in this manual to wire up the control unit. It is recommended that the wiring loom be installed alongside the OEM engine wiring ensuring that it is secured at regular intervals; this will provide protection from heat and abrasion, and any other excess damage that may occur with extended vehicle operation. When securing the loom to the OEM engine wiring, ensure that the loom is away from moving vehicle parts which could lead to loom damage. 3. Install the sensors/ switches (see below for more detail). All sensors/ switches should be installed using a suitable thread sealant. All sensors should be installed using a suitable thread sealant. Note: RCT recommends that all electrical connections be treated with electroguard grease (part number 2800). WIRING CONNECTIONS PIN NO. COLOUR DESCRIPTION 1 Purple Start input 2 Yellow/Blue ETR output 3 Black 0 V DC earth 4 Red 7-35 V DC ignition 5 Brown Idle control output 6 Green Fault alarm PIN NO. COLOUR DESCRIPTION 1 White Coolant level sensor 2 Pink Engine oil pressure switch 3 Yellow Engine coolant temperature sensor M0140.docx Rev 2.2 Modified on 02/10/2015 Copyright RCT 7 16

ENGINE TEMPERATURE SENSOR Ensuring the engine temperature sensor is installed on the engine side of the vehicle in front of the thermostat.

Install the switch using thread sealant. Note: Care should be taken when selecting a mounting port to allow sufficient depth for the bulb. Part No.

Ensure there is sufficient clearance within the radiator to accommodate the length of the coolant probe to be fitted.

Fit the sensor and pressure test, this can be achieved by running the engine until normal operating temperature has been reached.

8 ENGINE TEMPERATURE SENSOR Ensuring the engine temperature sensor is installed on the engine side of the vehicle in front of the thermostat. If the engine temperature sensor is not installed on the engine side, the engine temperature will not be sensed correctly. It is imperative that the switch sensing area (bulb) be immersed in coolant. Install the switch using thread sealant. Note: Care should be taken when selecting a mounting port to allow sufficient depth for the bulb. Part No F / 100 C Normally Closed Thread: 3/8 NPT ENGINE COOLANT LEVEL SENSOR It is recommended that the coolant level sensor be installed in the radiator tank (see figure below). Ensure there is sufficient clearance within the radiator to accommodate the length of the coolant probe to be fitted. Drill the required hole size in the tank and tap to the required thread size as specified below. Always clean debris away and remove any foreign objects before installing the sensor. Fit the sensor and pressure test, this can be achieved by running the engine until normal operating temperature has been reached. Do not install the coolant level sensor in the coolant flow points of the engine, i.e. hoses or piping. The application is designed to detect the coolant level of the entire vehicle; the coolant level sensor must be fitted in the top of the coolant tank (radiator) to enable it to get a correct reading of the coolant level. Part No Thread: 1/8 NPT Nylon Tapping drill: 21/64 Probe length: 30 mm from top of thread to tip of probe PROBE POSITION OPTIMUM PROBE LEVE IS ⅓ UP FROM THE BOTTOM OF THE TOP HOSE HOLE Part No Thread: 1/4 NPT Nylon Tapping drill: 7/16 Probe length: 72 mm from top of thread to tip of probe Note: Brass weld collar included RADIATOR Installation Example 8 16 M0140.docx Rev 2.2 Modified on 02/10/2015 Copyright RCT

ENGINE OIL PRESSURE SWITCH The engine oil pressure switch should be located in a suitable oil gallery access port. Use the OEM oil pressure switch as a guide for location.

Note: T-pieces are available in most thread types to enable both the OEM and Muirhead Oil Pressure Switches to be installed into the original port. Part No.

9 ENGINE OIL PRESSURE SWITCH The engine oil pressure switch should be located in a suitable oil gallery access port. Use the OEM oil pressure switch as a guide for location. Fit the oil pressure switch using thread sealant, being careful not to over tighten. Note: T-pieces are available in most thread types to enable both the OEM and Muirhead Oil Pressure Switches to be installed into the original port. Part No PSI Normally Open Thread: 1/8 NPT AUDIBLE ALARM There are three ways of mounting the audible warning alarm; 1. Through instrument panel (via a 29 mm hole) 2. Via an optional mounting bracket (part number 9655) 3. Under the instrument panel (cable tied to loom) M0140.docx Rev 2.2 Modified on 02/10/2015 Copyright RCT 9 16

10 EXTERNAL WIRING DIAGRAM (049f) A B C D E F G H REV ZONE DESCRIPTION BY DATE 1 2 updated titleblock GT 27/07/15 WH YL PK YL/BU BN COOLANT OIL COOLANT ENGINE LEVEL PRESSURE TEMP. FAULT GN PU RD BK P T -0V EARTH +7V - 35VDC IGNITION START INPUT FAULT ALARM OUTPUT IDLE CONTROL OUTPUT ETR RUN OUTPUT ENGINE OIL ENGINE ENGINE PRESSURE COOLANT COOLANT SWITCH TEMPERATURE LEVEL SWITCH PROBE ALL DIMENSIONS IN MILLIMETERS UNCONTROLLED DOCUMENT SCALE NTS A4 3rd ANGLE PROJECTION MALE PINS WIRING CODE MALE PINS WIRING CODE COPYRIGHT - ALL RIGHTS RESERVED This drawing is the property of REMOTE CONTROL TECHNOLOGIES PTY LTD (RCT), and is not to be copied or used in whole or in part for any purpose without the express authority of RCT. The drawing is to be returned to RCT, on demand CONTROL UNIT PLUG OPERATION 1 - PURPLE - START INPUT 2 - YELLOW/BLUE - ETR RUN SOLENOID OUTPUT 3 - BLACK - -0VDC EARTH 4 - RED - +7 TO 35VDC IGNITION 5 - BROWN - IDLE CONTROL OUTPUT 6 - GREEN - FAULT ALARM WHEN A CRITICAL ENGINE FAULT IS CONFIRMED THE OPERATOR IS ALERTED BY THE APPROPRIATE LED LAMP, AN AUDIBLE ALARM WILL OPERATE AND THE ENGINE FAULT LED WILL FLASH. THE IDLE CONTROL OUTPUT WILL ALSO DE-ACTIVATE. IF THE CRITICAL ENGINE FAULT CONTINUES FOR THE SHUTDOWN PERIOD THEN THE ETR RUN OUTPUT IS DE-ACTIVATED. 3 LIGHT VEHICLE ENGINE WARNING SYSTEM EXTERNAL WIRING PART NO 3206 STOCK CODE AIS-LV-EWS BY BT DRN RH DATE 03/05/04 APPD GS DATE ---- SHEET 1 of CONTROL UNIT PLUG 1 - WHITE - COOLANT LEVEL PROBE 2 - PINK - ENGINE OIL PRESSURE SWITCH 3 - YELLOW - ENGINE COOLANT TEMPERATURE SWITCH THE MANUFACTURER RECOMMENDS THAT THE IGNITION SUPPLY BE 15 AMP FUSED AT ITS SOURCE AND THAT ALL INDUCTIVE SOURCES BE DIODE PROTECTED. FAILURE TO DO SO MAY EFFECT PRODUCT PERFORMANCE AND WARRANTY. STATUS DWG No Released 049f REV 2 A B C D E F G H M0140.docx Rev 2.2 Modified on 02/10/2015 Copyright RCT

11 CALIBRATION Not applicable. SERVICE INFORMATION SERVICE SCHEDULE The manufacturer recommends that the following service procedure should be performed at each vehicle s scheduled service interval. SERVICE PROCEDURE 1. Perform a visual inspection; include the following: a) Control unit. b) Wiring connections and looms. c) All switches and sensors as below. d) Engine fluids. 2. Perform a system test as per the following: a) Refer to the Operation and Use section of this manual for the operation of the control unit and each function. b) Test each circuit individually as per the Test Procedure. Coolant Level Sensor Every 2000 hours or six months a) Remove the sensor from the radiator. b) Plug the hole to minimise coolant loss. c) Inspect the condition of the sensor ensuring the centre of the sensor is insulated from outer mounting. Ensure the sensor is free from grease, oil and dirt. d) Inspect electrical connection point for thread damage, burrs, corrosion and ensure the nut tightens on the thread (if applicable). e) Refit the sensor ensuring the thread is free from coolant leaks. Note: All monitoring switches should be changed when fitting a new or repaired engine to a vehicle. Coolant Temperature Switch Every 2000 hours or six months a) If temperature faults are present and tests performed on the electrical circuit prove inconclusive, it is recommended that the coolant temperature switch be replaced. b) Due to the critical function of this switch, it is recommended that the coolant temperature switch be replaced every 2000 hours or every six months. Note: All monitoring switches should be changed when fitting a new or repaired engine to a vehicle. Engine Oil Pressure Switch Every 2000 hours or six months a) If engine oil faults are present and tests performed on the electrical circuit prove inconclusive, it is recommended that the engine oil pressure switch be replaced. b) Due to the critical function of this switch, it is recommended that the engine oil pressure switch be replaced every 2000 hours or every six months. Note: All monitoring switches should be changed when fitting a new or repaired engine to a vehicle. M0140.docx Rev 2.2 Modified on 02/10/2015 Copyright RCT 11 16

12 TEST PROCEDURE Test each circuit individually. Coolant Level Sensor Every 250 hours or during vehicle scheduled service a) Turn the ignition switch to the ON position and verify the coolant level indicator is not illuminated. b) Disconnect the wire from the coolant level sensor. c) Verify, after five seconds, that the coolant level indicator is now illuminated. d) Reconnect the wire to the coolant level sensor. e) Remove sufficient coolant from the engine to allow the level to fall below the sensor. f) Verify that the coolant level indicator is illuminated. g) Refill coolant to the manufacturer s specifications. h) Check that the coolant level indicator is no longer illuminated. i) Turn the ignition off. Coolant Temperature Switch Every 250 hours or during vehicle scheduled service a) Turn the ignition switch to the ON position. b) Check that the coolant temperature indicator is not illuminated. c) Disconnect 1 x wire at the coolant temperature switch. d) Verify, after one second, that the coolant temperature indicator is now illuminated. e) Turn the ignition off and reconnect the electrical wiring. Engine Oil Pressure Switch Every 250 hours or during vehicle scheduled service a) Turn the ignition switch to the ON position. b) Verify that the fault alarm is sounding and the oil pressure indicator is illuminated. c) Bridge the wires at the oil pressure switch. d) Verify, after one second, that alarm has ceased and the oil pressure indicator is no longer illuminated. e) Remove bridging connector. f) Start and run vehicle until engine oil pressure reaches normal operating pressure. g) Verify that alarming has ceased and the oil pressure indicator is no longer illuminated. PARTS LIST PART NO. DESCRIPTION QTY 3369 EPS control unit Pressure switch, 8 PSI, 2 terminal, N/O, ⅛ NPT (light duty) Audible warning alarm 80 db Temperature switch, 212 F / 100 C, 3/8 NPT, N/C Coolant level probe, ⅛ NPT, 30 mm shaft length. (light duty, plastic body) Coolant level probe terminal Insulator to suit 7621 terminal Bush to suit ⅛ NTP Probe Universal engine warning system (EWS) loom 1 Note: A ⅛ NPT tap is required to tap the hole for the coolant sensing probe to fit into. The ⅛ NPT tap, part number 4289, is available separately for purchase M0140.docx Rev 2.2 Modified on 02/10/2015 Copyright RCT

13 TECHNICAL SPECIFICATIONS Dimensions, control unit only Dimensions, boxed for freight Weight, control unit only Weight, including harness / packaging for freight Input nominal voltage Length: 87 mm Width: 63 mm Height/Depth: 33 mm Length: 22 mm Width: 120 mm Height/Depth: 120 mm 0.15 kg 0.30 kg 12 to 24 V DC Operating temperate range 0 to 70 C Connection types Inputs Min & max input voltage Circuit protection Enclosure type Environmental protection IP rating Programming/adjustment Quick connector 6-socket, quick connector 3-socket, Earth, ignition key switch, pressure switch, engine switch, coolant probe 7 to 35 V DC Reverse polarity protected Black powder coated aluminium IP32 Not applicable COMPLIANCE AND STANDARDS TBA TROUBLESHOOTING FAULT Device not working. Intermittent fault. POSSIBLE CAUSE Check wiring and connections. Check wiring and connections. M0140.docx Rev 2.2 Modified on 02/10/2015 Copyright RCT 13 16

14 GLOSSARY A Amp (Ampere) N/A Not Applicable AC Alternating Current N/C Normally Closed AMS Advanced Management System N/O Normally Open CAN Controller Area Network OEM Original Equipment Manufacturer CMIO Control Master Input Output PCB O/P Outputs CMR Control Master Receiver Out Output CMT Control Master Transmitter PB Push Button CM2200 Control Master 2200 Remote Set PC Personal Computer COMMS Communications PCB Printed Circuit Board CPU Central Processor Unit PIN Personal Identification Number DC Direct Current PLC Programmable Logic Controller E.G. For example POT Potentiometer FET Field Effect Transistor PPM Pulses Per Metre GND Ground PWM Pulse Width Modulation H Hours PWR Power HEX Hexidecimal Numbering System RCT Remote Control Technologies Pty Ltd ID Identity Rev Revision i.e That is RF Radio Frequency In Input RH Relative Humidity IP Ingress Protection RPM Revolutions per minute kg Kilogram RX Receiver Recommended Standard (number 232) Km/h Kilometres Per Hour RS232 for serial data transfer LCD Liquid Crystal Display SYS System LED Light Emitting Diode TOV Text On Video LK Link TX Transmitter M Minutes V Volts ma Milli Amps VSC Variable Spray Controller MAX Maximum WSC Water Spray Controller MCU Multi Control Unit C Degrees Centigrade MFU Multi Function Unit # Number Mega Hertz (million(s) cycles per MHz second) < Less Than MIN Minimum > Greater Than mm millimetres % Percentage mw Milli Watts WARRANTY Please see the RCT standard warranty, available on our website M0140.docx Rev 2.2 Modified on 02/10/2015 Copyright RCT

15 NOTES M0140.docx Rev 2.2 Modified on 02/10/2015 Copyright RCT 15 16

PERTH Unit 2-5/511 Abernethy Road Kewdale WA 6105 Ph: +61 (0) 8 9353 6577 Fax: +61 (0) 8 9353 6578 BRISBANE Unit 6/26 Flinders Parade North Lakes QLD 4509 Ph: +61 (0) 7 3385 0172 Fax: +61 (0) 7 3385

16 PERTH Unit 2-5/511 Abernethy Road Kewdale WA 6105 Ph: +61 (0) Fax: +61 (0) BRISBANE Unit 6/26 Flinders Parade North Lakes QLD 4509 Ph: +61 (0) Fax: +61 (0) KALGOORLIE 24 Percy Road Kalgoorlie WA 6430 Ph: +61 (0) Fax: +61 (0) MT ISA 1A Ryan Road Mt Isa QLD 4825 Ph: +61 (0) Fax: +61 (0) MELBOURNE Unit 4 Hallmarc Office Park 15 Ricketts Road Mt Waverley VIC 3149 Ph: +61 (0) Fax: +61 (0) AFRICA: +27 (0) NORTH AMERICA: RUSSIA/CIS: +7 (910) SOUTH AMERICA:

PRODUCT MANUAL PARK BRAKE WARNING SYSTEM 12/24 VOLTS. Part No

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