vernier throttle for cat

1

DOC 101057C_c:\manuals\throttles\cats\catthrot.p65

101057 rev. C

VERNIER THROTTLE SYSTEMfor

Caterpillar Engines

Class1

607 NW 27 Ave.Ocala, FL 34475

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

2

DOC 101058C_c:\manuals\throttles\cat\catthrot.p65

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, 3116, 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 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 and has an internalidle 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 thefollowing components.

interface modulevernier controluser manual

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 10% 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 (C4) is available to bring the engine speed to a pre-determined engineRPM (High Idle) from a remotely mounted switch or load management device. When the interface ispowered up with this input active, the idle validation routine is bypassed and the interface will increasethe engine speed to the preset RPM. This speed can be set by an external potentiometer or resistornetwork.

Installation

Control Module The interface module requires minimal space (3.63” x 4.75” x1.00”). The moduleis watertight and may be mounted in any location that is not subject to extreme temperature or vibra-tion.

Wiring The interface package comes with cables and leads to make the following connections:Power and GroundEngine Control Extension CableHigh 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 informationon engine electrical interfacing.

Overview

3


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.

4


Connectors

Connector InformationC1 Connector 12015792 Terminal 12089188 Seal 12015899Position Wire Color DescriptionA Red Throttle InterlockB Black Ground

C2 Connector 12015793 Terminal 12089188 Seal 12015899Position Wire Color DescriptionA White Throttle groundB Blue Throttle SignalC Orange Throttle Source

C3 Connector 12010973 Terminal 12089040 Seal 12015899Position Wire Color DescriptionA Yellow PWM Signal

C4 Connector 12015791 Terminal 12089188 Seal 12015899Position Wire Color DescriptionA Green Fast Idle*

* This input bypasses idle validation and allows the interface to command engine speed assoon as power is applied.

Throttle Interfacefor

Caterpillar Engines

C1

C2

C3

C4

5


Wiring 3176

Cla

ss 1

Cat

erpi

llar

Inte

rfac

e

C1-

A12

VD

C

C3

C1-

BT

hrot

le P

ositi

on

PT

O E

ngag

ed

PT

O L

amp

Cat

erpi

llar

3176

/340

6

8 P

TO

On/

Off

29 S

enso

r C

omm

onG

roun

d

31 M

ultif

unct

ion

Inpu

t #3

PW

M

21 O

utpu

t #1

P

TO

On

Lam

p

Cat

erpi

llar

3176

/340

6

12 V

DC

PT

O

OE

M

Inte

rlock

s

Cat

erpi

llar

C10

, C12

, 317

6 &

340

6 E

CM

man

uals

\thro

ttles

\cat

_317

6.ai

..021

497

12

34

56

3536

3738

3940

7 13 19 23 29

12 18 22 28 34

CA

T L

ower

Con

nect

or (

J1/P

1)

Veh

icle

Har

ness

Con

nect

or

Rel

ay87

a

87

8586

30

Pro

gram

min

g C

onsi

dera

tions

Par

amet

er

Ava

ilabl

e

Def

ault

PT

O

Rem

ote

Thr

ottle

Off

PT

O T

op E

ngin

e Li

mit

600

-212

0

2120

P

TO

RP

M s

et s

peed

Idl

e-P

TO

TE

L

0

RP

MP

TO

Cab

Thr

ottle

RP

M

T

EL,

Idle

,PT

O T

EL

TE

LP

TO

act

ivat

es c

oolin

g fa

n

N

orm

al, C

ontin

uous

Nor

mal

Tor

que

Lim

it

200

lb-f

t to

Rat

ed

200

0 lb

-ft

Max

PT

O v

ehic

le s

peed

lim

it

1 to

127

MP

H

1 M

PH

6


HI-Idle

Class 1

CAT Interface

C2-A Throttle GroundC2-B Throttle SignalC2-C Throttle Source

C1-A12 VDC

12 VDC

FASTIDLE

OEM Interlocks

Fast Idle Switch

HIGH IDLE POT

C4

manuals\throttles\cat\cathigh.ai..110298

Wiring the Class1 Vernier Throttle with high idle option only

7

DO

C 101057C

_c:\manuals\throttles\cats\catthrot.p65

317

6/3

406

Class 1CAT Interface

C2-BThrottle Signal

C1-A12 VDC

12 VDC

Relay 2

87a

87

85 86

30

PTO

FASTIDLE

OEM Interlocks

Fast Idle Switch

HIGH IDLE POTRelay 1

87a

87

85 86

30

Relay 387a

87

85 86

30

VERNIER THROTTLE

C4

5 VDC

SIGNAL

GROUND C2-A

C2-C

C2-B

HOOKED IN PARALLEL TO HIGH IDLE POT.

CONNECT TO VERNIER THROTTLE INPUT AT RELAY 1

HOOKED IN PARALLEL TO HIGH IDLE POT.

VERNIER THROTTLE HIGH IDLE POT.

FROM C2-C

CONNECT TO HIGH IDLE POT INPUT AT RELAY 1

FROM 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

manuals\throttles\cat\catvthi.ai..110298

Wiring the Class1 Vernier Throttle with a remote high idle option

8

DO

C 101058C

_c:\manuals\throttles\cat\catthrot.p65

Caterpillar Interface

C2-BThrottle Signal

C1-A12 VDC C3

C1-BSensor Common(Ground)

Sensor Common

+8 VDC

Throttle Position

CAB Throttle

Throtle Position

Remote ThrottleSwitch(PTO Engaged)

Relay

PTO LampK998 Blue

C986 Brown

C985 Blue

C993 Brown

K999 Green

Caterpillar ECM 3126

8 PTO On/Off

29 Sensor CommonGround

35 8 VDC

37 TPS Input

21 Output #1 PTO On Lamp

Caterpillar ECM 312612 VDC

87a

87

85 86

30

PTO

FASTIDLE

OEM Interlocks

Fast Idle Switch

HIGH IDLE POT (10K)

VERNIER CONTROL (10K)

Caterpillar 3126 ECM

Wiring the Class1 Vernier Throttle Interface with a fast idle option

Manuals\Throttles\catvthi.ai..120996

C2-A

C2-C

C4

312

6

9


Cla

ss 1

Cat

erpi

llar

Inte

rfac

e

C1-

A12

VD

CC

3C

1-B

Sen

sor

Com

mon

(Gro

und)

Thr

otle

Pos

ition

PT

O E

ngag

ed

PT

O L

amp

Cat

erpi

llar

3126

B H

EU

I

56

P

TO

On/

Off

Gro

und

3 In

put S

enso

rC

omm

on #

2G

roun

d

68IN

PU

T #

8R

AP

SP

WM

30O

utpu

t #1

PT

O O

n La

mp

Gro

und

New

Cat

erpi

llar

3126

B

12 V

DC

PT

O

OE

M

Inte

rlock

s

Cat

erpi

llar

3126

B H

EU

I EC

MT

hrot

tle In

terf

ace

Mod

ule

man

uals

\thro

ttle\

cat\c

at31

26b.

ai..1

0019

8

12

34

56

712

CA

T J

1/P

1 C

onne

ctor

EC

M R

IGH

T S

IDE

Veh

aicl

e H

arne

ss C

onne

ctor

EC

M S

ide

Rel

ay

87a

87

8586

30

Pro

gram

min

g C

onsi

dera

tions

Par

amet

er

Ava

ilabl

e

Def

aults

PT

O

Rem

ote

Thr

ottle

Off

PT

O T

op E

ngin

e Li

mit

600

-212

0

2120

P

TO

RP

M s

et s

peed

Idl

e-P

TO

TE

L

0

RP

MP

TO

Cab

Thr

ottle

RP

M

T

EL,

Idle

,PT

O T

EL

TE

LP

TO

act

ivat

es c

oolin

g fa

n

N

orm

al, C

ontin

uous

Nor

mal

Tor

que

Lim

it

200

lb-f

t to

Rat

ed

200

0 lb

-ft

Idle

PT

O v

ehic

le s

peed

lim

it

1 to

15

MP

H

1 M

PH

89

1011

13

14 24 32 40 48

23 31 39 47 57

70

69

68

67 6

6 6

5 6

4 6

3 6

2 6

1 6

0 5

9 5

8

3126B HEUI

10


3126B HEUI

Cla

ss 1

Cat

erpi

llar

Inte

rfac

e

C1-

A 1

2 V

DC

C3

C1-

BS

enso

r C

omm

on(G

roun

d)

Thr

otle

Pos

ition

PW

M O

ut

PT

O E

ngag

ed

PT

O L

amp

56

PT

O O

n/O

ff

G

roun

d

3 I

nput

Sen

sor

C

omm

on #

2G

roun

d

68

INP

UT

#8

RA

PS

P

WM

30

Out

put #

1

P

TO

On

Lam

p

G

roun

d

New

Cat

erpi

llar

3126

B

12 V

DC

Cat

erpi

llar

3126

B E

CM

Thr

ottle

Inte

rfac

e M

odul

e

man

uals

\thro

ttle\

cat\3

126B

-HI.A

I....1

0239

8

12

34

56

712

CA

T J

1/P

1 C

onne

ctor

EC

M R

IGH

T S

IDE

Veh

aicl

e H

arne

ss C

onne

ctor

EC

M S

ide

Rel

ay87

a

87

8586

30

Pro

gram

min

g C

onsi

dera

tions

Par

amet

er

Ava

ilabl

e

CA

T D

efau

ltP

rogr

am

PT

O

Rem

ote

Thr

ottle

Off

ON

PT

O T

op E

ngin

e Li

mit

600

-212

0

2120

2120

P

TO

RP

M s

et s

peed

Idl

e-P

TO

TE

L

0

RP

Mxx

PT

O C

ab T

hrot

tle R

PM

TE

L, Id

le,P

TO

TE

L

T

EL

TE

LP

TO

act

ivat

es c

oolin

g fa

n

N

orm

al, C

ontin

uous

Nor

mal

Con

tinuo

usT

orqu

e Li

mit

2

00 lb

-ft t

o R

ated

2

000

lb-f

tR

ated

Idle

PT

O v

ehic

le s

peed

lim

it

1 to

15

MP

H

1 M

PH

Max

89

1011

13

14 24 32 40 48

23 31 39 47 57

70

69

68

67 6

6 6

5 6

4 6

3 6

2 6

1 6

0 5

9 5

8

C2-

A G

roun

d

C2-

C +

5VD

C

C2-

B T

hrot

Sig

C4

Idle

Val

idat

ion

Ove

rrid

e

PT

O

FA

ST

IDLE

OE

M

Inte

rlock

s

Fas

t Idl

e S

witc

h

HIG

H ID

LE P

OT

(10

K)

VE

RN

IER

CO

NT

RO

L (1

0K)

11


Mounting

1.0"

3.000"

4.25"4.75"

3.625"

Ø 0.201"

(4) HO

LES

Throttle Interface M

odule

12


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 by the safety (interlock) system the throttlemodule 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, theinterface module will not increase the PWM until the zero position is detected.

IMPORTANT The throttle interface module will not command increased speed from theengine until the zero position is detected. This feature is present to avoid unintentional in-creases in engine speed should the throttle be left in the open position.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 andturn 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 forremote throttle operations. This presents a timing and signal problem that must be overcometo use the interface module for Fast Idle.

vernier throttle for cat

Documents