PRODUCT MANUAL ENGINE PROTECTION SYSTEM 6-FUNCTION TO SUIT AIR COOLED ENGINES. Part No. 3747

Transcription

1 PRODUCT MANUAL ENGINE PROTECTION SYSTEM 6-FUNCTION TO SUIT AIR COOLED ENGINES Part No. 77

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. 8 m070.docx Rev. Modified on 08/0/05 Copyright RCT

3 Contents CAUTION. CONSULT THE SPECIFICATIONS DATA SHEET ON PAGE PRIOR TO THE INSTALLATION OF THE PRODUCT. INCORRECT FITMENT WILL VOID THE MANUFACTURER S WARRANTY. GENERAL SAFETY WARNINGS 5 PRODUCT OVERVIEW 6 FEATURES AND FUNCTIONS 6 OPERATION AND USE 7 CONTROL UNIT 7 WIRING CONNECTIONS 7 INPUTS 8 OUTPUTS 9 INSTALLATION GUIDE 0 CONTROL UNIT 0 AUDIBLE ALARM 0 ENGINE TEMPERATURE SWITCH FUNCTION ENGINE OIL PRESSURE SWITCH FUNCTION TRANSMISSION OIL TEMPERATURE SWITCH FUNCTION BELT BREAK PROXIMITY SWITCH FUNCTION HYDRAULIC OIL TEMPERATURE SWITCH FUNCTION 5 OIL/FUEL LEVEL SWITCH FUNCTION 6 LOW ENGINE OIL LEVEL SWITCH LOCATION DIAGRAM (59D) ENGINE PROTECTION SYSTEM LABELLING DETAILS 5 ALERT FUNCTION IDENTIFICATION LABELS 6 TYPICAL ENGINE PROTECTION SYSTEM SCHEMATIC TO SUIT 6-FUNCTION AIR COOLED ENGINES (68v) 7 CALIBRATION 8 SERVICE INFORMATION 8 SERVICE SCHEDULE 8 SERVICE PROCEDURE 8 ENGINE TEMPERATURE SWITCH 8 ENGINE OIL PRESSURE SWITCH 8 TRANSMISSION OIL TEMPERATURE SWITCH 8 BELT BREAK PROXIMITY SWITCH 8 HYDRAULIC OIL TEMPERATURE SWITCH 9 OIL/FUEL LEVEL SWITCH 9 TEST PROCEDURE 9 CONTROL UNIT 9 ENGINE TEMPERATURE SWITCH 0 ENGINE OIL PRESSURE SWITCH 0 TRANSMISSION OIL TEMPERATURE SWITCH 0 BELT BREAK PROXIMITY SWITCH 0 HYDRAULIC OIL TEMPERATURE SWITCH 0 OIL/FUEL LEVEL SWITCH 0 m070.docx Rev. Modified on 08/0/05 Copyright RCT 8

4 PARTS LIST DECALS SUPPLIED WITH THE PRODUCT WIRING LOOM TO SUIT 77 CONTROL UNIT ENGINE TEMPERATURE SWITCHES PRESSURE SWITCHES TO SUIT ENGINE OIL PRESSURE APPLICATIONS TEMPERATURE SWITCHES TO SUIT TEMPERATURE MONITORING APPLICATIONS BELT BRAKE PROXIMITY SWITCHES OIL/FUEL LEVEL SWITCHES TO SUIT THE OIL LEVEL MONITORING APPLICATIONS ALARMS TO SUIT THE WARNING ALERT FUNCTION OF THE CONTROL UNIT TECHNICAL SPECIFICATIONS COMPLIANCE AND STANDARDS TROUBLESHOOTING GLOSSARY 5 WARRANTY 5 APPENDIX 6 ETR IDLE TIMER / EPS / FIRE CONTROL UNIT DIAGRAM (78i) 6 8 m070.docx Rev. Modified on 08/0/05 Copyright RCT

5 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. m070.docx Rev. Modified on 08/0/05 Copyright RCT 5 8

6 PRODUCT OVERVIEW The Muirhead Engine Protection system (EPS), part number 77, is designed to monitor almost any alarm condition on virtually any machine. This system has been designed to monitor six inputs and three digital outputs; the system continuously monitors four areas of protection and alerts the operator of abnormal engine conditions. With no mechanical parts, the EPS control unit is extremely reliable, easy to install and simple to use. Every EPS control unit can be customised to monitor known problems and functions commonly associated with equipment failure. Note: Additional looms, fittings, switches, lights and audible alarm maybe required to perform a complete installation. FEATURES AND FUNCTIONS Multi-voltage (8 to volts) Alarm only, return to idle/shutdown modes System test function Custom fault indicator labelling Configurable inputs Reduces downtime Substantially reduces the risk of engine failure Simple installation Audio/visual indicators Six inputs and three outputs Individual fault indicators Compact and robust control panel design Extends machine life Multiple applications IP65 enclosure 6 8 m070.docx Rev. Modified on 08/0/05 Copyright RCT

7 OPERATION AND USE CONTROL UNIT Electronic circuitry within the EPS control unit monitors the state of the switches and sensors and then activates the corresponding alert indicator and control outputs when an alarm condition is sensed. The EPS labelling displays the alert indicator or function that has faulted. A test switch located on the front of the EPS control unit allows the operator to simulate a fault and test the complete system. A connector with contacts located on the rear of the EPS control unit facilitates the necessary wiring for the inputs and outputs. ALERT INDICATORS TEST SWITCH -PIN CONNECTOR WIRING CONNECTIONS NO. FUNCTION TYPE +8 V DC to + V DC Ignition supply 0 V DC ground Ground Output Alarm control Output Idle control 5 Output Energised to run control (ETR) 6 Input Start input 7 Function AC circuit/switch input 8 Function Switch input 9 Function Switch input 0 Function Switch input Function 5 Switch input Function 6 AC circuit/switch input m070.docx Rev. Modified on 08/0/05 Copyright RCT 7 8

8 INPUTS The following input functions indicate the factory defaults with all inputs and outputs being configurable. Refer to document number P00 for advanced programming information. Contact your local RCT branch or distributor for a copy of the document or for more information. FUNCTION This input is configured to have a five-second delay prior to pulsing the alert indicator and activating the alarm. After a further 0 seconds, the alert indicator will come on solid, the alarm will remain on and activate the idle and ETR control circuits. This circuit activates when the circuit changes state and becomes open. This input is specifically designed for coolant level detection. If this function is not required, pin 7 must be connected to ground. Typical use: Cylinder head temperature FUNCTION This input is configured to have a one-second delay prior to activating the corresponding alert indicator, external audible alarm, idle, and ETR control circuits. This circuit activates when the circuit changes state and becomes open. If this function is not required, pin 8 must be connected to ground. Typical use: Low engine oil pressure FUNCTION This input is configured to have a one-second delay prior to activating the corresponding alert indicator, external audible alarm, idle and ETR control circuits. This circuit activates when the circuit changes state and becomes open. If this function is not required, pin 9 must be connected to ground. Typical use: Transmission oil temperature FUNCTION This input is configured to have a one-second delay prior to activating the corresponding alert indicator, external audible alarm, idle, and ETR control circuits. This circuit activates when the circuit changes state and becomes open. If this function is not required, pin 0 must be connected to ground. Typical use: Belt brake FUNCTION 5 This input is configured to have a one-second delay prior to activating the corresponding alert indicator, external audible alarm, idle and ETR control circuits. This circuit activates when the circuit changes state and becomes open. If this function is not required, pin must be connected to ground. Typical use: Hydraulic oil temperature FUNCTION 6 This input is configured to have a one-second delay prior to activating the corresponding alert indicator, external audible alarm, idle and ETR control circuits. This circuit activates when the circuit changes state and becomes open. If this function is not required, pin must be connected to ground. Typical use: Hydraulic oil level. 8 8 m070.docx Rev. Modified on 08/0/05 Copyright RCT

9 OUTPUTS ALARM CONTROL OUTPUT This circuit is activated as soon as an alert indicator is active. This output remains active until the EPS control unit has no alert indicator active or the key is switched off. This output is disabled until a start signal is sensed. This allows servicing to be carried out with the key on without the alarm sounding. IDLE CONTROL This circuit operates as a direct opposite to the alarm control output. It switches off when the alarm control output is active. This output is used in conjunction with additional control systems that return the engine to idle when an alert indicator is activated. If return to idle is not required, this circuit should not be connected. This circuit overrides for 0 seconds after start is activated. ENGINE CONTROL (ETR) This circuit operates in a similar way to the idle control output; however, it has a 0 to 0-second adjustable time delay. This time delay is factory set to 0 seconds, allowing the machine to run for 0 seconds after an alert indicator has been activated. This circuit is an energised to run output. This output also incorporates an automatic system override circuit which allows the EPS control unit to override the engine oil pressure switch allowing the engine to be started. If shutdown is not required, this circuit should not be connected. WARNING! When an alert indicator is active, special care should be taken to assess safety considerations which may arise from shutting the machine down.. Will the machine be left uncontrollable, as shutdown affects the braking and steering of most machines?. Can the machine be parked in a safe environment? m070.docx Rev. Modified on 08/0/05 Copyright RCT 9 8

10 INSTALLATION GUIDE Note: If the EPS system is installed in conjunction with an idle timer and/or a fire status control unit, it is imperative that the units are installed in the correct order. Failure to do so may result in the machine not shutting down correctly. Refer to the appendix at the end of this manual for the correct sequence. CONTROL UNIT. The recommended location for the control unit is in the operator s cabin in clear view and within easy reach of the operator. Proximity to the operator is important as the control unit incorporates a system test switch/circuitry that allows service personnel and/or operators to test the system.. Drill two 8 mm diameter holes with the hole centres being 00 mm apart to suit the M8*0 hex screw that bolts to the control unit mounting bracket. Careful consideration should be given to the location of these holes before drilling to ensure adequate accessibility to the electrical connection located on the rear of the control unit.. 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 machine operation. When securing the loom to the OEM engine wiring, ensure that the loom is away from moving machine parts which could lead to loom damage.. Install the sensors/ switches (see below for more detail). All sensors/ switches should be installed using a suitable thread sealant. Options If a Muirhead Idle Timer is fitted, the machine will return to idle immediately. If a Muirhead Shutdown Control unit is fitted, the machine will return to idle for the specified time and then shutdown. Notes: Perform a system test using the test procedure in the Calibration section in this manual. For information on testing individual functions and/or parts of the EPS system, refer to the additional testing information in this manual. AUDIBLE ALARM There are three ways of mounting the audible warning alarm;. Through instrument panel (via a 9 mm hole). Via an optional mounting bracket (part number 9655). Under the instrument panel (cable tied to loom) 0 8 m070.docx Rev. Modified on 08/0/05 Copyright RCT

11 ENGINE TEMPERATURE SWITCH FUNCTION The engine temperature switch is to be installed in the back of the cylinder head in the 0 mm x.5 mm threaded hole provided by the manufacturer. Care must be taken when installing cylinder head temperature switches as the head of the switch can be easily broken. Part No. 65 F / 85 C Normally Open Thread: 0 mm x.5 mm brass Part No F / 50 C Normally Open Thread: 0 mm x.5 mm brass Part No F / 70 C Normally Open Thread: 0 mm x.5 mm brass WARNING! OVER TIGHTENING THE SWITCH WHEN INSTALLING MAY CAUSE DAMAGE TO THE SWITCH, RENDERING THE SWITCH UNSERVICEABLE AND MAY ALSO MAKE REMOVAL PROBLEMATIC. ENGINE OIL PRESSURE SWITCH FUNCTION The engine oil pressure switch should be located in a suitable oil gallery access port. Use the original equipment manufacturer (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. 008 PSI Normally Open Thread: /8 NPT Part No PSI Normally Open Thread: /8 NPT Part No PSI Normally Open Thread: /8 NPT m070.docx Rev. Modified on 08/0/05 Copyright RCT 8

12 TRANSMISSION OIL TEMPERATURE SWITCH FUNCTION The oil temperature switch can be used to monitor oil temperature in the transmission, engine or compressor etc. Install the switch in the required location as specified by the original equipment manufacturer (OEM). It is imperative that the switch sensing area (bulb) be immersed in oil. 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 / 5 C Normally Closed Thread: /8 NPT Part No F / C Normally Closed Thread: /8 NPT BELT BREAK PROXIMITY SWITCH FUNCTION It is recommended that the belt break proximity switch be installed with a 5 mm clearance with the switch sense facing the spring loaded idler pulley (metal). If the engine cooling belt breaks, the idler pulley will return to its rest position. The switch should be located so as to lose proximity with the pulley when the belt breaks. x Possible Mounting Example COOLING FAN PROXIMITY SWITCH 5 mm GAP BELT TENSION Part No. 8 Part No mm sensing 8 m070.docx Rev. Modified on 08/0/05 Copyright RCT

13 HYDRAULIC OIL TEMPERATURE SWITCH FUNCTION 5 The oil temperature switch can be used to monitor oil temperature in the transmission, engine or compressor etc. Install the switch in the required location as specified by the original equipment manufacturer (OEM). It is imperative that the switch sensing area (bulb) be immersed in oil. 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 / 96 C Normally Opened Thread: /8 NPT OIL/FUEL LEVEL SWITCH FUNCTION 6 The oil/fuel level switch is a capacitive type switch with a ¼ NPT mounting thread and used to monitor levels in tanks and reservoirs. The switch should be installed at the low level mark which is specified by the OEM. Ensure there is sufficient clearance within the tank so as not to interfere with the switch installation. Install switch using thread sealant. Note: Care should be taken when selecting a mounting position as the maximum allowable ambient temperature for the switch is 00 C. Also note that the oil/fuel level switch incorporates a three-second alarm delay. For operating temperatures above 00 C, installing the 8690 heavy duty switch is recommended. Part No. 07 Normally Open Thread: / NPT brass Tapping drill: 7/6 Part No Normally Open (Heavy Duty) m070.docx Rev. Modified on 08/0/05 Copyright RCT 8

14 LOW ENGINE OIL LEVEL SWITCH LOCATION DIAGRAM (59D) REV ZONE DESCRIPTION BY DATE new titleblock GT 6/07/07 rewrite step 5 BT 5/07/07 A I updated titleblock POINT REWORDED GT 0/08/5 MT 7/08/5 A B INSTALLATION DETAILS ENGINE FRONT VIEW B C C D D E 5 SLIDE UP OR DOWN TO DESIRED LEVEL E SWITCH POINT MUST LINE UP WITH LOW LEVEL IN SUMP F OIL PAN MOUNT SWITCH ON A BRACKET CLOSE TO OR ON ENGINE F G G H I FITTING INSTRUCTIONS. DRAIN ENOUGH OIL UNTIL THE DIPSTICK MARK IS ON LOW WITH THE ENGINE RUNNING AT NORMAL SPEED.. TEMPORARILY INSTALL A LENGTH OF CLEAR PLASTIC TUBING FROM THE LOWER OIL PAN AND RETURN TO THE UPPER PAN.. OIL LEVEL SIGHTED BY EYE ACROSS PLASTIC TUBE TO SIDE OF OIL PAN. THIS LEVEL DETERMINES THE LOCATION OF LOW OIL SWITCH POINT. ALL DIMENSIONS IN MILLIMETERS UNCONTROLLED DOCUMENT SCALE NTS rd ANGLE PROJECTION A 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. H I J. BRAISE " NPT FITTING IN THE SIDE OF THE PAN. INSTALL HOSE FITTING ADAPTOR - USE TEFLON TAPE TO SEAL THE THREADS. 5. THE MULTI LEVEL SWITCH MUST BE PLUMBED SO THAT THE LOWER HOSE PORT IS LOWER THAN THE LOW LEVEL SWITCH POINT AND THE TOP HOSE PORT MUST BE PLUMBED SO THAT IT IS HIGHER THAN THE LOW LEVEL SWITCH POINT. LOW ENGINE OIL LEVEL SENSOR LOCATION FITTING INSTRUCTIONS J K K PART NO 8690 STOCK MULTI LEVEL SWITCH CODE BY JL DRN RH DATE //0 APPD JL DATE ---- L SHEET of STATUS DWG No Released 59d 8 REV L 8 m070.docx Rev. Modified on 08/0/05 Copyright RCT

15 ENGINE PROTECTION SYSTEM LABELLING DETAILS AIR COOLED There are a wide range of decals available and also blank decals which can be used when not all six functions are required. The engine protection system incorporates a simple but effective labelling system that can be customised to suit individual needs. The construction of the label is a simple process;. Select the correct decal that is required for the application.. Remove the adhesive backing from the decal and place in the correct clear insert on the main label. Make sure the decal is aligned correctly (as shown in the above diagram).. Use a plastic card or similar tool to carefully push any air bubbles that form out to the edges of the label.. Once all the decals that are required have been placed in their correct clear inserts on the main label, remove the adhesive backing from the main label and fit it onto the engine protection control enclosure. 5. Remove all air bubbles and clean the label. The labelling process is now complete. m070.docx Rev. Modified on 08/0/05 Copyright RCT 5 8

16 ALERT FUNCTION IDENTIFICATION LABELS PART NO. LABEL PART NO. LABEL m070.docx Rev. Modified on 08/0/05 Copyright RCT

17 A TYPICAL ENGINE PROTECTION SYSTEM SCHEMATIC TO SUIT 6-FUNCTION AIR COOLED ENGINES (68v) REV ZONE DESCRIPTION BY DATE updated titleblock GT /08/5 Hyd Oil Temp and Level switches added to pins D, H6 +, wire colour changed MT /09/5 from WH to BU/RD at pin A B B C 8-0V SUPPLY GROUND OUT ALARM OUT IDLE CONTROL OUT ETR CONTROL START INPUT IN CYL. HEAD TEMP. IN OIL PRESSURE IN TRANS. OIL TEMP IN IN5 IN6 BELT BREAK HYD OIL TEMP HYD OIL LEVEL OR- BK- GN- BN- YL/BU- PU- BU/WH- PK- YL- GY- WH- BU/RD- GN-mm BK-mm BN- + BK FAULT ALARM CAUTION! OUTPUT CURRENT RATING 6AMP MAX IDLE CONTROL SOLENOID CAUTION! OUTPUT CURRENT RATING 6AMP MAX C D E ENGINE PROTECTION SYSTEM CONTROL NOTE THIS IS A TYPICAL ENGINE PROTECTION SYSTEM SCHEMATIC ILLUSTRATING ALL OUTPUT AND INPUTS. THIS SHOULD ONLY BE USED AS A GUIDE. DIFFERENT MACHINES REQUIRE DIFFERENT COMPONENTS. FOR MORE INFORMATION PLEASE CONTACT THE MANUFACTURER. YL/BU- + BK- - BU/WH- N/O BK- T PK- ETR RUN SOLENOID CAUTION! OUTPUT CURRENT RATING 6AMP MAX CYLINDER HEAD TEMP. D E F NOTE BK- N/O OIL PRESSURE SWITCH F IF NOT ALL FUNCTIONS ARE REQUIRED, A BLANK IS PLACED ON THE UNUSED FUNCTION AND THE CORRESPONDING INPUT WIRE MUST BE CONNECTED TO GROUND. YL- BK- P N/C TRANS OIL TEMP. G T G RD- GY- BK- A C B + S - BELT BREAK H WH- BK- N/C T HYDRAULIC OIL TEMPERATURE SWITCH ALL DIMENSIONS IN MILLIMETERS UNCONTROLLED DOCUMENT H I RD- BU/RD- BK- C A B + S - HYDRAULIC OIL LEVEL SWITCH SCALE NTS rd ANGLE PROJECTION A 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. I J 8-0VDC PROTECTED SUPPLY (RECOMMENDED 0AMP PROTECTION) TO START TERMINAL AT KEY SWITCH MACHINE (FRAME) GROUND TYPICAL ENGINE PROTECTION SYSTEM SCHEMATIC TO SUIT AIR COOLED ENGINES J EXTERNAL WIRING K K WIRE LEGEND BK - BLACK PK - PINK BU - BLUE PU - PURPLE L BN - BROWN RD - RED GN - GREEN WH - WHITE GY - GREY YL - YELLOW OR - ORANGE TQ - TURQUOISE PART NO 77 STOCK MH-EPS-6 CODE BY BT DRN MC DATE 0/07/06 APPD BT DATE ---- SHEET of STATUS DWG No Released 68v 8 REV L m070.docx Rev. Modified on 08/0/05 Copyright RCT 7 8

18 CALIBRATION Not applicable SERVICE INFORMATION SERVICE SCHEDULE The manufacturer recommends that the following service procedure should be performed at each machine s scheduled service interval. SERVICE PROCEDURE. Perform a visual inspection and include the following: a) Control unit b) Wiring connections and looms c) All switches and sensors as below d) Engine fluids. 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. Note: All monitoring switches should be changed when fitting a new or repaired engine to a machine. ENGINE TEMPERATURE SWITCH Every 000 hours or six months. If temperature faults are present and tests performed on the electrical circuit prove inconclusive, it is recommended that the coolant temperature switch be replaced.. Due to the critical function of this switch, it is recommended that the coolant temperature switch be replaced every 000 hours or every six months. ENGINE OIL PRESSURE SWITCH Every 000 hours or six months. 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.. Due to the critical function of this switch, it is recommended that the engine oil pressure switch be replaced every 000 hours or every six months. TRANSMISSION OIL TEMPERATURE SWITCH Every 000 hours or six months. If temperature faults are present and tests performed on the electrical circuit prove inconclusive, it is recommended that the oil temperature switch be replaced.. Due to the critical function of this switch, it is recommended that the oil temperature switch be replaced every 000 hours or every six months. BELT BREAK PROXIMITY SWITCH Every 000 hours or six months. Turn the ignition switch to the ON position.. The belt break alert indicator should not be illuminated.. Loosen the switch clamp mounting screws.. Remove the switch from the clamp. 5. Place switch in a position away from any metal objects (minimum 50 mm). 6. Verify that the belt break alert indicator is now illuminated. 7. If the switch tests okay, refit with a recommended 5 mm clearance. 8 8 m070.docx Rev. Modified on 08/0/05 Copyright RCT

19 HYDRAULIC OIL TEMPERATURE SWITCH Every 000 hours or six months. If temperature faults are present and tests performed on the electrical circuit prove inconclusive, it is recommended that the oil temperature switch be replaced.. Due to the critical function of this switch, it is recommended that the oil temperature switch be replaced every 000 hours or every six months. OIL/FUEL LEVEL SWITCH Every 000 hours or six months. It will be necessary to remove the switch for testing.. Remove switch and plug hole to prevent fluid loss.. Inspect the switch for physical damage.. Reconnect the -pin Deutsch plug. 5. Turn the ignition switch to the ON position. 6. Verify the oil/fuel level alert indicator is now illuminated. 7. Immerse the threaded end of the switch in oil and verify that the oil/fuel level alert indicator is no longer illuminated. 8. If the switch tests okay, refit the switch using thread sealant. TEST PROCEDURE The testing of the EPS control unit should ideally be performed when the operator first checks the machine at the beginning of each shift or when the machine is due for its scheduled service. The testing of the engine protection control unit incorporates a system test switch, this allows the service person and/or operator to easily test the EPS control unit. In order to test the EPS control unit, the following test procedure should be followed. System Test Switch CONTROL UNIT. Start and run the machine as per normal (raise the RPM above idle if the idle control function is used). All alert indicators on the control unit should light up and activate the alarm on initial start-up, and cease immediately once the control unit has detected that the engine oil pressure has been pressurised.. If the control unit has detected a fault upon start-up, for example, if the engine temperature is high, the fault will be present on the control unit upon start-up of the machine.. Press and hold the control unit test switch, all alert indicators on the control unit should illuminate immediately and the alarm control circuit will activate, sounding the alarm.. Having depressed the system test switch for 0 seconds, the engine ETR output will turn off, shutting down the engine if the engine shutdown option of the control unit is being utilised. If the shutdown option is not being used, the machine will return to idle when an alert indicator is activated. 5. Once the system test switch has been released, the EPS system will return the machine to its normal operation so that the machine can be restarted and returned to normal operation if machine shutdown has occurred. Note: The 0-second period is adjustable. System Fault Procedure. If the test procedure has been performed and the system has not functioned as per above, report the malfunction to the supervisor before operating the machine.. Should any fault (visual or audible) be detected while operating the machine or if the engine RPM drops below its normal operating level, the machine should be parked safely ensuring the park brake is applied. The engine should then be shut down, and the malfunction reported to the supervisor. m070.docx Rev. Modified on 08/0/05 Copyright RCT 9 8

20 ENGINE TEMPERATURE SWITCH Every 50 hours or six months. Turn the ignition switch to the ON position.. Check that the engine temperature alert indicator is not illuminated.. Disconnect one wire at the engine temperature switch.. Verify that the engine temperature alert indicator is now illuminated. 5. Turn the ignition off and reconnect electrical wiring. ENGINE OIL PRESSURE SWITCH Every 50 hours or during machine scheduled service. Turn the ignition switch to the ON position.. Verify that the fault alarm is sounding and the oil pressure alert indicator is illuminated.. Bridge the wires at the oil pressure switch.. Verify that alarming has ceased and the oil pressure alert indicator is no longer illuminated. 5. Remove bridging connector. 6. Start and run machine until engine oil pressure reaches normal operating pressure. 7. Verify that alarming has ceased and the oil pressure alert indicator is no longer illuminated. TRANSMISSION OIL TEMPERATURE SWITCH Every 50 hours or six months. Turn the ignition switch to the ON position.. Check that the transmission oil temperature alert indicator is not illuminated.. Disconnect one wire at the transmission oil temperature switch.. Verify that the transmission oil temperature alert indicator is now illuminated. 5. Turn the ignition off and reconnect electrical wiring. BELT BREAK PROXIMITY SWITCH Every 50 hours or six months. Turn the ignition switch to the ON position.. Check that the belt break alert indicator is not illuminated.. Disconnect one wire at the belt break switch.. Verify that the belt break alert indicator is now illuminated. 5. Turn the ignition off and reconnect electrical wiring. HYDRAULIC OIL TEMPERATURE SWITCH Every 50 hours or six months. Turn the ignition switch to the ON position.. Check that the hydraulic oil temperature alert indicator is not illuminated.. Disconnect one wire at the hydraulic oil temperature switch.. Verify that the hydraulic oil temperature alert indicator is now illuminated. 5. Turn the ignition off and reconnect electrical wiring. OIL/FUEL LEVEL SWITCH Every 50 hours or during machine scheduled service. Turn the ignition switch to the ON position.. Check that the oil level alert indicator is not illuminated.. Disconnect the -pin Deutsch plug at the level switch.. Verify that the oil level alert indicator is now illuminated. 5. Turn the ignition off and reconnect electrical wiring. 0 8 m070.docx Rev. Modified on 08/0/05 Copyright RCT

21 PARTS LIST PART NO. DESCRIPTION 77 EPS 6-function air cooled control unit DECALS SUPPLIED WITH THE PRODUCT PART NO. DESCRIPTION QTY 56 Hydraulic Oil Temperature Transmission Oil Temperature Label 5 Engine Temperature Label 569 Belt Brake Label 565 Hydraulic Oil Level 07 Blank with Red Dot Label The following sensors and switches are NOT supplied with the control unit as there may be a particular type of switch and/or sensor required to suit a particular type of machine for the application that it is needed for. WIRING LOOM TO SUIT 77 CONTROL UNIT PART NO. DESCRIPTION 599 Loom 0 m to Suit 77 & 565 EPS Control unit ENGINE TEMPERATURE SWITCHES PART NO DESCRIPTION 65 F / 85 C, N/O M0 Thread Brass F / 50 C, N/O M0 Thread Brass F / 70 C, N/O M0 Thread Brass PRESSURE SWITCHES TO SUIT ENGINE OIL PRESSURE APPLICATIONS PART NO. DESCRIPTION 008 Pressure Switch 9 PSI /8 NPT, N/O 07 Pressure Switch 8 PSI, Terminal, N/O, /8 NPT (light duty) 875 Pressure Switch 8 PSI, Terminal, N/O, /8 NPT (heavy duty) 9976 Pressure Switch PSI, Sure-Seal Connection, 9/6 UNO 7968 O-ring seal to suit 9976 Pressure Switch (Recommended) 9 Pressure Switch 6 PSI Falling, N/O, /8 NPT 0 Pressure Switch 9 PSI Falling, N/O, /8 NPT m070.docx Rev. Modified on 08/0/05 Copyright RCT 8

22 TEMPERATURE SWITCHES TO SUIT TEMPERATURE MONITORING APPLICATIONS PART NO. DESCRIPTION 07 Temperature Switch 05 F / 96 C, N/C, Terminal, /8 NPT 76 Temperature Switch F / 00 C, N/C, Terminal, /8 NPT 765 Temperature Switch 0 F / 0 C, N/C, Terminal, /8 NPT 766 Temperature Switch 0 F / 0 C, N/C, Terminal, /8 NPT 767 Temperature Switch 50 F / 0 C, N/C, Terminal, /8 NPT 768 Temperature Switch 75 F / 5 C, N/C, Terminal, /8 NPT 89 Temperature Switch 5 F / 07 C, N/C, Terminal, O-ring, / UNO 79 Adaptor Bush /8 NPT Female to / NPT Male, To Suit /8 NPT Temperature Switches BELT BRAKE PROXIMITY SWITCHES PART NO. DESCRIPTION 8 Metal Proximity Switch 0 mm Sense -Wire N/O 07 Plastic Proximity Switch 0 mm Sense -Wire, N/O OIL/FUEL LEVEL SWITCHES TO SUIT THE OIL LEVEL MONITORING APPLICATIONS PART NO. DESCRIPTION 07 Oil Level Switch Capacitive, N/O, / NPT, Used For Temperatures Below 00 C 8690 Oil Level Switch (Heavy Duty), N/O, Multilevel Switch is Recommended For Applications That Exceed 5 C ALARMS TO SUIT THE WARNING ALERT FUNCTION OF THE CONTROL UNIT PART NO. DESCRIPTION 7 Warning Alarm, 80 db Constant or Intermittent Siren / V 66 Warning Alarm 0 db / V Heavy Duty Note: The sensors and switches listed in this manual are only a small selection available from RCT. If a sensor is required for a specific application, please contact your local RCT branch or distributor; alternatively, sales@rct.net.au. 8 m070.docx Rev. Modified on 08/0/05 Copyright RCT

23 TECHNICAL SPECIFICATIONS CAUTION! PLEASE READ CAREFULLY PRIOR TO THE INSTALLATION OF THE PRODUCT. INCORRECT FITMENT WILL VOID THE MANUFACTURER S WARRANTY. Dimensions, control unit only Dimensions, boxed for freight Weight, control unit only Weight, including harness / packaging for freight Input nominal voltage Length: 5 mm Width: 0 mm Height/Depth: 80 mm Length: 0 mm Width: 0 mm Height/Depth: 70 mm 0.65 kg 0.85 kg to V Operating temperate range 0 to 70 C Connection types Inputs Min & max input voltage Circuit protection Enclosure type Environmental protection IP rating Programming/adjustment -pin Deutsch receptacle Ignition, ground switches and sensors 8 to V DC Reverse polarity protected, outputs are current overload protected Aluminium powder coated IP65 Refer to document number P00 ADDITIONAL SPECIFICATIONS Power Supply Supply spike withstand Absolute maximum spike (J) 50 A (8/0 µs pulse) event 00 A / 50 µs, 8 A / ms 0 events 0 A / 50 µs, A / ms 00 events 0 A / 50 µs, A / ms 000 events 5 A / 50 µs,.5 A / ms Inputs Spiked supply voltage 00 V 00 ms 00 V 0 ms 00 V ms Outputs Current rating Inrush current rating Maximum 6 A continuously Maximum 0 A Note:. Outputs have protection incorporated to protect from installation error causing shorted outputs.. Outputs are current overload protected. m070.docx Rev. Modified on 08/0/05 Copyright RCT 8

24 COMPLIANCE AND STANDARDS TBA TROUBLESHOOTING Troubleshooting the engine protection system requires additional information from the manual that is supplied with the Muirhead EPS system. As a guide, a typical engine protection schematic is provided in this manual. During troubleshooting, inspect all components and connectors before any components are replaced. If connectors are not tight and clean they can cause intermittent or permanent electrical faults. Ensure the connectors are tight and clean before any other tests are carried out. Failure of an electrical component can cause, or be caused by the failure of one or more other components. Always attempt to find and correct the cause of the engine protection system failure before replacing a component. Tools needed: Part no. 005 Digital Multimeter x Part no Circuit Tester x Digital Multimeter Use the part number 005 digital multimeter or equivalent for making continuity checks and voltage measurements. It is recommended that the circuit tester, part number 7599 or equivalent only, be used to test the three outputs of the EPS control unit. Note: If the EPS system is being installed in conjunction with an idle timer and/or a fire status control unit, it is imperative that the units are installed in the correct order. Failure to do so may result in the machine not shutting down correctly. Refer to the appendix at the end of this manual for the correct sequence. 8 m070.docx Rev. Modified on 08/0/05 Copyright RCT

25 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 CM00 Control Master 00 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 ) Km/h Kilometres Per Hour RS 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 - m070.docx Rev. Modified on 08/0/05 Copyright RCT 5 8

26 PROTECTION SYSTEMS APPENDIX ETR IDLE TIMER / EPS / FIRE CONTROL UNIT DIAGRAM (78i) REV ZONE DESCRIPTION BY DATE Reordered wiries, L-J7, removed glands and MT 6// H5 wiring from EPS and replaced 7650 with 588, A THE FIRE CONTROLLER RED WIRE CAN BE CONNECTED TO THE ORANGE WIRE OF THE PRESSURE SWITCH TERMINAL TO AVOID THE FIRE CONTROLLER TIMING OUT AFTER SIX (6) SECONDS WHEN THE IGNITION IS SWITCHED OFF. A B RD- PU- YL/BU- RD- PU- OR- BR OR PU YL B S C R NOTE. FOR OFF HIGHWAY TRUCKS (OHT) AND OTHER MACHINES THAT USE THE C TERMINAL OF THE IGNITION SWITCH; B ENSURE THAT BOTH "AUX CONTROL" WIRES FROM THE CONTROLLERS ARE CONNECTED AS SHOWN. NOTE THAT THE C TERMINAL IS DISCONNECTED FROM THE KEY SWITCH WHEN AUX CONTROL WIRE IS USED AS SHOWN BELOW. C TO MACHINE RD- PU- YL/BU- RD- OR- BR OR PU YL B S C R C D E NOTE. WHERE THE YELLOW / BLUE AND ORANGE WIRES JOIN, USE A PIN DEUTSCH PLUG TO MAKE THIS CONNECTION. NOTE. THE IGNITION SWITCH CONNECTIONS ARE MADE BY USING DEUTSCH PLUGS TO INTERFACE DIRECTLY INTO THE CATERPILLAR IGNITION SWITCH CONNECTOR PLUG. NOTE. THE IDLE TIMER, EPS AND FIRE CONTROLLER MUST BE CONNECTED IN THE ORDER AS SHOWN, TO FACILITATE CORRECT SHUTDOWN PRIORITY SEQUENCE. NOTE 5. A DIODE IS INSTALLED AS INDICATED WHEN AN EPS SYSTEM IS INSTALLED. D E AUX CONTROL PU ! IDLE TIMER 50 7 N596 F OR- 6 5 F YL/BU- BK- RD- IDLE TIMER CONTROLLER (50) G G OR- BK- H YL/BU- PU- 5 6 COOLANT LEVEL OIL PRESSURE H 7 ENGINE TEMP I OIL LEVEL WARNING Machine may return to idle or shutdown on fault EPS (565)(77) (900)(90) SYSTEM TEST ALL DIMENSIONS IN MILLIMETERS UNCONTROLLED DOCUMENT SCALE NTS A rd ANGLE PROJECTION 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. I J K AUX CONTROL RD- YL/BU- PU- OR- BK POWER ON / CYLINDER PRESSURE OK SYSTEM FAULT / CYLINDER PRESSURE LOW SYSTEM DISCHARGE / ENGINE SHUTDOWN WARNING WHEN FIRE UNIT IS ACTIVATED SIREN WILL OPERATE AND ENGINE WILL SHUT DOWN AFTER TIME DELAY FIRE STATUS PANEL PANEL TEST SHOT O'RIDE SHUTDOWN BYPASS ENERGISED TO RUN (ETR) IDLE TIMER (50)/EPS/FIRE CONTROLLER CIRCUIT TO SUIT CATERPILLAR MACHINES EXTERNAL WIRING J K FIRE CONTROL (588) PART NO ---- STOCK CODE ---- BY EY DRN CW DATE /05/ APPD DAS DATE /05/ L SHEET of STATUS Work in Progress DWG No 78i 8 REV L 6 8 m070.docx Rev. Modified on 08/0/05 Copyright RCT

27 NOTES m070.docx Rev. Modified on 08/0/05 Copyright RCT 7 8

28 PERTH Unit -5/5 Abernethy Road Kewdale WA 605 Ph: +6 (0) Fax: +6 (0) BRISBANE Unit 6/6 Flinders Parade North Lakes QLD 509 Ph: +6 (0) Fax: +6 (0) KALGOORLIE Percy Road Kalgoorlie WA 60 Ph: +6 (0) Fax: +6 (0) MT ISA A Ryan Road Mt Isa QLD 85 Ph: +6 (0) Fax: +6 (0) MELBOURNE Unit Hallmarc Office Park 5 Ricketts Road Mt Waverley VIC 9 Ph: +6 (0) Fax: +6 (0) AFRICA: +7 (0) NORTH AMERICA: RUSSIA/CIS: +7 (90) -7 SOUTH AMERICA: