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105216

VERNIER THROTTLE SYSTEM for

Caterpillar Electronic Engines

Class1 607 NW 27 Ave. Ocala, FL 34475 Ph: (352) 629-5020 Fax: (352) 629-2902

DOC 105216_e:\manuals\throttles\cat\New_CAT_Throt.p65-04252000

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Overview

Throttle Interface Control Module

System Overview The Class1 Vernier Throttle Interface is designed to allow industry standard vernier style controls (such as the Felsted Electronic Vernier II Control) and other potentiometer controls to be used with electronically controlled engines. This unit will work with electronically controlled Caterpillar Engines (C10, C12, 3176, 3406, 3116B and 3126B) using a Pulse Width Modulated (PWM) Signal. The interface converts a linear voltage input (potentiometer) into a PWM signal to control the engine. True variable speed control is attained and the unit will maintain a selected engine RPM irrespective of the engine load within it's horsepower and torque capabilities. The interface can be used to govern engine speed for various applications including PTO driven generators and pumps. There is an internal fast idle function that can be activated with a remote fast idle input (12 VDC) Included in the package The throttle control is available alone or as a package shipped with the following components.

Interface module Vernier control User manual Mating Connector and wiring

Operation Variable Throttle Control When the interface has power provided by the interlock circuit, variable engine control is available to the operator using the vernier control. If the vernier control is open more than 50% when power is applied to the interface, the interface will maintain the engine at idle RPM until the throttle is closed and then re-opened. This feature prevents sudden unexpected increases in engine speed when the unit is initially activated. High Idle Control An input is available to bring the engine speed to a pre-determined engine RPM (High Idle) from a remotely mounted switch or load management device. This speed is set by an internal potentiometer. Installation Control Module The interface module requires minimal space (5" x 6" x1.5"). The module is watertight and may be mounted in any location that is not subject to extreme temperature or vibration. Wiring The interface package comes with cables and leads to make the following connections: Vernier Control Power and Ground Engine Control Signal High Idle connection

Refer to the diagrams in the manual for specific wiring requirements. Refer to the engine manufacturer's Electronic Application & Installation Guides for detailed information on engine electrical interfacing.

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Interlocks

Class1 provides a variety of engine controls that are used in a broad range of applications, therefore it is impossible for Class1 to determine the suitability of a particular control for any specific application. The flexibility of our products allows them to be used in a limitless number of custom applications. Class1 can advise you of the features that are available on a given product so that you can determine what product will meet your needs. We believe that the Original Equipment Manufacturer's (OEM) engineering departments should be qualified experts in their product field and are the authorities on product application and safety. Since our products are typically used in safety critical applications, the OEM must undertake appropriate testing to prevent injury to the end user.

WARNING

!

IT IS THE PURCHASER'S RESPONSIBILITY TO DETERMINE THE SUITABILITY OF ANY PRODUCT FOR AN INTENDED APPLICATION, AND TO INSURE THAT IT IS INSTALLED AND GUARDED IN ACCORDANCE WITH ALL APPLICABLE FEDERAL, STATE, LOCAL AND NFPA SAFETY AND HEALTH REGULATIONS, CODES AND STANDARDS.

NOTE: The interlock schemes shown in this manual are examples only and may not be suitable for specific applications. The throttle interface is active whenever power is applied. Special Programming The ECM must be programmed for remote throttle operation and there are several considerations including vehicle speed and max RPM that need to be configured.

DOC 105216_e:\manuals\throttles\cat\New_CAT_Throt.p65-04252000

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Connector

DTM06-12SA Connector

2 CAN HI 11 CAN LO 3 CAN S 1 4 5 6 7 8 9 10 12 Ground

Not used

Power IN +12 VDC 1 +5 vdc OUT to Vernier 4 Signal IN from Vernier 5 NC 6 NC 7 PWM output to ECM 8 Ground OUT to Vernier 9 High Idle Request IN 10 12 Ground

Caterpillar

Control Module

Connector Information

Connector Deutsh DTM06-12SA Terminal

Position 1 2 3 4 5 6 7 8 9 10 11 12

Description 12 VDC Module Power Supply Not Used Not Used Vernier Supply Voltage (+5 VDC) Vernier Analog Signal (0-4.5 VDC) Not Used Not Used Pulse Width Modulated Engine Control Signal (12%-87%) Vernier Signal Ground High Idle Request Input (12 VDC) Not Used Module Ground Supply

DOC 105216_e:\manuals\throttles\cat\New_CAT_Throt.p65-04252000

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CAT ECM

Caterpillar ECM Throttle Interface Module

Caterpillar ECM J1 PTO ON/OFF Relay

30 87a

56

87 85 86

Input #1 PTO On/Off (Ground)

Sensor Common (Ground) High Idle Fast Idle Interlocks OEM Interlocks

3

Input Sensor Common #2 (Sensor Ground)

10

1

Power PTO ON Lamp

12 VDC

Class 1

8 9 5 4 12 PWM Signal Ground Signal Source Ground A B C

30 Output #1 PTO On Lamp (Ground) 68 INPUT #8 RAPS PWM

Caterpillar Interface

Programming Considerations Parameter PTO PTO Top Engine Limit PTO RPM set speed PTO Cab Throttle RPM PTO activates cooling fan Torque Limit Idle PTO vehicle speed limit Maximum PTO vehicle speed

CAT ECM J1 Connector Suggested Remote Throttle 2120 or TEL NA NA Continuous Rated Torque 1 to 15 MPH 100+ MPH

CAT J1/P1 Connector ECM RIGHT SIDE

13 12 11 10 9 23 31 39 47 57

8

7

6

5

4

3

2

1 14 24 32 40 48 14 24 32 40 48

1

2

3

4

5

6

7

8

9 10 11 12 13 23 31

35

36

39 47 57

70 69 68 67 66 65 64 63 62 61 60 59 58

58 59 60 61 62 63 64 65 66 67 68 69 70

Vehicle Harness Connector ECM Side

manuals\throttle\cat\CATvt3126B.ai..04142000

Vehicle Harness Connector Harness Side

The Caterpillar ECM has two 70 pin AMP Connectors. The J1 connector is for OEM use and is located on the right side of the ECM toward the rear of the engine. The mating connector is an AMP 776183-1 and terminals can be AMP 776093-1 for 14, 16 or 18 Gauge wire or Deutsch 0462-209-16141 for 14 Ga. and Deutsch 0462-201-16141 for 16 and 18 Ga. wires. Caterpillar uses a Pulse Width Modulated Control Signal for remote throttle operations. This is a single wire input to the OEM Input #8, terminal 68. Idle is 10% to 22% duty cycle and Maximum Throttle is 75% to 90% duty cycle. The Class1 Interface signal is 12% for idle and 87% for maximum throttle. The ECM must be programmed for Remote Throttle under Dedicated PTO Operations. Input #1at terminal 56 is the PTO ON/OFF switch. Supplying Input Sensor Common #2 (ground) from terminal 3 turns on the Remote Throttle. Output #1 (PTO ON Lamp) at terminal 56 switches to ground when the PTO ON /OFF switch is enabled.

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Indicators

PWR INP OUT

7 6

8 5

9 4

10 3

11 2

12 1

On Unit Troubleshooting: Is the PWR LED (Red) illuminated? It requires 12 VDC at terminal #1 and Ground at terminal #12 to operate. Is the INP LED (Yellow) Flashing? The flash rate should increase as the vernier is turned out. If the flash rate changes with the vernier position, then the interface is correctly reading the input. Does the intensity of the OUT LED (Green) increase as the vernier is turned out? The intensity is based on the PWM duty cycle. If the LED changes from dim at closed throttle to full bright at fully open throttle, then the interface output is correct. Does the INP LED stay on for 2 seconds and then off for 2 seconds repeatedly? This indicates you are in Fast Idle Mode and the Throttle Input is ignored. Does the INP LED flash twice rapidly and then pause for 1 second and repeat? This indicates too high a signal input voltage. Unplug the vernier and check to see if the INP LED returns to a slow flash rate. A missing gound to the vernier or a short to the signal wire can cause this.

DOC 105216_e:\manuals\throttles\cat\New_CAT_Throt.p65-04252000

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0.63"

SPECIFICATIONS: Suggested mounting hardware: 1/4"Hex Bolt Mating Connector: Deutsch DTM06-12SA Mating Terminals Hand Crimp Tool 16-20 Ga 1062-20-0122 DTT-20-00 18-24 Ga 0462-201-20141 HDT-48-00] Gold* 18-24 Ga 0462-201-2031 HDT-48-00 *Gold Contacts recommended for CAN BUS

PWM SIG GND HI IDLE GND

Mounting

7 8 9 10 11 12 6 5 4 3 2 1

SIGNAL +5 OUT VIGN

Phone 352 629 5020 Fax 352 629 2902 PN 104997

2.36"

http://www.class1.com

DOC 105216_e:\manuals\throttles\cat\New_CAT_Throt.p65-04252000

607 NW 27th Ave Ocala, FL 34475

PWR INP OUT

7

Operation

When the throttle interface module is powered up, it performs a self check and the module then outputs an idle PWM signal of 12 % if the throttle is in the closed position. The interface will verify that the throttle is not open more than half way. If the throttle is open more than half way, the interface module will not increase the PWM until the throttle is closed to less than half way. When finished operating the remote throttle, the operator should return the throttle to idle and turn the control to it's full clockwise position. This will insure a zero throttle position.

NOTE: Caterpillar Engines perform their own idle validation for remote throttle operations.

For questions or concerns regarding the interface module, call Class1==at 352-629-5020 FAX 352-629-2902

DOC 105216_e:\manuals\throttles\cat\New_CAT_Throt.p65-04252000

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Information

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