vernier throttle system for caterpillar electronic engines · vernier throttle system for...

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

105216

VERNIER THROTTLE SYSTEMfor

CaterpillarElectronicEngines

Class1607 NW 27 Ave.Ocala, FL 34475

Ph: (352) 629-5020Fax: (352) 629-2902

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Throttle Interface Control Module

System OverviewThe Class1 Vernier Throttle Interface is designed to allow industry standard vernier style controls (suchas the Felsted Electronic Vernier II Control) and other potentiometer controls to be used with electroni-cally 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 ofthe engine load within it’s horsepower and torque capabilities. The interface can be used to governengine speed for various applications including PTO driven generators and pumps. There is an inter-nal 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 thefollowing components.

Interface moduleVernier controlUser manualMating Connector and wiring

Operation

Variable Throttle Control When the interface has power provided by the interlock circuit, variableengine control is available to the operator using the vernier control. If the vernier control is open morethan 50% when power is applied to the interface, the interface will maintain the engine at idle RPM untilthe throttle is closed and then re-opened. This feature prevents sudden unexpected increases inengine 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 aninternal potentiometer.

Installation

Control Module The interface module requires minimal space (5” x 6” x1.5”). The module iswatertight 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 ControlPower and GroundEngine Control SignalHigh 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 informationon engine electrical interfacing.

Overview

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Interlocks

NOTE: The interlock schemes shown in this manual are examples only and may not be suit-able for specific applications. The throttle interface is active whenever power is applied.

Special Programming The ECM must be programmed for remote throttle operation and thereare several considerations including vehicle speed and max RPM that need to be configured.

Class1 provides a variety of engine controls that are used in a broad rangeof applications, therefore it is impossible for Class1 to determine the suitabil-ity of a particular control for any specific application. The flexibility of ourproducts 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 productso that you can determine what product will meet your needs. We believethat the Original Equipment Manufacturer’s (OEM) engineering departmentsshould be qualified experts in their product field and are the authorities onproduct application and safety. Since our products are typically used in safetycritical applications, the OEM must undertake appropriate testing to preventinjury to the end user.

WARNING

!

IT IS THE PURCHASER’S RESPONSIBILITY TO DETERMINETHE SUITABILITY OF ANY PRODUCT FOR AN INTENDEDAPPLICATION, AND TO INSURE THAT IT IS INSTALLEDAND GUARDED IN ACCORDANCE WITH ALL APPLICABLEFEDERAL, STATE, LOCAL AND NFPA SAFETY AND HEALTHREGULATIONS, CODES AND STANDARDS.

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Connector

Connector Information

Connector Deutsh DTM06-12SA Terminal Position Description

1 12 VDC Module Power Supply2 Not Used3 Not Used4 Vernier Supply Voltage (+5 VDC)5 Vernier Analog Signal (0-4.5 VDC)6 Not Used7 Not Used8 Pulse Width Modulated Engine Control Signal (12%-87%)9 Vernier Signal Ground

10 High Idle Request Input (12 VDC) 11 Not Used 12 Module Ground Supply

2 CAN HI11 CAN LO 3 CAN S

1 4 5 6 7 8 910

12 Ground

CaterpillarControlModule

DTM06-12SAConnector

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

5


CAT ECM

Class 1

CaterpillarInterface

Sensor Common(Ground)

PTO ON/OFFRelay

PTO ON Lamp

Caterpillar ECM J1

56 Input #1 PTO On/Off (Ground)

3 Input Sensor Common #2

(Sensor Ground)

68 INPUT #8 RAPS PWM

30 Output #1 PTO On Lamp (Ground)

CAT ECM J1 Connector

OEM Interlocks

Caterpillar ECMThrottle Interface Module

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

123456712

CAT J1/P1 ConnectorECM RIGHT SIDE

Vehicle Harness ConnectorECM Side

87a

87

85 86

30

Programming Considerations

Parameter Suggested

PTO Remote Throttle PTO Top Engine Limit 2120 or TEL PTO RPM set speed NA PTO Cab Throttle RPM NA PTO activates cooling fan Continuous Torque Limit Rated Torque Idle PTO vehicle speed limit 1 to 15 MPHMaximum PTO vehicle speed 100+ MPH

89101113

14

24

32

40

48

23

31

39

47

57

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

12 VDC

Fast Idle Interlocks10

1

8

9 5 4

12

ABC

GroundSignalSource

High Idle

Power

PWM Signal

Ground

131211109872

Vehicle Harness ConnectorHarness Side

65431

23

31

39

47

57

14

24

32

40

48

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

35 36

The Caterpillar ECM has two 70 pin AMP Connectors. The J1 connector is for OEM use andis located on the right side of the ECM toward the rear of the engine. The mating connector isan AMP 776183-1 and terminals can be AMP 776093-1 for 14, 16 or 18 Gauge wire or Deut-sch 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 isa single wire input to the OEM Input #8, terminal 68. Idle is 10% to 22% duty cycle and Maxi-mum 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 switchesto ground when the PTO ON /OFF switch is enabled.

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Indicators

PWR

INP

OUT

6 5 4 3 2 1

7 8 9 10 11 12

On Unit Troubleshooting:

Is the PWR LED (Red) illuminated?It requires 12 VDC at terminal #1 and Ground at terminal #12 to oper-

ate.

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 turnedout?

The intensity is based on the PWM duty cycle. If the LED changesfrom dim at closed throttle to full bright at fully open throttle, thenthe interface output is correct.

Does the INP LED stay on for 2 seconds and then off for 2 seconds repeat-edly?

This indicates you are in Fast Idle Mode and the Throttle Input is ig-nored.

Does the INP LED flash twice rapidly and then pause for 1 second andrepeat?

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.

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Mounting

SIGNAL+5 OUT

VIGN

PWMSIG GNDHI IDLE

GND

6 5

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3

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7 8

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Operation

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

When the throttle interface module is powered up, it performs a self check and the modulethen 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 openmore than half way, the interface module will not increase the PWM until the throttle is closedto less than half way.

When finished operating the remote throttle, the operator should return the throttle to idle andturn 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.

vernier throttle system for caterpillar electronic engines · vernier throttle system for...

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