Electric Drill 7/16, 1/4, 1/2 and 3/4 Drill Bits Phillip Head Screw Driver Ratchet Set Current Probe

Transcription

1 LS00 (Deutz Engine) Cold Start Relay Kit The following instructions are intended to assist the user in the installation of the Cold Start Relay Kit used on the LS00 Concrete Pump. Please read all instructions before installing the cold start relay kit. Required tools/components Electric Drill 7/6, /, / and / Drill Bits Phillip Head Screw Driver Ratchet Set Current Probe Parts Verify that all parts are accounted for. Reference Table. Item No. Table. Required Parts Part No. Description QTY. Remarks N/A Cold Start Relay Box Includes items -6 N/A /-0X" Bolt N/A /-0" Hex Nut N/A /" Lock Washer Work safely! Only a qualified service technician with proper training should perform this installation. Follow all shop safety rules when performing this installation. Engine Hood Removal. Place the pump in an area free of dirt and debris.. Disconnect negative battery cable from the battery.. Remove the rain cap (A) from the muffler pipe as shown in Figure.. Using a /-inch socket, remove the bolts (B) that secure the exhaust pipe to the engine cover.. Using a 7/6-inch socket, remove the bolts (C) that secure the engine hood to the pump. A N/A /" Flat Washer 6 N/A Fuse 7 N/A Terminal Block Includes items 8-8 N/A #0-X/8 Screw 9 N/A #0/ Hex Nut 0 N/A #0 Lock Washer C C B B MUFFLER PIPE N/A #0 Flat Washer Heating Element Includes items- N/A M Lock Washer N/A M Flat Washer N/A M Hex Nut 6 N/A Lamp 7 N/A Grommet P N/A Plug W N/A Wire, 0 AWG. RED TB/IGN. C W N/A Wire, 0 AWG. ORANGE TB/Splice W N/A Wire, 0 AWG. RED Splice/Lamp W6 N/A Wire, 0 AWG. RED IGN./Splice W8 N/A Wire, AWG BLUE Glow Plug/TB Figure. Hood Removal LS00 COld start relay kit Rev. #0 (06/0/) Page

2 6. Lift engine hood from the pump and place in a safe location where it will not get damaged. 7. Place all engine hood mounting hardware in a bag where it will not get lost. This mounting hardware will be needed during reasssembly. Cold start relay control Box mounting. Grasp and turn the spring loaded butterfly latch located on the access door and open the door. This will provide easy access to where the cold start relay control box will be mounted.. Using a /-inch drill bit, drill holes as shown in Figure for the mounting of the Cold Start Relay Control Box.. Using a phillip-head screw driver remove the screws () that secure the cover (Figure ) to the Cold Start Relay Control Box. Mount the Cold Start Relay Control Box using a /-0 X bolt (), /-inch lock washer (), /-inch flat washer () and /-0 nut (). BOLT LOCK WASHER FLAT WASHER FLAT WASHER COLD START RELAY LOCK NUT REMOVE COVER BUTTERFLY LATCH ACCESS DOOR HYDRAULIC TANK DRILL HOLES HERE REMOVE SCREW () BUTTERFLY LATCH Figure. Cold Start Relay Control Box Mounting Holes Figure. Cold Start Relay Control Box Mounting. Reinstall the cover. LS00 Cold start relay kit Rev. #0 (06/0/) Page

3 Digital Control Box Modification. Remove the screws () that secure the Digital Control Box front panel (Figure ) to the pump. FRONT VIEW - / - 7 /8 - /8 CL / Dia. () 8 / Dia. TERMINAL BLOCK SCREW FLAT WASHER LOCK WASHER NUT REMOVE SCREW () Figure. Digital Control Box Front Panel Removal. Tilt the front panel downward (Figure ) and let it hang. This will allow for easy access inside the control box. RUBBER GROMMET PANEL Figure. Digital Control Box Access. Using a /-inch drill, drill holes inside the Digital Control Box for the mounting of the terminal block.. Next, drill a /-inch diameter hole inside the Digital Control Box as referenced in Figure 6. After hole has been drilled insert supplied grommet. Figure 6. Digital Control Box Modification. Drill a /-inch diameter hole as referenced in Figure 7. This hole will be for the mounting of the glow plug indicator lamp. LS00 COld start relay kit Rev. #0 (06/0/) Page

4 LAMP O-RING CL LOCKING NUT STAR WASHER Digital control box connections Refer to Figure 8 for connections from the Cold Start Relay Control Box to the Digital Control Box (existing).. Connect one end of the wire labeled W (RED) to TB-.. Connect the other end of the wire labeled W (RED to pin 7 on the ignition switch.. Connect the free end of the wire labeled W (RED) to TB-.. Connect one end of the wire labeled W (ORANGE) to TB-.. Connect the other end of the wire labeled W (ORANGE) to butt splice. 6. Connect one end of the wire labeled W (RED) to one side of the glow plug indicator light. 7. Connect the other end of the wire labeled W (RED) to butt splice. 8. Connect wire W6 (RED) between the free end of the butt splice and pin / on the ignition switch. NOTICE There may be existing wiring on pin / of the ignition switch. If the terminal next to pin / is vacant then use that terminal as a connection point. If the terminal is not vacant splicing will be required. / Dia. / Figure 7. Glow Plug Indicator Lamp Mounting 6. Once the hole has been drilled, insert the glow plug indicator lamp into the hole and secure lamp with the supplied mounting hardware. 7. Remove all shavings from the control box. 9. Connect the free end of the wire labeled W (ORANGE) to TB-. 0. Connect the free end of the wire labeled W7 (BLUE) to TB-.. Connect one end of the wire labeled W8 (BLUE) to TB-.. Connect the other end of the wire labeded W8 (BLUE) to one side of the glow plug indicator light.. Reinstall the front panel onto the control box. NOTICE After wiring has been routed, use tie wraps to secure wiring to pump frame, engine and inside Digital Control Box. LS00 Cold start relay kit Rev. #0 (06/0/) Page

5 W (RED) J COLD START RELAY W (RED) W6 (RED) / P W7 (BLUE) W (ORANGE) 7 INSIDE DIGITAL SPLICE W (RED) TB IGNITION SWITCH W8 (BLUE) W (ORANGE) PRE-HEAT INDICATOR LAMP RUBBER GROMMET Figure 8. Digital Control Box Connections LS00 COld start relay kit Rev. #0 (06/0/) Page

6 manifold heating element installation There are manifold heating elements that need to be installed into the engine inlet manifold. Perform the following procedure to install the heating elements.. Using a 0 mm allen wrench, remove the two inlet manifold port plugs located on the inlet manifold. (Figure 9). ALLEN WRENCH (0 mm) REMOVE PORT PLUG (). Insert the supplied heating elements (Figure 0) into the same location where the inlet manifold plugs were removed. Be sure that the copper seal ring has been installed. HEATING ELEMENT HEATING ELEMENT COPPER SEAL RING () INLET INLET Figure 0. Heating Element Installation. Tighten each heating element securely. DO NOT over tighten. FUSE, heating elements and GROund connections Refer to Figure for connections from the cold start relay box to the engine glow plugs and fuses.. Connect BLACK wire W9 (junction of fuses F and F) to starter solenoid (+ VDC).. Connect BLACK wire W0-HE to HEATING ELEMENT # using supplied hardware.. Connect BLACK wire W-HE to HEATING ELEMENT #.. Connect BLACK wire W to STARTER SOLENOID GND. Figure 9. Inlet Manifold Plug Removal. Discard both inlet manifold port plugs. NOTICE For proper operation, wire W0 must be connected to HEATING ELEMENT #. DO NOT connect wire W0 to HEATING ELEMENT #. LS00 Cold start relay kit Rev. #0 (06/0/) Page 6

7 NUT LOCK WASHER FLAT WASHER NUT FLAT WASHER COLD START RELAY W-HE (BLACK) COPPER O-RING GLOW PLUG W (BLACK) W (BLACK) W0-HE (BLACK) HEATING ELEMENT HEATING ELEMENT W (BLACK) SPLICE FUSE FUSE GROUND STARTER SOLENOID W9 (BLACK) Figure. Engine Wiring Connections LS00 COld start relay kit Rev. #0 (06/0/) Page 7

8 test verification Perform the following procedure to test the cold start relay control box installation.. Reconnect battery. As shown in Figure, connect a current probe around wire W0 (Heating Element #).. Make sure battery is fully charged.. Turn ignition key to position and verify that glow plug lamp is lit (ON).. Verify that glow plug lamp remains ON for approximately 0- seconds. 6. When the glow plug lamp goes OFF, turn ignition key all the way clockwise to the start position (engine cranking). 7. Once the engine has started verify that current probe attached to Heating Element # reads approximately 0 amps. 8. Next, connect the current probe around wire W (Heating Element #) and verify that it also reads approximately 0 amps. 9. Next, verify that both heating elements read approximately 0 amps for approximately to minutes. 0. After glow plugs have warmed (- minutes) verify that the current probe reads zero amps for each heating element. W0 0.0 AMPS 0.0 AMPS HEATING ELEMENT W CURRENT PROBE CURRENT PROBE HEATING ELEMENT Figure. Heating Element Measurement reassembly Reattach hood and rain cap to pump in the reverse order in which they were removed. LS00 Cold start relay kit Rev. #0 (06/0/) Page 8

9 FUSE HOLDER REAR VIEW J J J J YELLOW WHITE YELLOW WHITE YELLOW WHITE J J J J AMP FUSE F 0 AWG RED STARTER GND. 0 AWG RED SPLICE EXISTING WIRING REFERENCE ONLY W6 W W RED 0 AWG ORANGE 0 AWG BLUE AWG. W IGNITION SWITCH 0 AWG RED / 0A W INSIDE P AWG RED J MALE INTERFACE CONNECTOR (YELLOW) INSIDE TB INSIDE OUTSIDE OUTSIDE P AWG RED RED 0 AWG. STARTER ENERGIZE ORANGE AWG. KEY SWITCH ON BLUE AWG. PRE-HEAT LAMP POS. NEG. BATTERY W9 W W W7 GND. SIGNAL R + VDC PRE-HEAT INDICATOR LAMP BLACK6 AWG. W 0 HEATER ELEMENT TIMER RELAY R 0 L TK H WHITE (8) SLAVE COIL RELAY K BLACK (86) CHASSIS GND FUSE F BLACK 0 AWG. K-0 W STARTER INPUT SIGNAL PRE-HEAT LAMP HEATER TIMER/HOT RUN COLD START K-87 P W0 J W P PIN BLACK 0 AWG. TIMER RELAY PIN CONNECTIONS DESIGNATION W L PRE-HEAT LAMP SIGNAL R SLAVE RELAY (ND HEATER ELEMENT) TK HEATER TIMING 0 BATTERY + VDC 0 STARTER ENERGIZE SIGNAL INPUT GROUND HOT IN RUN H HEATER ELEMENT W9 60 AMP FUSE F HEATER ELEMENT # HEATER ELEMENT # 60 AMP + VDC Figure. Cold Start Relay Wiring Diagram LS00 COld start relay kit Rev. #0 (06/0/) Page 9