FleetguardFIT Installation Instructions

Transcription

1 RM FleetguardFIT Installation Instructions for QSK60 and QSK78 Engines Description Number 1 Filter Monitor System (FMS) Module SM Sensor reakout Harness SP Data Link Harness SP72084 (for Specto 1.0) SP72086 (for Specto 1.0+) 4 ir Intake Restriction Kit SM Fuel/Lube Differential Pressure Kit (See Page 2) 6 Oil Quality Sensor Kit SM CUTION: These instructions are for use by professional mechanics who are trained in the proper use of power and hand tools, using appropriate safety precautions (including eye protection).

2 page 2 ir Intake Restriction Kit C Description Number ir Restriction Sensor SM15865 Tee-connector, 1/8 NPT Female to 1/8 NPT Female to 1/8 NPT Male * N/ D E C D Coupler, 1/8 NPT Male to 1/8 NPT Male Elbow, 1/8 NPT Female to 1/8 NPT Male * N/ * N/ ir Intake Kit SM15860 E Electrical Cable, 20 ft long SP72082 *Off the shelf standard fittings not included as a service part. Oil Quality Sensor Kit for Engine Lubrication System Description Number Oil Quality Sensor M14 x 1.5 Electrical Cable, 20 ft SM15866 SP72087 Oil Quality Sensor Kit SM15858

3 page 3 Differential Pressure Sensor Kit for Lubrication Filter Systems Description Quantity in Kit C Generic Specific Number SM15859 Lube Kit Fuel Kit Suction Differential Pressure Sensor Manifold M14 x 1.5 Male, M18x1.5 Female, 1/8-NPT Female SP Fluid Differential Pressure Sensor Pressure M18x1.5 Male SM D E C *Electrical Cable 20 ft long SP F D Hose to Filter Outlet dapter 1/8 NPT Male to #6 Hose dapter, Straight *N/ 1 E Hose to M14 x 1.5 dapter #6 Hose to M14 x 1.5 Male 90 Degree Elbow *N/ 1 F Steel-raided Hose ssembly 54" long with 9/16-18 Female Swivels *N/ 1 *Off the shelf standard fittings not included as a service part.

4 page 4 Differential Pressure Sensor Kits for Stage 1 Fuel/Water Separator Description Quantity in Kit Generic Specific Number SM15854 SM15855 SM15856 Differential Pressure Sensor Manifold M14 x 1.5 Male, M18x1.5 Female, 1/8-NPT Female SP C D Fluid Differential Pressure Sensor Suction M18x1.5 Male SM C *Electrical Cable 20 ft long SP E F D Hose to Filter Outlet dapter 1/8 NPT Male to #6 Hose dapter, 90 Degree Elbow *N/ E Hose to M14 x 1.5 dapter #6 Hose to M14 x 1.5 Male 90 Degree Elbow *N/ G 18" long with 9/16-18 Female Swivels *N/ 1 *N/ *N/ F Steel-raided Hose ssembly 30" long with 9/16-18 Female Swivels *N/ 0 1 *N/ 42" long with 9/16-18 Female Swivels *N/ 0 *N/ 1 G dapter M14x1.5 to M42x1.5 Straight dapter with O-ring SP *N/ *N/ *Off the shelf standard fittings not included as a service part.

5 page 5 Differential Pressure Sensor Kits for Stage 2 Fuel Filter C Generic Description Specific Number Quantity in Kit SM15857 Fuel Kit Pressure Differential Pressure Sensor Manifold M14 x 1.5 Male, M18x1.5 Female, 1/8-NPT Female SP Fluid Differential Pressure Sensor Pressure M18x1.5 Male SM D E C *Electrical Cable 20 ft long SP F G D Hose to Filter Outlet dapter 1/8 NPT Male to #6 Hose dapter, 90 Degree Elbow *N/ 1 E Hose to M14 x 1.5 dapter #6 Hose to M14 x 1.5 Male 90 Degree Elbow *N/ 1 F Steel-raided Hose ssembly 30" long with 9/16-18 Female Swivels *N/ 1 G dapter M14x1.5 to M18x1.5 Straight dapter with O-ring SP *Off the shelf standard fittings not included as a service part. Note: *Provided electrical cables for the dp sensor cannot be daisy chained together. Modifications to connectors are required.

6 page 6 FleetguardFIT QSK60L / QSK78L Kit Installation Preparation FleetguardFIT is used to monitor and predict various filtration system pressures and fluid properties. This system requires the use of a telematics service provider to remotely broadcast data. efore attempting an installation, read this document in its entirety to ensure that all requirements are met. The abbreviations below are used throughout this document: FMS Filter Monitor System TSP Telematics Service Provider dp Differential Pressure This documentation outlines the procedure for installing the kits on page 16 only. To request additional kits for additional engines and/or telematics providers, please contact FILTER ( ). Prior to installation of any part of the FleetguardFIT system: 1. Turn the engine off and wait for the engine to reach ambient temperature. 2. Disconnect the battery and/or isolate the engine starting system. 3. Ensure all components needed are available. The FleetguardFIT base kits are designed to have the plumbing components and electrical connections for most applications. In some cases additional connectors or adapters may be needed. Note: For first time installations, it is recommended to place all components on a floor or table next to the vehicle. This allows one to visualize where each component is to be installed and ensures that no components are missed during the kit installation. 4. Ensure the below tools are available Standard hand tools Cordless drill with hole saw Multimeter Deutsch 3 pin crimp tool, pins, connectors & wedges. Common Materials that may be needed (Not Included): Cable Ties P-Clips Cable Glands or Grommets Weatherproof Electrical Cabinet Thread Sealant Hook & Loop Tape 5. Confirm that the resistance of the data link backbone measures ~60 Ω (Range Ω). a. Turn the keyswitch to the OFF position. b. Measure the resistance from the SE J1939 (+) pin to the SE J1939 negative (-) pin. CONNECTOR TYPE J PIN Refer to the troubleshooting section of this document, and/or an OEM service manual if the resistance is not within specification. 3 PIN J PIN 3 Pin 9 Pin C D 9 PIN Figure 1 - Examples of data link connectors that can be used to measure data link resistance

7 page 7 Filter Monitor System (FMS) Module Installation Figure 2 - FMS module used to receive and transmit engine and filtration system data via the public data link 1. Determine an appropriate location for the FMS module. The preferred location is the vehicle electrical cabinet near the TSP module. The location should be protected from weather, vibration, debris, and extreme heat. Note: If no electrical cabinet exists it is recommended to add a weatherproof cabinet to protect the FMS module and TSP module. CUTION: Do not locate the FMS module in the engine compartment; this will cause damage. 5. Determine the resistance across the data link with FMS module connected. The data link harness may affect the resistance of the backbone. The labeled removable terminal resistors on the harness may be removed to increase the resistance. Do not remove the terminal resistor in the Oil Quality Sensor node. This resistor is required and removing it will not affect the resistance of the backbone. 6. Connect the data link harness power and ground wires. The "GND" must be connected to a common ground. The "KEY" wire must be wired to a key switched power source. The "TT" wire must be connected to a 12 V or 24V power source. This connection is required to reduce the power draw of the system while the engine is not running. 7. Connect the FMS module to the sensor breakout harness using the 12 pin DEUTSCH connector. Use an appropriate cable gland or grommet to pass the harness through the electrical cabinet or similar. 1.5 in OD diameter hole or larger will be needed to pass the 12 pin connector through. 8. Proceed to the sections on the various filtration systems and install the hardware as required. 2. Mount the FMS module using hook & loop tape or fasteners. Do not over torque if you are using fasteners. See page 15 for FMS module mounting details. 3. Connect the data link harness to the FMS module using the 12 pin DEUTSCH connector. 4. Connect the data link harness to the engine's public data link. Examples are shown on page 8.

8 RM RM page 8 Instrument Cluster Shield 120Ω 120 Terminating Resistor efore FleetguardFIT Installation C K O N E 9-Pin Connector TSP MODULE Ω Terminating Resistor ECM 1 ECM n OEM CONTROLLER Figure 3 efore FleetguardFIT fter FleetguardFIT Installation [Example 1] 9-Pin Connector 120 Ω Terminating Resistor Instrument Cluster Shield C K O N E C K O N E 120 Ω Terminating Resistor TSP MODULE ECM 1 ECM n OEM CONTROLLER FMS Module Figure 4 Example 1 fter Fleetguard FIT Installation Instrument Cluster Shield Ω Terminating Resistor fter FleetguardFIT Installation [Example 2] C K O N E 9-Pin Connector Ω Terminating Resistor TSP MODULE ECM 1 ECM n OEM CONTROLLER FMS Module Figure 5 Example 2 fter Fleetguard FIT Installation

9 page 9 ir Intake System The air intake system is monitored using a digital air restriction sensor. ir restriction sensors can be applied for up to four individual air filters. Not all fittings included with the kit will be needed in every application. 1. Determine an appropriate location for the restriction sensor. The sensor has a 1/8 NPT female fitting that interfaces with many indicator ports on air cleaner housings. dapters may be used as well. 1/8-27 NPT THREDED INSERT (PRESSURE TP FILTERED) The kit comes with various fittings to accommodate the restriction sensor installation. tee fitting is included if it is desired to use both a visual indicator and the restriction sensor. When assembling fittings for the air restriction sensor tape or liquid sealant may be used. Follow the torque specifications on page 15. QSK 60/78L kits include 4 air restriction sensors. For applications with more than 4 air cleaners or intake pipes it is recommended to install the sensors on the 4 most restrictive air cleaners. Figure 6 Restriction indicator port on air cleaner housing example If a fitting is not included on the clean side of the air cleaner or intake pipe, one fitting must be added. n appropriate location would be in a straight section of metal pipe at least one duct diameter away from the engine air inlet. 2. Install the restriction sensor. If installing an extra fitting in the clean side of the air intake a sintered filter (not included) must be installed. sintered filter is required to protect the engine in case of sensor removal or damage. Sintered filters are common in the pressurized air industry and available from many suppliers. Sintered Filter Figure 7 Example of air intake restriction sensor with sintered filter (not included) Figure 8 - Recommended install of air restriction sensors on air cleaners labeled 1,3,4, and 6 for Komatsu haul trucks with six air cleaners 3. Ensure the sensor(s) and fittings are protected in heavy duty applications. Heavy duty applications include those that can cause the sensor to be covered in thick layers of dust or mud, high velocity debris during operation, as well as service practices such as beating or knocking on the sensor and/or harness with high pressure water. 4. Ensure that the air intake system is free of the air leaks. 5. Proceed to the routing of electrical components. Note: It is recommended to label the air cleaners 1,2,3,4 and connect accordingly to the sensor breakout harness. This will help analyze data from the TSP.

10 IN page 10 Diesel Fuel System The diesel fuel system is monitored using a differential pressure sensor. Typical diesel fuel systems consist of two stages of filtration; the stage 1 filter is a fuel water separator located on the suction side of the fuel system, while the stage 2 filter is a particle filter located on the pressure side of the fuel system. QSK60 and QSK78 engines with HPI fuel systems only require a single stage filter on the suction side of the fuel system. WRNING: When diesel fuel is circulated through an operating engine, it can become very hot. OUT OUT Figure 9 Stage 1 fuel filter head for QSK 60 HPI engines with M42x2 ports Open inlet M42 x 2 Female IN Open Outlet M42 2 Female WRNING: Scalding Hazard! Do not allow heated liquid fuel to come in contact with eyes or unprotected skin. WRNING: Heated diesel fuel can form combustible vapor mixtures in the area around the fuel source. To eliminate the potential for fire, keep open flames, sparks, or other potential ignition sources away from the work area, and do not smoke during filter replacement or service operations which could result in the escape of diesel fuel or fuel vapors. WRNING: lways perform engine or vessel fuel system maintenance in a well ventilated area that is free of bystanders. Installation Steps 1. Turn off the fuel shutoff valve, if equipped. 2. Locate an available inlet port and outlet port (diagnostic ports) on the concerned fuel filter head or module. The included sensor manifold requires a female M14x1.5 interface. The FH234 and FH239 Industrial Pro products come with M14 diagnostics ports. Refer to the FH234 and FH239 installation instructions for more information. QSK HPI engines utilize the stage 1 suction side filter head shown in figure 7 and 8. HPI kits come with M422 to M14x1.5 reducers. Figure 10 Stage 1 fuel filter head for QSK 78 HPI engines QSK 78 HPI engines utilize two of the stage 1 filter heads in figure 7 plumbed in parallel. Figure 9 shows the appropriate inlet/ports to utilize. QSK MCRS engines utilize the stage 2 filter pressure side head shown in figure 11. The MCRS FIT kits come with M18x1.5 to M14x1.5 reducer kits. Open Outlet M18 x 1.5 Female Open Inlet M18 x 1.5 Female Figure 11 QSK MCRS Stage 2 Pressure Fuel Filter

11 page ssemble the differential presure sensor and tee adapter according to figure 12. Fuel/Water Separator To inlet of fuel filter dp sensor Jamb nut To stainless braided hose on outlet side of the filter Figure 12 Differential pressure sensor and manifold assembly - see page 15 for torque specifications CUTION: The differential pressure sensors used for pressure side and suction side fuel systems are not interchangeable. Ensure the correct sensor is used for each system. 4. Plumb the differential pressure manifold assembly to the appropriate locations on the filter heads. Requirements for Plumbing the Differential Pressure Manifold ssembly: The kit comes with braided lines and fittings to connect the differential pressure sensor assembly to the fuel head. Some installations may require additional adapters or different length braided lines (not included). Use pipe sealant on all pipe threads. Care should be exercised to prevent pipe sealant from contacting the wetted part of the sensor. Do not use sealing tape or similar. The sensor manifold M14 thread must have at least 3 full rotation for proper thread engagement. The jamb nut shall then be tightened to orient the manifold in the desired location. Engine Lubrication System Differential Pressure Manifold Figure 13 Completed DP hardware installation example The engine lubrication system is monitored using an oil quality sensor and/or differential pressure sensor. The differential pressure sensor monitors the status of the lubrication filter. The oil quality sensor monitors the status of the lubrication fluid based on fluid properties. Filter monitoring via differential pressure is not necessary for Eliminator or bypass rotor style filtration. Instead, these systems should be monitored by measuring contaminant weight at each service event. WRNING: lubricating oil can become very hot. Let engine come to ambient temperature before installing any part of the FleetguardFIT kit. WRNING: Sensors must be handled with care. Dropping will damage the differential pressure sensor and fluid property sensor. 5. Ensure that the fuel system is free of leaks. 6. Proceed withthe routing of electrical components.

12 page 12 Oil Quality Sensor 1. Determine an appropriate location for the sensor. CUTION: Do not install the sensor near components that radiate heat. Keep the sensor greater than 3 inches away from surfaces that reach a temperature of 350 C. heat shield is one way of reducing the impact of radiant heat. The recommended location is on the left bank side of the front gear cover. There are two M14 ports that may be available. For engines utilizing canister filters, use an available port on the filter head. See figures 15 and 16. If an additional location is desired it must be in turbulent oil flow, such as the oil rifle. void the oil sump, recessed areas, areas with large temperature changes, and areas where air pockets can be present. The preferred mounting orientation is horizontal. If no M14 ports are available, a simple manifold can be procured. See figure 14 for mounting details. Differential Pressure Sensor Installation (Optional) 1. Locate an unused M14x1.5 inlet port and outlet port (diagnostic ports) on the lube filter head. If the M14 diagnostic ports are not available, use an adapter (not included). Outlet M14 Diagnostic port Outlet M14 Diagnostic port Outlet M14 Diagnostic port QSK78 HPI QSK60 HPI Inlet 3/4-14 NPTF Inlet M14 Diagnostic port Figure 15 Options for QSK 60 HPI engines Inlet M14 Diagnostic Port 7.6 ± ± ± 0.2 Outlet 3/4-14 NPTF Inlet M14 Diagnostic port (not visible) 73.3 ± 2 Figure 16 Options for QSK MCRS engines M14x1.5 Straight Thread O-Ring 30 ± 0.3 HE Figure 14 Oil Quality Sensor mounting details

13 page ssemble the differential presure sensor and tee adapter according to figure CUTION: The differential pressure sensors used for pressure side and suction side fuel systems are not interchangeable. Ensure the correct sensor is used for each system. Plumb the differential pressure manifold assembly to the appropriate locations on the filter heads. Requirements for Plumbing the Differential Pressure Manifold ssembly: The kit comes with braided lines and fittings to connect the differential pressure sensor assembly to the fuel head. Some installations may require additional adapters or different length braided lines (not included). Use pipe sealant on all pipe threads. Care should be taken to prevent pipe sealant from contacting the wetted part of the sensor. Do not use sealing tape or similar. The sensor manifold M14 must have at least 3 full rotations for proper thread engagement. The jamb nut shall then be tightened again in order for the inlet port to be placed in the desired orientation. 4. Ensure that the lubrication fuel system is free of leaks. 5. Proceed with the routing of electrical components. Routing of Electrical Components NOTE: ll electrical connections for the FleetguardFIT kit are keyed such that only the appropriate connectors can mate. Do not force connectors that do not mate. Each connector has a locking tab that must be engaged after the connector is fully seated. 1. Prior to routing the electrical cables from each sensor to the breakout harness install each sensor and check for leaks. 2. Route the electrical cable from each sensor to the correct connector on the breakout harness. 3. Ensure there is enough slack in wiring to prevent wear or breakage during machine movement and vibration. 4. Secure the harnesses to the machine using cable ties and/or P clips. 5. Ensure sharp edges that contact sections of harnesses, such as through holes in panels and sharp corners, are modified with grommets in order to protect the harness from long-term damage. 6. Ensure that electrical components are at least 3 inches away, or are otherwise shielded, from high temperature components such as exhaust and aftertreatment. 7. Ensure the electrical cables are protected from the environment during operation and potentially damaging cleaning practices. 8. Connect the electrical cable extensions from all sensors to the sensor breakout harness. CUTION: Connecting a sensor to the incorrect connector on the breakout harness will result in incorrect data from the TSP. NOTE: The sensor breakout harness has caps on each connector which must remain in place unless used for connecting a sensor.

14 RM RM RM page 14 Testing the System 1. Ensure that all sensors have been installed and there are no leaks. 2. Ensure that all electrical components have been connected or appropriately capped. 3. Check for FMS Module Functionality. See figure Check with the TSP provider to ensure data is being collected. Power OFF: No LEDs illuminated Power supplied: -ny LEDs illuminated -lue LED indicates Key- Switch power Data Transmitting: Flashing green and red LEDs Figure 17 Lights on the Fit Control Unit Data Output The data will be available to the TSP from the FleetguardFIT system. The typical range column represents what values should be expected for each system's data. The warnings and terminal limits are accepted as industry standard for each system, but can be adjusted with the TSP. The oil quality Cumulative Degradation Number (CDN) is a proprietary value that represents the overall oil quality. This value takes many parameters into consideration and represents overall oil quality on a scale from 0 to 100. Zero represents high quality, and 100 represents the low quality. The user should be mindful of both quality parameters, as some contaminations may be represented by a change in KV100, while not changing overall CDN and vice versa. System Stage 1 Fuel Filter (Fuel/Water Separator) Data Provided Unit of Data Typical Range Warning Limit Terminal Limit dp kpa 1 to kpa 35 kpa Stage 2 Fuel Filter dp kpa 1 to kpa 345 kpa Lubrication Filter dp kpa 1 to kpa 175 kpa ir Filter dp kpa 1 to kpa 6.25 kpa Oil Quality Figure 18 Data Output Details Kinematic 100C Oil Condemnation Number centistokes 9 to 13 for 10W to 16.7 for 15W40 N/ 0 to

15 page 15 est Practices For first time installations it is recommended to layout all components on the floor or table next to the vehicle. This allows one to visualize where each component is to be installed and ensure no components are missed during the kit installation If the vehicle already has telematics ensure TSP module is working properly before FIT installation. Notify TSP that you will be adding a FleetguardFIT kit to understand requirements If installing telematics and a FIT kit at the same time activate TSP module and connect FMS module on a bench before installing on a vehicle. This will significantly reduce the downtime of the vehicle. Troubleshooting Telematics provider does not see data Ensure the FMS module has power (see figure 18). Ensure firmware has been installed if using Specto 1.0. Remove the engine data link connection from the TSP and FMS module. Connect the FMS directly to the TSP so that only Filtration data will be sent. Once the TSP confirms the data connection, reconnect both modules to the engine data link. Cleaning / Removal of Oil Quality Sensor Kit If the fluid property sensor must be removed during a service event the following recommendations are given for cleaning Rinse sensing portion of sensor only with Isopropanol Rinse with Deionized water ir dry (do not use pressurized air) Leakage from sensor or plumbing Ensure pipe sealant is used on pipe fittings and sensor torque specification in figure 20 are followed. pplication Torque in-lb N-m ir Restriction Sensor ir System Plumbing Differential Pressure Sensor N/ Fluid Property Sensor N/ Figure 19 Torque Values REF ±.50 Depth of box is ~36 No data / faulty data from a system Ensure all connectors are properly mated. Ensure there is no damage to harness from wear. Clean or replace sensor if sensor was damaged during installation or operation REF Terminal Resistance is not with Specification Ensure that they key is off and a portable battery supply from TSP or similar is isolated while measuring resistance. Determine resistance with and without the removable resistor in the data link harness. Refer to vehicle owners manual if still not within specification ±.50 Figure 20 FMS ox Dimensions (in mm)

16 page 16 FleetguardFIT Ordering Information for QSK60 / QSK78 Engines Step 1: Choose a base FleetguardFIT Kit asic Systems Supported with ase Kit ase Fit Kit Number Stage 1 Fuel Water Separator (FWS) Stage 2 Fuel Filter ir Cleaner Lube System Comments SM15854 SM15856 SM15855 SM15857 SM15860 SM15858 SM15859 SK SK SK SK HPI with Legacy FWS HPI with Extended Service FWS MCRS with Legacy FWS MCRS with Extended Service FWS Step 2: Choose a FMS to TSP Kit, based on the telematics system. FMS to TSP Kit Options FMS Kit Number SM15861 SM15862 Description FMS + Sensor Harness + TSP for SPECTO 1.0 only FMS + Sensor Harness + Universal TSP Integration Harness

17 page 17 Step 3: Choose extra system kits (if needed). Filtration System Supported with Kit Service Kit Legacy Spin-on (FS1006 or FS19870) Stage 1 (FWS) FH234 Series *FH239 Series Stage 2 Fuel Filter Spin-on (FF5782 or FF256) ir Cleaner ny Oil Quality Sensor Lube System Spin-on SM15854 SM15855 SM15856 SM15857 SM15858 SM15859 SM15860 * FH239 Series with Extended Service Interval Options Step 4: Choose any extra required wiring. Recommended for pplication Service Kit Description QSK78 Haul Truck QSK60 Haul Truck SP72082 Electrical Cable, 20ft long, IR QTY 2 QTY 2 SP72089 Electrical Cable, 20ft long, dp Sensor *N/ *N/ SP72087 Electrical Cable, 20ft long, Oil Quality Sensor *Off the shelf standard fittings not included as a service part. QTY 1 QTY 1 For more information, visit cumminsfiltration.com LT36610