PRODUCT MANUAL
ENGINE PROTECTION SYSTEM PANEL
4-FUNCTION WATER COOLED
VERSION 2
Part No. 9200
DISCLAIMER
Copyright © Remote Control Technologies Pty Ltd (RCT) All rights reserved.
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2 | 24
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.
M0488a.docx | Rev 1.1 | Modified on 08/10/2015 | Copyright © RCT
Contents
CAUTION. CONSULT THE SPECIFICATIONS DATA SHEET ON PAGE Error! Bookmark not defined. 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
WIRING CONNECTIONS
INPUTS
OUTPUTS
7
7
7
8
INSTALLATION GUIDE
9
CONTROL UNIT
AUDIBLE ALARM
COOLANT LEVEL SENSOR – FUNCTION 1
ENGINE OIL PRESSURE SWITCH – FUNCTION 2
ENGINE TEMPERATURE SWITCH – FUNCTION 3
OIL/FUEL LEVEL SWITCH – FUNCTION 4
LOW ENGINE OIL LEVEL SWITCH LOCATION DIAGRAM (159D)
ENGINE PROTECTION SYSTEM LABELLING
ALERT FUNCTION IDENTIFICATION LABELS
TYPICAL ENGINE PROTECTION SYSTEM SCHEMATIC TO SUIT 4-FUNCTION WATER COOLED
ENGINES (390x)
9
9
10
10
11
11
12
13
14
15
CALIBRATION
16
SERVICE INFORMATION
16
SERVICE SCHEDULE
SERVICE PROCEDURE
COOLANT LEVEL SENSOR
ENGINE OIL PRESSURE SWITCH
ENGINE TEMPERATURE SWITCH
OIL/FUEL LEVEL SWITCH
TEST PROCEDURE
CONTROL UNIT
COOLANT LEVEL SENSOR
ENGINE OIL PRESSURE SWITCH
ENGINE TEMPERATURE SWITCH
OIL/FUEL LEVEL SWITCH
PARTS LIST
DECALS SUPPLIED WITH THE PRODUCT
WIRING LOOMS TO SUIT 9200 CONTROL UNIT
COOLANT LEVEL SENSORS
PRESSURE SWITCHES TO SUIT ENGINE OIL PRESSURE APPLICATIONS
TEMPERATURE SWITCHES TO SUIT TEMPERATURE MONITORING APPLICATIONS
OIL/FUEL LEVEL SWITCHES TO SUIT OIL LEVEL MONITORING APPLICATIONS
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16
16
16
16
16
16
17
17
17
17
18
18
18
18
18
18
19
19
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3 | 24
ALARMS TO SUIT THE WARNING ALERT FUNCTION OF THE CONTROL UNIT
19
TECHNICAL SPECIFICATIONS
20
COMPLIANCE AND STANDARDS
21
TROUBLESHOOTING
21
GLOSSARY
22
WARRANTY
22
APPENDIX
23
ETR IDLE TIMER / EPS / FIRE CONTROL UNIT DIAGRAM (478i)
4 | 24
23
M0488a.docx | Rev 1.1 | Modified on 08/10/2015 | Copyright © RCT
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.
M0488a.docx | Rev 1.1 | Modified on 08/10/2015 | Copyright © RCT
5 | 24
PRODUCT OVERVIEW
®
The Muirhead Engine Protection system (EPS), part number 9200, is designed to monitor almost any alarm
condition on virtually any machine.
This system has been designed to monitor four inputs including an AC input for detecting coolant loss 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 may be required to perform a complete
installation.
FEATURES AND FUNCTIONS
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Multi-voltage (8 to 32 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
Individual fault indicators
Compact and robust control panel design
Extends machine life
Multiple applications
IP65 enclosure
M0488a.docx | Rev 1.1 | Modified on 08/10/2015 | Copyright © RCT
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 label 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 12 contacts located on the rear of the EPS control unit facilitates the necessary wiring for
the inputs and outputs.
ALERT
INDICATORS
TEST SWITCH
12-PIN
CONNECTOR
WIRING CONNECTIONS
No.
1
2
3
4
5
6
7
8
9
10
11
12
FUNCTION
+8 V DC to +30 V DC
−0 V DC ground
Output
Output
Output
Input
Function 1
Function 2
Function 3
Function 4
Not used
Not used
TYPE
Ignition supply
Ground
Alarm control
Idle control
Energised to run control (ETR)
Start input
AC circuit/switch input
Switch input
Switch input
Switch input
Not used
Not used
INPUTS
The following input functions indicate the factory defaults with all inputs and outputs being configurable.
Refer to document number P0021 for advanced programming information. Contact your local RCT branch or
distributor for a copy of the document or for more information.
FUNCTION 1
This input is configured to have a five-second delay prior to pulsing the alert indicator and activating the
alarm. After a further 10 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.
Note: This function uses an AC (alternating current) circuit. This reduces electrolysis and corrosion of the
coolant level sensor. This will assist to keep the probe in good working order.
M0488a.docx | Rev 1.1 | Modified on 08/10/2015 | Copyright © RCT
7 | 24
FUNCTION 2
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 3
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: High engine temperature
FUNCTION 4
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 10 must be connected to ground.
Typical use: Low engine oil level or transmission temperature
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.
ENGINE CONTROL (ETR)
This circuit operates in a similar way to the idle control output; however, it has a 0 to 40-second adjustable
time delay. This time delay is factory set to 10 seconds, allowing the machine to run for 10 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.
1. Will the machine be left uncontrollable, as shutdown affects the braking
and steering of most machines?
2. Can the machine be parked in a safe environment?
8 | 24
M0488a.docx | Rev 1.1 | Modified on 08/10/2015 | Copyright © RCT
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
1.
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.
2.
Drill two 8 mm diameter holes with the hole centres being 100 mm apart to suit the M8*30 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.
3.
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.
4.
Install the sensors/ switches (see below for more detail). All sensors/ switches should be installed using
a suitable thread sealant.
Note: RCT recommends that all electrical connections be treated with electroguard grease (part number 2800).
Options
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®
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
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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;
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)
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9 | 24
COOLANT LEVEL SENSOR – FUNCTION 1
It is recommended that the coolant level sensor be installed in the radiator tank (refer to the details below).
Ensure there is sufficient clearance within the radiator to accommodate the length of the coolant. 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 probe. Fit the coolant level sensor and pressure
test, this can be achieved by running the engine until normal operating temperature has been reached.
PROBE POSITION
OPTIMUM PROBE LEVE IS ⅓ UP
FROM THE BOTTOM OF THE
TOP HOSE HOLE
Part No. 2006
Thread: 1/8 NPT Nylon
Tapping drill: 21/64”
Probe length: 30 mm
Part No. 2887
Thread: 1/4 NPT Nylon
Tapping drill: 7/16”
Probe length: 72 mm
Note: Brass weld
collar included
Part No. 2205
Thread: 1/4 NPT Brass
Probe length: 60 mm
Tapping drill: 7/16”
RADIATOR
Installation Example
ENGINE OIL PRESSURE SWITCH – FUNCTION 2
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.
10 | 24
Part No. 0018
12 PSI
Normally Open
Thread: 1/8 NPT
Part No. 3074
8 PSI
Normally Open
Thread: 1/8 NPT
Part No. 8725
9 PSI
Normally Open
Thread: 1/8 NPT
Part No. 9976
12 PSI
Normally Open
Thread: 9/16 UNO
Part No. 3429
16 PSI
Normally Open
Thread: 1/8 NPT
Part No. 3430
9 PSI / 62 kPa
Normally Open
Thread: 1/8 NPT
M0488a.docx | Rev 1.1 | Modified on 08/10/2015 | Copyright © RCT
ENGINE TEMPERATURE SWITCH – FUNCTION 3
The coolant temperature switch should be installed on the engine side of the thermostat control. 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. 1764
212°F / 100°C
Normally Closed
Thread: 3/8 NPT
Part No. 1765
220 °F / 104 °C
Normally Closed
Thread: 3/8 NPT
Part No. 1766
230 °F / 110 °C
Normally Closed
Thread: 3/8 NPT
Part No. 8491
Heavy Duty Temp Switch
225 °F / 107 °C
Normally Closed
Thread: 3/8 UNO
OIL/FUEL LEVEL SWITCH – FUNCTION 4
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 100 °C. Also note that the oil/fuel level switch incorporates a three-second
alarm delay. For operating temperatures above 100 °C, installing the 8690 heavy duty switch is
recommended.
Part No. 3072
Normally Open
Thread: 1/4 NPT brass
Tapping drill: 7/16”
M0488a.docx | Rev 1.1 | Modified on 08/10/2015 | Copyright © RCT
Part No. 8690
Normally Open
(Heavy Duty)
11 | 24
LOW ENGINE OIL LEVEL SWITCH LOCATION DIAGRAM (159D)
1
3
2
4
5
7
6
8
REV ZONE
1
rewrite step 5
2
updated titleblock
3
A
4
DESCRIPTION
new titleblock
I4
POINT 2 REWORDED
BY
DATE
GT
16/07/07
BT
25/07/07
GT
20/08/15
MT
17/08/15
A
INSTALLATION DETAILS
ENGINE
FRONT VIEW
B
B
C
C
1
2
D
D
5
SLIDE UP OR DOWN
TO DESIRED LEVEL
E
3
E
SWITCH POINT MUST
LINE UP WITH LOW
LEVEL IN SUMP
F
F
MOUNT SWITCH ON A
BRACKET CLOSE TO OR
ON ENGINE
4
OIL PAN
G
G
FITTING INSTRUCTIONS
H
H
1. DRAIN ENOUGH OIL UNTIL THE DIPSTICK MARK IS ON LOW WITH THE ENGINE
RUNNING AT NORMAL SPEED.
ALL DIMENSIONS IN MILLIMETERS
UNCONTROLLED DOCUMENT
SCALE
I
NTS A4
2. TEMPORARILY INSTALL A LENGTH OF CLEAR PLASTIC TUBING FROM THE LOWER OIL
PAN AND RETURN TO THE UPPER PAN.
3rd ANGLE
PROJECTION
I
www.rct.net.au
3. OIL LEVEL SIGHTED BY EYE ACROSS PLASTIC TUBE TO SIDE OF OIL PAN. THIS LEVEL
DETERMINES THE LOCATION OF LOW OIL SWITCH POINT.
J
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.
4. BRAISE 14" NPT FITTING IN THE SIDE OF THE PAN. INSTALL HOSE FITTING ADAPTOR USE TEFLON TAPE TO SEAL THE THREADS.
J
LOW ENGINE OIL
LEVEL SENSOR
LOCATION
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.
FITTING
INSTRUCTIONS
K
K
PART
8690
NO
STOCK
CODE MULTI LEVEL SWITCH
BY
JL
DRN
RH
APPD JL
SHEET
L
DATE 14/11/03
DATE ----
1 of 1
L
STATUS
Released
DWG No
1
12 | 24
2
3
4
5
6
7
159d
REV
4
8
M0488a.docx | Rev 1.1 | Modified on 08/10/2015 | Copyright © RCT
ENGINE PROTECTION SYSTEM LABELLING
WATER COOLED
There are a wide range of decals available and also blank decals which can be used when not all four
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;
1.
Select the correct decal that is required for the application.
2.
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).
3.
Use a plastic card or similar tool to carefully push any air bubbles that form out to the edges of the label.
4.
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.
M0488a.docx | Rev 1.1 | Modified on 08/10/2015 | Copyright © RCT
13 | 24
ALERT FUNCTION IDENTIFICATION LABELS
PART NO.
14 | 24
LABEL
PART NO.
5636
6143
0427
1526
1372
5630
5629
5635
0426
5634
0437
5637
0428
1413
0442
4352
0453
5638
0486
5633
3465
4350
3144
5631
5785
5632
5780
4348
5782
1411
5784
4349
5779
5628
5781
1417
5783
8424
5778
1368
LABEL
M0488a.docx | Rev 1.1 | Modified on 08/10/2015 | Copyright © RCT
TYPICAL ENGINE PROTECTION SYSTEM SCHEMATIC TO SUIT 4-FUNCTION
WATER COOLED ENGINES (390x)
1
3
2
4
5
7
6
8
REV ZONE
1
C2
DESCRIPTION
Pins re-ordered
BY
DATE
MT
23/09/15
A
A
B
B
C
8 - 30V SUPPLY
1
GROUND
2
ALARM
3
IDLE CONTROL
4
ETR CONTROL
5
START INPUT
6
COOLANT LEVEL
7
OIL PRESSURE
8
BK-4
OIL LEVEL
GN-4
GN-4
BN-4
BK-4
+
-
YL/BU-4
WH-4
10
YL-4
BN-4
GY-4
BK-4
+
-
11
NOT USED
12
YL/BU-4
NOTE 1
+
BK-4
-
THIS IS A TYPICAL ENGINE
PROTECTION SYSTEM SCHEMATIC
ILLUSTRATING ALL INPUTS AND
OUTPUTS. THIS SHOULD ONLY BE
USED AS A GUIDE AS DIFFERENT
MACHINES REQUIRE DIFFERENT
COMPONENTS.
IDLE CONTROL
SOLENOID
CAUTION !
OUTPUT CURRENT
RATING
12AMP MAX
ENGINE PROTECTION
SYSTEM CONTROL
D
ETR RUN
SOLENOID
CAUTION !
OUTPUT CURRENT
RATING
12AMP MAX
E
WH-4
GROUND VIA
COOLANT
TO TANK
FOR MORE INFORMATION PLEASE
CONTACT THE MANUFACTURER.
F
C
PK-4
NOT USED
E
FAULT
ALARM
CAUTION !
OUTPUT CURRENT
RATING
12AMP MAX
PU-4
9
ENGINE TEMP
D
OR-4
COOLANT
LEVEL
PROBE
F
OIL
PRESSURE
SWITCH
G
L
PK-4
NOTE 2
IF NOT ALL FUNCTIONS ARE
REQUIRED, A BLANK LABEL IS PLACED
ON THE UNUSED FUNCTION AND THE
CORRESPONDING INPUT WIRE MUST
BE CONNECTED TO GROUND.
G
N/O
BK-4
P
YL-4
ENGINE
TEMPERATURE
SWITCH
N/C
BK-4
T°
H
RD-4
C
GY-4
A
BK-4
B
H
+
OIL
LEVEL
SWITCH
S
-
ALL DIMENSIONS IN MILLIMETERS
UNCONTROLLED DOCUMENT
SCALE
NTS A4
3rd ANGLE
PROJECTION
I
I
8 - 30VDC
TO START
PROTECTED TERMINAL AT
KEY SWITCH
SUPPLY
(RECOMMENDED
10AMP
PROTECTION)
MACHINE
(FRAME)
GROUND
www.rct.net.au
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.
J
J
PANEL EPS 4
FUNCTION WATER
COOLED VER 2
EXTERNAL WIRING
K
K
PART
9200
NO
STOCK
CODE MH-EPS-4-01
BY
SD
WIRE LEGEND
L
BK
BU
BN
GN
GY
OR
-
BLACK
BLUE
BROWN
GREEN
GREY
ORANGE
1
PK
PU
RD
WH
YL
TQ
-
PINK
PURPLE
RED
WHITE
YELLOW
TURQUOISE
2
DRN
GT
APPD SD
SHEET
DATE 08/03/10
DATE ----
1 of 1
L
STATUS
Released
DWG No
3
M0488a.docx | Rev 1.1 | Modified on 08/10/2015 | Copyright © RCT
4
5
6
7
390x
REV
1
8
15 | 24
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
1. Perform a visual inspection and include the following:
a)
b)
c)
d)
Control unit
Wiring connections and looms
All switches and sensors as below
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.
Note: All monitoring switches should be changed when fitting a new or repaired engine to a machine.
COOLANT LEVEL SENSOR
Every 2000 hours or six months
1. Remove the sensor from the radiator.
2. Plug the hole to minimise coolant loss.
3. 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.
4. Inspect electrical connection point for thread damage, burrs, corrosion and ensure the nut tightens on the
thread (if applicable).
5. Refit the sensor ensuring the thread is free from coolant leaks.
ENGINE OIL PRESSURE SWITCH
Every 2000 hours or six months
1. 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.
2. 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.
ENGINE TEMPERATURE SWITCH
Every 2000 hours or six months
1. If temperature faults are present and tests performed on the electrical circuit prove inconclusive, it is
recommended that the coolant temperature switch be replaced.
2. 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.
OIL/FUEL LEVEL SWITCH
Every 2000 hours or six months
1. It will be necessary to remove the switch for testing.
2. Remove switch and plug hole to prevent fluid loss.
3. Inspect the switch for physical damage.
4. Reconnect the 3-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.
16 | 24
M0488a.docx | Rev 1.1 | Modified on 08/10/2015 | Copyright © RCT
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.
System Test
Switch
In order to test the EPS control unit, the following test
procedure should be followed.
CONTROL UNIT
1. 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.
2. If the control unit has detected a fault upon start-up, for example, if the machine coolant level is low, the
fault will be present on the control unit upon start-up of the machine.
3. 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.
4. Having depressed the system test switch for 10 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 10-second period is adjustable.
System Fault Procedure
6. 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.
7. 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.
COOLANT LEVEL SENSOR
Every 250 hours or during machine scheduled service
1. Turn the ignition switch to the ON position and verify the coolant level alert indicator is not illuminated.
2. Disconnect the wire from the coolant level sensor.
3. Verify that the coolant level alert indicator is now illuminated.
4. Reconnect the wire to the coolant level sensor.
5. Remove sufficient coolant from the engine to allow the level to fall below the sensor probe.
6. Verify that the coolant level alert indicator is illuminated.
7. Refill coolant to the manufacturer’s specifications.
8. Check that the coolant level alert indicator is no longer illuminated.
9. Turn the ignition off.
ENGINE OIL PRESSURE SWITCH
Every 250 hours or during machine scheduled service
1. Turn the ignition switch to the ON position.
2. Verify that the fault alarm is sounding and the oil pressure alert indicator is illuminated.
3. Bridge the wires at the oil pressure switch.
4. 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.
M0488a.docx | Rev 1.1 | Modified on 08/10/2015 | Copyright © RCT
17 | 24
ENGINE TEMPERATURE SWITCH
Every 250 hours or six months
1. Turn the ignition switch to the ON position.
2. Check that the engine temperature alert indicator is not illuminated.
3. Disconnect one wire at the engine temperature switch.
4. Verify that the engine temperature alert indicator is now illuminated.
5. Turn the ignition off and reconnect electrical wiring.
OIL/FUEL LEVEL SWITCH
Every 250 hours or during machine scheduled service
1. Turn the ignition switch to the ON position.
2. Check that the oil level alert indicator is not illuminated.
3. Disconnect the 3-pin Deutsch plug at the level switch.
4. Verify that the oil level alert indicator is now illuminated.
5. Turn the ignition off and reconnect electrical wiring.
PARTS LIST
PART NO.
9200
DESCRIPTION
EPS 4-Function Water Cooled Control unit
DECALS SUPPLIED WITH THE PRODUCT
PART NO.
DESCRIPTION
QTY
5635
Coolant Level Label
1
5634
Oil Level Label
1
5637
Oil Pressure Label
1
5638
Engine Temperature Label
1
0427
Blank with Red Dot Label
1
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 LOOMS TO SUIT 9200 CONTROL UNIT
PART NO.
DESCRIPTION
8797
Loom 5 m To Suit 9301 & 9200 EPS Control unit
8805
Loom 10 m To Suit 9301 & 9200 EPS Control unit
COOLANT LEVEL SENSORS
PART NO.
18 | 24
DESCRIPTION
2006
Coolant level sensor Light Duty 1/8 NPT (Plastic Body)
2887
Coolant level sensor Light Duty 1/4 NPT (Complete with Brass Bush)
2205
Coolant level sensor Heavy Duty 1/4 NPT (Brass Body)
M0488a.docx | Rev 1.1 | Modified on 08/10/2015 | Copyright © RCT
PRESSURE SWITCHES TO SUIT ENGINE OIL PRESSURE APPLICATIONS
PART NO.
DESCRIPTION
0018
Pressure Switch 9 PSI 1/8 NPT, N/O
3074
Pressure Switch 8 PSI, 2 Terminal, N/O, 1/8 NPT (Light Duty)
8725
Pressure Switch 8 PSI, 2 Terminal, N/O, 1/8 NPT (Heavy Duty)
9976
Pressure Switch 12 PSI, Sure-Seal Connection, 9/16 UNO
7968
O-ring Seal To Suit 9976 Pressure Switch (Recommended)
3429
Pressure Switch 16 PSI Falling, N/O, 1/8 NPT
3430
Pressure Switch 9 PSI Falling, N/O, 1/8 NPT
TEMPERATURE SWITCHES TO SUIT TEMPERATURE MONITORING APPLICATIONS
PART NO.
DESCRIPTION
1764
Temperature Switch 212°F, N/C, 2 Terminal 3/8 NPT
1765
Temperature Switch 220°F, N/C, 2 Terminal 3/8 NPT
1766
Temperature Switch 230°F, N/C, 2 Terminal 3/8 NPT
1767
Temperature Switch 250°F, N/C, 2 Terminal 3/8 NPT
1768
Temperature Switch 275°F, N/C, 2 Terminal 3/8 NPT
8491
Temperature Switch 225°F, N/C, 2 Terminal, O-ring, 3/4 UNO
3379
Adaptor Bush 3/8 NPT Female to 1/2 NPT Male To Suit 3/8 NPT Temperature Switches
OIL/FUEL LEVEL SWITCHES TO SUIT OIL LEVEL MONITORING APPLICATIONS
PART NO.
DESCRIPTION
3072
Oil Level Switch Capacitive, N/O , 1/4 NPT, Used For Temperatures Below 100°C
8690
Oil Level Switch (Heavy Duty), N/O, Multilevel Switch is Recommended for Applications
That Exceed 125 °C
ALARMS TO SUIT THE WARNING ALERT FUNCTION OF THE CONTROL UNIT
PART NO.
DESCRIPTION
1723
Warning Alarm, Constant or Intermittent Siren 12/24 V
6162
Warning Alarm, 102 dB 12/24 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,
email [email protected].
M0488a.docx | Rev 1.1 | Modified on 08/10/2015 | Copyright © RCT
19 | 24
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
Length: 125 mm | Width: 40 mm | Height/Depth: 80 mm
Dimensions, boxed for freight
Length: 140 mm | Width: 140 mm | Height/Depth: 70 mm
Weight, control unit only
0.65 kg
Weight, including harness /
packaging for freight
0.85 kg
Input nominal voltage
12 to 24 V
Operating temperate range
0 to 70 °C
Connection types
12-pin Deutsch receptacle
Inputs
Ignition, ground switches and sensors
Min & max input voltage
8 to 32 V DC
Circuit protection
Reverse polarity protected, outputs are current overload protected
Enclosure type
Aluminium powder coated
Environmental protection IP rating
IP65
Programming/adjustment
Refer to document number P0021
ADDITIONAL SPECIFICATIONS
Power Supply
Supply spike withstand
Absolute maximum spike (1J)
250 A (8/20 µs pulse)
−
1 event
100 A / 50 µs, 8 A / 1 ms
−
10 events
30 A / 50 µs, 4 A / 1 ms
−
100 events
20 A / 50 µs, 3 A / 1 ms
−
1000 events
15 A / 50 µs, 2.5 A / 1 ms
Inputs
Spiked supply voltage
100 V DC @ 200 ms | 200 V DC @ 20 ms | 300 V DC @ 2 ms
Outputs
Current rating
Maximum 6 A continuously
Inrush current rating
Maximum 30 A
Note:
1. Outputs have protection incorporated to protect from installation error causing shorted outputs.
2. Outputs are current overload protected.
20 | 24
M0488a.docx | Rev 1.1 | Modified on 08/10/2015 | Copyright © RCT
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. 2005 – Digital Multimeter x 1
■ Part no. 7599 – Circuit Tester x 1
Digital Multimeter
Use the part number 2005 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.
.
M0488a.docx | Rev 1.1 | Modified on 08/10/2015 | Copyright © RCT
21 | 24
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
Km/h
Kilometres Per Hour
RS232
Receiver
Recommended Standard (number 232)
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
#
Number
MHz
Multi Function Unit
Mega Hertz (million(s) cycles per
second)
<
Less Than
MIN
Minimum
>
Greater Than
mm
millimetres
%
Percentage
mW
Milli Watts
WARRANTY
Please see the RCT standard warranty, available on our website - www.rct.net.au.
22 | 24
M0488a.docx | Rev 1.1 | Modified on 08/10/2015 | Copyright © RCT
APPENDIX
ETR IDLE TIMER / EPS / FIRE CONTROL UNIT DIAGRAM (478i)
1
3
2
5
4
7
6
8
REV ZONE
1
L1-J7,
H5
BY
DESCRIPTION
Reordered wiries,
removed glands and
MT
wiring from EPS and
replaced 7650 with 5884,
DATE
16/12/14
A
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.
B
4
3
RD-4
RD-4
PU-4
PU-4
2
4
3
2
YL/BU-4
1
OR
PU
NOTE 1. 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.
B
S
C
YL
R
TO MACHINE
1
OR-4
BR
C
4
3
RD-4
RD-4
PU-4
2
1
4
3
2
YL/BU-4
OR-4
1
B
BR
OR
S
C
PU
C
YL
R
NOTE 2. WHERE THE YELLOW / BLUE AND ORANGE WIRES JOIN,
USE A 2 PIN DEUTSCH PLUG TO MAKE THIS CONNECTION.
NOTE 3. THE IGNITION SWITCH CONNECTIONS ARE MADE BY USING
DEUTSCH PLUGS TO INTERFACE DIRECTLY INTO THE
CATERPILLAR IGNITION SWITCH CONNECTOR PLUG.
D
D
NOTE 4. 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.
E
E
12
11
10
PU-4
AUX CONTROL
9
!

IDLE TIMER
11450
8
N12596
7
www.rct.net.au
6
F
OR-4
F
5
4
YL/BU-4
BK-4
RD-4
3
2
1
IDLE TIMER CONTROLLER
(11450)
G
1
G
2
OR-4
BK-4
1
2
3
PROTECTION SYSTEMS
4
H
YL/BU-4
PU-4
H
COOLANT LEVEL
5
OIL PRESSURE
6
7
ENGINE TEMP
8
OIL LEVEL
9
WARNING
Machine may return to idle
or shutdown on fault
SYSTEM
TEST
ALL DIMENSIONS IN MILLIMETERS
UNCONTROLLED DOCUMENT
SCALE
10
NTS A4
11
3rd ANGLE
PROJECTION
12
I
I
1
EPS
(3565)(3747)
(9200)(9301)
2
www.rct.net.au
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.
J
ENERGISED TO RUN
(ETR) IDLE TIMER
(11450)/EPS/FIRE
CONTROLLER
CIRCUIT TO SUIT
CATERPILLAR
MACHINES
PANEL
TEST
POWER ON /
CYLINDER PRESSURE OK
RD-4
YL/BU-4
8
SYSTEM FAULT /
CYLINDER PRESSURE LOW
7
SYSTEM DISCHARGE /
ENGINE SHUTDOWN
6
PU-4
AUX CONTROL
OR-4
5
WARNING
WHEN FIRE UNIT IS ACTIVATED
SIREN WILL OPERATE AND ENGINE WILL
SHUT DOWN AFTER TIME DELAY
4
1 SHOT O'RIDE
SHUTDOWN
BYPASS
FIRE STATUS PANEL
EXTERNAL WIRING
3
K
2
BK-4
J
K
1
PART
---NO
STOCK
CODE ---BY
EY
FIRE CONTROL
(5884)
DRN
CW
APPD DAS
SHEET
L
DATE 21/05/13
DATE 21/05/13
1 of 1
L
STATUS
Work in Progress
DWG No
1
2
3
M0488a.docx | Rev 1.1 | Modified on 08/10/2015 | Copyright © RCT
4
5
6
7
478i
REV
1
8
23 | 24
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 0173
KALGOORLIE
24 Percy Road
Kalgoorlie WA 6430
Ph: +61 (0) 8 9021 1600
Fax: +61 (0) 8 9091 4927
MT ISA
1A Ryan Road
Mt Isa QLD 4825
Ph: +61 (0) 7 4749 0233
Fax: +61 (0) 7 4749 0232
MELBOURNE
Unit 4 Hallmarc Office Park
15 Ricketts Road
Mt Waverley VIC 3149
Ph: +61 (0) 3 9545 5859
Fax: +61 (0) 3 9545 6193
AFRICA: +27 (0) 83 292 4246
NORTH AMERICA: +1 801 712 6077
RUSSIA/CIS: +7 (910) 411 11-74
SOUTH AMERICA: +56 9 7387 2385