101057 rev. C
VERNIER THROTTLE SYSTEM
for
Caterpillar Engines
Class1
607 NW 27 Ave.
Ocala, FL 34475
Ph: (352) 629-5020
Fax: (352) 629-2902
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Overview
Throttle Interface Control Module
System Overview
The
Class1
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, 31 16, 3126, 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 and has an internal
idle validation circuit that can be overriddenusing an input that allows for a fast idle activation.
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
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 10% 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 (C4) is available to bring the engine speed to a pre-determined engine
RPM (High Idle) from a remotely mounted switch or load management device. When the interface is
powered up with this input active, the idle validation routine is bypassed and the interface will increase
the engine speed to the preset RPM. This speed can be set by an external potentiometer or resistor
network.
Installation
Control Module The interface module requires minimal space (3.63” x 4.75” x1.00”). 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:
Power and Ground
Engine Control Extension Cable
High Idle connector with leads
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
!
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 GUARDED IN ACCORDANCE WITH ALL APPLICABLE
FEDERAL, ST ATE, LOCAL AND NFP A SAFETY AND HEALTH
REGULA TIONS, CODES AND ST ANDARDS.
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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Connectors
Throttle Interface
for
Caterpillar Engines
Connector Information
C1 Connector 12015792 T erminal 12089188 Seal 12015899
Position Wire Color Description
A Red Throttle Interlock
B Black Ground
C1
C2
C3
C4
C2 Connector 12015793 T erminal 12089188 Seal 12015899
Position Wire Color Description
A White Throttle ground
B Blue Throttle Signal
C Orange Throttle Source
C3 Connector 12010973 T erminal 12089040 Seal 12015899
Position Wire Color Description
A Yellow PWM Signal
C4 Connector 12015791 T erminal 12089188 Seal 12015899
Position Wire Color Description
A Green Fast Idle*
* This input bypasses idle validation and allows the interface to command engine speed as
soon as power is applied.
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Wiring 3176
Caterpillar 3176/3406
PTO Engaged
87a
Relay
30
8 PTO On/Off
86
87
85
Class 1
Caterpillar Interface
Ground
29 Sensor Common
31 Multifunction Input #3
PWM
C3
Throtle Position
C1-B
C1-A
12 VDC
OEM
Interlocks
21 Output #1
PTO On Lamp
PTO Lamp
PTO
Caterpillar 3176/3406
manuals\throttles\cat_3176.ai..021497
12 VDC
Caterpillar C10, C12, 3176 & 3406 ECM
28
12
6
45
3
2
Vehicle Harness Connector
1
18
7
13
22
19
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39 40
38
CAT Lower Connector (J1/P1)
35 36 37
23
29
Programming Considerations
Parameter Available Default
PTO Remote Throttle Off
PTO Top Engine Limit 600-2120 2120
PTO RPM set speed Idle-PTO TEL 0 RPM
PTO Cab Throttle RPM TEL, Idle,PTO TEL TEL
PTO activates cooling fan Normal, Continuous Normal
Torque Limit 200 lb-ft to Rated 2000 lb-ft
Max PTO vehicle speed limit 1 to 127 MPH 1 MPH
5
HI-Idle
Wiring the Class1 Vernier Throttle with high idle option only
HIGH IDLE POT
12 VDC
Fast Idle
Switch
OEM
Interlocks
FAST
IDLE
C2-A Throttle Ground
C2-B Throttle Signal
C2-C Throttle Source
Class 1
CAT Interface
C1-A
12 VDC
C4
manuals\throttles\cat\cathigh.ai..110298
DOC 101058C_c:\manuals\throttles\cat\catthrot.p65
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Wiring the Class1 Vernier Throttle with a remote high idle option
DOC 101057C_c:\manuals\throttles\cats\catthrot.p65
Fast Idle
Switch
12 VDC
5 VDC
SIGNAL
C2-C
C2-B
PTO
OEM
Interlocks
FAST
IDLE
VERNIER THROTTLE
HOOKED IN PARALLEL TO HIGH IDLE POT.
CONNECT TO VERNIER THROTTLE INPUT AT RELAY 1
85
30
Relay 3
HIGH IDLE POT
VERNIER THROTTLE
87a
87
86
FROM C2-C
CONNECT TO HIGH IDLE POT INPUT AT RELAY 1
HIGH IDLE POT.
87a
87
85
87a
87
85
Relay 1
Relay 2
86
86
30
30
3176/3406
C2-B
Throttle Signal
Class 1
CAT Interface
C1-A
12 VDC
C4
GROUND
7
C2-A
RELAY 3 DISABLES HIGH IDLE WHEN OK TO PUMP/PTO ENGAGED SIGNAL IS PRESENT
RELAY 2 SELECTS THE SOURCE OF THE INTERLOCK (HIGH IDLE OR PTO)
RELAY ONE SELECTS WHICH THROTTLE SIGNAL (HIGH IDLE OR VERNIER) IS DELIVERED TO THE INTERFACE MODULE
HOOKED IN PARALLEL TO HIGH IDLE POT.
FROM C2-A
manuals\throttles\cat\catvthi.ai..110298
8
Caterpillar 3126 ECM
VERNIER CONTROL (10K)
HIGH IDLE POT (10K)
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OEM
Interlocks
PTO
FAST
IDLE
Fast Idle
Switch
C2-A
Sensor Common
(Ground)
C2-C
C4
Caterpillar Interface
C2-B
Throttle Signal
C1-A
12 VDC
Throtle Position
C1-B
C3
CAB Throttle
Sensor Common
+8 VDC
Throttle Position
12 VDC
Remote Throttle
Switch
(PTO Engaged)
Relay
87a
87
85
PTO Lamp
30
86
K999 Green
C993 Brown
C985 Blue
C986 Brown
K998 Blue
Caterpillar ECM 3126
8 PTO On/Off
29 Sensor Common
Ground
35 8 VDC
37 TPS Input
21 Output #1
PTO On Lamp
Caterpillar ECM 3126
3126
Wiring the Class1 Vernier Throttle Interface with a fast idle option
Manuals\Throttles\catvthi.ai..120996
3126B HEUI
Ground
Ground
Common #2
RAPS
PWM
Ground
Caterpillar 3126B HEUI
Relay
PTO Engaged
87a
30
56 PTO On/Off
87
86
85
Sensor Common
3 Input Sensor
(Ground)
Class 1
Caterpillar Interface
68 INPUT #8
C3
Throtle Position
C1-B
C1-A
12 VDC
OEM
Interlocks
30 Output #1
PTO On Lamp
PTO Lamp
PTO
New Caterpillar 3126B
manuals\throttle\cat\cat3126b.ai..100198
12 VDC
Throttle Interface Module
Caterpillar 3126B HEUI ECM
1424324048
123456712
ECM Side
89101113
Vehaicle Harness Connector
2331394757
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ECM RIGHT SIDE
CAT J1/P1 Connector
70 69 68 67 66 65 64 63 62 61 60 59 58
Programming Considerations
Parameter Available Defaults
PTO Remote Throttle Off
PTO Top Engine Limit 600-2120 2120
PTO RPM set speed Idle-PTO TEL 0 RPM
PTO Cab Throttle RPM TEL, Idle,PTO TEL TEL
PTO activates cooling fan Normal, Continuous Normal
Torque Limit 200 lb-ft to Rated 2000 lb-ft
Idle PTO vehicle speed limit 1 to 15 MPH 1 MPH
9
56 PTO On/Off
87
87a
Ground
86
Ground
3 Input Sensor
Common #2
68 INPUT #8
RAPS PWM
30 Output #1
PTO On Lamp
Ground
3126B HEUI
New Caterpillar 3126B
manuals\throttle\cat\3126B-HI.AI....102398
1424324048
123456712
Relay
30
PTO Engaged
85
Sensor Common
(Ground)
C1-B
Class 1
Caterpillar Interface
C2-A Ground
Caterpillar 3126B ECM
Throttle Interface Module
HIGH IDLE POT (10K)
C2-C +5VDC
VERNIER CONTROL (10K)
C2-B Throt Sig
C3
Throtle Position
PWM Out
C4
IdleValidation
Override
C1-A 12 VDC
FAST
PTO Lamp
Fast Idle
Switch
IDLE
12 VDC
OEM
Interlocks
ECM Side
89101113
Vehaicle Harness Connector
2331394757
PTO
ECM RIGHT SIDE
CAT J1/P1 Connector
70 69 68 67 66 65 64 63 62 61 60 59 58
10
DOC 101058C_c:\manuals\throttles\cat\catthrot.p65
Programming Considerations
Parameter Available CAT Default Program
PTO Remote Throttle Off ON
PTO Top Engine Limit 600-2120 2120 2120
PTO RPM set speed Idle-PTO TEL 0 RPM xx
PTO Cab Throttle RPM TEL, Idle,PTO TEL TEL TEL
PTO activates cooling fan Normal, Continuous Normal Continuous
Torque Limit 200 lb-ft to Rated 2000 lb-ft Rated
Idle PTO vehicle speed limit 1 to 15 MPH 1 MPH Max
Mounting
1.0"
3.000"
4.25"
4.75"
3.625"
Ø 0.201"
(4) HOLES
Throttle Interface Module
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Operation
When the throttle interface module is powered up by the safety (interlock) system the throttle
module will perform a self check and the module will then output a PWM signal of 12 %.
The interface will verify that the throttle is fully closed. If the throttle is not fully closed, the
interface module will not increase the PWM until the zero position is detected.
IMPORTANT
engine until the zero position is detected. This feature is present to avoid unintentional increases in engine speed should the throttle be left in the open position.
The throttle interface module will not command increased speed from the
The fast idle input overrides this feature and should be used with caution.
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: The new 3126B and 3116B HEUI engines perform their own idle validation for
remote throttle operations. This presents a timing and signal problem that must be overcome
to use the interface module for Fast Idle.
For questions or concerns regarding the interface module, call Class1 at 352-629-5020
FAX 352-629-2902
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