RCT Muirihead 3747 User manual

PRODUCT MANUAL
ENGINE PROTECTION SYSTEM
6-FUNCTION TO SUIT AIR COOLED ENGINES
Part No. 3747

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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.

M0170.docx | Rev 1.2|Modified on 20/04/2016 | © Remote Control Technologies P/L
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Contents
CAUTION. CONSULT THE SPECIFICATIONS DATA SHEET ON PAGE 23 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 7
WIRING CONNECTIONS 7
INPUTS 8
OUTPUTS 9
INSTALLATION GUIDE 10
CONTROL UNIT 10
AUDIBLE ALARM 10
ENGINE TEMPERATURE SWITCH – FUNCTION 1 11
ENGINE OIL PRESSURE SWITCH – FUNCTION 2 11
TRANSMISSION OIL TEMPERATURE SWITCH – FUNCTION 3 12
BELT BREAK PROXIMITY SWITCH – FUNCTION 4 12
HYDRAULIC OIL TEMPERATURE SWITCH – FUNCTION 5 13
OIL/FUEL LEVEL SWITCH – FUNCTION 6 13
LOW ENGINE OIL LEVEL SWITCH LOCATION DIAGRAM (159D) 14
ENGINE PROTECTION SYSTEM LABELLING DETAILS 15
ALERT FUNCTION IDENTIFICATION LABELS 16
TYPICAL ENGINE PROTECTION SYSTEM SCHEMATIC TO SUIT 6-FUNCTION AIR COOLED ENGINES
(268v) 17
CALIBRATION 18
SERVICE INFORMATION 18
SERVICE SCHEDULE 18
SERVICE PROCEDURE 18
ENGINE TEMPERATURE SWITCH 18
ENGINE OIL PRESSURE SWITCH 18
TRANSMISSION OIL TEMPERATURE SWITCH 18
BELT BREAK PROXIMITY SWITCH 18
HYDRAULIC OIL TEMPERATURE SWITCH 19
OIL/FUEL LEVEL SWITCH 19
TEST PROCEDURE 19
CONTROL UNIT 19
ENGINE TEMPERATURE SWITCH 20
ENGINE OIL PRESSURE SWITCH 20
TRANSMISSION OIL TEMPERATURE SWITCH 20
BELT BREAK PROXIMITY SWITCH 20
HYDRAULIC OIL TEMPERATURE SWITCH 20
OIL/FUEL LEVEL SWITCH 20

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PARTS LIST 21
DECALS SUPPLIED WITH THE PRODUCT 21
WIRING LOOM TO SUIT 3747 CONTROL UNIT 21
ENGINE TEMPERATURE SWITCHES 21
PRESSURE SWITCHES TO SUIT ENGINE OIL PRESSURE APPLICATIONS 21
TEMPERATURE SWITCHES TO SUIT TEMPERATURE MONITORING APPLICATIONS 22
BELT BRAKE PROXIMITY SWITCHES 22
OIL/FUEL LEVEL SWITCHES TO SUIT THE OIL LEVEL MONITORING APPLICATIONS 22
ALARMS TO SUIT THE WARNING ALERT FUNCTION OF THE CONTROL UNIT 22
TECHNICAL SPECIFICATIONS 23
COMPLIANCE AND STANDARDS 24
TROUBLESHOOTING 24
GLOSSARY 25
WARRANTY 25
APPENDIX 26
ETR IDLE TIMER / EPS / FIRE CONTROL UNIT DIAGRAM (478i) 26

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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®Engine Protection system (EPS), part number 3747, is designed to monitor almost any alarm
condition on virtually any machine. This system has been designed to monitor six inputs 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 maybe 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
Six inputs and three outputs
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 labelling 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.
WIRING CONNECTIONS
NO. FUNCTION TYPE
1 +8 V DC to +32 V DC Ignition supply
2 −0 V DC ground Ground
3 Output 1 Alarm control
4 Output 2 Idle control
5 Output 3 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 Function 5 Switch input
12 Function 6 AC circuit/switch input
ALERT INDICATORS
TEST SWITCH 12-PIN
CONNECTOR

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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.
Typical use: Cylinder head temperature
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: Transmission oil 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: Belt brake
FUNCTION 5
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 11 must be connected to ground.
Typical use: Hydraulic oil temperature
FUNCTION 6
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 12 must be connected to ground.
Typical use: Hydraulic oil level.

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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.
This circuit overrides for 10 seconds after start is activated.
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.
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 shutdown.
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)

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ENGINE TEMPERATURE SWITCH – FUNCTION 1
The engine temperature switch is to be installed in the back of the cylinder head in the 10 mm x 1.5 mm
threaded hole provided by the manufacturer. Care must be taken when installing cylinder head temperature
switches as the head of the switch can be easily broken.
Part No. 1232
365°F / 185°C
Normally Open
Thread: 10 mm x 1.5 mm brass
Part No. 7516
302°F / 150°C
Normally Open
Thread: 10 mm x 1.5 mm brass
Part No. 9779
338°F / 170°C
Normally Open
Thread: 10 mm x 1.5 mm brass
WARNING!
OVER TIGHTENING THE SWITCH WHEN INSTALLING MAY CAUSE DAMAGE TO
THE SWITCH, RENDERING THE SWITCH UNSERVICEABLE
AND MAY ALSO
MAKE REMOVAL PROBLEMATIC.
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.
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

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TRANSMISSION OIL TEMPERATURE SWITCH – FUNCTION 3
The oil temperature switch can be used to monitor oil temperature in the transmission, engine or compressor
etc. Install the switch in the required location as specified by the original equipment manufacturer (OEM). It
is imperative that the switch sensing area (bulb) be immersed in oil. 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. 1768
275°F / 135°C
Normally Closed
Thread: 3/8 NPT
Part No. 1767
250°F / 121°C
Normally Closed
Thread: 3/8 NPT
BELT BREAK PROXIMITY SWITCH – FUNCTION 4
It is recommended that the belt break proximity switch be installed with a 15 mm clearance with the switch
sense facing the spring loaded idler pulley (metal). If the engine cooling belt breaks, the idler pulley will
return to its rest position. The switch should be located so as to lose proximity with the pulley when the belt
breaks.
Part No. 1218
Part No. 4072
30 mm sensing
COOLING FAN
PROXIMITY SWITCH
BELT TENSION
15 mm GAP
1 x Possible Mounting Example

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HYDRAULIC OIL TEMPERATURE SWITCH – FUNCTION 5
The oil temperature switch can be used to monitor oil temperature in the transmission, engine or compressor
etc. Install the switch in the required location as specified by the original equipment manufacturer (OEM). It
is imperative that the switch sensing area (bulb) be immersed in oil. 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. 2073
205°F / 96 °C
Normally Opened
Thread: 3/8 NPT
OIL/FUEL LEVEL SWITCH – FUNCTION 6
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”
Part No. 8690
Normally Open
(Heavy Duty)

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M0170.docx | Rev 1.2|Modified on 20/04/2016 | © Remote Control Technologies P/L
LOW ENGINE OIL LEVEL SWITCH LOCATION DIAGRAM (159D)
8
7
6
5
4
3
21
A
B
C
D
E
F
G
H
I
J
K
L
A
B
C
D
E
F
G
H
I
J
K
L
8
7
6
5
4
3
21
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.
LOW ENGINE OIL
LEVEL SENSOR
LOCATION
FITTING
INSTRUCTIONS
www.rct.net.au
UNCONTROLLED DOCUMENT
REV
4
DWG No
159d
STATUS
NTS
SCALE
Released
SHEET
1of 1
BY
JL
DRN
RH
DATE
14/11/03
APPD
JL
DATE
----
STOCK
CODE
MULTI LEVEL SWITCH
PART
NO
8690
3rd ANGLE
PROJECTION
ALL DIMENSIONS IN MILLIMETERS
FITTING INSTRUCTIONS
1. DRAIN ENOUGH OIL UNTIL THE DIPSTICK MARK IS ON LOW WITH THE ENGINE
RUNNING AT NORMAL SPEED.
2. TEMPORARILY INSTALL A LENGTH OF CLEAR PLASTIC TUBING FROM THE LOWER OIL
PAN AND RETURN TO THE UPPER PAN.
3. OIL LEVEL SIGHTED BY EYE ACROSS PLASTIC TUBE TO SIDE OF OIL PAN. THIS LEVEL
DETERMINES THE LOCATION OF LOW OIL SWITCH POINT.
4. BRAISE
14
" NPT FITTING IN THE SIDE OF THE PAN. INSTALL HOSE FITTING ADAPTOR -
USE TEFLON TAPE TO SEAL THE THREADS.
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.
INSTALLATION DETAILS
1
2
4
3
5
OIL PAN
MOUNT SWITCH ON A
BRACKET CLOSE TO OR
ON ENGINE
SWITCH POINT MUST
LINE UP WITH LOW
LEVEL IN SUMP
SLIDE UP OR DOWN
TO DESIRED LEVEL
ENGINE
FRONT VIEW
REV ZONE DESCRIPTION BY DATE
1new titleblock GT 16/07/07
2rewrite step 5 BT 25/07/07
3updated titleblock GT 20/08/15
4I4 POINT 2 REWORDED MT 17/08/15

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ENGINE PROTECTION SYSTEM LABELLING DETAILS
AIR COOLED
There are a wide range of decals available and also blank decals which can be used when not all six
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.

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M0170.docx | Rev 1.2|Modified on 20/04/2016 | © Remote Control Technologies P/L
ALERT FUNCTION IDENTIFICATION LABELS
PART NO. LABEL PART NO. LABEL
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

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TYPICAL ENGINE PROTECTION SYSTEM SCHEMATIC TO SUIT 6-FUNCTION AIR
COOLED ENGINES (268v)
1
2
3
4
5
6
7
8
9
10
11
12
ENGINE PROTECTION
SYSTEM CONTROL
T°
BK-4
YL-4
N/C TRANS OIL
TEMP.
P
OIL
PRESSURE
SWITCH
N/O
BK-4
PK-4
BU/WH-4
CYLINDER
HEAD
TEMP.
RD-4
GY-4
BK-4
A
C
B
BELT
BREAK
+
-FAULT
ALARM
CAUTION
OUTPUT CURRENT
RATING
6AMP MAX
BK-4
BN-4 +
-
NOTE 1
THIS IS A TYPICAL ENGINE
PROTECTION SYSTEM SCHEMATIC
ILLUSTRATING ALL OUTPUT AND
INPUTS. THIS SHOULD ONLY BE USED
AS A GUIDE. DIFFERENT MACHINES
REQUIRE DIFFERENT COMPONENTS.
FOR MORE INFORMATION PLEASE
CONTACT THE MANUFACTURER.
IDLE CONTROL
SOLENOID
CAUTION
OUTPUT CURRENT
RATING
6AMP MAX
!
BK-4
YL/BU-4 +
-
ETR RUN
SOLENOID
CAUTION
OUTPUT CURRENT
RATING
6AMP MAX
!
8 - 30VDC
PROTECTED
SUPPLY
(RECOMMENDED
10AMP
PROTECTION)
TO
START
TERMINAL
AT
KEY
SWITCH
MACHINE
(FRAME)
GROUND
NOTE 2
IF NOT ALL FUNCTIONS ARE
REQUIRED, A BLANK IS PLACED ON
THE UNUSED FUNCTION AND THE
CORRESPONDING INPUT WIRE MUST
BE CONNECTED TO GROUND.
+
S
-
TRANS. OIL TEMP
OIL PRESSURE
CYL. HEAD TEMP.
BELT BREAK
ALARM
IDLE CONTROL
ETR CONTROL
START INPUT
HYD OIL TEMP
HYD OIL LEVEL
8 - 30V SUPPLY
GROUND
YL-4
PK-4
BU/WH-4
GY-4
GN-4
BN-4
YL/BU-4
PU-4
OR-4
BK-4
WH-4
BU/RD-4
!
BK-4mm
GN-4mm
IN3
IN2
IN1
IN4
OUT1
OUT2
OUT3
IN5
IN6
T°
N/O
BK-4
T°
BK-4
WH-4
N/C HYDRAULIC OIL
TEMPERATURE
SWITCH
RD-4
BU/RD-4
BK-4
C
A
B
HYDRAULIC
OIL LEVEL
SWITCH
+
S
-
8
7
654
3
21
A
B
C
D
E
F
G
H
I
J
K
L
A
B
C
D
E
F
G
H
I
J
K
L
8
7
65
4321
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.
TYPICAL ENGINE
PROTECTION
SYSTEM SCHEMATIC
TO SUIT AIR COOLED
ENGINES
EXTERNAL WIRING
www.rct.net.au
UNCONTROLLED DOCUMENT
REV
2
DWG No 268v
STATUS
NTS
SCALE
Released
SHEET 1of 1
BY BT
DRN MC DATE 20/07/06
APPD BT DATE ----
STOCK
CODE MH-EPS-6
PART
NO 3747
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
1updated titleblock GT 11/08/15
2D2, H6
Hyd Oil Temp and Level
switches added to pins 11
+ 12, wire colour changed
from WH to BU/RD at pin
1
MT 23/09/15

18 | 28
M0170.docx | Rev 1.2|Modified on 20/04/2016 | © Remote Control Technologies P/L
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) 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.
Note: All monitoring switches should be changed when fitting a new or repaired engine to a machine.
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.
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.
TRANSMISSION OIL 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 oil temperature switch be replaced.
2. Due to the critical function of this switch, it is recommended that the oil temperature switch be replaced
every 2000 hours or every six months.
BELT BREAK PROXIMITY SWITCH
Every 2000 hours or six months
1. Turn the ignition switch to the ON position.
2. The belt break alert indicator should not be illuminated.
3. Loosen the switch clamp mounting screws.
4. Remove the switch from the clamp.
5. Place switch in a position away from any metal objects (minimum 50 mm).
6. Verify that the belt break alert indicator is now illuminated.
7. If the switch tests okay, refit with a recommended 15 mm clearance.

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HYDRAULIC OIL 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 oil temperature switch be replaced.
2. Due to the critical function of this switch, it is recommended that the oil 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.
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.
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 engine temperature is high, 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
1. 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.
2. 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.
System Test
Switch

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M0170.docx | Rev 1.2|Modified on 20/04/2016 | © Remote Control Technologies P/L
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.
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.
TRANSMISSION OIL TEMPERATURE SWITCH
Every 250 hours or six months
1. Turn the ignition switch to the ON position.
2. Check that the transmission oil temperature alert indicator is not illuminated.
3. Disconnect one wire at the transmission oil temperature switch.
4. Verify that the transmission oil temperature alert indicator is now illuminated.
5. Turn the ignition off and reconnect electrical wiring.
BELT BREAK PROXIMITY SWITCH
Every 250 hours or six months
1. Turn the ignition switch to the ON position.
2. Check that the belt break alert indicator is not illuminated.
3. Disconnect one wire at the belt break switch.
4. Verify that the belt break alert indicator is now illuminated.
5. Turn the ignition off and reconnect electrical wiring.
HYDRAULIC OIL TEMPERATURE SWITCH
Every 250 hours or six months
1. Turn the ignition switch to the ON position.
2. Check that the hydraulic oil temperature alert indicator is not illuminated.
3. Disconnect one wire at the hydraulic oil temperature switch.
4. Verify that the hydraulic oil 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.