Universal Remote Control Console (URCC)
The Universal Remote Control Console (URCC) is used to control the pumping unit. The following functions can be controlled: deck engine, gear selection, throttle control, pump delivery rate and emergency shutdown. This console is portable up to a distance of
Store the URCC in the storage box that is located next to the packing lube tank. The legs for the console are stored in the storage container that is located near the fire extinguisher. Warning lamps and indicator lamps are provided in order to monitor critical system parameters.
The URCC is connected to the control system through a
| |
| Illustration 1 | g02954977 |
|
(1) Module for pump delivery rate and tachometer
(2) Discharge pressure module (3) "LAMP TEST" switch (4) "NEUTRAL TRIPPED WARNING" lamp (5) "DECK ENGINE WARNING" lamp (6) "DECK TRANSMISSION WARNING" lamp (7) "CONVERTER LOCKUP INDICATION" lamp (8) "DECK PUMP WARNING" lamp (9) "LINE TEST INDICATION" lamp (10) Panel illumination lights (11) "PUMP BRAKE" switch (12) "INSTANT NEUTRAL/LINE TEST" switch (13) "EMERGENCY KILL" switch (14) "MASTER POWER" switch (15) "TRUCK START/RUN/KILL" switch (16) "TRUCK RPM INC/DEC" switch (17) "DECK START/RUN/KILL" switch (18) "DECK RPM CONTROL" switch (19) "GEAR SELECTOR" switch | |
Module for Pump Delivery Rate and Tachometer
The module for the pump delivery rate and the module for tachometer (1) provide a digital display of the pump delivery rate in BPM. The module also displays the speed of the deck engine in RPM. The operator must configure the pump delivery rate and the tachometer module. For more information, refer to the "OEM Service Manual".
The discharge pressure module (2) provides a digital display in psi of pump discharge pressure. The module will provide overpressure shutdown protection. The operator must configure the discharge pressure module. The overpressure trip point may be selected by using the module. This module will also allow the operator to calibrate the fluid end pressure transducer. For more information, please see the "OEM Service Manual".
The "LAMP TEST" switch (3) is a two-position toggle switch. The ON position will momentarily establish contact. Moving the switch to the ON position illuminates all the warning lights on the remote panel.
"NEUTRAL TRIPPED WARNING" Lamp
The red "NEUTRAL TRIPPED WARNING" lamp (4) indicates that the deck transmission has been set to neutral due to a fault condition. The "NEUTRAL TRIPPED WARNING" lamp will illuminate when the following fault conditions exist:
- Pump discharge overpressure is sensed by the discharge pressure module.
- "EMERGENCY KILL" has been initiated by the discharge pressure module.
- "INSTANT NEUTRAL/LINE TEST" switch is in the INSTANT NEUTRAL position.
In order to turn off the lamp during an instant neutral condition, the "DECK RPM CONTROL" knob must be turned counterclockwise. Turn the knob past the "RESET START" position. Press the "RESET" switch on the discharge pressure module to turn off the lamp in the case of overpressure or an emergency stop condition. Also, select the RESET START position on the "DECK RPM CONTROL".
The red "DECK ENGINE WARNING" lamp (5) indicates the following conditions: low engine oil pressure, high coolant temperature, low coolant levels and high fuel filter differential pressure. The set points for each of these conditions are determined by the electronic control module (ECM). The high coolant warning is a preset, programmed point. Also, the warning for low engine oil pressure is a preset, programmed point. The "DECK ENGINE WARNING" lamp is set to activate at the following values:
- Low engine oil pressure is
48.3 kPa (7 psi) at 600 rpm. - Low engine oil pressure is
179.3 kPa (26 psi) at 1900 rpm. - High coolant temperature is
102.2 °C (216 °F) .
| NOTICE |
|---|
|
This lamp operates via pressure transducers and temperature transducers that supply information to the ECM. This lamp is protected by a 1-A circuit breaker that shields the ECM from electrical damage. The ECM is only able to source 250 mA for this lamp indication. |
"DECK TRANSMISSION WARNING" Lamp
The red "DECK TRANSMISSION WARNING" lamp (6) indicates low oil pressure or high oil temperature of the transmission. This lamp is also illuminated when the transmission filter goes into bypass mode which indicates a filter restriction. The "DECK TRANSMISSION WARNING" lamp is set for the following conditions:
- Low oil pressure of
206.8 kPa (30 psi) - High oil temperature of
110 °C (230 °F) - Filter differential pressure of
241.3 kPa (35 psi)
| NOTICE |
|---|
|
This lamp operates via pressure switches and temperature switches that are located on the gauges themselves. The gauges are plumbed directly into the pump. These switches do not have adjustable set points. |
"CONVERTER LOCKUP INDICATION" Lamp
The amber "CONVERTER LOCKUP INDICATION" lamp (7) indicates that the deck transmission is in the lockup mode. When the lamp is off, the transmission is operating in the converter mode.
The red "DECK PUMP WARNING" lamp (8) indicates low engine oil pressure or high engine oil temperature of the pump. This lamp is also illuminated when the pump filter goes into bypass mode and indicates a filter restriction. The "DECK PUMP WARNING" lamp is set for the following conditions:
- Low oil pressure of
206.8 kPa (30 psi) - High oil temperature of
66.1 °C (151 °F)
| NOTICE |
|---|
|
This lamp operates via pressure switches and temperature switches that are located on the gauges themselves. The gauges are plumbed directly into the pump. These switches do not have adjustable set points. |
The "LINE TEST INDICATION" lamp (9) is an incandescent amber lamp. The lamp indicates that the "INSTANT NEUTRAL/LINE TEST" switch is set to the LINE TEST position. When the "INSTANT NEUTRAL/LINE TEST" switch is set to the LINE TEST position, the deck transmission operates in the continuous converter mode.
Two panel illumination lights (10) on the face of the universal remote control console provide the operator with complete illumination of the control panel.
The "PUMP BRAKE" switch (11) is a two-position toggle switch. The normal position of the "PUMP BRAKE" switch is downward. The "PUMP BRAKE" switch must be lifted in order to activate the pump brake. This switch is only active while the gear selector is in the NEUTRAL position. The deck engine will not start with the pump brake switch in the ON position.
| NOTICE |
|---|
|
When the pump brake is on, pump packing lubrication is automatically turned off. |
"INSTANT NEUTRAL/LINE TEST" Switch
The "INSTANT NEUTRAL/LINE TEST" switch (12) is a three-position toggle switch. The INSTANT NEUTRAL position will momentarily establish contact. The other two switch positions maintain contact.
Placing the "INSTANT NEUTRAL/LINE TEST" switch into the INSTANT NEUTRAL position shifts the deck transmission into neutral. This shift into neutral brings the deck engine to idle speed and illuminates the "NEUTRAL TRIP" lamp. The "NEUTRAL TRIP" lamp will remain illuminated until the "NEUTRAL TRIP" condition is reset.
In order to reset a "NEUTRAL TRIP" condition, the "RESET START" switch must be activated. In order to activate the "RESET START" switch, turn the "DECK RPM CONTROL" switch counterclockwise to the RESET START position. Placing the "DECK RPM CONTROL" switch counterclockwise to the RESET START position extinguishes the "NEUTRAL TRIP" lamp and allows the transmission to return to the selected gear.
to reset an overpressure condition, Press the "RESET" switch on the pressure module and move the "DECK RPM CONTROL" switch to the RESET START position. Move the "INSTANT NEUTRAL/LINE TEST" switch to the LINE TEST position in order to activate the downshift enable solenoid. Activating the downshift enable solenoid takes the transmission out of the lockup mode. The transmission is in converter mode when the transmission is not in lockup mode.
The LINE TEST position is used in order to test for leaks in the treating line. In order to accomplish the line test, the operator must place the switch in the LINE TEST position. The operator must now select the desired gear. The operator must slowly increase the speed of the deck engine. When the transmission remains in the converter mode, a smoother line test and a safer line test may be accomplished.
The "EMERGENCY KILL" switch (13) is a two-position toggle switch. Operation of the switch will immediately shut off the fuel and the air supply to the deck engine resulting in a shutdown of the system . To activate the switch, the red switch guard must be lifted. The switch must then be moved to the opposite keyway. A switch guard is necessary in order to prevent an accidental shutdown. This switch is wired in order to allow the emergency shutdown even if the "MASTER POWER" switch is in the OFF position. To reset the switch after an emergency shutdown, manually open the flapper valves of the air intake shutoff and cycle the "MAIN POWER DISCONNECT" and the URCC main power switch for at least 15 seconds.
The "MASTER POWER" switch (14) is a two-position toggle switch. This switch serves as the power switch for the universal remote control console. Activation of the "MASTER POWER" switch will energize certain auxiliary equipment and will drain the batteries of the trailer while the system is not in operation. Activation of the "MASTER POWER" switch does not affect operation of the "EMERGENCY KILL" switch or the floodlight switches.
The "TRUCK START/RUN/KILL" switch (15) is a three-position toggle switch. The START position will momentarily establish contact. The other two switch positions maintain contact. This switch serves as the remote control switch for the truck engine. When the switch is placed in the START position and the switch is held in the START position, the Engine will start. If the switch is placed in the downward "KILL" position, fuel to the truck engine will be shut off, and the engine will shut down. The "START/RUN/KILL" switch is only active when the "REMOTE/CAB CONTROL" switch which is located in the truck cab is in the REMOTE position. The ignition key switch which is located in the cab must also be in the ON position.
The "TRUCK RPM INC/DEC" switch (16) is a three-position toggle switch. This switch controls the engine rpm. The "TRUCK RPM INC/DEC" switch will increase the speed of the Engine. The "TRUCK RPM INC/DEC" switch also decreases the speed of the Engine. The engine speed will increase or the engine speed will decrease according to the preset speed ramp time. The "TRUCK RPM INC/DEC" switch is only active when the "REMOTE/CAB CONTROL" switch which is located in the truck cab is in the REMOTE position. The ignition key switch which is located in the cab must also be in the ON position.
The "DECK START/RUN/KILL" switch (17) is a three-position toggle switch. The START position will momentarily establish contact . The other two switch positions maintain contact. The "DECK START/RUN/KILL" switch functions as the remote control switch for the deck engine. When the switch is placed and held in the START position, the speed of the truck engine will ramp up to the preset RPM. In order to start the deck engine, hold the "DECK START/RUN/KILL" switch in the START position. If the "DECK START/RUN/KILL" switch is placed in the "KILL" position, the deck engine will be shut off and the fuel to and the deck engine will shut down.
The START position of this switch is inactive when the following conditions exist:
- The "PUMP BRAKE" switch is activated.
- The transmission is not in the NEUTRAL position.
The "DECK RPM CONTROL" switch (18) is a rotary control that is used to control the speed of the deck engine. Turning the knob in a clockwise direction will increase the speed of the engine. The throttle control assembly includes a reset start switch. The "RESET/START" switch activates at idle speed and functions as a reset for the throttle control in when an overpressure or neutral tripped condition. This switch prevents the engine from returning to full throttle speed once the overpressure or neutral tripped condition has been corrected.
The "GEAR SELECTOR" switch (19) is an eight-position rotary switch that is used in order to select the gear for the deck transmission . The handle of the switch must be depressed in order to select a gear. The downshift enable solenoid is activated when the handle is depressed. Activating the downshift enable solenoid takes the transmission out of the lockup mode. The transmission is in converter mode when the transmission is not in lockup mode. When the transmission is in converter mode, the transmission shifts more smoothly.
| NOTICE |
|---|
|
The transmission will automatically go into neutral in the event of electrical power failure, overpressure, or neutral tripped conditions. |
The JUNCTION BOX is the central location for the electrical wiring of the pumper. The junction box also contains the following components:
- Service Hour Meter
- "WARNING" Lamp
- "PUMP STROKE" Counter
| |
| Illustration 2 | g02954979 |
|
(20) "MAIN POWER DISCONNECT" Switch
(21) "FLOOD LAMP" Switch (Front) (22) "FLOOD LAMP" Switch (Rear) (23) "FUEL CUTOFF SWITCH" (24) Remote Cable Connector (25) Service Hour Meter (26) "WARNING" lamp (27) "PUMP STROKE" Counter | |
"MAIN POWER DISCONNECT" Switch
The "MAIN POWER DISCONNECT" Switch (20) is a two-position toggle switch. The switch controls the power to the electrical system.
The "FLOOD LAMP" Switch (Front) (21) is a two-position toggle switch. The switch controls the floodlights that are located on the front of the pumper.
The "FLOOD LAMP" Switch (Rear) (22) is a two-position toggle switch. The switch controls the floodlights that are located on the rear of the pumper.
The "FUEL CUTOFF SWITCH" (23) is a two-position toggle switch. Operation of the switch will immediately shut off the fuel supply to the deck engine and will result in a shutdown of the system. To activate the switch, the red switch guard must be lifted. The switch must then be moved to the opposite keyway. A switch guard is necessary in order to prevent an accidental shutdown.
The Remote Cable Connector (24) is a connector that connects to one end of the
The Service Hour Meter (25) indicates the total operating hours of the deck engine. Use the display to determine the service hour maintenance intervals.
The "WARNING" lamp (26) is an incandescent red lamp. The lamp indicates a fault condition of the deck engine. The Caterpillar Electronic Technician (ET) can be used to troubleshoot problems that are related to the deck engine. Refer to Troubleshooting for additional information.
The "PUMP STROKE" Counter (27) provides a running total of pump strokes for pump life recording and determination of pump packing replacement intervals.