Post on 10-Jan-2016
description
Information BookletWW20072
Included in the box
1 x InformationBooklet
1 x ElectricalKit
1 x WaterWatchUnit
1 x WaterWatchEquippedSticker
1 x WarningSticker
Bracket kits & instructions supplied separately
For after sales support or if you have further questions,pleasecontacttheWaterWatchteamat:
Responsive Engineering Australia Pty Ltd Tel 02 6280 4334 Fax 02 6280 0179 Email responsiveengineering@bigpond.com www.responsiveengineering.com.au
Please ensure that you have read and understand this information booklet completely. Incorrect installation or servicing may void warranty.
IMPORTANT!
ProductInformationWW20072| 3
Why is Water Watch essential for common rail diesel fuel systems? 4
Location Diagram 5
Fitting Instructions 6-8
Wiring Diagram 9
Service Instructions 10-11
Notes on Proper Use 12
Lifetime Warranty Guarantee 13
Parts List 14-15
Log 16-17
More Products 18
Important Information & Warnings 19-20Read this information first!
ContentsCongratulations, you have purchased an Australian designed and built Water Watch, made from quality components, built and tested in Australia before each purchase.
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Why is Water Watch essential for common rail diesel fuel systems?
Approximately85%ofthefuelinacommonrailfuelsystemiscirculatedthroughouttheentirefuelsystemandisreturnedtothetankeveryhourtheengineisoperated.
Thishighfuelflowrate,combinedwiththehightemperatureandpressurewithinacommonrailfuelsystemmakesitextremelyvulnerabletodamageifwaterispresentinthefuel.
Justfittinganextrafuelfilterorwatertrapwillnotadequatelyprotectyourcommonraildieselenginefuelsystemfromexpensivedamageduetowaterinthefuel.
WaterWatchtrapsandretainsfreewaterfromthefuelandprovidesatimelywarningbothvisualandaudibletothedriverthatwaterispresentinthefuelsystem.
WaterWatchalarmsoundswhenonly5mlsofwateristrappedinthebowl,givingthedrivertheopportunitytostopandremovethewaterbeforedamageoccurs.
Otherwatertrapswithoutanalarm,watercanaccumulateandbecirculatedthroughoutthefuelsystemwithoutthedriversknowledge.Thesewatertrapsmayonlybeinspectedforwateratvehicleservicingtimesoratirregularintervals.Thiswillbetoolateanddamagetoexpensivefuelsystemcomponentsmayhavealreadyoccurred.
Water Watch is proudly made in Australia and specifically designed for Common Diesel Rail Vehicles.
ProductInformationWW20072| 5
Location Diagram
Fuel Tank
Fuel Return
Fuel in Common Rail Diesel is also used to cool the system, so it is circulated through the system up to 60 litres per hour.
HighPressure Pump
FactoryFitted Filter
Common Rail
Injectors
Water Watch is located in the supply line from the fuel tank and before the original fuel filter.
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Fitting Instructions
1. MounttheWaterWatchassemblyafter the fuel tankandbefore the original fuel filterinyourvehicle,besuretomountasverticalaspossible.Ensurefuelflowisaccordingtothearrowonthetopofthefilterhousing.
2. BoltrelayintosuitablepositionnearWaterWatchunitusing6mmbolt,washerandnut.
3. MountthesuppliedLEDLamptoavisibleplaceonyourdashboard.RemovenutandwasherbehindLED-slidestickerontobackofLEDandmountondash,securingwithwasherandnut.
4. Mountsuppliedbuzzerbehind/underyourvehiclesdashboard-thealarmsoundislouderwhenthebuzzerfacesintothecab.Adjustdirectiontosuityourownrequirements.
5. LocatewirewhichhasbatteryvoltagewhenignitionisonandconnecttoaWhitewireateithertherelayendoralternativelytheoppositeend(underdashend)ofthewiringharness.Ifthiswireisnotfromafusedsource,fitthefuseholderand5ampfuseassupplied(refertothewiringdiagram).
6. Whitewireatrelayendoftheharnessshouldbesecuredtotherestoftheharnessandinsulatedorremovedifnotused.
7. ConnecttheBlackwirewitheyeterminalattherelayendtovehicleearth.
8. ConnecttheRedwirefromboththeLEDlightandbuzzertothewireattheunderdashendofthewiringharness.
These instructions are for fitting to a 12/24 Volt system. we recommend consulting an auto electrician for wiring of your vehicle.
ENSURE THAT THE VEHICLES BATTERY IS DISCONNECTED PRIOR TO INSTALLATION. AND THE ENGINE BAY IS FREE OF DUST AND DIRT.
DO NOT REMOVE THE VEHICLES GENUINE FUEL FILTER ASSEMBLY.
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Continued On Following Pages 1
Fuse
WhitewiretoRedwireon
buzzerandlight.
LEDLight
Buzzer
SensorPlug
EarthWire
ToIGNONwhitewire.Select 1 only
Relay&Plug
BrownwiretoBlackwire
onlight.BrownwiretoBlueorBlackwireon
buzzer.
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Fitting Instructions (continued)
Buzzer Options
9A Option 1
Continuous WarningConnecttheblackwireoftheLEDlightandbuzzertothebrownwireatthedashendofthewiringharness.
9B Option 2
Pulse WarningConnecttheblue wireofthebuzzerandtheblackwireoftheLEDlighttothebrownwireunderthedashendofthewiringharness.Note:redwiretopower(whitewire)
Note: LED light and buzzer wiring connections should be soldered at joins.
TheWaterWatchassemblyincorporatesaselfcheckcircuit.TheLEDlightandbuzzerwillactivateforapproximately3-4secondswhentheignitionswitchisturnedON.
IftheLEDlightandbuzzerdoesnotfunctionwhentheignitionisturnedontheremaybeamalfunctioninthecircuit.Anymalfunctionofthewarningsystemshouldbeinspectedandrectifiedimmediatelytoachievethemaximumprotectionforyourvehiclesfuelsystem.
Apply warning sticker supplied on appropriate area on vehicles windscreen.
Place this information booklet and other appropriate paperwork in glove box for future reference.
More information, photos and videos are available on our website www.responsiveengineering.com.au
ProductInformationWW20072| 9
Brown wire(signal)
White wire to Positive (+) fromignition switch
Red wire tovehicle battery voltagevia ignition switch
Black wire to vehicle earth orbattery negative (-)
Probe
RelayLight
Earth
Pin 87
Pin 30Pin 86
Pin 85
Ignition Switch
Buzzer
Fuse
White Wire = Power in Harness
Wiring Diagram
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Service Instructions
Note:Ifitisnecessarytoremoveglassbowlassembly,thenthecentre bolt (4)mustonlybetightenedtoatensionofapprox25inch/pounds(2.8NM).
(1) Electrical Plug
(2) Sensor Screw
(3) O Ring Seal
(4) Centre Bolt
Bleeder Bolt
Water Watch must sound the alarm for 3-4 seconds each time the ignition is switched on to check the circuit and to let you know that it is working.
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Service Instructions WATER WATCH
WARNING!
Ifthisalarmactivatesafter the initial pre-check alarmorduringnormaloperationSTOP THE ENGINEassoonasitissafetodosoandfollowthesesimpleinstructions.
Read the instructions fully before proceeding to drain.
Check visually for water in the glass bowl.
Itmaybedifficulttoseethewater.WerecommendasaprecautiontoproceedwithdrainingtheWaterWatchbowl-thesensorisveryaccurate,thewatermaybedispersedwithinthefuel.
1. Unplug electrical plug (1) on sensor from the wiring harness.
2. Unscrewsensor (2) andremovemomentarilytoallowwatertoflushfrombowl.Fluidsshoulddrainfromglassbowlveryquickly.(Bleeder/Banjoboltmaybeloosenedifdrainingisslow)
3. Whenliquidhasdrained,carefullyretightenthesensorscrew-90degreesafterORing(3)makescontact.
Warning - Do Not Overtighten Sensor-seenotesonpage19
4. Reattachtheelectricalplug(1)towiringharness.
5. Primetheenginesfuelsystem(refertoownersmanual).
6. CheckthatnofurtherwaterisenteringtheglassbowlandWaterWatchwarningceasestosoundalarmafterpre-check.
7. Ifnomorewaterisevidentand/oralarmwarningsoundsagain,thiswillindicatemorewaterinyourfuelsupply(tank).
8. Ifyoustillhavewaterinyourfuelsupply,do not operate engine as damage to fuel injection components will occur.
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Notes on Proper Use
Water Watch is fitted to assist in detecting and removing water in the fuel supply during normal operation of the vehicle.
Water Watch is installed in the fuel supply line PRIOR to the factory filter.
DO NOT OVER TIGHTEN SENSOR. Screw the sensor into the adaptor until the seal washer just touches the adaptor, then tighten a further 90 degrees by hand pressure only.
WaterWatchisdesignedtoenhancetheoriginalfiltrationsystembyremoving water and debrisandwarningtheoperatorofcontaminatedfuelwithoutcausingrestrictiontofuelflow.
Ifthewarningbuzzerandlampareactivatedaftertheinitialstart-uppre-test,thenyoumuststoptheengineasquicklyasitissafetodoso,drainthecontentsofthebowlasdetailedintheserviceinstructions(pages10&11)beforeproceedingtooperatetheengineagain.
ShouldWaterWatchalarmsreactivate,indicatingcontinuedamountsofwaterenteringyourfuelsupply,thecontentsofyourfuelsupplyshouldberemovedandthesupplytankscleaned.
Failuretodosomaycauseseriousdamagetothefuelsystemandenginecomponents.WaterWatchsabilitytoprotectthesesystemsislimitedbythecapacityofthecollectionbowlwherewateranddebrisarecollected.
ItisrecommendedthattheWaterWatchunitischeckedregularlyforfuelqualityandtheremovalofdebrisfromthebowl.
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Lifetime Warranty Guarantee
Our commitment to quality includes our service. Should you, contrary to expectations, experience defects due to manufacturing faults, Responsive Engineering will provide you with a lifetime warranty against defects as follows:
Theproductisguaranteedtobefreeofmanufacturingandworkmanshipdefectswhenusedundernormalconditionsandcareandinaccordancewithourinstructionsonuse.
Defectsthatdooccurwillberepaired,replacedatourdiscretion,solelyatouroptionwithnochargeforparts.ThebenefitsconferredbythiswarrantyareinadditiontoallrightsandremediesinrespectoftheproductthattheconsumerhasundertheCompetitionandConsumerAct2010andsimilarstateandterritorylaws.
Extent of Warranty ThewarrantyislimitedtodefectsinworkmanshiporpartsoftheWaterWatchunit.Alldefectiveproductsorpartswillbereplaced.Thiswarrantydoesnotextendtomanualsandpackaging,electricallinesorelectricalcomponents,fuellinesorotherinstallationaccessoriestotheWaterwatchunit.
Exclusions Thiswarrantydoesnotcover:
>Anydefectcausedbyanaccident,misuse,abuse,improperinstallationoroperationorlackofreasonablecare.
>Anyproductthathasnotbeeninstalled,operatedormaintainedinaccordancewiththemanufacturersinstructionsprovidedwiththisproduct.
>Anydamagecausedbyimproperpowerinput,impropercableconnection,failuretounplugthesensorfromwiringpriortoremovalandinstallation,orovertighteningthesensorintotheWaterWatchunit.
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WW20072 Parts List
REM2017
REM2018
REM2016 REM2014
REM2013
REM2001
REM2015
REM2012REM2002REM2003
REM2004
REM2005
REM2003A
REM2006
REM2021
REM2011
REM2007
REM2008
REM2007A
ProductInformationWW20072| 15
Qty WW20072 Part
2 REM2001 BanjoBolt
1 REM2002 ORing
1 REM2003 ORing
1 REM2003A ORing
1 REM2004 Diffuser
1 REM2005 Skirt
1 REM2006 Bowl
1 REM2007 Sensor
1 REM2007A SensorSeal
1 REM2008 CnectorLoom
1 REM2011 Adapter
2 REM2012A Banjo8mm
2 REM2012B Banjo10mm
2 REM2012C Banjo12mm
2 REM2013 Washer
1 REM2014 BleedBolt
1 REM2015 Washer
1 REM2016 CentreBolt
1 REM2017 ORing
1 REM2018 Seating
1 REM2021 ORing
1 REM2000 SealKit
Should your Water Watch require replacement parts due to damage or reinstallation in another vehicle, please contact Responsive Engineering.
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Log
For notes on Water Watch system e.g: Last time Water Watch indicated alarm.
Water Watch Installation Date:
ProductInformationWW20072| 17
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More Products
Responsive Engineering is an Australian company dedicated to finding innovative solutions to protect your Diesel Fuel System
WaterWatchMounting bracket kitsaresuppliedseparatelytoWaterWatchunitsandaredesignedtosuitmanydieselvehicles.
Fulllistavailableonourwebsitewww.responsiveengineering.com.au
Contents include:qualitypowdercoatedsteelbracketspecificallydesignedtofityourvehicle,additionalfuelhose,clampsorquickconnectfittings,nuts,bolts,washersandfittinginstructionsspecifictoyourvehiclesrequirements.
Also available from Responsive Engineering:
Diesel Keypreventsmiss-fuellingwithpetrol.DieselKeyhasalockingsystemwhichwillonlyopenwhenexactlythecorrectnozzlesizeisinsertedintothereceiver.DieselKeypreventsanyaccesstothefueltankeithertoputfuelinoroutwithoutthecorrectnozzle.
Responsive Fuel AdditivefuelconditionerspecificallydesignedforCommonRailDieselfuelsystems
ProductInformationWW20072| 19
WARNING!DO NOT DAMAGE YOUR SENSOR!
1 UNCLIP SENSOR FROM WIRING HARNESS BEFORE TURNING SENSOR SCREW.Twistingthewiringcomingfromthesensorwilldamagethecircuitboardinsidethesensorunit.
2 Afterloosening/removingsensorunitfromWaterWatchtoremovewater/contamination.Reinstallsensorwithcare.Screwthesensorintotheadapteruntilthesealwasherjusttouchestheadapter,thentightenafurther90degreesbyhandpressureonly.
3 Takecarenottoputunduestrainonthewirefromthesensorunitwhenreconnectingtothewiringharnessplug.
Roughhandlingorexcessiveforcecandamagetheconnectionandallowwatertoentertheplug;thismaygiveyouafalsewarningorcauseamalfunctionwiththeWaterWatchAlarmoperation.
The sensor should not require adjustment on installation. It is only if the sensor is removed and replaced that the above instructions apply.
For after sales support or if you have further questions,pleasecontacttheWaterWatchteamat:
Responsive Engineering Australia Pty Ltd Tel 02 6280 4334 Fax 02 6280 0179 Email responsiveengineering@bigpond.com www.responsiveengineering.com.au
Please ensure that you have read and understand this information booklet completely. Incorrect installation or servicing may void warranty.
Should Water Watch alarm activate when driving - Pull up as soon as it is safe to do so and go to service instructions on pages 10-11.
IMPORTANT!
WATER WATCH
WARNING!