RCT Muirhead 9200 User manual

PRODUCT MANUAL
ENGINE PROTECTION SYSTEM PANEL
4-FUNCTION WATER COOLED
VERSION 2
Part No. 9200

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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 permissionor licencefrom 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
⚠Caution
Consult the specifications data sheet on page 21 prior to installing the product. Incorrect fitment will void the
manufacturer’s warranty.
General Safety Warnings 6
Personal Safety 6
Machine 6
Product 6
Product Overview 7
Features and Functions 7
Operation and Use 8
Control Unit 8
Wiring Connections 8
Inputs 8
Function 1 8
Function 2 9
Function 3 9
Function 4 9
Outputs 9
Alarm Control Output 9
Idle Control 9
Engine Control (ETR) 9
Installation Guide 10
Control Unit 10
Options 10
Audible Alarm 10
Coolant Level Sensor –Function 1 11
Engine Oil Pressure Switch –Function 2 11
Engine Temperature Switch –Function 3 12
Oil/Fuel Level Switch –Function 4 12
Engine Protection System Labelling (Water Cooled) 13
Alert Function Identification Labels 14
Typical Engine Protection System Schematic to suit 4-Function Water Cooled Engines (390x) 15
Calibration 16
Service Information 16
Service Schedule 16
Service Procedure 16
Coolant Level Sensor 16
Engine Oil Pressure Switch 16
Engine Temperature Switch 16
Oil/Fuel Level Switch 17
Test Procedure 17
Control Unit 17
Coolant Level Sensor 18
Engine Oil Pressure Switch 18
Engine Temperature Switch 18
Oil/Fuel Level Switch 18

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Parts List 19
Decals Supplied with the Product 19
Wiring Looms to suit 9200 Control Unit 19
Coolant Level Sensors 19
Pressure Switches to suit Engine Oil Pressure Applications 19
Temperature Switches to suit Temperature Monitoring Applications 19
Oil/Fuel Level Switches to suit Oil Level Monitoring Applications 20
Alarms to suit the Warning Alert Function of the Control Unit 20
Technical Specifications 21
Additional Specifications 21
Power Supply 21
Inputs 21
Outputs 21
Compliance and Standards 22
Troubleshooting 22
Digital Multimeter 22
Appendix 23
ETR Idle Timer / EPS / Fire Control Unit Diagram (478i) 23
Glossary 24
Warranty 24
Revision History 25

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Table of Figures
Figure 1 MuirHead®Engine Protection System................................................................................................ 7
Figure 2 Features of the EPS........................................................................................................................... 8
Figure 3 Coolant level sensor installation example........................................................................................ 11
Figure 4 Drawing 390x –Typical engine protection system schematic ......................................................... 15
Figure 5 Drawing 478i –ETR Idle Timer / EPS / Fire Control Unit Diagram.................................................. 23

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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 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®Engine Protection System
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 alternating current (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
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

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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.
Figure 2 Features of the EPS
Wiring Connections
No.
Function
Type
1
+8 Vdc to +30 Vdc
Ignition supply
2
−0 Vdc ground
Ground
3
Output
Alarm control
4
Output
Idle control
5
Output
Energised to run control (ETR)
6
Input
Start input
7
Function 1
Ac circuit/switch input
8
Function 2
Switch input
9
Function 3
Switch input
10
Function 4
Switch input
11
Not used
Not used
12
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.
Alert Indicator
Test Switch
12-pin Connector

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Note
This function uses an ac circuit. This reduces electrolysis and corrosion of the coolant level sensor. This will
assist to keep the probe in good working order.
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?

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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
■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
shut down.
Notes
■Perform a system test using the test procedure in the Calibration section in this manual.
■For information on testing individual functions and/or parts of the EPS system, refer to the additional testing
information in this manual.
Audible Alarm
There are three ways of mounting the audible warning alarm;
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)