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FRC PumpBoss PBA100, Preliminary Document

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FRC PumpBoss PBA100 Preliminary Document Download Page 2

PBA100 Rev0305PreLim

2

PRELIMINAR

Y

 DOCUMENT

FOR REFERENCE/REVIEW

 ONL

Y

CONTENTS

Table of Contents

CONTENTS ............................................................................................................... 2
INTRODUCTION ...................................................................................................... 4

Overview ................................................................................................................ 4
Features.................................................................................................................. 4
Specifications ......................................................................................................... 5

GENERAL DESCRIPTION ....................................................................................... 6

Controls and Indicators ......................................................................................... 8

INSTALLATION ...................................................................................................... 10

Install Control Module ......................................................................................... 10
Install Pressure Sensor ......................................................................................... 12
Install Sensors ...................................................................................................... 13
Install Buzzer ........................................................................................................ 13

OPERATION ............................................................................................................ 14

Display Stored Data ............................................................................................. 16

PROGRAMMING.................................................................................................... 18

Program Code Descriptions ................................................................................ 19

WIRING ................................................................................................................... 20

Pressure Transducer ............................................................................................ 20
Common OME Diagnostic Connector ................................................................ 21
Connectors and Cables........................................................................................ 22
Cummins Harness Connections ........................................................................... 24
Detroit Diesel Harness Connections .................................................................... 25
Navistar  Harness Connections ............................................................................ 26
Caterpillar Harness Connections .......................................................................... 27
Mercedes Harness Connections .......................................................................... 28

Summary of Contents for PumpBoss PBA100

Page 1: ...RENCE REVIEW ONLY FIRE RESEARCH CORPORATION www fireresearch com 26 Southern Blvd Nesconset NY11767 TEL 631 724 8888 FAX 631 360 9727 TOLL FREE 1 800 645 0074 PRESSURE GOVERNORAND ENGINE STATUS DISPLAY PRELIMINARY DOCUMENT FORREFERENCE REVIEWONLY PBA100 ...

Page 2: ...nstall Control Module 10 Install Pressure Sensor 12 Install Sensors 13 Install Buzzer 13 OPERATION 14 Display Stored Data 16 PROGRAMMING 18 Program Code Descriptions 19 WIRING 20 Pressure Transducer 20 Common OME Diagnostic Connector 21 Connectors and Cables 22 Cummins Harness Connections 24 Detroit Diesel Harness Connections 25 Navistar Harness Connections 26 Caterpillar Harness Connections 27 Me...

Page 3: ...ors 9 Figure 2 Control Module Mounting Dimensions 11 Figure 3 Pressure Sensor 12 Figure 4 Pressure Transducer Wiring 20 Figure 5 Common OEM 9 Pin Diagnostic Connector 21 Figure 6 12 Pin Connector Wiring 22 Figure 7 8 Pin Connector Wiring 23 Figure 8 Cummins PBA101 Wiring 24 Figure 9 Detroit Diesel PBA102 Wiring 25 Figure 10 Navistar PBA104 Wiring 26 Figure 11 Caterpillar PBA105 Wiring 27 Figure 12...

Page 4: ... pressure is monitored it can vary but will be limited to an increase of 30 PSI If the discharge pressure increases 30 PSI the pressure governor will automatically lower the engine RPM to reduce the discharge pressure All controls and indicators are located on the front of the control module Features J1939 CAN Bus for Engine Information and Control Power Up in Pressure Mode Automatic Regulation of...

Page 5: ...y 6 75 High LED Bar Graphs Oil Pressure 10 100 PSI 10 PSI Increments Temperature Engine Coolant 130 240 F 10 Increments BatteryVoltage 11 5 16 Volts 0 5 Volt Increments Engine Sensors Engine Coolant Temperature 100 250 F 1 2 14 NPT Engine Oil Pressure 0 100 PSI 1 8 NPTF Transmission Temperature 140 320 F 1 8 NPTF Pressure Sensor Model Number XE PRO31PT2 S0A Pressure Range 0 300 PSI Proof Pressure ...

Page 6: ...6 0 or GMC engine These engines may also require seperate engine coolant and oil pressure sensors Components The information available on the J1939 databus varies depending on the particular engine type Not all wires are used for all engines Refer to the engine specific wiring diagram for interface connections The sensors if any that need to be installed will also vary depending on the engine The ...

Page 7: ...e that is proportional to the discharge pressure Engine Coolant Temperature Sensor The engine coolant temperature sensor is installed as necessary Engine Oil Pressure Sensor The oil pressure sensor is installed as necessary Audible Alarm Buzzer Optional The optional buzzer is installed as required Transmission Temperature Sensor Optional The optional transmission fluid temperature sensor is instal...

Page 8: ...t engine RPM in bright red digits It also shows error codes stored data and program features STOP ENGINE LED Repeats the stop engine warning from the cab BATTERY VOLTAGE LED Display Shows battery voltage The LEDs will be green when the voltage is within normal limits and red when it is not SILENCE Button Press to suppress audio alarms PRESET Button Press to set the pump pressure or RPM to a pre pr...

Page 9: ...s on to indicate operation in the PSI mode MODE Button Press to change modes Used when accessing stored data and program features Day Night Sensor Adjusts the brightness of the LED displays for best day or night viewing MENU Button Used when accessing stored data and program features RPM Display Message Display OIL PRESSURE LED Display TEMPERATURE LED Display SILENCE Button MENU Button BATTERY VOL...

Page 10: ...ing screw holes Make sure there is clearance behind the panel for the module and cables before cutting holes Refer to Figure 2 for layout and dimensions 2 Cut out a 3 7 16 by 5 11 16 inch hole 3 Drill four holes clearance or tapped for 10 32 mounting screws 4 Place control module in position and secure with screws 5 Connect cables at rear of the control module Refer to Wiring section ...

Page 11: ...11 PRELIMINARY DOCUMENT FOR REFERENCE REVIEW ONLY Figure 2 Control Module Mounting Dimensions 1 3 4 4 5 8 6 3 4 Mounting holes are clearance or tapped for 10 32 screws 3 7 16 5 11 16 Panel Cutout 5 3 4 4 Maximum Radius 1 2 ...

Page 12: ... a 1 4 18 NPT hole Caution Do not use the main body that houses the electronics to tighten the pressure sensor Damage to the sensor may occur 2 Tighten the sensor with a 9 16 inch wrench on the lower hex fitting 3 Connect the pressure sensor cable from the control module to the pressure sensor Refer to Wiring section Figure 3 Pressure Sensor Caution Do not use the main body that houses the electro...

Page 13: ...sors are wired to the 12 pin connector at the rear of the control module Refer to the Wiring section for pinout and wire color information An input is provided for an optional transmission temperature sensor Install Buzzer Pin 6 on the 12 pin connector at the rear of the control module is provided to connect an optional buzzer Connect the ground side of the buzzer to pin 6 Maximum current through ...

Page 14: ...enables are active and the interlock circuit is complete the THROTTLE READY LED will light and the remote throttle will be controlling engine RPM The engine RPM control signal will be set at idle regardless of the control knob position Remote Hand Throttle The remote hand throttle is used to adjust PSI and RPM settings The PumpBoss will sense how fast and in what direction the control knob is rota...

Page 15: ... sensor not detected E06 N A N A E07 N A N A E08 TRANS T Sensor cable not connected Broken wire bad connector contact on sensor cable Defective temperature sensor E09 ENG OIL Sensor cable not connected Broken wire bad connector contact on sensor cable Defective pressure sensor E10 ENG T Sensor cable not connected Broken wire bad connector contact on sensor cable Defective temperature sensor RPM Me...

Page 16: ...ours will be displayed The RPM display will show the number of hours The message display will show what the hours are for Press the MENU button to show the next stored hours Each time the MENU button is pressed the displays will change to show the next block of stored accumulated hours Press and hold the MENU button for 5 seconds The displays will continuously cycle to show all of the stored accum...

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Page 18: ...t program code to be input 2 Press the MENU button The RPM display will show the number 1000 Each time the MENU button is pressed the first digit will scroll up by 1 Set the first digit to the number desired 3 Press the SILENCE button Each time the SILENCE button is pressed the second digit will scroll up by 1 Set the second digit to the number desired 4 Press the MENU button Each time the MENU bu...

Page 19: ... Warnings 1120 Maximum Engine RPM This code will display the maximum RPM that the engine has attained Parameter Settings Codes 2000 2110 Clock This code will allow the clock display to be changed 2120 Date This code will allow the date display to be changed 2130 Clear Fault Warnings This code will allow the stored fault warnings to be cleared from memory It will clear the history of all five 5 fau...

Page 20: ...rams and cables for the PumpBoss series governors Pressure Transducer Figure 4 Pressure Transducer Wiring Pressure Transducer Cable from 12 Pin Connector Pressure Transducer Pressure Transducer Cable 3 Pin Connector Pin Wire Description A Black Ground B Red SupplyVoltage C White Signal Pressure Transducre Top View Supply Voltage Signal Output Ground ...

Page 21: ...ch diagnostic connector Pin C J1939 CAN Positive Pin D J1939 CAN Negative Pin E J1939 CAN Shield FRONT VIEW B F E A C D G H J Figure 5 Common OEM 9 Pin Diagnostic Connector The diagnostic or datalink connector is commonly found under the driver side dashboard Common OME Diagnostic Connector ...

Page 22: ... Idle Active Input 12 VDC 8 White Check Engine LED Input 9 Black CAN J1939 10 Red CAN J1939 11 Green Transmission Temp Sensor Signal 12 Yellow RPM Signal Notes Not all wires are used for all engines For Ford 6 0L engines the yellow RPM signal wire pin 12 should be connected to the Clean Tachometer Output green white wire circuit 76 12 Pin Deutsch Connector 12 Pin Cable Butt Connectors BLU ORG BRN ...

Page 23: ...al Return From ECM 6 Yellow Interlock Input 12 or 24 VDC 7 Blue Throttle Enable Signal Output 8 Brown Foot Pedal Signal Input Note Not all wires are used for all engines Refer to the engine specific wiring diagram for interface connections Control Module Rear View 8 Pin Connector Pin 1 12 Pin Connector Pin 1 8 Pin Cable RED BLK ORG WHT GRN YEL BLU BRN 12 12 12 12 12 1 1 1 1 1 8 Pin Deutsch Connect...

Page 24: ...ins Harness Connections Interface Information For use on 2004 or newer engines ISB ISC ISL and ISM Engine Interface J1939 Datalink Black Wire Red Wire J1939 Datalink 47 46 2004 and NEWER ISB02 ISC03 ISL03 CM850 Model Engines ISM02 CM870 Model Engines J1939 Datalink Refer to Figure 6 ECM 50 Pin J2 Connector ...

Page 25: ...CE REVIEW ONLY Figure 9 Detroit Diesel PBA102 Wiring Detroit Diesel Harness Connections Interface Information For use on DDEC V 2003 and newer engines ECM J1939CAN J1939CAN V 43 V 58 DkBlu Red DkBlu DDEC V J1939 Datalink Refer to Figure 6 Red Wire Black Wire ...

Page 26: ... to activate the remote throttle 12 VDC can be picked up from the interlock circuit Note 2004 and newer model engines with code 12VXY and the Remote Engine Speed Controller Module RESCM installed ATA Datalink Connector J1939 CAN Black Wire Red Wire Pin D J1939 CAN Pin C J1939 Datalink Refer to Figure 6 RPS Input rem Accelerator RESCM RVAR Variable PTO Enable Vcref Voltage Ref 5v RPS_RTN Rem Accel ...

Page 27: ...B 3176B 3406E C7 C10 C11 C12 C13 C15 Engine Interface Engines with 70 pin OEM connector J1939 Datalink Refer to Figure 6 Engine Control Refer to Figure 7 J1939 Datalink Negative J1939 Datalink Positive Green Wire White Wire K999 GN 993 BR G845 PU Input Sensor Common 2 Input 1 PTO ON OFF Switch Input 8 Remote Throttle PWM ECM Black Wire Red Wire 70 Pin Vehicle Harness Connector 3 68 56 34 50 BlueWi...

Page 28: ...12 Mercedes PBA110 Wiring J1939 19 21 14 Sensor Ground Throttle Pedal Remote Black Wire Green Wire J1939 VCU 21 Pin Connector VCU 18 Pin Connector 17 18 Remote Throttle SignalAnalog Remote PTO Power Supply Orange Wire White Wire J1939 Datalink Refer to Figure 6 Engine Control Refer to Figure 7 7 Throttle Select BlueWire Red Wire ...

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