RCT Muirhead 3206 User manual

PRODUCT MANUAL
LIGHT VEHICLE/FORKLIFT ENGINE
PROTECTION SYSTEM
Part No. 3206/9303

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LEGAL NOTICE
1. You acknowledge that this document is protected under copyright law and Remote Control Technologies Pty Ltd or its related bodies
corporate (“RCT”) owns the copyright in this document or otherwise have permission or licence from the relevant owner to use certain
specific works.
2. You must not make any changes, amendments, variations, alterations or modifications to the document.
3. You must not reproduce this document in any form or by any means, or to make copies of this document without RCT’s prior written
consent.
4. The contents in this document constitute confidential information of RCT. You must not circulate, distribute or otherwise allow the
document to be available in the public domain, or to disclose or share the document with any third party, without RCT’s prior written
consent.
5. RCT provides the document to you on an “as is” basis. RCT is not required to provide any updates to this version of the document.
RCT may make any change, amendment or modification to the contents in this document without notice to you.
6. RCT takes a best endeavour basis to ensure that the contents in this document are accurate, complete and reliable. RCT does not
warrant that the document will continue to be reliable, relevant, accurate or complete due to RCT’s continuous efforts in product
development, innovation and technology.
7. Any trademarks used in this document belongs to RCT or is used under a licence. The trademarks are not to be used for any
purposes, without RCT’s prior written consent.
8. Any illustrations used in this document are for illustration purposes only. Illustrations are intended as aids to facilitate your
understanding of the subject matter or issue.
9. RCT disclaims all liability, loss or damage that you suffer as a result of your reliance on this document.
10. By your conduct of using or reading this document, you agree to and accept the terms in this notice.

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Contents
General Safety Warnings 4
Personal Safety 4
Machine 4
Product 4
Product Overview 5
Features and Functions 5
Operation and Use 6
Engine Coolant Level 6
Engine Temperature 6
Engine Oil Pressure Low 6
Audible Alarm Output 6
Idle Output (Optional) –Not Used 6
Shutdown ETR (Optional) –Not Used 6
Installation Guide 7
Wiring Connections 7
Engine Temperature Sensor 8
Engine Coolant Level Sensor 8
Engine Oil Pressure Switch 8
Audible Alarm 8
External Wiring Diagram (049f) 9
Calibration 10
Service Information 10
Service Schedule 10
Service Procedure 10
Coolant Level Sensor 10
Coolant Temperature Switch 10
Engine Oil Pressure Switch 10
Test Procedure 11
Coolant Level Sensor 11
Coolant Temperature Switch 11
Engine Oil Pressure Switch 11
Parts List 12
3206 –Kit EPS Light Vehicle 12/24 V ETR 12
9303 –Kit EPS Forklift 12/24 V 12
Technical Specifications 13
Compliance and Standards 13
Troubleshooting 13
Glossary 14
Warranty 14
Revision History 15

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Table of Figures
Figure 1 Muirhead® Light Vehicle Engine Protection System, part number 3206 ............................................ 5
Figure 2 Muirhead® Forklift Engine Protection System, part number 9303...................................................... 5
Figure 3 Radiator installation example ............................................................................................................. 8
Figure 4 Drawing 049f –Engine warning system external wiring diagram ...................................................... 9
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 pre-start 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.

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Product Overview
Figure 1 Muirhead® Light Vehicle Engine
Protection System, part number 3206
Figure 2 Muirhead® Forklift Engine Protection
System, part number 9303
The Muirhead®Light Vehicle Engine Protection system, part number 3206, and the Muirhead®Forklift Engine
Protection system, part number 9303, offer engine protection for light commercial vehicles, forklifts and off-
road mobile equipment.
The system operates by monitoring three critical areas of potential engine failure—engine coolant level, engine
temperature, and engine oil pressure—and alerts the operator when there is an issue. This greatly reduces
premature engine failure, damage, and costly repairs.
The system provides audible and visual warnings and incorporates additional outputs for return to idle or
shutdown modes, this product is compact in design and easy to install.
Features and Functions
Audio and visual indication on reader
Australian made and tested
Universal applications
Multi-voltage applications
Tamper proof
User friendly display
Customised electronic circuitry
Guards against engine failure
Reduces costly engine repairs
Easy diagnosis of engine problems
Optional idle or shutdown function in the event of engine fault
Reduces operator responsibility
Supply voltage 12–24 volts DC
Environmentally sealed –IP32

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Operation and Use
When the ignition is switched on, the oil pressure indicator will illuminate along with the engine fault indicator
and the audible alarm will sound. Once the engine has started and gained sufficient oil pressure, all alarms
will stop. The unit is now monitoring the engine. Once a fault has been detected, the engine fault indicator will
flash for ten seconds, along with the indicator of the particular circuit that has caused the fault and the audible
alarm will sound.
The Muirhead®Light Vehicle/Forklift Engine Protection system has been designed as a generic engine
protection system incorporating three inputs (one designated as a special alternating current (ac) circuit for
detecting coolant) and three outputs. The configuration of these inputs and outputs are as follows;
Engine Coolant Level
(White Wire)
This circuit detects low engine coolant. It is configured to have a five-second delay prior to activating its
individual warning indicator and the external audible alarm and optional shutdown process. This circuit
activates when the circuit becomes open.
Engine Temperature
(Yellow Wire)
This circuit detects high engine temperature. It is configured to have a one-second delay prior to activating its
corresponding warning indicator and the external audible alarm and optional shutdown process. This circuit
activates when the circuit becomes open.
Engine Oil Pressure Low
(Pink Wire)
This circuit detects low engine oil pressure. It is configured to have a one-second delay prior to activating its
corresponding warning indicator and the external audible alarm and optional shutdown process. This circuit
activates when the circuit becomes open.
Audible Alarm Output
(Green Wire)
The audible alarm output circuit switches on as soon as an individual warning indicator has been activated.
The alarm will remain on in a constant state until the operator has rectified the individual engine fault that was
registered on the control unit. Once the engine fault has been rectified, the fault indicator that was illuminated
on the control unit will cease along with the sounding of the alarm.
Idle Output (Optional) –Not Used
(Brown Wire)
This circuit operates as a direct opposite to the audible alarm circuit. It switches off when the audible alarm
switches on. This circuit is only used in conjunction with additional control systems that can return the engine
to idle on detection of a fault.
Shutdown ETR (Optional) –Not Used
(Yellow/Blue Wire)
This circuit operates similar to the idle output. However, this time delay is factory set to 10 seconds and
therefore allows the vehicle to run for 10 seconds after the detection of a fault and the warning system has
become active. The circuit is powered to run. The circuit switches off once a fault has been active for 10
seconds. This circuit also incorporates an override circuit to allow the vehicle to start when no oil pressure is
present.

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Installation Guide
1. Install the control unit in a suitable location in full visibility of the driver, preferably on the instrument panel.
2. Refer to the wiring table below and the wiring diagram in this manual to wire up the control unit. It is
recommended that the wiring loom be installed alongside the OEM engine wiring ensuring that it is secured
at regular intervals; this will provide protection from heat and abrasion, and any other excess damage that
may occur with extended vehicle operation. When securing the loom to the OEM engine wiring, ensure
that the loom is away from moving vehicle parts which could lead to loom damage.
3. Install the sensors/ switches (see below for more detail). All sensors/ switches should be installed using a
suitable thread sealant. All sensors should be installed using a suitable thread sealant.
Note
RCT recommends that all electrical connections be treated with Electroguard grease (part number 2800).
Wiring Connections
Pin No.
Colour
Description
1
Purple
Start input
2
Yellow/Blue
ETR output (4 A max)
3
Black
0 Vdc earth
4
Red
7 - 35 Vdc ignition
5
Brown
Idle control output (4 A max)
6
Green
Fault alarm
Pin No.
Colour
Description
1
White
Coolant level sensor
2
Pink
Engine oil pressure switch
3
Yellow
Engine coolant temperature sensor

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Engine Temperature Sensor
Ensuring the engine temperature sensor is installed on the engine side
of the vehicle in front of the thermostat. If the engine temperature sensor
is not installed on the engine side, the engine temperature will not be
sensed correctly. It is imperative that the switch sensing area (bulb) be
immersed in coolant. Install the switch using thread sealant.
Note
Care should be taken when selecting a mounting port to allow sufficient
depth for the bulb.
Engine Coolant Level Sensor
It is recommended that the coolant level sensor be installed in the
radiator tank (see figure below). Ensure there is sufficient clearance
within the radiator to accommodate the length of the coolant probe to be
fitted. Drill the required hole size in the tank and tap to the required
thread size as specified below. Always clean debris away and remove
any foreign objects before installing the sensor. Fit the sensor and
pressure test, this can be achieved by running the engine until normal
operating temperature has been reached.
Do not install the coolant level sensor in the coolant flow points of the
engine, i.e. hoses or piping. The application is designed to detect the
coolant level of the entire vehicle; the coolant level sensor must be fitted
in the top of the coolant tank (radiator) to enable it to get a correct
reading of the coolant level.
Figure 3 Radiator installation example
Engine Oil Pressure Switch
The engine oil pressure switch should be located in a suitable oil gallery
access port. Use the OEM oil pressure switch as a guide for location. Fit
the oil pressure switch using thread sealant, being careful not to over
tighten.
Note
T-pieces are available in most thread types to enable both the OEM and
Muirhead®Oil Pressure Switches to be installed into the original port.
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)
Part No. 1764
212 °F / 100 °C
Normally Closed
Thread: 3/8 NPT
Part No. 1766
230 °F / 110 °C
Normally Closed
Thread: 3/8 NPT
Part No. 2006
Thread: 1/8 NPT Nylon
Tapping drill: 21/64”
Probe length: 30 mm from top of
thread to tip of probe
Part No. 2887
Thread: 1/4 NPT Nylon
Tapping drill: 7/16”
Probe length: 72 mm from top of
thread to tip of probe
Note: Brass weld collar included
Part No. 3074
8 PSI
Normally Open
Thread: 1/8 NPT
Probe position
Optimum probe level is ⅓ up
from the bottom of the top
hose hole

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External Wiring Diagram (049f)
Figure 4 Drawing 049f –Engine warning system external wiring diagram
BK
RD
PU
GN
BN
YL/BU
PK
YL
WH
-0V
EARTH +7V - 35VDC
IGNITION START
INPUT FAULT
ALARM
OUTPUT
ENGINE OIL
PRESSURE
SWITCH
P
ENGINE
COOLANT
TEMPERATURE
SWITCH
ENGINE
COOLANT
LEVEL
PROBE
T°
IDLE
CONTROL
OUTPUT
4 A MAX *
(OPTIONAL)
ETR
RUN
OUTPUT
4 A MAX *
(OPTIONAL)
COOLANT
LEVEL
OIL
PRESSURE
COOLANT
TEMP.
ENGINE
FAULT
RL
85 86
30 87
87A
1
IGNITION OUTPUT
IGNITION INPUT
YL/BU
* OPTIONAL WIRING FOR OUTPUTS GREATER THAN 4 A
12345678910 11 12
B
A
C
D
E
F
G
H
B
A
C
D E
F
G
H
12345678910 11 12
A4
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.
LIGHT VEHICLE
ENGINE WARNING
SYSTEM
EXTERNAL WIRING
www.rct.net.au
UNCONTROLLED DOCUMENT
REV
3
DWG No 049f
STATUS
NTS
SCALE
Released
SHEET 1 of 1
BY BT
DRN RH DATE 03/05/04
APPD GS DATE ----
STOCK
CODE AIS-LV-EWS
PART NO 3206
3rd ANGLE
PROJECTION
ALL DIMENSIONS IN MILLIMETERS
OPERATION
WHEN A CRITICAL ENGINE FAULT IS CONFIRMED THE OPERATOR IS ALERTED BY THE
APPROPRIATE LED LAMP, AN AUDIBLE ALARM WILL OPERATE AND THE ENGINE FAULT
LED WILL FLASH.
THE IDLE CONTROL OUTPUT WILL ALSO DE-ACTIVATE. IF THE CRITICAL ENGINE FAULT
CONTINUES FOR THE SHUTDOWN PERIOD THEN THE ETR RUN OUTPUT IS
DE-ACTIVATED.
1
2
3
MALE PINS
MALE PINS
CONTROL
UNIT PLUG
WIRING CODE
1-WHITE -COOLANT LEVEL PROBE
2-PINK -ENGINE OIL PRESSURE SWITCH
3-YELLOW -ENGINE COOLANT TEMPERATURE SWITCH
THE MANUFACTURER RECOMMENDS THAT THE IGNITION SUPPLY BE 15 AMP
FUSED AT ITS SOURCE AND THAT ALL INDUCTIVE SOURCES BE DIODE
PROTECTED. FAILURE TO DO SO MAY EFFECT PRODUCT PERFORMANCE AND
WARRANTY.
WIRING CODE
1-PURPLE -START INPUT
2-YELLOW/BLUE -ETR RUN SOLENOID OUTPUT (4 A MAX)
3-BLACK --0 VDC EARTH
4-RED -+7 TO 35 VDC IGNITION
5-BROWN -IDLE CONTROL OUTPUT (4 A MAX)
6-GREEN -FAULT ALARM
CONTROL
UNIT PLUG
123
456
REV ZONE DESCRIPTION BY DATE
1
2updated titleblock GT 27/07/15
3E2,
D7-8,
F5
4 A max & optional
notes/wiring added JB 25/06/19
WIRE LEGEND
BK - BLACK PK - PINK BU - BLUE PU -P U R P L E BN - BROWN RD - RED
GN - GREEN WH - WHITE GY - GREY YL - YELLOW
OR - ORANGE TQ - TURQUOISE

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Calibration
Not applicable.
Service Information
Service Schedule
The manufacturer recommends that the following service procedure should be performed at each vehicle’s
scheduled service interval.
Service Procedure
1. Perform a visual inspection; include the following:
a) Control unit
b) Wiring connections and looms
c) All switches and sensors as below
d) Engine fluids
2. Perform a system test as per the following:
a) Refer to the Operation and Use section of this manual for the operation of the control unit and each
function.
b) Test each circuit individually as per the Test Procedure.
Coolant Level Sensor
Every 2000 hours or six months;
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.
Note
All monitoring switches should be changed when fitting a new or repaired engine to a vehicle.
Coolant Temperature Switch
Every 2000 hours or six months;
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 thecoolant temperature switch be replaced
every 2000 hours or every six months.
Note
All monitoring switches should be changed when fitting a new or repaired engine to a vehicle.
Engine Oil Pressure Switch
Every 2000 hours or six months;
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.
Note
All monitoring switches should be changed when fitting a new or repaired engine to a vehicle.

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Test Procedure
Test each circuit individually.
Coolant Level Sensor
Every 250 hours or during vehicle scheduled service;
1. Turn the ignition switch to the ON position and verify the coolant level indicator is not illuminated.
2. Disconnect the wire from the coolant level sensor.
3. Verify, after five seconds, that the coolant level 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.
6. Verify that the coolant level indicator is illuminated.
7. Refill coolant to the manufacturer’s specifications.
8. Check that the coolant level indicator is no longer illuminated.
9. Turn the ignition off.
Coolant Temperature Switch
Every 250 hours or during vehicle scheduled service;
1. Turn the ignition switch to the ON position.
2. Check that the coolant temperature indicator is not illuminated.
3. Disconnect 1 x wire at the coolant temperature switch.
4. Verify, after one second, that the coolant temperature indicator is now illuminated.
5. Turn the ignition off and reconnect the electrical wiring.
Engine Oil Pressure Switch
Every 250 hours or during vehicle scheduled service;
1. Turn the ignition switch to the ON position.
2. Verify that the fault alarm is sounding and the oil pressure indicator is illuminated.
3. Bridge the wires at the oil pressure switch.
4. Verify, after one second, that alarm has ceased and the oil pressure indicator is no longer illuminated.
5. Remove bridging connector.
6. Start and run vehicle until engine oil pressure reaches normal operating pressure.
7. Verify that alarming has ceased and the oil pressure indicator is no longer illuminated.

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Parts List
3206 –Kit EPS Light Vehicle 12/24 V ETR
Part No.
Description
Quantity
3369
EPS control unit
1
3074
Pressure switch, 8 PSI, 2 terminal, N/O, ⅛NPT (light duty)
1
1723
Audible warning alarm 80 dB
1
1764
Temperature switch, 212 °F / 100 °C, 3/8 NPT, N/C
1
2006
Coolant level probe, ⅛NPT, 30 mm shaft length. (light duty, plastic body)
1
7621
Coolant level probe terminal
1
8145
Insulator to suit 7621 terminal
1
0029
Bush to suit ⅛NTP Probe
1
5641
Universal engine warning system (EWS) loom
1
9303 –Kit EPS Forklift 12/24 V
Part No.
Description
Quantity
3369
EPS control unit
1
3074
Pressure switch, 8 PSI, 2 terminal, N/O, ⅛NPT (light duty)
1
1723
Audible warning alarm 80 dB
1
1766
Temperature switch, 230 °F / 110 °C, 3/8 NPT, N/C
1
2006
Coolant level probe, ⅛NPT, 30 mm shaft length. (light duty, plastic body)
1
7621
Coolant level probe terminal
1
8145
Insulator to suit 7621 terminal
1
0578
Adaptor nipple ⅛- ⅛BSPTM
1
1247
Adaptor T-piece ⅛NPT fixed
1
0029
Bush to suit ⅛NTP Probe
1
5641
Universal engine warning system (EWS) loom
1
Note
A ⅛ NPT tap is required to tap the hole for the coolant sensing probe to fit into. The ⅛ NPT tap, part number
4289, is available separately for purchase.

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Technical Specifications
Dimensions, control unit only:
Length: 87 mm | Width: 63 mm | Height/Depth: 33 mm
Dimensions, boxed for freight:
Length: 22 mm | Width: 120 mm | Height/Depth: 120 mm
Weight, control unit only:
0.15 kg
Weight, including harness /
packaging for freight:
0.30 kg
Input nominal voltage:
12 to 24 Vdc
Operating temperate range:
0 to 70 °C
Connection types:
Quick connector 6-socket, quick connector 3-socket,
Inputs:
Earth, ignition supply @ key switch, pressure switch, engine
switch, coolant probe
Output continuous current ratings:
4 A
Min & max input voltage:
7 to 35 Vdc
Circuit protection:
Reverse polarity protected
Enclosure type:
Black powder coated aluminium
Environmental protection IP rating:
IP32
Programming/adjustment:
Not applicable
Compliance and Standards
Not applicable
Troubleshooting
Fault
Possible Cause
Device not working.
Check wiring and connections.
Intermittent fault.
Check wiring and connections.

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Glossary
Warranty
Please see the RCT standard warranty, available on our website - www.rct-global.com.
A
Amp (Ampere)
MIN
Minimum
ac
alternating current
mm
millimetres
AMS
Advanced Management System
mW
Milliwatts
Aux
Auxiliary Output
N/A
Not Applicable
CAN
Controller Area Network
N/C
Normally Closed
CMIO
ControlMaster® Input Output PCB
N/O
Normally Open
CMR
ControlMaster® Receiver
OEM
Original Equipment Manufacturer
CMT
ControlMaster® Transmitter
O/P
Outputs
CM2200
ControlMaster® 2200 Remote Set
Out
Output
COMMS
Communications
PB
Push Button
CPU
Central Processor Unit
PC
Personal Computer
dc
direct current
PCB
Printed Circuit Board
E.G.
For example
PIN
Personal Identification Number
ETR
Energised To Run
PLC
Programmable Logic Controller
ETS
Energised To Stop
POT
Potentiometer
ESD
Engine Shutdown
PPM
Pulses Per Metre
FET
Field Effect Transistor
PWM
Pulse Width Modulation
GND
Ground
PWR
Power
H
Hours
Rev
Revision
HEX
Hexadecimal Numbering System
RF
Radio Frequency
ID
Identity
RH
Relative Humidity
i.e
that is
rpm
Revolutions per minute
In
Input
RX
Receiver
IP
Ingress Protection
RS232
Recommended Standard (number 232) for
serial data transfer
kg
Kilogram
SYS
System
Km/h
Kilometres Per Hour
TOV
Text On Video
LCD
Liquid Crystal Display
TX
Transmitter
LED
Light Emitting Diode
USB
Universal Serial Bus
LK
Link
V
Volts
M
Minutes
°C
Degrees Centigrade
mA
Milliamps
#
Number
MAX
Maximum
<
Less Than
MCU
Multi-Control Unit
>
Greater Than
MFU
Multi-Function Unit
%
Percentage
MHz
Mega Hertz (million(s) cycles per
second)

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Revision History
Rev
Date
By
Details of change
1.0
10/05/2005
-
Initial document draft and approval
1.1
17/06/2014
CC
Added revision table and Glossary
2.0
27/07/2015
GT
Updated manual format.
2.1
25/09/2015
CamB
Revised manual.
2.2
06/10/2015
GT/DH
Updated Service Procedures section, etc.
2.3
13/02/2018
JB
Updated Technical Specifications table.
2.4
12/02/2019
CC
Updated manual; added Table of Figures and Revision History sections.
2.5
26/06/2019
JB
Updated Overview, Operation & Use, Installation Guide, Parts List,
drawing 049f.

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