RCT MUIRHEAD User manual

PRODUCT MANUAL
OVERCRANK PROTECTION CONTROLLER
Part No. 11966 | 12725 | 12726

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M0879.docx | Rev 1.6 | Modified on 11/01/2018 | © Remote Control Technologies Pty Ltd
DISCLAIMER
© Remote Control Technologies Pty Ltd.
■No part of this manual may be reproduced, copied, translated, or transmitted in any form or by any means without the written
permission of RCT.
■Information provided in this manual is intended to be accurate and reliable. However, 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.
RCT will accept no responsibility for actual use of the product based on these illustrative examples.
■Please contact your nearest RCT branch for more information concerning applications in life critical situations or high reliability.
■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.

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Contents
GENERAL SAFETY WARNINGS 4
PRODUCT OVERVIEW 5
FEATURES AND FUNCTIONS 5
OPERATION AND USE 6
CONTROLLER STATUS INDICATOR OPERATION 6
INSTALLATION GUIDE 7
WIRING CONNECTIONS 7
EXTERNAL WIRING DIAGRAM (501d) 8
CALIBRATION 9
SERVICE INFORMATION 9
SERVICE SCHEDULE 9
SERVICE PROCEDURE 9
PARTS LIST 9
12726 OVERCRANK CONTROLLER LOW VOLTAGE KIT (12 V) 9
12725 OVERCRANK CONTROLLER KIT (24 V) 10
TECHNICAL SPECIFICATIONS 10
COMPLIANCE AND STANDARDS 10
TROUBLESHOOTING 11
GLOSSARY 11
WARRANTY 11

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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.

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PRODUCT OVERVIEW
The Muirhead®Overcrank Protection controller, part number 11966, is designed to be installed onto machines
to protect the starter motor from over-cranking.
The overcrank protection controller will stop the engine starter motor being cranked for an excessive amount
of time and provides a cooling down period between long cranking.
FEATURES AND FUNCTIONS
■Multi-voltage 12-24 V
Environmentally sealed – IP65
Overcrank visual warning
Protects starter circuit from unnecessary damage caused by overcranking
Overcrank timeout function
Compact and robust design

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OPERATION AND USE
The overcrank protection controller will allow the operator to crank the vehicle for a maximum of 30 seconds
(adjustable) after which the output is turned off. If the crank time exceeds 10 seconds (adjustable), there is a
lockout period of 60 seconds (adjustable) before it can be cranked again. An LED (usually mounted in the
instrument panel) will illuminate during this time to indicate that the start circuit is in lockout.
The bypass switch functionality has been designed so that maintenance staff can perform tasks without being
inhibited by the overcrank protection controller. When the bypass switch is on, the controller will allow the
operator to crank the vehicle for as long as necessary.
The timings mentioned above are the default time settings. Refer to the Calibration section of this manual if
you require different time settings.
CONTROLLER STATUS INDICATOR OPERATION
STATE INDICATOR SEQUENCE
Battery Power-up ■All indicators will turn on.
■All indicators will turn off.
■After power-up, the controller will revert to normal operation.
Status Indicator in Operation RED – Fault.
■If outputs have problems, this will turn on.
■Outputs 1 & 2 – high current outputs: checked for over current.
■Output 3 – not checked as it is a low side driver.
■Output 4 – checked for correct output voltage.
■Temperature – checked for board temperature exceeding 80 °C.
YELLOW – Pulses during normal operation, indicates system OK.
■Flashes on and off at one-second intervals (on for one second, off for
one second).
GREEN – On for normal operation.
■Flashes when valid input goes active (number of flashes = input
number).
■Allows checking that inputs are correctly wired and that the hardware is
seeing the input toggle.
Alarm
Indication
System
Status
Power I
ndication

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INSTALLATION GUIDE
WARNING!
A RELAY IS REQUIRED IN THIS SYSTEM AS A FAIL TO SAFE CIRCUIT. FAILURE
TO INCLUDE A RELAY IN THE CIRCUIT MAY RESULT IN DAMAGE TO THE
ENGINE AND/OR COMPONENTS.
1. Install the control unit, relay and bypass switch in a suitable location, preferably in the cabin.
2. Refer to the wiring table below and the wiring diagram in this manual to connect the controller. It is
recommended that the wiring is installed alongside the OEM 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 wiring to the OEM wiring, ensure that the loom is
away from moving vehicle parts which could lead to loom damage.
3. Mount the LED in a suitable location that is visible to the operator.
4. Remove the engine start/crank wire from the ignition switch and connect it to terminal 87 of the relay.
5. Connect the yellow wire (pin 8) to terminal 30 of the relay, run a second wire from the engine start/crank
terminal of the ignition switch and connect the other end to terminal 30 of the relay. There should now be
two wires connected to terminal 30 of the relay.
6. Connect the yellow/blue wire (pin 3) to terminal 86 of the relay.
Note: It is recommended that a suppression diode be fitted across all inductive loads
WIRING CONNECTIONS
NO. COLOUR FUNCTION DESCRIPTION
1 Red Ignition +VE Connect to the permanent battery supply at the key switch
(supply 12-24 V DC).
2 Black Ground Earth (ground).
3 Yellow/Blue Output 1
(ignition output) Engine start/crank output (10 A continuous output).
4 Green Output 3 Not used.
5 White Input 1 Not used.
6 Orange Input 3 Bypass key.
7 Pink Input 4 Not used.
8 Yellow Input 2 Engine start/crank input.
9 Blue Output 4 Not used.
10 Purple Output 2 Positive terminal of overcrank warning LED
11 Black/white - VE Ground terminal of overcrank warning LED
12 Red/white Battery +VE Not used.

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EXTERNAL WIRING DIAGRAM (501d)
OVERCRANK
WARNING LED
1
2
3
4
5
6
7
8 9
10
11
12
(11966)
OVERCRANK PROTECTION CONTROLLER
BYPASS KEY
SWITCH
(CONNECT TO
+VE PROTECTED
IGNITION SUPPLY)
START SIGNAL
OUTPUT
(ENGINE CRANK)
AT IGNITION
KEY SWITCH
STARTER
MOTOR SLAVE
SOLENOID(S)
GROUND +VE
PROTECTED
IGNITION
SUPPLY
(BLUE)
8586
30 87
!

www.rct.net.auN12596
OVERCRANK PROTECTION
CONTROLLER
11966
RD-4
BK-4
YL/BU-4
OR-4
YL-FVT
PU-FVT BK/WH-3
REF NOTE
GN-FVT
WH-FVT
PK-FVT BU-FVT
RD/WH-3
NOTE:
WHEN USING LED PART NO 11111, OR AN EQUIVALENT NO LOAD LED, A
RESISTOR SHOULD BE CONNECTED ACROSS THE LED TO PREVENT
CURRENT LEAKAGE WHICH CAUSES A FALSE INDICATION. RESISTOR TYPE
IS (1W 1.2K OHM RCT PART NUMBER 11981)
WARNING! A RELAY IS REQUIRED IN THIS SYSTEM AS A FAIL TO SAFE
CIRCUIT. FAILURE TO INCLUDE A RELAY IN THE CIRCUIT MAY RESULT IN
DAMAGE TO THE ENGINE AND OR COMPONENTS.
1 2 3 4 5 6 7 8 9 10 11 12
B
A
C
D
E
F
G
H
B
A
C
D
E F
G
H
1 2 345 6 78 9 10 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.
OVERCRANK
PROTECTION
CONTROLLER
EXTERNAL WIRING
www.rct.net.au
UNCONTROLLED DOCUMENT
REV
5
DWG No
501d
STATUS
NTS
SCALE
Released
SHEET
1of 1
BY
RD
DRN
CW
DATE
05/02/14
APPD
DW
DATE
05/02/14
STOCK
CODE
MH-MV-OCC
PART NO
11966
3rd ANGLE
PROJECTION
ALL DIMENSIONS IN MILLIMETERS
WIRE LEGEND
BK -BLACK PK -PINK
BU -BLUE PU -PURPLE
BN -BROWN RD -RED
GN -GREEN WH -WHITE GY -GREY YL -YELLOW
OR -ORANGE TQ -TURQUOISE
REV ZONE DESCRIPTION BY DATE
1
LED wire changed from
pin 9 to 10, key startwire
changed from pin 5 to 8,
bypass key, key switch
and protected battery supply descriptions amended
DW 25/03/14
2
CHANGE TO RELAY
AND BATTERY SUPPLY
TEXT. OPERATION
REWRITTEN, TITLE
CHANGE
RD 26/03/14
3D7 bypass switch changed to
N/O DAS 05/12/14
4C3, E3,
B5-E6
text added to label and
below controller, wire
colours added, earth changed for LED CamB 02/11/15
5H1-3,
E1-3,
F7, F11
Wiring Connections table
added, Warning note added, Pin 1 and 6 label
changed MT 06/05/16
WIRING CONNECTIONS
PIN WIRE FUNCTION
1RD 12/24V IGNITION SUPPLY
2BK GROUND
3YL/BU ENGINE START/CRANK CONTROL OUTPUT
4GN NOT USED
5WH NOT USED
6
OR BYPASS KEY INPUT
7 PK NOT USED
8YL ENGINE START/CRANK SIGNAL INPUT
9 BU NOT USED
10 PU POSITIVE OUT PUT TO LED
11 BK/WH GROUND FOR LED
12 RH/WH NOT USED

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CALIBRATION
SETTING
NO.
DESCRIPTION UNITS* DEFAULT
1** Crank time period
The time period the engine can be cranked without causing a
lockout period, adjustable between 5 and 12 seconds.
Seconds 10
2** Max crank time period
The maximum allowable time for the engine to be cranked at
any point, adjustable between 15 and 30 seconds.
Seconds 30
3** Lockout time period
The amount of time the controller will lock out the ability to crank
the engine after exceeding the long crank time period,
adjustable between 30 seconds and two minutes.
Seconds 60
* Note: The units’ column indicates the value that the setting will increase by with each increment.
**Note: These parameters can be changed through programming; however, this will require the use of the
programmable controller utility available from RCT.
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; include the following:
a) Controller
b) Wiring connections and looms
c) Switches
2. Perform a system test as per the Operation and Use section of this manual for the operation of the
controller.
PARTS LIST
12726 OVERCRANK CONTROLLER KIT (12 V)
PART NO. DESCRIPTION QUANTITY
INCLUDED PARTS SUGGESTED SPARES
11966 Overcrank Controller 1 1
1523 12 V Relay 1 1
12738 Generic Loom 1 -
11112 Blue LED 1 -
12048 Warning LED Label 1 -
12049 Overcrank Bypass Label 1 -
3543 Key Switch Head Stay Put L/H 1 -
9476 Switch Body with 1 x N/O contact 1 -
11981 LED Resistor 1 -

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12725 OVERCRANK CONTROLLER KIT (24 V)
PART NO. DESCRIPTION
QUANTITY
INCLUDED PARTS
SUGGESTED SPARES
11966 Overcrank Controller
1
1
2401
24 V Relay
1
1
12738
Generic Loom
1
-
11112
Blue LED
1
-
12048
Warning LED Label
1
-
12049
Overcrank Bypass Label
1
-
3543
Key Switch Head Stay Put L/H
1
-
9476
Switch Body with 1 x N/O Contact
1
-
11981 LED Resistor 1 -
TECHNICAL SPECIFICATIONS
Dimensions, controller only
Length: 119 mm | Width: 80 mm | Height/Depth: 65 mm
Dimensions, boxed for freight
Length: 220 mm | Width: 120 mm | Height/Depth: 120 mm
Weight, controller only
255 g
Input nominal voltage
12 to 24 V DC
Min and max input voltage
9 to 35 V DC
Ignition output rated continuous
current
10 A
Connection types 12-pin receptacle
Inputs
Ignition supply, bypass input, battery supply, chassis ground
Circuit protection
External control
Enclosure type
ABS
Environmental protection IP rating
IP65
Programming/adjustment
Refer to Calibration section
COMPLIANCE AND STANDARDS
RCT has an obligation as a manufacturer to comply with the regulations as required by the relevant regulatory
bodies, depending on the market and location.
This product currently complies with the following:
ACMA
■IEC 61000-6-1:2005 Electromagnetic Compatibility (EMC) – Part 6-1: Generic Standards – Immunity for
Residential, Commercial and Light Industrial Environments.
■IEC 61000-6-3:2006, A1:2010 Electromagnetic Compatibility (EMC) – Part 6-3: Generic Standards –
Emissions for Residential, Commercial and Light Industrial Environments.
EU
■IEC 61000-6-1:2005 Electromagnetic Compatibility (EMC) – Part 6-1: Generic Standards – Immunity for
Residential, Commercial and Light Industrial Environments.
■IEC 61000-6-3:2006, A1:2010 Electromagnetic Compatibility (EMC) – Part 6-3: Generic Standards –
Emissions for Residential, Commercial and Light Industrial Environments.
■RoHS 2 Directive 2011/65/EU
FCC
This device is exempt from FCC regulations under 47 CFR 15.103 Exempted devices.
IC
This device is exempt from IC regulations under ICES-003 — Information Technology Equipment (ITE) —
Limits and Methods of Measurement.