Class1 CAT 105216 User Manual

105216

VERNIER THROTTLE SYSTEM

for

Caterpillar

Electronic

Engines

Class1

607 NW 27 Ave.

Ocala, FL 34475

Ph: [phone]

Fax: [phone]

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Overview

Throttle Interface Control Module

System Overview

Class1

The
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.

Vernier Throttle Interface is designed to allow industry standard vernier style controls (such

Interface module
Vernier control
User manual
Mating Connector and wiring

Operation

Variab le 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

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

(5” x 6” x1.5”). The module is

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.

W ARNING

!

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.

IT IS THE PURCHASER’S RESPONSIBILITY TO DETERMINE
THE SUIT ABILITY OF ANY PRODUCT FOR AN INTENDED
APPLICA TION, AND TO INSURE THA T IT IS INST ALLED
AND GU ARDED IN ACCORDANCE WITH ALL APPLICABLE
FEDERAL, ST A TE, LOCAL AND NFP A SAFETY AND HEAL TH
REGULA TIONS, CODES AND ST AND ARDS.

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.

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DTM06-12SA

Connector

Not used

Connector

2 CAN HI
11 CAN LO
3 CAN S

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

1
4
5
6
7
8
9
10

12 Ground

Connector Information

Caterpillar

Control
Module

Connector Deutsh DTM06-12SA Terminal

Position Description

1 12 VDC Module Power Supply
2 Not Used
3 Not Used
4 Vernier Supply Voltage (+5 VDC)
5 Vernier Analog Signal (0-4.5 VDC)
6 Not Used
7 Not Used
8 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

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CAT ECM

Caterpillar ECM

Throttle Interface Module

Fast Idle
Interlocks

A
B
C

Class 1

Caterpillar
Interface

10

1

8

9
5
4

12

High Idle

Power

PWM Signal

Ground
Signal
Source

Ground

PTO ON/OFF

Relay

87a

30

87

85

86

Interlocks

12 VDC

CAT J1/P1 Connector

ECM RIGHT SIDE

OEM

Caterpillar ECM J1

56 Input #1
PTO On/Off
(Ground)

Sensor Common
(Ground)

PTO ON Lamp

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 MPH
Maximum PTO vehicle speed 100+ MPH

3 Input Sensor
Common #2

(Sensor Ground)

30 Output #1
PTO On Lamp
(Ground)

68 INPUT #8
RAPS PWM

CAT ECM J1 Connector

89101113

23
31
39
47
57

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

Vehicle Harness Connector

ECM Side

123456712

14
24
32
40
48

14
24
32
40
48

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

65431

35

Vehicle Harness Connector

Harness Side

36

131211109872

23
31
39
47
57

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 #1 at 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 8 9 10 11 12
6 5 4 3 2 1

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 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.

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Mounting

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

0.63"

GND

HI IDLE
SIG GND
PWM

7 8 9 10 11 12

6 5 4 3 2 1

VIGN

+5 OUT

SIGNAL

PN 104997

Phone [phone]

Fax [phone]

http://www.class1.com

607 NW 27th Ave

Ocala, FL 34475

2.36"

PWR

I N P

OUT

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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

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Class1

==at 352-629-5020

FAX [phone]