HomeMy WebLinkAbout310.104 - FRC Pump Boss Pressure GovernorPBA400 Rev170705
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FIRE RESEARCH CORPORATION
www.fireresearch.com
26 Southern Blvd., Nesconset, NY 11767
TEL 631.724.8888 FAX 631.360.9727 TOLL FREE 1.800.645.0074
PRESSURE GOVERNOR
and ENGINE MONITORING
MODEL: PBA400
Document Number:XE-PBA4PM-R0A 310.104 FRC Pump Boss Pressure Governor
PBA400 Rev170705
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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 Engine Sensors ..........................................................................................13
Install Buzzer .......................................................................................................13
Install High Idle Kit .............................................................................................13
Install Remote Governor Option..........................................................................13
OPERATION ............................................................................................................14
Controls ................................................................................................................14
Error Codes and Fault Warnings ..........................................................................15
Pressure Mode Operation.....................................................................................16
RPM Mode Operation ..........................................................................................18
Switching Between Operating Modes .................................................................19
Pump Discharge Pressure is High at Engine Idle ................................................19
RPM Limit with Discharge Pressure Less than 100 PSI .....................................19
Remote Governor Option.....................................................................................19
Detailed Information ............................................................................................20
High-Idle ..............................................................................................................20
Preset Settings (Pressure or RPM) .......................................................................21
PROGRAMMING ....................................................................................................22
Access Password Protected Programs .................................................................24
CALIBRATION ........................................................................................................26
Pump Pressure Sensor (Code C1 and C2) ...........................................................27
Engine RPM (Code C3) .......................................................................................27
WIRING ....................................................................................................................28
Connectors and Cables.........................................................................................28
Secondary Controller, Cables and Connections ...................................................29
Pressure Sensor ....................................................................................................30
Common OEM Diagnostic Connector .................................................................31
Cummins Harness Connections ...........................................................................32
Detroit Diesel Harness Connections ....................................................................33
Navistar Harness Connections .............................................................................34
Navistar / International Chassis Harness Connections ........................................35
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List of Tables
Table 1. Pressure Sensor Output Voltage ...................................................................5
Table 2. Error Codes ................................................................................................15
Table 3. Fault Warning Codes ..................................................................................15
Table 4. Operator Password Protected Program Functions .....................................25
Table 5. Calibration Codes Quick Reference Chart .................................................26
List of Figures
Figure 1. Controls and Indicators ...............................................................................9
Figure 2. Control Module Mounting Dimensions....................................................11
Figure 3. Pressure Sensor Dimensions .....................................................................12
Figure 4. PBA Connectors .......................................................................................28
Figure 5. PBA Connector Wiring .............................................................................29
Figure 6. Pressure Sensor Wiring .............................................................................30
Figure 7. Common OEM 9-Pin Diagnostic Connector ............................................31
Figure 8. Cummins PBA401 Wiring ........................................................................32
Figure 9. Detroit Diesel PBA402 Wiring .................................................................33
Figure 10. Navistar PBA404 Wiring .........................................................................34
Figure 11. Navistar/International Chassis PBA404 Wiring ......................................35
Figure 12. Caterpillar PBA405 Wiring .....................................................................36
Figure 13. Ford PBA406 J1939 Translator Module Wiring .....................................38
Figure 14. Ford PBA406 PCM Wiring .....................................................................39
Figure 15. Mack PBA407 Wiring .............................................................................40
Figure 16. Scania PBA408 Wiring ............................................................................41
Figure 17. Mercedes PBA410 Wiring .......................................................................42
Figure 18. John Deere PBA416 Wiring ....................................................................43
Figure 19. MAN PBA424 Wiring .............................................................................44
Figure 20. IVECO PBA426 Wiring ..........................................................................45
Figure 21. High-Idle Wiring .....................................................................................46
Figure 22. Flyback Diode ........................................................................................47
Caterpillar Harness Connections .........................................................................36
Ford Harness Connections ...................................................................................37
Mack Harness Connections .................................................................................40
Scania Harness Connections ................................................................................41
Mercedes Harness Connections ...........................................................................42
John Deere Harness Connections ........................................................................43
MAN Harness Connections .................................................................................44
IVECO Harness Connections ..............................................................................45
High-Idle Wiring ..................................................................................................46
FLYBACK DIODE INFORMATION .................................................................47
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INTRODUCTION
Overview
The Fire Research pressure governor uses state-of-the-art-programmable
microprocessor technology and operates in one of two modes, pressure or RPM. It
maintains a steady pump discharge pressure within system capabilities by controlling
the engine speed or holds a selected engine RPM.
The PBA400 has two pressure sensors that monitor both the pump intake and
discharge pressure. The duel sensor configuration provides improved defense against
pump cavitations.
In pressure mode the governor maintains a constant pump discharge pressure.
The discharge pressure is monitored and compared to the selected pressure setting, the
engine RPM is varied to keep the discharge pressure at the selected setting.
In RPM mode the governor maintains a constant engine RPM. The pump discharge
pressure is monitored, it can vary but is limited to an increase of 30 PSI. If the discharge
pressure increases 30 PSI, the pressure governor automatically lowers 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 Pump Discharge Pressure
Manual Control of Pressure or Engine RPM Settings
Programmable Presets
Diagnostic Capabilities
No Pressure or RPM Variation When Changing Modes
Limits Increase of Pressure When in RPM Mode
Recognition of No Water Condition With Automatic Response
Interlock Signal Recognition with Throttle Ready LED
Return to Engine Idle With the Push of a Button
Display Brightness Automatically Adjusts for Day or Night Operations
High Idle
Audible Alarm Buzzer (Optional)
KPa / Bar (Optional)
Remote Governor Option
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Specifications
The governor is available in various models. Each model is programmed to interface
with specific engines. All models provide the same functions, controls, and digital
readouts for the management of pump discharge pressure.
Display Module
Supply Power: 12/24 VDC
Supply Current: 0.5 Amps
Dimensions: 4 5/8" Wide by 6 3/4" High
LED Bar Graphs
Oil Pressure: 10 - 100 PSI
Temperature (Engine Coolant): 150 - 240 °F
Transmission Temperature: 140 - 300 °F
Battery Voltage: 11.5 to 15.5 VDC (12 V)
23.0 - 30 VDC (24 V)
Engine Sensors
Engine Oil Pressure: 0 - 100 PSI, 1/8" NPTF
Engine Coolant Temperature: 100 - 250 °F, 1/2" - 14 NPT
Transmission Temperature: 140 - 320 °F, 1/8" NPTF
Pressure Sensor
Discharge Intake
Model Number: XE-FP4000PT3 XE-IO3100PT3
Pressure Range: 0 - 600 PSI -30 in/Hg - 600 PSI
Proof Pressure: 1200 PSI 1200 PSI
Excitation Voltage: 5 VDC 5 VDC
Output Voltage: 0.5 - 4.75 VDC (See Table 1)
Table 1. Pressure Sensor Output Voltage
0psi 100psi 150psi 200psi 250psi 300psi 600psi
Discharge Sensor
XE-FP4000PT3 0.5vdc 1.21vdc 1.56vdc 1.92vdc 2.27vdc 2.625vdc 4.75vdc
Intake Sensor
XE-IO3100PT3 0.604vdc 1.295vdc 1.640vdc 1.985vd 2.331vdc 2.667vdc 4.75vdc
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GENERAL DESCRIPTION
The pressure governor is compatible with the following engines:
PBA401 Cummins IS Series
PBA402 Detroit Diesel
PBA404 Navistar
PBA405 Caterpillar
PBA406 Ford
PBA407 Mack
PBA408 Scania
PBA410 Mercedes
PBA416 John Deere
PBA424 MAN
PBA426 IVECO
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 also
vary depending on the engine.
The governor consist of the following components:
Control Module
Discharge Pressure Sensor
Intake Pressure Sensor
Engine Oil Pressure Sensor (As Necessary)
Engine Coolant Temperature Sensor (As Necessary)
Transmission Temperature Sensor (As Necessary)
Audible Alarm Buzzer (Optional)
Cables
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Control Module
The control module is waterproof and uses 4 5/8 by 6 3/4 inches of panel space.
All controls and indicators are located on the front of the control module. (Refer to
Controls and Indicators.)
Discharge Pressure Sensor
The pressure sensor is mounted on the pump discharge manifold. It provides an
input signal to the control module that is proportional to the pressure.
Intake Pressure Sensor
The pressure sensor is mounted on the pump intake manifold. It provides an input
signal to the control module that is proportional to the intake pressure.
Engine Oil Pressure Sensor
The oil pressure sensor is installed as necessary.
Engine Coolant Temperature Sensor
The engine coolant temperature sensor is installed as necessary.
Transmission Temperature Sensor
The transmission fluid temperature sensor is installed as necessary.
Audible Alarm Buzzer (Optional)
The optional buzzer is installed as required. A ground is provided at the 12-pin
connector pin 6 to activate the buzzer (max current: 300mA). The buzzer will sound
when a fault code becomes activated. (See Table 3 for the Fault Warning Codes list/
descriptions on page 15.)
Cables
There are three cables that connect to the control module. The 8-pin connector
is for the remote throttle interface, the 12-pin connector is for the discharge sensor,
monitoring, and display interface. The 6-pin connector is for the intake pressure sensor,
FRC datalink, and the auxiliary interlock.
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Controls and Indicators
All controls and indicators are located on the front of the control module. (Refer
to Figure 1.) See Operation and Programming Sections for more information.
MENU Button
Used to access stored data and program features.
Oil Pressure LED Display
Shows engine oil pressure. The LEDs are green when the pressure is within normal
limits and red when it is not.
CHECK ENGINE LED, STOP ENGINE LED
Repeats the warnings from the cab.
Engine Temperature LED Display
Shows engine coolant temperature. The LEDs are green when the temperature is
within normal limits and red when it is not.
Transmission Temperature LED Display
Shows transmission temperature. The LEDs are green when the temperature is
within normal limits and red when it is not.
RPM Display
Shows the current engine RPM in bright red digits. It also shows error codes, stored
data, and program features.
Battery Voltage LED Display
Shows battery voltage. The LEDs are green when the voltage is within normal
limits and red when it is not.
Day/Night Sensor
Adjusts the brightness of the displays for day or night operations.
SILENCE Button
Press to suppress audio alarms.
Message Display
The message display shows the pressure or RPM setting during normal operations
and warning alarms as they occur. It shows the time and date when the throttle ready
LED is off. It also shows stored data and program features.
THROTTLE READY LED
This LED is on when the required interlock conditions are met to begin pump operations.
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Figure 1. Controls and Indicators
PRESET Button
Press to change/select a pre-programmed value for pressure or RPM setting.
IDLE Button
When pressed immediately sets the engine RPM to idle.
Control Knob
When rotated changes the pressure or RPM setting. The setting increases or
decreases proportionally to the speed and direction the control knob is rotated.
RPM Button
Press to select RPM mode. The LED is on to indicate operation in the RPM mode.
PRESSURE Button
Press to select pressure mode. The LED is on to indicate operation in the pressure mode.
RPM Display
Message Display
Day/Night Sensor
Oil Pressure LED Display Engine Temperature LED Display
Transmission Temperature LED Display
SILENCE Button
MENU Button
Battery VoltageLED Display
Control Knob IDLE Button
THROTTLE READYLEDPRESSUREMode Button and LED
RPMMode Button and LED
PRESET Button
STOP ENGINELED
CHECK ENGINELED
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INSTALLATION
Install Control Module
1. Measure and mark mounting location for control module panel cutout and
mounting 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 1/2 by 5 3/4 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.)
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Figure 2. Control Module Mounting Dimensions
4 5/8"
6 3/4"
Mounting holes are clearance or tapped for 10-32 screws.
3 1/2"
5 3/4"
Panel Cutout 5 3/4"
4"
Maximum Radius 1/2"
1 1/2"
1 3/4"
2 1/2"
4"
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Install Pressure Sensor
The discharge pressure sensor is mounted on the pump discharge manifold. If there
is a check valve in the discharge side of the pump, mount the discharge sensor before
the check valve. The intake pressure sensor is mounted on the pump intake manifold.
T-fittings can be used to mount the pressure sensors.
Note: Install the pressure sensor upright so that the water in the end of the
sensor is able to drain back into the pipe.
1. Screw the sensor into 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 7/8-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 Dimensions
Caution: Do not use the main body that houses the electronics to tighten the sensor. Damage to the sensor may occur.
1/4-18 NPT
7/8" Hex
0.75 [18.95]
2.37 [60.30]
Inch [mm]
Packard Metri Pack Connector
0.87 [22.05]Across Flats
Caution: The discharge and intake pressure sensors are the same size. Ensure the correct sensor is installed on the correct manifold. Refer to Table 1.
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Install Engine Sensors
For most engines, the governor receives engine RPM, oil pressure, coolant
temperature, and transmission temperature data over the J1939 databus. Some engines
do not broadcast this data over the databus and sensors may need to be installed.
Note: The PumpBoss may need a programming change for some sensor inputs
to be recognized. If the sensor was not ordered as part of the PumpBoss kit
you may need to contact FRC technical support for programming information.
The sensors are wired to the 12-pin connector at the rear of the control module.
Refer to the Wiring Section.
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 pin 6 is 300 mA. The buzzer ordered from FRC requires a 1-1/8 inch
diameter mounting hole. (Refer to the Wiring section.)
Install High Idle Kit
The high idle is activated when + VDC is provided to pin 7 (High Idle Active
Input) of the 12-pin connector and pin 6 (Interlock Input) of the 8-pin connector. Refer
to High Idle Wiring.
Note: It is important that the connection to the Interlock Input from the High
Idle circuit be isolated from the apparatus interlock wiring with the two
diodes. The pump must NOT be engaged when using the high idle
function and the THROTTLE READY LED will be off.
Install Remote Governor Option
Refer to Install Control Module for dimensions. The remote governor is connected
to power, the J1939 CAN Bus, and the FRC datalink. Refer to Wiring Section.
Note: Program code P303 SYS TYPE must be set to REMOTE in the
remote governor program.
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OPERATION
Note: When power is applied to the governor the message display shows the
Software Program Revision Number for five (5) seconds. It can also be
viewed with P101 code, refer to Programming Section.
On power-up the governor is in the pressure mode of operating. The RPM display
shows engine RPM, the four LED bar graphs are green indicating readings within
normal ranges, and the message display alternates between showing the date and time.
If a monitored function is not within normal parameters the display flashes, the RPM
display shows an error or fault warning code and a description shows in the message
display. (Refer to Table 2. Error Codes or Table 3. Fault Warning Codes.)
If one of the inputs displayed by the LED bar graphs is not within normal range
the LEDs will be red.
When all necessary throttle enables are active and the interlock circuit is complete,
the THROTTLE READY LED comes on and the governor is ready to control the
engine RPM. The control signal is set at idle regardless of the control knob position.
Controls
Control Knob
The control knob is used to adjust pressure and RPM settings. The governor senses
how fast and in what direction the control knob is rotated and sends a signal to the
ECM to increase or decrease the engine RPM proportionally.
If the control knob is rotated quickly; the engine RPM changes quickly.
If the control knob is rotated slowly; the engine RPM changes slowly.
• Rotate the control knob clockwise* to increase engine RPM.
• Rotate the control knob counterclockwise* to decrease engine RPM.
• Press the red IDLE button to immediately return the engine to idle.
*NOTE: Opposite knob rotation option is available to increase/decrease the
engine RPM.
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Table 2. Error Codes
Table 3. Fault Warning Codes
RPM
Display
Message Display Description Factory
Default Setting
F01 HI BATT VOLTAGE High Battery Voltage 15.5 V
F02 LOW BATT VOLTAGE Low Battery Voltage 11.8 V*
F03 HI TRANS TEMP High Transmission Temperature 300 °F
F04 LOW OIL PRESSURE Low Engine Oil Pressure 8 PSI**
F05 DPFR Discharge Sensor High Voltage
F06 IPFR Intake Sensor High Voltage
F07 HI ENG TEMP High Engine Coolant Temperature 220 °F**
F08 NO WATER Out of Water Mode
F09 ENG NOT RESPOND Engine Does Not Respond
* 11.8 engine running, 11.7 engine off.
Error Codes and Fault Warnings
RPM
Display
Message
Display
Probable Cause
Note: Not all inputs are used for all engines.
E01 NO DATA >J1939 CAN bus cable not connected / connected to wrong port
>Broken wire / bad connector contact on cable
E02 NO RPM Engine RPM not detected
>Data cable not connected / connected to wrong port
>Engine not running / ignition key on
>Broken wire / bad connector contact on alternator cable
E04 NO OIL
SENSOR
No Engine Oil Pressure Data Detected (w/separate sensor input)
>Sensor cable not connected
>Broken wire / bad connector contact on sensor cable
>Defective pressure sensor
E05 NO D. PSR
SENSOR
No Discharge Pressure Sensor Detected
>Sensor cable not connected
>Broken wire / bad connector contact on sensor cable
>Defective pressure sensor
E06 NO I. PSR
SENSOR
No Intake Pressure Sensor Detected
>Sensor cable not connected
>Broken wire / bad connector contact on sensor cable
>Defective pressure sensor
E07 NO ENG T
SENSOR
No Coolant Temperature Data Detected (w/separate sensor input)
>Sensor cable not connected
>Broken wire / bad connector contact on sensor cable
>Defective temperature sensor
E16 NO FRC
DATALINK
>FRC datalink cable not connected / connected to wrong port
>Broken wire / bad connector contact on cable
Note: E5 and E6 show on a remote governor not programmed correctly (code P303).
** J1939 compliant—engine ECM will issue this warning.
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Pressure Mode Operation
In the pressure mode of operation the PRESSURE LED is on. The governor
maintains a constant discharge pressure within system capabilities. It adjusts the engine
RPM automatically to compensate for variations in pressure.
There is a maximum engine RPM programmed in the governor for pressure mode.
If the engine reaches the programmed maximum RPM the message display flashes MAX
RPM / OPERATOR and the engine RPM is not allowed to go higher. (The maximum
engine RPM is normally set at 2100 and is programmable.)
If the discharge pressure is below 15 PSI when the operator increases the pressure
setting, the display shows PRESS LOW.
Note: When changing from RPM to pressure mode during operations, hold
the PRESSURE button for 3 seconds. The pressure setting is the pressure
that the pump was operating at in RPM mode.
1. Press PRESSURE button to select the pressure mode.
Result: PRESSURE LED goes on.
2. Press PRESET and/or rotate control knob to select pressure setting.
Result: Message display shows pressure setting, engine RPM changes.
3. Press IDLE button after operations to set engine to idle RPM.
Result: Message display shows IDLE ENGINE, engine at idle RPM.
Opening/Closing Discharge Valves
In pressure mode the governor maintains the pressure setting regardless of the
number of discharge lines that are opened or closed providing there is sufficient water
supplied. As lines are opened the discharge pressure starts to drop and the governor
raises the engine RPM to maintain the required pressure. As lines are closed and the
discharge pressure starts to rise, the governor lowers the engine RPM to maintain the
required pressure.
Operating From a Pressurized Supply
When operating from a pressurized water source (hydrant, in-relay, etc.), the intake
supply should be routed through a valve. If the pressurized source fails, the pump
operator can close the valve. This eliminates the chance of sharp pressure spikes at
the pump intake if the supply is resumed suddenly. The operator must open this valve
slowly when the supply is resumed to help prevent pressure spikes.
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Running Away From Water, Low Water, or No Supply Water
There are situations during pump operations when there may be low or no supply
water. This can be due to an empty water tank, a problem on the intake line, air in the
pump, changing the water source, or an insufficient water supply.
The governor constantly monitors discharge pressure and compares it to engine
RPM. It is programmed to limit RPM increases when conditions arise that fall outside
of normal operating parameters.
Running Away From Water: If the discharge pressure starts dropping while
operating in pressure mode, the governor increases the engine RPM and attempts to
maintain the selected pressure setting. If pressure drops and an increase in RPM does
not bring the pressure back up, the governor recognizes this as a running away from
water condition. When this condition occurs the governor switches to the RPM limit
mode and controls the engine RPM accordingly.
RPM Limit Mode: When the RPM limit mode is in effect the PRESSURE
LED stays on. To alert the operator the RPM LED and the RPM display flash, and the
message display flashes OPERATOR / RPM LIMIT. In this mode the pressure setting
does not change and the PRESET button is disabled. When the pressure comes back
up to the selected pressure setting, the RPM limit mode is canceled and the governor
switches to normal operation in pressure mode at the selected pressure.
In some cases the pressure may not come back up but remains at a level above
45 PSI. In the RPM limit mode, the governor behaves like a manual throttle and the
operator can raise or lower the engine RPM by rotating the control knob. If the RPM
is manually lowered to a point where the pump is not running away from water and
pressure is stable, the RPM limit mode is canceled. The governor switches to normal
operation in pressure mode with the current discharge pressure as the new pressure
setting.
If the engine is set to idle using the IDLE button, the governor comes out of RPM
Limit Mode and cancels the pressure setting.
Low Water Cycle: If the discharge pressure is below 45 PSI, but stays above 15
PSI, the governor enters a low water cycle and the message display flashes LO WATER.
It sets the engine at 1100 RPM. If the pressure does not rise above 45 PSI in 7 seconds,
the governor sets the engine RPM at idle. The governor repeats the low water cycle as
long as the discharge pressure is between 15 and 45 PSI. When the pressure rises above
45 PSI the governor resumes normal operation. (The values for RPM and PSI in the
low water cycle are programmable and may vary for some engine/pump combinations.)
No Supply Water: If the discharge pressure is below 15 PSI, the engine RPM
is set at idle and the message display flashes NO WATER. If, within 3 minutes, the
discharge pressure rises above 15 PSI the governor enters the low water cycle. If the
discharge pressure does not rise above 15 PSI within 3 minutes, the governor switches
to idle mode and cancels the pressure setting. To restart pump operations, the operator
must take action (press PRESET and/or rotate control knob to select pressure setting).
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RPM Mode Operation
In the RPM mode of operation the RPM LED is on. The governor maintains a
constant engine RPM.
The pump discharge pressure can vary but, as a safety feature, the governor limits
the increase in pressure to 30 PSI over the last established PSI value. As the discharge
pressure approaches this limit the governor automatically lowers the RPM to prevent
a high pressure surge. The RPM LED blinks as the governor sets a lower RPM. This
lower RPM will be the new operating RPM setting.
Note: When changing from pressure to RPM mode during operations, hold
the RPM button for 3 seconds. The RPM setting is the RPM that the pump
was operating at in pressure mode.
1. Press RPM button to select RPM mode.
Result: RPM LED goes on.
2. Press PRESET and/or rotate control knob to select RPM setting.
Result: Message display shows RPM setting, engine RPM changes.
3. Press IDLE button after operations to bring engine to idle RPM.
Result: Message display shows IDLE ENGINE, engine at idle RPM.
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Switching Between Operating Modes
• No variation in discharge pressure or RPM occurs when changing between
pressure and RPM modes.
• When changing to RPM mode, the RPM setting is the RPM that the pump was
operating at in pressure mode.
• When changing to pressure mode the pressure setting is the pressure that the
pump was operating at in RPM mode.
When the engine is at idle RPM:
Press the mode button and the governor changes modes immediately.
When the engine RPM is above idle:
Press and hold the mode button for 3 seconds and the governor changes modes.
(This is to avoid an accidental change over if the buttons get bumped.)
Pump Discharge Pressure is High at Engine Idle
Once the governor has set the engine RPM at idle, it can do no more to reduce
discharge pressures. To reduce discharge pressure the pump operator can gate incoming
water, reduce pressure at the intake relief valve, gate discharges, or disable the pump.
RPM Limit with Discharge Pressure Less than 100 PSI
The level II programming code P221 sets the maximum RPM when the pump is
operating with a discharge pressure less than 100 PSI. The factory set default is for
code P221 is 1500. Access to level II programming required a password. Contact FRC
if this default limit needs to be changed.
Remote Governor Option
The remote governor option duplicates the primary governor functions.
The remote governor control module is required to be programmed as a remote
(program code P303). If error codes E5 and E6 show on power up, check the
programming.
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Detailed Information
The four LED bar graphs provide constant display of safe operating ranges for
engine oil pressure, engine coolant temperature, transmission temperature, and battery
voltage. They do not show exact numbers or units of measure. Detailed information
is shown in the message display when the MENU button is pressed. Engine hours and
pump hours are also shown.
Show Detailed Information
Note: Detailed information is a display only mode and no changes can be
made to the data.
The MENU button allows the operator to gain access to detailed information. Each
time the MENU button is pressed the display scrolls to show the next value.
The message display indicates the following:
ENG TEMP ### °F (programmable for °C)
ENG OIL ### PSI (programmable for kPa or Bar)
BATT VDC ##.# V (programmable for 12V or 24V)
ENG HRS ####
PUMP HRS ####
TRANS T. ### °F (programmable for °C)
D.SENSOR #### PSI (programmable for kPa or Bar)
I.SENSOR #### PSI (programmable for kPa or Bar)
The message display reverts to normal operation after 20 seconds if no buttons are
pressed. When a button other than the MENU button is pressed, the display immediately
reverts to normal operation. The SILENCE button should be used during operations.
High-Idle
The governor programming includes a high-idle function. To activate the high-idle
set all interlocks as called for by local SOP (normally this would include the transmission
in neutral and the parking brake on). Set the High-Idle switch to ON.
Note: The pump must NOT be engaged when using the high-idle function
and the THROTTLE READY LED will be off.
Change High-Idle Setting
Note: The high-idle is set at about 1000 RPM at the factory. (This value
varies depending on the specific engine.)
1. With the engine running, set the high-idle switch to ON.
Result: Engine goes to high idle RPM.
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Preset Settings (Pressure or RPM)
The preset button allows the operator to go to a pre-programmed pressure or
RPM setting during operations. The preset value shows in the message display. This
procedure is to change the pre-programmed setting. (Factory default preset maximum
limits are: pressure = 200 PSI; RPM = 1500.)
Note: The engine must be running and the pump engaged interlock circuit
must be closed (the THROTTLE READY LED must be on).
1. Press IDLE button.
Result: Engine goes to idle RPM
2. Press PRESSURE or RPM button to select the setting to be changed.
Result: LED indicator goes on for mode selected.
Note: The message display must show IDLE ENGINE before changing the
preset.
3. Press and hold PRESET button. (Continue to hold through step 4.)
Result: Message display shows PRESET. After 5 seconds the current setting
flashes. The preset value is set at this time but is not allowed to exceed the
factory default limits of pressure = 200; RPM = 1500.
Note: If the factory default limits are to be exceeded, step 3a. must be included, if not proceed with step 4.
3a. Press and hold the SILENCE button for 5 seconds to unlock the default limits.
Result: Message display shows UNLOCKED. Release the SILENCE button
(continue to hold the PRESET button). The preset value is now allowed to exceed
the default limit.
4. Rotate control knob to change preset setting.
5. Release PRESET button.
Result: The new preset value is programmed. Message display shows IDLE
ENGINE.
2. Press and hold PRESET button for 3 seconds.
Result: RPM display flashes and shows the high-idle setting.
3. Keep pressing the PRESET button and rotate control knob to desired RPM.
4. Release PRESET button to store the new high idle setting.
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PROGRAMMING
The following program functions are always available to view and change:
P101 - Software Program Revision Number - Read Only
P102 - Product Manufacturing Date - Read Only
P103 - Set Current Date - Read/Write
P104 - Set Current Time - Read/Write
P105 - Retrieve Fault Codes - Read Only
P106 - Engine Type Code - Read Only
Access Program Features
Note: When the program (P) code is flashing in the RPM display, press the
PRESSURE or RPM button to scroll through the P-codes or press the
SILENCE button to exit the programming mode.
1. Press the SILENCE button and hold it until the RPM display shows four dashes – – – –
and the message display shows ENTER--- CODE. Release the button.
Result: P 1 0 1 flashes in the RPM display. The message display shows the program
revision number PROG REV V500.03.
2. Press the PRESSURE button.
Result: P 1 0 2 flashes in the RPM display. The message display shows the
manufacturing date MFG DATE 16JAN'15 (ddmmm'yy).
3. Press the PRESSURE button.
Result: P 1 0 3 flashes in the RPM display. The message display shows the current date
SET DATE 16JAN'15.
4. To Change the Date: (If not, go to step 5.)
a. Press the MENU button.
Result: P 1 0 3 stops flashing. The message display shows the current date with
the year flashing.
b. Press the PRESSURE or RPM button to change the year.
c. Press the MENU button.
Result: The month flashes.
d. Press the PRESSURE or RPM button to change the month.
e. Press the MENU button.
Result: The day flashes.
f. Press the PRESSURE or RPM button to change the day.
g. Press and hold the SILENCE button to store the new date.
Result: P 1 0 4 flashes in the RPM display. The message display shows SET
TIME 10:30AM . Go to step 6.
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5. Press the PRESSURE button.
Result: P 1 0 4 flashes in the RPM display. The message display shows SET TIME
10:30AM .
6. To Change the Time: (If not, go to step 7.)
a. Press the MENU button.
Result: P 1 0 4 stops flashing. The message display shows the current time with
the AM or PM flashing.
b. Press the PRESSURE or RPM button to change AM or PM.
c. Press the MENU button.
Result: The minute flashes.
d. Press the PRESSURE or RPM button to change the minutes.
e. Press the MENU button.
Result: The hour flashes.
f. Press the PRESSURE or RPM button to change the hours.
g. Press and hold the SILENCE button to store new time.
Result: P 1 0 5 flashes in the RPM display. The message display shows NO
WARNING or LOGGED DATA. Go to step 8.
7. Press the PRESSURE button.
Result: P 1 0 5 flashes in the RPM display. The message display shows NO
WARNING or LOGGED DATA.
8. Press the MENU button when it shows LOGGED DATA or go to step 9.
Result: 5 1 flashes in the RPM display. The fault, date, and time that the fault code
was recorded shows in the message display.
a. To scroll through the logged fault code data, press the PRESSURE or RPM
button.
b. Press the SILENCE button to exit viewing logged data.
9. Press the PRESSURE button.
Result: P 1 0 6 flashes in the RPM display. The message display shows the engine type
code that is set in the program. (Refer to the Engine Code Reference Table, Document
Number XE-ECRTREF01-R0A.)
10 Press the PRESSURE or RPM button to scroll through the P-codes or press the SILENCE
button to exit the programming mode.
PBA400 Rev170705
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Access Password Protected Programs
The following program functions are available to view and change after the
password code has been entered:
Calibration Password Code 1111
C1 - Discharge Pressure Sensor Zero Calibration
C2 - Intake Pressure Sensor Zero Calibration
C3 - Engine RPM Calibration
Refer to Calibration Section.
Operator Password Code 1221
Operator Password Code 1221 allows the parameter settings of limited program
functions to be changed. Refer to Table 4. Operator Password Protected Program
Functions.
P318 - RPM Limit for Pressure Control (Factory default is 2100.)
Enter Password Code
Note: To exit the programming mode, press the SILENCE button when the
program code flashes in the RPM display.
1. Press the SILENCE button and hold it until the RPM display shows four
dashes – – – – and the message display shows ENTER--- CODE.
Release the button.
2. Press the MENU button within three seconds. The message display shows
CODE ENTRY. The RPM display shows the number 1000. Each time the
MENU button is pressed the first digit increments by 1. Set the first digit to
the desired number.
3. Press the SILENCE button to move the curser to the next digit. Press the
MENU button to change the digit.
4. Repeat step 3 and enter the password code. (Calibration password is 1111.
Operator password is 1221.)
Result: When a correct password code is entered C 1 for calibration or
P 3 1 8 flashes in the RPM display.
5. Press the PRESSURE or RPM button when the program code is flashing to
scroll through the program codes.
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6. Press the MENU button to enter the programming mode to view and change
parameter settings.
Result: The program code stops flashing. The message display shows a
selectable option or a numerical value.
7. Press the MENU button to change a selectable option or the PRESSURE
or RPM button to change a numerical value.
8. Press the SILENCE button to save the changes and exit the programming
mode.
Result: The program code advances to the next code and flashes.
9. Repeat steps 5 through 8 as necessary.
10. Press the SILENCE button when the program code is flashing to exit.
CODE DESCRIPTION MESSAGE DISPLAY Press MENU button to
select; change value with
PRESSURE or RPM
P318 RPM limit for pressure
control
MAX RPM
LIMIT <> 2100
Table 4. Operator Password Protected Program FunctionsValues shown are standard factory default and may vary with engine type selected.
PBA400 Rev170705
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CODE DESCRIPTION MESSAGE
DISPLAY
Press MENU
Button Again
Press MENU
Button Again
C1 Discharge Pressure
Sensor Zero Calibration
D.PSI D.PSI
SET P=0?
D.PSI
D.PSI=0
C2 Intake Pressure Sensor
Zero Calibration
I.PSI I.PSI
SET P=0?
I.PSI
I.PSI=0
C3 Engine RPM Calibration CAL.
ENG RPM
SET RPM
XXXX
Table 5. Calibration Codes Quick Reference Chart
CALIBRATION
Three programs are available after the calibration password code has been entered:
C1 - Discharge Pressure Sensor Zero Calibration
C2 - Intake Pressure Sensor Zero Calibration
C3 - Engine RPM Calibration
Refer to Table 5. Calibration Codes Quick Reference Chart.
Enter Calibration Password Code 1111
Note: To exit the programming mode, press the SILENCE button when the
program code flashes in the RPM display.
1. Enter the password code 1111. (Refer to Programming Section.)
Result: When the correct password code is entered C 1 flashes in the
RPM display. The message display shows D.PSI.
2. Press the PRESSURE or RPM buttons when the program (C) code is
flashing to scroll through the program codes.
Refer to specific calibration section for detailed procedures.
Note: If there is a failure during calibration the message display shows
SENSOR PROBLEM.
3. Press the SILENCE button when the program (C) code is flashing to exit.
PBA400 Rev170705
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Pump Pressure Sensor (Code C1 and C2)
The program for the pump pressure sensor(s) is self-calibrating. There are no
adjustments that can be made to the sensors. When the calibration program is activated
the signal from the sensor(s) is assumed to be 0 PSI.
Note: If there is pressure in the plumbing where the sensor is mounted this
causes the program to be calibrated to a false 0. To prevent false zeroing,
drain the pump and plumbing to ensure there is no residual pressure before
running the calibration procedure.
1. Apply power to the display module.
2. Enter the calibration password.
3. Scroll to code C1 D.PSI or C2 I.PSI.
4. Press the MENU button SET P=0? flashes.
5. Press the MENU button again to set at 0. D.PSI=0 or I.PSI=0 flashes.
6. Press and hold the SILENCE button for 3 seconds to save the setting
into memory.
7. Press the SILENCE button when the program (C) code is flashing to exit
calibration. Press the MENU button to enter the next program. Press the
PRESSURE or RPM buttons to scroll through program codes.
Engine RPM (Code C3)
This code is not applicable for engines with the J1939 CAN connected. To perform
the following calibration, a reference tachometer is needed to verify the correct engine
RPM.
1. Apply power to the display module.
2. Enter the calibration password.
3. Scroll to code C3 CAL. ENG RPM.
4. Press the MENU button to show SET RPM.
Result: Flashing digit is ready to be changed.
5. Set the RPM to match the reference RPM. Press the PRESSURE or RPM
buttons to change the value. Press the MENU button to change the digit.
6. Press the SILENCE button to save the setting into memory.
7. Press the SILENCE button when the program (C) code is flashing to exit
calibration. Press the MENU button to enter the next program. Press the
PRESSURE or RPM buttons to scroll through program codes.
PBA400 Rev170705
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Notes:- Not all wires are used for all engines. Refer to the engine specific wiring diagram for interface connections.- An adapter and cable assembly replaces the basic 8-pin cable when connecting the governor to a GMC engine. Refer to the engine specific wiring diagram.
Notes:- Not all wires are used for all engines.- High idle is not available for GMC.- When using an FRC provided engine sensor cable, the red wire is sensor signal and the black wire connects to a ground.
Figure 4. PBA Connectors
WIRING
The following figures include the schematics, wiring diagrams, block diagrams,
and cables for the governor.
Connectors and Cables
For most engines the governor receives engine RPM, oil pressure, and coolant
temperature data over the J1939 data link from the ECM. Some engines do not broadcast
this data over the data link and sensors may need to be installed.
When a remote governor is installed ensure that the control module program code
P303 is set to REMOTE. Refer to Figure 5 for wiring details.
12 Pin Connector/CablePin Wire Color Description 1 Red + 5 VDC Discharge Pressure Sensor2 Black Ground Discharge Pressure Sensor3 White Signal Discharge Pressure Sensor4 Blue Engine Oil Press. Sensor Signal5 Orange Engine Temp. Sensor Signal6 Brown Buzzer Ground (300mA)7 Violet High Idle Active Input (+ VDC)8 White J1939 CAN (Shield)9 Black J1939 CAN (–)10 Red J1939 CAN (+)11 Green Transmission Temp. Sensor Signal12 Yellow RPM Signal
8 Pin Connector/CablePin Wire Color Description 1 Red Supply Power (12/24 VDC)2 Black Ground3 Orange +5 VDC Reference From ECM4 White Throttle Signal To ECM 5 Green Signal Return From ECM6 Yellow Interlock Input (+ VDC)7 Blue Throttle Enable Signal Output8 Brown Foot Pedal Signal Input
Control Module Rear View8-Pin Connector Pin 1
12-Pin Connector Pin 1
6-Pin Connector Pin 1
USBAccess Port
Vent
PBA400 Rev170705
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Figure 5. PBA Connector Wiring
Notes:- Pump intake sensor on PBA400 only.
6 Pin Connector/CablePin Wire Color Description 1 Red + 5 VDC Intake Pressure Sensor2 Black Ground Intake Pressure Sensor3 White Signal Intake Pressure Sensor4 Green FRC Datalink (–)5 Yellow FRC Datalink (+)6 N/C
12-Pin Connector
Note: The program code P303 must be set to REMOTE on the Secondary Controller control module.
To J1939(See Engine Specific Wiring)
Secondary Controller12, 8 and 6 Pin Connector Wiring
+12 VDC
GND
Ignition Key
RED
BLK
8-Pin Connector
NOTE: Terminating resistor and adapters are included in the kit for connection to the primary display; no other wires are required for remote operation.
6-Pin Connector
YELGRN
FRC Datalink (+)FRC Datalink (–)
To the Primary Controller
Data Bus Terminator
6-Pin Connector
YELGRN
FRC Datalink (+)FRC Datalink (–)
To the Secondary Controller
Data Bus TerminatorTo Intake Pressure Sensor
GRN
Secondary Controller, Cables and Connections
PBA400 Rev170705
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Figure 6. Pressure Sensor Wiring
Pressure Sensor Side View
Pressure Sensor Cable 3-Pin ConnectorPin/Wire DescriptionA/Black GroundB/Red Supply VoltageC/White Signal
Pressure Sensor
Pressure SensorTop View
Pressure Sensor Cable
Caution: The discharge and intake pressure sensors are the same size. Ensure the correct sensor is installed on the correct manifold. Refer to Table 1.
Signal Output
Supply Voltage
Ground
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Figure 7. Common OEM 9-Pin Diagnostic Connector
Common OEM Diagnostic Connector
Typical 9-pin Deutsch Diagnostic Connector.Commonly found under the driver side dashboard.
9-Pin ConnectorPin Description A BATTERY GROUND B +12 VDC C J1939 CAN (+) D J1939 CAN (–) E J1939 SHIELD F J1587 DATA BUS (+) G J1587 DATA BUS (–) H PLUG J PLUGFRONT VIEW
BF
E
A
C
D
G
H
J
PBA400 Rev170705
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Figure 8. Cummins PBA401 Wiring
Cummins Harness Connections
Interface Information
For use on 2004 or newer engines.
The governor is designed to control engine throttle directly over the SAE J1939
databus.
If the PUMPBOSS is being used on a COMMERCIAL CHASSIS with a Cummins
Engine, ENSURE that the Cummins Engine EMERGENCY VEHICLE CALIBRATION
is programmed in the engine ECM for the PUMPBOSS to work.
Note: Refer to Figure 5. PBA Connector Wiring for power and interlock wire connections.
1817
J1939 Datalink (–)Pin 9 Black Wire
Pin 10 Red Wire J1939 Datalink (+)
12-Pin Connector (Refer to Figure 5)
ECM OEM Connector
2010ISC8.3/CM2250/ISL9Model Engines
4622
J1939 Datalink (–)Pin 9 Black Wire
Pin 10 Red Wire J1939 Datalink (+)
12-Pin Connector (Refer to Figure 4)
ECM OEM Connector
2013CM2350Model Engines
PBA400 Rev170705
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Figure 9. Detroit Diesel PBA402 Wiring
Detroit Diesel Harness Connections
Interface Information.
The governor is designed to control engine throttle directly over the SAE J1939
databus. Remote throttle does not need to be enabled in the ECM.
Note: Refer to Figure 5. PBA Connector Wiring for power and interlock connections.
ECU
J1939 CAN (–)
J1939 SHIELD
J1939 CAN (+)
2/16
2/17
2/18
DDECVI
12-Pin Connector (Refer to Figure 5)
Vehicle Interface Harness 18-Pin Connector #2
For DDEC VI 2007 and Newer Engines
Pin 9 Black Wire
Pin 8 White Wire
Pin 10 Red Wire
ECU
J1939 CAN (+)
Shield
J1939 CAN (–)
V-43
V-44
V-58
Dk Blu/Red
Dk Blu/Yel
Dk Blu
DDEC V
12-Pin Connector (Refer to Figure 5)
Vehicle Interface Harness Connector
For DDEC V 2003 to 2006 Engines.
Pin 10 Red Wire
Pin 9 Black Wire
Pin 8 White Wire
PBA400 Rev170705
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Navistar Harness Connections
Interface Information
The ECM must be programmed for remote variable throttle operation.
Note: Check the governor engine code to verify the program setting (for
J1939 control use 4C and for voltage control use 4D). Wire accordingly
or change the code.
Figure 10. Navistar PBA404 Wiring
EST Connector
J1939 CAN (–)
J1939 CAN (Shield)
Pin 9 Black WirePin 8 White Wire
Pin 10 Red Wire J1939 CAN (+)
Pin EPin DPin C
12-Pin Connector (Refer to Figure 5)
Note: Refer to Figure 5. PBA Connector Wiring for power and interlock wire connections.
Voltage ControlPost 2007 MAXXFORCE 7, DT, 9, 10, 11, and 13 Engines
8-Pin Connector (Refer to Figure 5)
Split Shaft Only
ECM Function
Voltage Ref 5V
Signal Return
REM Accelerator
Variable PTO Enable
Transfer Case
Circuit #(V8)
K95
K95R
K97RPS
K97RVAR
K97SCX
Circuit #(IBBE)
K92A4
K92A3
K92A5
K92A12
K92A7
Pin 3Orange Wire
Pin 5Green Wire
Pin 4White Wire
Pin 7Blue Wire
X1-27
X1-35
X1-50
X1-60
X1-11
X1-14
X1-6
X1-20
X3-20
X4-6
Circuit #(I6)
K97FV
K97WA
K99F
K97CC
K97XC
J1939 CAN Bus Control 12VXY2010 and Newer MAXXFORCE 11 and 13 Engines
C1-47
C1-34
J1939 (–)
J1939 (+)
Pin 9 Black Wire
Pin 10 Red Wire
12-Pin Connector (Refer to Figure 5)
ECM 58-PinC1 Connector
12VZA 12VZB
PBA400 Rev170705
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Figure 11. Navistar/International Chassis PBA404 Wiring
Navistar / International Chassis Harness Connections
Interface Information
Note: This function is not available on custom chassis, refer to Figure 10.
Navistar PBA Wiring.
Vehicles must be equipped with an Electronic System Controller (ESC) and have
the Body Builder J1939 Datalink available.
Remote Engine Speed must be set to ON (Feature Code 0595AHA)
Connect the Body Builder J1939 Datalink to the FRC Datalink for engine control
as shown below.
ATA Datalink Connector
J1939 CAN (Shield)
J1939 CAN (–)
J1939 CAN (+)
Pin 8 White Wire
Pin 9 Black Wire
Pin 10 Red Wire
Pin E
Pin D
Pin C
12-Pin Connector (Refer to Figure 5)
Note: Refer to Figure 5. PBA Connector Wiring for power and interlock wire connections.
Body Builder J1939 Datalink (–)
Body Builder J1939 Datalink (+)
FRC Datalink (–)
FRC Datalink (+)
F5
F6
6-Pin Connector (Refer to Figure 5)
1602(ESC J5) Connector
Pin 4 Green Wire
Pin 5 Yellow Wire
Note: The Body Builder J1939 Datalink is for engine control, the J1939 CAN Bus provides engine information to the governor.
Engine Control Output
Engine Information Input
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Caterpillar Harness Connections
Interface Information
The parameter settings for PTO Configuration is programmed to Remote Throttle
or Remote Throttle with J1939 Speed Command.
ECM software with a Personality Module release date of May08 for C7, C9, C13,
C15 engines, has the Remote Throttle with J1939 Speed Command setting available.
This setting allows the engine speed to be controlled during PTO operations by a J1939
compliant device.
Refer to an authorized dealer to program one of these options.
C7, C9, C10, C11, C12, C13, C15 Engine Interface
Engines with 70-pin OEM connector.
Note: Refer to Figure 5. PBA Connector Wiring for power and interlock wire connections.
Figure 12. Caterpillar PBA405 Wiring
12-Pin Connector (Refer to Figure 5)
8-Pin Connector (Refer to Figure 5)
J1939 Datalink Negative (–)
J1939 Datalink Shield
J1939 Datalink Positive (+)
993-BR
G845-PU
K999-GN
Input Sensor Common #2
Input #1 PTO ON/OFF Switch
Input #8 (Remote Throttle PWM)
ECM
70-Pin Vehicle Harness Connector
3
68
56
34
42
50
Pin 5 Green Wire
Pin 4 White Wire
Pin 7 Blue Wire
Pin 8 White Wire
Pin 9 Black Wire
Pin 10 Red Wire
A249-BK
K990-GN
K900-YL
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Ford Harness Connections
J1939 Interface Information
A J1939 CAN input is required to provide engine information to the governor. The
Ford vehicle CAN Bus information needs to be interpreted. A J1939 Translator Module
with a harness to connect it to the ODB-II connector must be installed.
Note: The ODB-II connector and wiring is accessed under the dash.
There are two scenarios:
I. The J1939 Translator Module is installed as a component with governor kit
(no Seat Belt Monitoring System is installed).
Install the J1939 Translator Module and the ODB-II interconnecting harness
(provided with the governor kit). A 2-Pin connector is provided for the wires
to governor.
II. The J1939 Translator Module is installed as part of the NFPA1901 compliant
Seat Belt Monitoring and VDR System.
The Translator Module/ODB-II/VDR harness is under the driver side dash.
A T-cable (provided with the governor kit) needs to be installed at the 4-Pin
connector that is between the harness and the VDR.
Stationary Elevated Idle Control (SEIC) Interface Information
Note: Access wires for SEIC are located in cabin, tagged and bundled above
the parking brake pedal assembly behind datalink connector.
SEIC is used in two modes: stationary and split shaft. The governor provides a
variable RPM control to the Ford Power train Control Module (PCM) when all enabling
conditions are met. Refer to Figure 14 Ford PBA PCM Wiring.
SEIC Enablers: Parking brake applied; Foot off of service brake; Vehicle in
park; Foot off of accelerator pedal; Vehicle speed is 0 mph (stationary); Engine
at a stable base idle speed.
Note: Do not press the accelerator or service brake pedal when engaging the
fire pump, this prevents the switch into SEIC.
PBA400 Rev170705
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Translator Module Harness(2-Pin Connector)
J1939 (+)
J1939 (–)
Pin 10 Red Wire
Pin 9 Black Wire
PBA406 12-Pin Connector (Refer to Figure 5)
Figure 13. Ford PBA406 J1939 Translator Module Wiring
Mounting holes are clearance for #8 screws.
Install the J1939 Translator Module with the ODB-II Interconnecting Harness
or Install the T-cable between 4-Pin connectors.
To install the J1939 Translator Module with ODB-II harness, read and follow the
installation instructions provided with the Translator Module kit.
J1939 Translator Module
2"
4"
3 1/2"
1"
J1 ConnectorTEST Pad
Disconnect VDR harness 4-Pin connector and connect the T-cable provided with the governor kit.
J1939 Translator Module and VDR HarnessTo OEM ODB-II Connector
Pass Through ODB-II Connector
To Translator Module J1 Connector
To FRC VDR 8-Pin Connector
2-Pin Connector1-Red J1939 (+)2-Blk J1939 (–)
4-Pin VDR Connector
To Governor12-Pin Connector
Note: The TEST pad on the module circuit board has to be held at ground when the harness connector is plugged into the J1 connector.
To OEM ODB-II Connector
To Translator Module J1 Connector
Pass Through ODB-II Connector
2-Pin Connector1-Red J1939 (+)2-Blk J1939 (–)
To Governor12-Pin Connector
J1939 Translator Module Harness
Translator Module Harness to Governor
Note: Refer to Figure 5. PBA Connector Wiring for governor power and interlock wire connections.
PBA400 Rev170705
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Figure 14. Ford PBA406 PCM Wiring
2011 Model F-250/350/450/550 - 6.7L Diesel EngineStationary Elevated Idle Control (SEIC)
Note: Do not press the accelerator or service brake pedal when engaging the
fire pump, this prevents the switch into SEIC.
8-Pin Connector (Refer to Figure 5)
PCM
PTO REF
PTO RTN
PTO RPM
PTO RS1
Circuit #Wire Color
LE434White/Brown
RE327Gray/Violet
CE914Green
CE912Yellow/Green
Pin 3 Orange Wire
Pin 5 Green Wire
Pin 4 White Wire
55
22
8
6+12 (24) VDCPump in Gear
C1232B-
Split Shaft Mode
Stationary Mode
Split Shaft Mode is activated by applying supply voltage to both the PTORS1 and PTORS2 PCM circuits simultaneously.1. Assure engine is running and fully warmed-up.2. Apply parking brake.3. Transmission in neutral to disengage drive wheels.4. With foot off brake and accelerator, switch Split-Shaft PTO on.5. While pressing the service brake, shift transmission into drive.6. Engage PTO load.
NOTE: *Refer to Ford SVE Bulletin for SEIC details. (For 2017, see Q-256 Ford bulletin.)
(For 2016 and older, see Q-180R4 Ford SVE Bulletin.)
Once the system enablers are met voltage may be added to the SEIC system for activation.If power is applied prior to the enablers being met, a system error may occur, and the SEIC system will have to be reset.If an SEIC disabler occurs the engine requires a change-of-state, meaning the operator is required to turn off voltage to the PTO-Request circuit, and back on again to re-invoke SEIC and PTO operation.
Access wires for SEIC are located in cabin, tagged and bundled above the parking brake pedal assembly behind datalink connector.
PCM
PTO REF
PTO RTN
PTO RPM
PTO RS1
PTO RS2
Circuit #Wire Color
LE434White/Brown
RE327Gray/Violet
CE914Green
CE912Yellow/Green
CE933Blue/Orange
Pin 3 Orange Wire
Pin 5 Green Wire
Pin 4 White Wire
55
22
8
6
4
+12 (24) VDCPump in Gear
C1232B-
8-Pin Connector (Refer to Figure 5)
Note: Refer to Figure 5. PBA Connector Wiring for power and interlock wire connections.
PBA400 Rev170705
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Figure 15. Mack PBA407 Wiring
Mack Harness Connections
Interface Information.
For V-MACK IV 07 and newer, the governor is designed to control engine throttle
directly over the SAE J1939 databus.
J1939 CAN Bus Control
VC5
VC4
J1939 (–)
J1939 (+)
Pin 9 Black Wire
Pin 10 Red Wire
12-Pin Connector (Refer to Figure 5)
VECUConnector C
Note: Refer to Figure 5. PBA Connector Wiring for power and interlock wire connections.
PBA400 Rev170705
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Scania Harness Connections
Interface Information
For use on P, R, and T-series trucks equipped with a bodywork control unit (BWS).
Connector C259 is available on all vehicles ordered with any of the bodywork options. It
is located on the plate for the electrical bodywork interface for body builders. Connector
C259 is white and has 21 pins. (February 2005 and newer.)
Figure 16. Scania PBA408 Wiring 12 15 18 21 Contact Housing (MCP)
C259
3 6 9 Note: Refer to Figure 5. PBA Connector Wiring for power and interlock wire connections.
The EXT switch must be in the ON position when operating the PumpBoss.
12-Pin Connector (Refer to Figure 5)
8-Pin Connector (Refer to Figure 5)
C259 Connector
8Engine RPM Control 2 +24 Volts
CAN high 21
9 Engine RPM Control 2 Earth
11
10 Engine RPM Control 2 Signal
Engine RPM Control 2 +5 Volts
CAN low 20
Note: Signal to pin 10 is 0.6 to 3.0 V
Pin 9 Black Wire
Pin 10 Red Wire
Pin 4 White Wire
Pin 5 Green Wire
Pin 3 Orange Wire
Pin 7 Blue Wire
PBA400 Rev170705
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Mercedes Harness Connections
Interface Information.
For 2007 and newer engines, the governor is designed to control engine throttle
directly over the SAE J1939 databus. Remote throttle does not need to be enabled in
the ECM.
Note: Refer to Figure 5. PBA Connector Wiring for power and interlock wire connections.
Figure 17. Mercedes PBA410 Wiring
VCU21-Pin Connector
VCU18-Pin Connector
17
18Remote Throttle Signal Analog
Remote PTO Power Supply
7Remote Accelerator Select Switch
J1939 (–)
J1939 (Shield)
1921
20
J1939 (+)
14Sensor Ground (Throttle Pedal & Remote)
12-Pin Connector (Refer to Figure 5)
8-Pin Connector (Refer to Figure 5)
For 2006 and Older Engines
7
10Remote PTO Switch
Pin 7 Blue Wire
Pin 4 White Wire
Pin 3 Orange Wire
Pin 5 Green Wire
Pin 9 Black Wire
Pin 8 White Wire
Pin 10 Red Wire
For 2007 and Newer Engines
J1939 CAN (–)
J1939 CAN (+)
2/16
2/17
2/18
12-Pin Connector (Refer to Figure 5)
Vehicle Interface Harness 18-Pin Connector #2
J1939 SHIELD
Pin 10 Red Wire
Pin 9 Black Wire
Pin 8 White Wire
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J1939 CAN Bus Control
U
V
J1939 (–)
J1939 (+)
Pin 9 Black Wire
Pin 10 Red Wire
12-Pin Connector (Refer to Figure 4)
Figure 18. John Deere PBA416 Wiring
John Deere Harness Connections
Interface Information
CAN Controller will request a torque by means of TSC1. This option is disabled by
default and is selectable in the Trim Options page for this application. Source address
57 should be programmed.
Note: Refer to Figure 4 and Figure 5 Connector Wiring for Power and Interlock wire connections.
Circuit No. 905 Green
Circuit No. 904 Yellow
21 Pin Deutsch Connector
TIER-3PowerTech Engines
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J1939 CAN Bus Control
X1997/18
X1997/17
J1939 (–)
J1939 (+)
Pin 9 Black Wire
Pin 10 Red Wire
12-Pin Connector (Refer to Figure 4)
18-Pin Connector X1997
Figure 19. MAN PBA424 Wiring
MAN Harness Connections
Interface Information
Parameters for various functions can be set on the KSM using MAN-cats II.
The KSM can accept the Engine speed request from the Governor on the A-CAN.
Note: Refer to Figure 4 and Figure 5 Connector Wiring for Power and Interlock wire connections.
Brown-Orange/0.75 A-CAN-L
Orange/0.75 A-CAN-H
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CAN Bus Control
4
6
(–)
(+)
Pin 9 Black Wire
Pin 10 Red Wire
12-Pin Connector (Refer to Figure 5)
IVECO Harness Connections
Interface Information
The vehicles shall be ordered with EM w/ CANopen (OPT0384) and FMS
(OPT14569). The CANopen XDC needs to be downloaded. This service is available
from the official IVECO TeleService tool-chain worldwide. Also an adapter cable
needs to be installed to connect Controller to the CAN Bus. This option is currently
available only for EUROCARGO-V.
Note: Refer to Figure 5 for the Connector Wiring for Power and Interlock wire connections.
Wiring with PumpBoss device
VCM
EM 120Pump
Boss120ST13
ST72072C ST72072C ST72072CST72072D
ST72070ST13
Vehicle Interface Harness9 Pin 72072C Connector
Pin 4 +
Pin 6 –AdapterNOTE: Contact IVECO dealer for information regarding the Adapter
Figure 20. IVECO PBA426 Wiring
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Figure 21. High-Idle Wiring
High-Idle Wiring
The governor programming includes a high-idle function. To activate the high-
idle provide + VDC to pin 7 (High-Idle Active Input) of the 12-pin connector and pin
6 (Interlock Input) of the 8-pin connector. The high-idle connection to pin 6 must be
isolated form the interlock circuit using two diodes (see schematic).
Note: It is important that the connection to the Interlock Input from the High-
Idle circuit be isolated from the apparatus interlock wiring with the two
diodes. Refer to the wiring diagram. The pump must NOT be engaged
when using the high idle function.
The high-idle is set at about 1000 RPM at the factory. (This value will vary
depending on the specific engine.) To adjust this setting refer to High-Idle in the
Operation Section.
A High-Idle Kit is available from FRC.Includes:ON/OFF SwitchIndicator LightTwo Diodes
To 8-Pin ConnectorPin 6 Yellow WireInterlock Input
To 12-Pin ConnectorPin 7 Violet WireHigh-Idle Active Input
High-Idle ON/OFF Switch
Diodes(IN4002 or equivalent)
From TransmissionNeutral+ VDC
Pump Engaged Indicator Light
NC
NO
C
ON
OFF
High-Idle Indicator Light
GND
FromPump Engaged +12 VDC
GND
NC
NO
C
From Parking BrakeGND
NC
NO
C
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FLYBACK DIODE INFORMATION
It is good engineering practice to include a flyback diode when switching an
inductive load (solenoid coil, relay coil, electric motor winding, etc.). It is recommended
that a flyback diode be installed on inductive devices that share a common power
source/ground with an FRC governor.
Figure 22. Flyback Diode
Typical circuit showing a flyback diode installed across an inductive load.
Diagram showing a flyback diode connected on a typical pump primer motor solenoid.
Diode
Inductive Load
GND
+V
Primer Motor Solenoid
+ VDC Supply
From Primer Motor Switch
To Primer Motor
Ground
+–
Diode
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