ROAD SPEED LIMITER...Appendix 2: Cat PWM Throttle RSL Applications 38 Appendix 3: Road Speed Limiter – Optional Torque Reduction 40 Overview 40 Programming Information 40 Example

PRODUCT MANUAL ROAD SPEED LIMITER

Part No. 11186 | 11506

2 | 46 M0704.docx | Rev 2.7 | Modified on 20/11/2019 | © Remote Control Technologies Pty Ltd

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M0704.docx | Rev 2.7 | Modified on 20/11/2019 | © Remote Control Technologies Pty Ltd 3 | 46

Contents

General Safety Warnings 6 Personal Safety 6 Machine 6 Product 6

Product Overview 7

Features and Functions 7

Operation and Use 8

Installation Instructions 9 Throttle Position Sensor (TPS) Connections 10 Typical OEM Dual TPS Pedal 10 Typical Interfacing of the Speed Limiter Loom into the OEM TPS Circuit 10 Locating the 5-Volt Reference Voltage(s) 10 Locating the Signal Ground(s) 11 Locating the TPS Pedals 11 Examples of Other Typical TPS Pedals 12 Single Potentiometer 12 Single Potentiometer with Idle Validation 12 Diagrams 13 System Wiring Diagram (476j) 13 11068 Loom Configuration Diagram (423m) 14 12505 Fitting Guide (537s) 15

Calibration 16 Opening the Deutsch Enclosure 16 Pre-Installation Setup of 11186 Control 16 Full DIP Switch Options Table 17 Switch Bank 1 17 Switch Bank 2 17 Programming Information 19 Default Factory Settings for 11186 Speed Limiter Control Unit 19 Setting up ‘Volt In1’ – Minimum Level Percentage 20 Setting up ‘Volt In1’ – Maximum Level Percentage 21 Setting the Minimum Pull Back 22 Setting Unit for Multiple Speed Zone Application 25 Single Speed Operation 26 Dual Speed Operation 26 Multi-Speed Operation 27 How to Enter Graph Screens When Trouble Shooting 28 Interpreting Graph Screens 29 Check Sensor Feature on Power Master Software Version V245c and Higher 32

Service Information 33 Service Schedule 33 Service Procedure 33

Parts List 33

Technical Specifications 33


Compliance and Standards 34

Troubleshooting 34 The Effect of a Speed Signal Spike 35

Appendix 1: Example of an Installation to VDJ Series Toyota LandCruiser 36 Typical Wiring Diagram 37

Appendix 2: Cat PWM Throttle RSL Applications 38

Appendix 3: Road Speed Limiter – Optional Torque Reduction 40 Overview 40 Programming Information 40 Example of Before and After Settings 42

Glossary 43

Warranty 43

Revision History 44


Table of Figures

Figure 1 Muirhead® Electronic Road Speed Limiter ......................................................................................... 7

Figure 2 Drawing 476j – System wiring diagram ............................................................................................ 13

Figure 3 Drawing 423m – Loom configuration diagram ................................................................................. 14

Figure 4 Drawing 537s – 12505 Fitting guide ................................................................................................. 15

Figure 5 Screenshot – Setup for multiple speed zone application ................................................................. 25

Figure 6 Screenshot – Set up contact inputs ................................................................................................. 25

Figure 7 Screenshot – Single speed operation .............................................................................................. 26

Figure 8 Screenshot – Dual speed operation ................................................................................................. 26

Figure 9 Screenshot – Multi-speed operation ................................................................................................ 27

Figure 10 Screenshot – Mapping screen for multi-speed setting ................................................................... 27

Figure 11 Screenshot – How to enter graph when troubleshooting ............................................................... 28

Figure 12 Screenshot – Interpreting graph screens 1 .................................................................................... 29



Figure 15 Screenshot – Check sensor feature on PowerMaster v245c & higher .......................................... 32

Figure 16 Screenshot – Speed signal spike ................................................................................................... 35

Figure 17 Possible mounting method to a VDJ series Toyota LandCruiser ................................................... 36

Figure 18 Typical wiring diagram (reference drawing 477v) .......................................................................... 37

Figure 19 Screenshot – Caterpillar PWM throttle RSL applications ............................................................... 38

Figure 20 OEM pedal connections ................................................................................................................. 39

Figure 21 Screenshot – Programming information ......................................................................................... 40


General Safety Warnings

Personal Safety

■ Everyone is responsible for safety. ■ The installer/service personnel should be trained and authorized to complete the required work. ■ Ensure that the machine is safely isolated during installation and testing to protect all personnel. ■ Complete all required risk assessments and job safety analysis (JSA) before commencing work. ■ Observe all site-specific and machine OEM procedures regarding the following:

– working at heights – working in heat – working in confined spaces – all other site-specific occupational health and safety (OH&S) procedures

Machine

■ Carry out all pre-start operations as per site and machine OEM procedures. ■ Ensure the machine is safely isolated during installation and testing to protect the machine and other

equipment in the area. ■ Do not operate any machine with a known fault and report all findings to the supervisor in writing. ■ Test and operate machine as per machine OEM and site procedures. ■ Read and understand machine and site-specific operational and testing instructions.

Product

Before applying power to the equipment, the user/repairer/installer must read all product instructions. If in doubt, seek assistance.

■ Ensure electrical connections are made as per RCT’s recommendations. Test circuits prior to connecting power to any component.

■ The equipment contains no user-serviceable parts inside. Return the unit to RCT for repairs. ■ Retain product and installation instructions for future use. ■ Ensure that RCT’s recommended service procedures are included in the machine’s service routine. ■ Observe all machine, site and RCT product warnings. ■ Follow all machine, site and RCT product operating procedures at all time.

The application of safety should not be limited to the above recommendations.


Product Overview

Figure 1 Muirhead® Electronic Road Speed Limiter

The Muirhead® Electronic Road Speed Limiter, part number 11186, prevents the machine from over speeding independently of the operator. This is achieved by comparing the programmed speed that is imposed within the workplace to the frequency input from the OEM speed sensor.

When the maximum programmed speed is approached, the road speed limiter starts to de-rate the throttle to slow the machine down.

The road speed limiter is easy to install, fully programmable, tamper-resistant, increases workplace safety and still allows the operator to use all gears to maximise efficiency.

Never start, run or drive the vehicle until the setups contained in this manual have been completed and checked. Use a controlled test driving area or road of sufficient length to allow full testing at the desired top speed and still allow a safe stopping distance. If possible, initial testing should be performed on a flat area.

All adjustments to the software with the vehicle running must be performed by a passenger; alternatively, a Bluetooth serial link (12531) is available for single seat vehicles where a separate driver will still be required. The driver should at no time attempt to make adjustments whilst operating a vehicle.

Exercise caution if adjustments are to be made to the software settings whilst the vehicle is in motion as changes may cause a loss of throttle control.

Features and Functions

■ Rugged design suited to harsh operating environments. ■ Simple machine integration. ■ Easily configured throttle and speed control using the PowerMaster software. Changing the settings for

this unit is a simple process and is detailed further in this manual.

■ Integration with a GPS zone control unit module (11020) allows for automatic speed limiting dependent on geographic location.

■ An option is available to ramp the throttle up and down. When carrying delicate goods, it can be a distinct disadvantage to accelerate or decelerate quickly. The PowerMaster software allows the option to ramp up and down when speeding up and slowing down. This allows smoother acceleration and deceleration during this time.


Operation and Use

The road speed limiter is a programmable device suitable for 12 to 24 volt vehicles that are fitted with fly-by-wire throttle systems utilising a single or dual 0 to 5-volt throttle potentiometers.

The control unit is connected in series with the original equipment manufacturer (OEM) throttle system.

The system operates by sensing the voltage signal coming from the throttle using the throttle position sensors and outputs exactly the same signal to the electronic engine management system. The road speed limiter will replicate this signal until the system initiates an action to limit the vehicles road speed.

The system also has a frequency signal input that senses the speed of the machine and is programmable in its calibration. When the machine approaches the maximum desired speed, the limiter starts to de-rate the throttle signal to slow the machine down. The rate and timing in which the throttle is de-rated is programmable and is also dependent on machine acceleration.

The control unit is fitted with an internal relay that when activated, will connect the machine throttle through the control unit and will allow the unit to control the speed when the programmed limit is reached. If power is lost to the control unit, the throttle circuit will revert to standard machine throttle and remove the speed limiter from the system. This feature is fitted to allow for continued operation if the speed limiter power fails.

Note

The speed limiter should be turned off when the vehicle is being driven on a highway.

This product can be used for limiting the top-end speeds of suitable vehicles in dangerous areas where road conditions and pedestrians are not conducive to high speeds. Using this system still allows the machine to have access to all gears and there is no need to lock out gears to try and reduce the speed of the vehicle.

The 11186 road speed limiter is suitable for both direct current (three-wire) and alternating current (two-wire) speed sensor types. Internal circuitry is used to amplify low level speed signals below approximately four volts peak-to-peak. Both types of speed sensor signals are filtered to remove extraneous noise which may otherwise interfere with the correct operation of the speed limiter.

DIP switch options bank 2, switch 8 is ON for both filtering and amplification of the input speed signal whereas it will provide filtering only in the OFF position. The factory default setting for this switch is the ON position.

Contact your local RCT technical staff for assistance if you have any concerns regarding the use of this product.


Installation Instructions

1. Study and understand the wiring diagrams in this manual to aid in installation.

2. Install the control unit in a suitable position under the instrument panel or in a convenient location under the bonnet away from any major heat sources or engine vibration.

3. Locate the OEM connector for the throttle position sensor(s) (TPS). If the OEM machine diagrams are available, determine which wire(s) are sending the signal(s) to the engine ECU. This will be dependent on how many TPS circuits are in the accelerator pedal. Interface the speed limiter loom into the OEM TPS circuit as shown in the examples under the TPS Connections section of this manual. Some installations may require additional connectors or alternate connections, for example, soldered connections.

Note

If there is no OEM diagram available, the OEM TPS connector will need to be back-probed with the use of a multimeter. Determine which wire(s) are sending the signal(s) to the engine ECU as shown in the TPS Connections section of this manual.

⚠ Caution All two-way radio coaxial cables should be separated by at least 100 mm from all electronic pedal or TPS wiring, as it may induce interference into the system.

4. Install the loom in a suitable position and connect to a fused ignition supply and sensor ground (using the sensor ground will prevent fault codes being locked in the OEM ECU). Ensure that the 3-pin programming connector is positioned in a convenient place allowing for easy access when connecting a laptop or a Bluetooth serial link dongle.

Note

■ If the engine ECU is logging throttle fault codes on ignition power up, the speed limiter may need to be connected to a fused battery supply. The fault code is due to the time the speed limiter takes to switch the TPS output(s) on following power up.

■ If there are no fault codes indicated on ignition power up, however codes become active during operation of the machine when the TPS switch incorporates an idle validation switch, follow the instructions in the Programming Information section of this manual.

5. If the machine has an OEM speed sensor and is of the two-wire type, it will require both the blue (+VE signal) and blue/white (−VE signal) to be connected/spliced to the sensor wiring. Ensure that any OEM wiring modifications are carried out on the OEM loom side, to allow for speed sensor replacement in the event of a speed sensor failure.

6. For low speed industrial equipment with no provision for an OEM speed sensor, a 3 wire proximity sensor will be required (0465). This is required to be fitted into the differential housing so that it faces the crown-wheel teeth. This is achieved by drilling and tapping a 12mm x 1.0mm pitch hole into the differential housing. The sensor needs to be screwed into a depth of 2 mm from the face of the crown-wheel teeth. Please seek expert advice from the machine supplier if you are unsure of where this hole is to be located.

Note

When using a 3-wire proximity sensor (0465) the DIP switches on the PCB require configuring as per instructions found in the Pre-installation Setup of 11186 Control section of this manual.

7. If the machine has an OEM CAN speed sensing system ONLY, a CAN-to-ground speed converter will be required (12505). This unit will need to be spliced onto the wiring of the OBD-II connector, refer to diagram 537s for fitting instructions


Throttle Position Sensor (TPS) Connections

Typical OEM Dual TPS Pedal

Typical Interfacing of the Speed Limiter Loom into the OEM TPS Circuit

■ The speed limiter loom should be connected into the machine side of the accelerator loom. This is so that the OEM pedal can still be replaced for any reason in the future.

■ The OEM loom should be cut and, by using the connectors provided, the loom should be installed between the pedal and the machine.

Note

The pin connections indicated above are a guide only and may differ on the various machines.

Locating the 5-Volt Reference Voltage(s)

The example below illustrates the location and measurement of the 5-volt supply to the TPS.

1. Set the multimeter to read dc voltage. 2. Connect the common lead (black) to battery negative. 3. With the pedal connected and the ignition turned on, back probe the plug with the red lead until the meter

reads 5 V.

OEM

CONNECTOR

OEM

PEDAL

ENGINE

ECU

RD

RD

BK

BK

YL

WH

5 VOLTS SUPPLY

5 VOLTS SUPPLY

0 VOLTS OR GROUND

0 VOLTS OR GROUND

TPS OUTPUT

TPS OUTPUT

1

2

3

4

5

6

NOTE: THE CONNECTOR IS AN EXAMPLE ONLY

THE PINS MAY DIFFER ON THE MACHINE

3

4

5

6

CUT LOOM

RD

RD

BK

BK

YL

WH

5 VOLTS SUPPLY

5 VOLTS SUPPLY

0 VOLTS OR GROUND

0 VOLTS OR GROUND

1

2

3

4

5

6

RD

RD

BK

BK

YL/BU

WH/BU

5 VOLTS SUPPLY

5 VOLTS SUPPLY

0 VOLTS OR GROUND

0 VOLTS OR GROUND

TPS OUTPUT

TPS OUTPUT

1

2

3

4

5

6

OEM

CONNECTOR

OEM

PEDAL

ENGINE

ECU

SPEED LIMITER

LOOM

TPS OUTPUT

TPS OUTPUT

1

2

5 VOLTS SUPPLY

5 VOLTS SUPPLY

0 VOLTS OR GROUND

0 VOLTS OR GROUND

V

OFFACDC

COM V

V

OFFACDC

COM V

1

2

3

4

5

6

OEM

PEDAL

TPS OUTPUT

TPS OUTPUT

+5 V +5 V + 5

Volts + 5

Volts

Ref: 463h

Ref: 463h

Ref: 463h


Locating the Signal Ground(s)

The example below illustrates the location and measurement of the signal ground.

1. Leave the red lead in the pin that indicated 5 V. 2. Back probe the plug with the black lead until the meter again reads 5 V.

Locating the TPS Pedals

The example below illustrates the location and measurement of the TPS signal that goes to the engine ECU noting that it should be between 0.5 – 4.5 volts approximately.

1. Leave the black lead in the pin with the signal ground. 2. Back probe the remaining two pins with the red lead. 3. Slowly press the accelerator pedal and the voltage on the meter should scale up or down accordingly.

Note

The pin connections indicated above are a guide only and may differ on various machines.

5 VOLTS SUPPLY

5 VOLTS SUPPLY

0 VOLTS OR GROUND

0 VOLTS OR GROUND

V

OFFACDC

COM V

V

OFFACDC

COM V

OEM

PEDAL

TPS OUTPUT

TPS OUTPUT

1

2

3

4

5

6

OEM

PEDAL

1

2

3

4

5

5 VOLTS SUPPLY

5 VOLTS SUPPLY

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0 VOLTS OR GROUND

V

OFFACDC

COM V

V

OFFACDC

COM V

TPS OUTPUT

TPS OUTPUT

6

+5V +5V

+ 5 Volts

Ref: 463h

Ref: 463h

+ 0.5 – 4.5 Volts +0.5V +0.5V


Examples of Other Typical TPS Pedals

Single Potentiometer

Single Potentiometer with Idle Validation

5 VOLTS SUPPLY

0 VOLTS OR GROUND

TPS INPUT

POT 1

THROTTLE PEDAL

1

2

3

5 VOLTS SUPPLY

5 VOLTS SUPPLY

0 VOLTS OR GROUND

0 VOLTS OR GROUND

IDLE SIGNAL

TPS 1 INPUT

POT 1

THROTTLE PEDAL

NC

NO

C

1

2

3

4

5

6

Ref: 463h

Ref: 463h


Diagrams

System Wiring Diagram (476j)

Figure 2 Drawing 476j – System wiring diagram

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Calibration

Opening the Deutsch Enclosure

1. With a small flat blade screwdriver, gently prise the two locking tabs on either side of the enclosure (one side at a time) until the circuit board (PCB) can be removed.

2. Place the PCB on a rag or piece of paper to ensure that no components can come in contact with the metal frame of the machine (ground). This would result in a short circuit to ground which may cause irreversible damage to internal components.

Pre-Installation Setup of 11186 Control

Configuration of the 11186 road speed limiter to correctly interpret the vehicle speed sensor amplitude

The 11186 road speed limiter is factory set to sense speed sensor signals that have amplitude lower than four volts peak-to-peak. This means that the DIP switch options bank 2, switch 8 is ON, providing filtering and signal amplification functions.

Having this switch to the ‘ON’ position in most cases, will not affect the operation if the speed signal amplitude is greater than four volts peak-to-peak. However, if high noise is present on the throttle signal input, it will be amplified and may be interpreted as an actual speed signal. This will result in sporadic speed limiting operation and/or throttle control.

Note: There are no user serviceable parts inside. A faulty unit should be replaced with a spare unit, and the unserviceable unit should be returned to RCT for repairs.

⚠ Caution Check the vehicle’s speed sensor signal amplitude and confirm the control unit configuration before initial power-on.

Locking tabs

ON OFF

For signal amplification and filtering, set switch 8 to the ON position. (On position for switch 8 is the factory default).

For filter only setting, switch 8 is set to the off position.


Full DIP Switch Options Table

Switch Bank 1

Switch No. Description Function when ON Function when OFF Default

SW 1 Grey receptacle pin 5 Input 1 pulled up Input 1 not pulled up Off




SW 5 Grey receptacle pin 5 Input 1 pulled down Input 1 not pulled down On




SW 9 Grey receptacle pin 3 Puts a load onto TPS Input 1. (Only used with PWM TPS input)

No load on TPS input 1 Off

SW 10 Grey receptacle pin 3 TPS Input 1 will read 0-33 Vdc scale

TPS Input 1 will read 0–5 Vdc scale

Off

Switch Bank 2

Switch No. Description Function when ON Function when OFF Default

SW 1 Grey receptacle pin 9 TPS 1 out scaled 0–10 V TPS out 1 scaled 0–5 V Off

SW 2 Grey receptacle pin 10 TPS 2 out scaled 0–10 V TPS out 2 scaled 0–5 V Off

SW 3 Grey receptacle pin 9 TPS 1 analogue output TPS 1 PWM output On

SW 4 Grey receptacle pin 10 TPS 2 analogue output TPS 2 PWM output On

SW 5 Grey receptacle pin 4 Filter is enabled for TPS Input 2

Filter is disabled for TPS input 2

On

SW 6 Grey receptacle pin 4 TPS Input 2 will read 0–33 Vdc scale

TPS Input 2 will read 0–5 Vdc scale

Off

SW 7 Grey receptacle pin 3 Filter is enabled for TPS Input 1

Filter is disabled for TPS input 1

On

SW 8 Grey receptacle pin 11 Ground speed signal amplifier on

Ground speed signal amplifier off

On

SW 9 Grey receptacle pin 11 Noise reduction (typically blocks frequency above 2 kHz)

Noise reduction disabled On

SW 10 Grey receptacle pin 12 Speed signal negative common with Gnd

Speed signal negative isolated from Gnd

Off

Note

■ If analogue voltage outputs are required, switches 3 and 4 of switch bank 2 must be on for the required output(s).

■ The standard output is 0–5 Vdc. Switches 1 and 2 of switch bank 2 should be turned on for a 0–10 Vdc output.

■ If the speed signal has a frequency above 2000 Hz, switch 9 of switch bank 2 must be turned off.

■ Pull up is used when detecting a negative input. Pull down is used when detecting a positive input.


When using a three-wire proximity or hall-effect type speed sensor, the DIP switches on the PCB need to be reconfigured as detailed below.

Options Switch Bank 1 Options Switch Bank 2

Switch 1 Off Switch 1 Off

Switch 2 Off Switch 2 Off

Switch 3 Off Switch 3 On


Switch 5 On Switch 5 Off







Programming Information

⚠ Caution Never operate a vehicle while working with a laptop. it is recommended to have a second person operating the vehicle.

If you are working on a single seat vehicle, RCT recommends the use of a wireless communications system such as the 12531 Bluetooth serial link.

Please contact your nearest RCT branch for more information on this product.

RCT recommends that a controlled test driving area or road of sufficient length be used to carry out testing of the machine. This will allow full testing at the desired top speed while still providing a safe stopping distance. If possible, initial testing should be performed on a flat area.

Connect the laptop to the speed limiter control unit using the RCT 10795 programming lead (three-pin Deutsch-to-serial connector). The Deutsch programming connector is part of the loom connecting the speed control unit to the machine.

For single seat vehicles, the programming lead will plug into the serial connection on the Bluetooth serial adaptor. The USB Bluetooth adaptor can then be plugged into the laptop computer.

For further information on this Bluetooth connection, refer to the 12531 Bluetooth serial link product manual supplied with the Muirhead® Bluetooth equipment.

Once connected:

1. Launch the PowerMaster software. 2. Click Yes to all warnings and authority windows messages.

Note

The machine’s ignition must be TURNED ON for communication to occur.

Default Factory Settings for 11186 Speed Limiter Control Unit

1) Com Port 1 is

selected Note: This many

need to be configured to the com port that the

programming lead is connected to.

2) Key 1 is set (default)

4) Road Speed Limiting is selected (default)

3) Address 1 is set (default)

5) Speed Limiter with Voltage in is

selected. This is selected for vehicles with 0-5 V throttle circuit (default)

5a) Speed Limiter with PWM in is selected.

This is selected for vehicles with PWM throttle circuit (default)

6) 0-100% PWM

is selected

7) Force Zero is not selected

8) Freq is set to 4000 Hz

9) PWM Fast is

selected

10) Hi res is

selected.

Note:

Only selected for low speed

applications under 25 km/h


Setting up ‘Volt In1’ – Minimum Level Percentage

1. For vehicles with a 0–5 V throttle circuit, follow this step to set up Volt In1. While leaving your foot OFF the accelerator pedal, record the throttle minimum input voltage percentage output from the pedal as indicated in the circle below for potentiometer 1. The Min Level percentage will need to have a flat two percent added to the value, as indicated below.

Note

This step is only required if the pedal has two potentiometers connected.

Select the Ch2 tab on the lower left of screen. While leaving your foot OFF the accelerator pedal, record and then enter the throttle minimum input voltage percentage coming from the pedal as indicated in the circle below for potentiometer 2.

2. For vehicles with a PWM throttle circuit, follow this step to setup PWM In1. Speed limiter with PWM In must be selected in the control unit option section. While leaving your foot OFF the accelerator pedal, record the throttle minimum PWM in percentage being output from the pedal as indicated in the circle below for potentiometer 1. The Min Input PWM percentage will need to have a flat two percent added to the value, as indicated below:

Enter the percentage level, plus 2% (e.g. 10% 12%), that will be indicated in the

circle above, here. This can be typed in or adjusted

using the arrows.

Enter the percentage level, indicated in the circle above, here. This can be typed in or

adjusted using the arrows.

Note: It is not necessary to

add 2% here.

CH2 tab

Add 2% to this value (e.g.10% 12%

Enter the percentage level, plus 2% (e.g. 10% 12%), that will be indicated in the

circle above, here. This can be typed in or adjusted

using the arrows.

Enter the percentage level, indicated in the

circle above, here. This can be typed in or adjusted using the

arrows.

Note: It is not necessary to add 2% here.


Setting up ‘Volt In1’ – Maximum Level Percentage

1. For vehicles with a 0-5 V throttle circuit, follow this step to setup Volt In1. Fully depress the accelerator pedal, record the throttle maximum input voltage percentage output from the pedal as indicated in the circle below for potentiometer 1. The Max Level percentage will need to be reduced by a flat two percent, as indicated below.

Note

This step is only required if the pedal has two potentiometers connected.

Select the Ch2 tab on the lower left of screen. Fully depress the accelerator pedal, record and then enter the throttle maximum input voltage percentage coming from the pedal as indicated in the circle below for potentiometer 2.

2. For vehicles with a PWM throttle circuit, follow this step to setup PWM In1. Speed limiter with PWM In must be selected in the control unit option section. Fully depress the accelerator pedal, record the throttle maximum PWM in percentage output from the pedal as indicated in the circle below for potentiometer 1. The Max Input PWM percentage will need to be reduced by a flat two percent, as indicated below:

Enter the percentage level, reduced by 2% (e.g. 90

% 88%) that will be indicated in the circle

above. This can be typed in or adjusted using the

arrows.

Enter the percentage level indicated in the circle above here. This can be typed in or adjusted using the arrows.


CH2 tab

Reduce this value by 2% (e.g.90% 88%

Enter the percentage level, reduced by 2% (e.g. 90 % 88%) that will be indicated in

the circle above. This can be typed in or adjusted

using the arrows.

Enter the percentage level indicated in the circle above

here. This can be typed in or adjusted using the arrows.



Setting the Minimum Pull Back

1. Select the Extras tab on the lower left of screen. Then, set the minimum pull back.

This is required if the throttle pedal assembly is equipped with an idle validation switch. The idle validation switch changes state when the throttle pedal is depressed just beyond the idle position. The ECM uses this change of state to check that the pedal is working within set limits. The switch trip point percentage can be either measured by using a multimeter in conjunction with the observed Calculated Value software, or it may sometimes be heard to change state when depressing the pedal.

2. Once the percentage of throttle pedal travel required to trigger the validation switch has been established, enter a value approximately one percent higher into the set minimum pull back field

Determining where the Idle Validation Switch Changes State

To determine the point where the idle validation switch changes state:

1. Connect the common lead (black) of the multimeter to battery negative. (ground)

2. Back probe the idle signal pin with the red lead.

3. Whilst watching the meter, slowly depress the accelerator pedal. When the indication on the meter changes state from + 5 volts to 0 volts or from 0 volts to +5 volts, take note of the Input Voltage percentage of Volt In1 at the time of the switchover.

.

1

2

3

4

5

6

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5 VOLTS SUPPLY

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0 VOLTS OR GROUND

IDLE SIGNAL

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POT 1

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NC

NO

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V

OFFACDC

COM V

Select Extras tab.

Set the min pull back value approximately 1% higher.

Observed

calculated value

Dwg 463h


4. Enter the percentage into the Set min pullback box as shown on the preceding page.

5. Click Save.

Note

■ If the display on the multimeter does not change, then the idle validation switch may be switching negative. If this is the case, connect the red lead to battery positive and back probe the idle signal pin with the black lead.

■ The idle validation switch may be normally open (N/O), normally closed (N/C), or a combination of both. It is irrelevant what way it switches; the only information required for the speed limiter is at what point it does switch.

6. Select the Speed tab on the lower left of screen. Set Desired Top Speed (limiting speed).

7. Setting Absolute MAX Speed. This is set and adjusted to provide a smooth transition between the operators throttle position and the limiter’s output to the ECM while speed limiting occurs.

Tip: For light commercial vehicles with lower desired speeds (e.g. 30 kph) a suggested absolute max speed would be approximately 1.5 x the desired speed (e.g. 1.5 x 30 kph = 45 kph).

At higher desired speeds or larger commercial vehicles, the value is generally reduced (e.g. 1.2 x desired top speed).

8. Setting for dual or multiple speeds. Refer to the Setting Unit for Multiple Speed Zone Application section of this manual for detailed information on setting up more than one speed limit setting.

9. Initial setting of the pulses per meter (PPM). If the value is already known it may be entered directly.

a) Alternatively, under the Speed tab, click . When the Cal. screen appears, double-click

. Mark both the ‘wheel diameter’ and ‘number of turns’ fields as ‘0’. Change the distance in the bottom right to 20 m.

Note

Any input here will override the distance checkbox to the left. Mark out a 20 m test length and position the vehicle at the start point.

b) Depress and hold and have the vehicle driven along the 20 m test length, releasing the button at the 20 m mark.

c) Click and the resulting pulses per meter (PPM) will be displayed.

Select Speed tab

Set Desired Top Speed

Set Absolute

MAX Speed

Setting for dual or

multiple speeds


10. Disconnect communications lead 10795 from the laptop.

11. Start the vehicle and check for normal throttle response.

12. Reconnect the communications lead to the laptop and check that is illuminated green. If COMS Good is not illuminated, shut down and restart the PowerMaster software.

13. Calibrate the road speed limiter (RSL) with the vehicle’s speedometer for confirmation of speed limiting, if required. Test drive the vehicle, preferably on a flat area, at the desired top speed. If the vehicle is felt to be limiting but the speedometer is reading above the desired top speed, reduce the PPM by small increments until the limiting is matching the speedometer. Conversely, if the speedometer is reading below the desired speed during limiting, then increase the PPM until calibrated.

14. The button located on the Speed tab can be invaluable when making adjustments. Click

and the following screen will appear.

Tip: This screen can be maximised for better viewing. You can also start (press ), stop (press

) or clear the screen (press ) during testing.

The screen can also be minimised during setting changes and maximised to see the graph again.

20 metres


Setting Unit for Multiple Speed Zone Application

The 11186 control is capable of limiting a vehicle’s speed to four separate speed settings.

Note

More than four is possible – please contact RCT if this is a requirement.

An example of how this feature is set up can be seen on diagram 476j in this manual. The GPS zoning option is drawn in blue.

In the PowerMaster programming software, the 11186 unit can be configured to limit a single speed, dual speed, or multiple speeds for different areas of operation.

Depending on how the contact inputs have been set up will determine whether a negative or positive input to either pin 3, 4, 5 or 6 of the speed zoning input plug will trigger the unit for that speed input setting (refer to plug C on the 1186 loom in drawing 423m).

Figure 5 Screenshot – Setup for multiple speed zone application

In the example below, the contact inputs are set up so that any positive voltage greater than 5 volts will trigger that particular input. If the Sw-Invert checkboxes for IN1 to IN4 are not selected, then any voltage less than 5 volts or simply grounding the input to 0 volts will enable that input speed setting.

Figure 6 Screenshot – Set up contact inputs

Set up the speed limiting inputs for either positive or

negative switching.

Trip level set for each input. Note: IN3 and IN4 trip level set point is tied for each.

Example: Select Invert1 to Invert4 checkboxes to

trigger above the trip level set at 5 V. Clear Invert1 to Invert4 checkboxes to trigger below the trip level set at 5 volts.


Single Speed Operation

For single speed operation, clear both the Dual Speed and Multi Speed checkboxes as shown in the following screenshot.

Figure 7 Screenshot – Single speed operation

Dual Speed Operation

For dual speed operation select the Dual Speed checkbox and leave the Multi Speed checkbox clear as shown in the following screenshot.

Figure 8 Screenshot – Dual speed operation


As shown in the preceding screenshot, when the Dual Speed checkbox is selected, a second set of boxes are displayed to allow the second speed setting to be entered.

The settings for Absolute MAX Speed and Desired Top Speed for dual or multi operation are the same as steps 6 and 7 on page 23 of this manual.

In this example, if a positive voltage greater than 5 V is put to pin 3 of the zoning plug in the loom, then IN1 will be enabled and the vehicle will have a speed limit 15 kph.

If the signal is removed from pin 3 of the zoning plug, then the speed limit setting will revert to 20 kph.

Multi-Speed Operation

For multi-speed operation, select the Multi Speed checkbox and leave the Dual Speed checkbox deselected.

Figure 9 Screenshot – Multi-speed operation

The speed limiting range is set between the minimum of 15 kph and 20 kph in the above example.

Selecting the Multi Speed checkbox also enables the button to appear. Click to show the following screen below.

Figure 10 Screenshot – Mapping screen for multi-speed setting

This is the speed setting with no inputs triggered (15.0 kph as set to be the lowest speed on previous screen shot).

This is the speed setting with pin 3 of zoning plug in the loom greater than 5 volts and all other inputs not triggered (IN1) (16.0 kph).


These sliders can be moved to any desired speed between the lowest speed and the highest speed.


This is the speed setting with pin 6 of zoning plug in the loom greater than 5 volts and all other inputs not triggered (IN4) (20.0 kph as set to be the highest speed on the previous screenshot).


How to Enter Graph Screens When Trouble Shooting

Figure 11 Screenshot – How to enter graph when troubleshooting

Select the Speed tab

Click GRAPH/PID


Interpreting Graph Screens

Figure 12 Screenshot – Interpreting graph screens 1

Green = Absolute max speed – used to adjust how the speed limiter reacts to the actual speed approaching the desired speed.

Yellow = Desired top speed – the speed limit speed.

White = Max allowable throttle output – this is the max percentage of throttle output permitted from the limiter at the given speed.

Grey = Actual throttle output from the speed limiter (this is a voltage of between 0–5 volts shown as a percentage of 5 volts).

Red = Vehicle actual ground speed – supplied from the vehicle speed sensor (VSS).



Actual speed approaching desired top speed.

Maximum allowable throttle percentage is lowered as desired top speed approaches.

Actual throttle output is limited to reduce power output as the desired top speed nears.

Operator depressing the throttle pedal to the maximum position and holding down, providing maximum actual throttle output.



This shows the operator lifting off the throttle, slowing the vehicle to 10 kph and then re-applying variable throttle to try and maintain 10 kph.

The speed limiter constantly monitors the actual speed as it fluctuates over undulations on the road surface.

By continually adjusting the maximum throttle output limit, engine power is regulated to maintain the desired speed.


Check Sensor Feature on PowerMaster Software Version V245c and Higher

No speed limiting device is failsafe in operation because it depends on a valid speed signal to operate effectively. For example, if a wire is broken between the speed sensor and the speed limiting device, then the speed signal will not be sensed. The speed limiter will then calculate that the vehicle is stationary and will not actively speed limit even though the vehicle may be travelling at speed. A new version of software has been developed to de-rate the vehicle engine when a frequency signal is not sensed for a pre-set time. This feature is factory set to not be enabled (the check sensor checkbox shown in the diagram below will not be selected).

PowerMaster software, version V245c and higher, has a ‘check sensor’ option. This option when selected will automatically ramp the throttle down to 20 percent of full throttle after a set time (30 seconds RCT factory set) when a speed signal is not detected. The timer is reset when the operator’s foot is removed from throttle position sensor peddle so that the engine returns to idle. When the operator reapplies pressure to the throttle peddle, it will provide full power when starting to move off. The throttle will continue to be ramped down every 30 seconds with no speed signal sensed. This allows the operator to sense there is a fault to the vehicle whilst not making it completely inoperable.

Figure 15 Screenshot – Check sensor feature on PowerMaster v245c & higher

Select the Sensor tab.

Select Sensor Smoothing and Check

Sensor checkboxes.

Set the Read sensor as box to ‘kph’.

Set the time delay for throttle to be backed off.

(RCT recommends a 30-second delay.)


Service Information

Service Schedule

The manufacturer recommends that the following service procedure should be performed at each machine’s scheduled service interval.

Service Procedure

1. Perform a visual inspection; include the following:

a) Wiring connections and looms

b) Speed limiter device enclosure and internal condition

2. Perform a thorough inspection of the actuator. If it appears jittery or noisy, it is recommended to replace the actuator.

3. Operate the vehicle to confirm that the device is operating correctly.

Parts List

Part No. Description

11186 Limiter, road speed generic

11068 Loom to suit dual TPS FBW speed limiter

9990 PowerMaster software

10795 Programming loom

12076 USB-to-serial adaptor kit

12531 Bluetooth serial link kit

5947 Key switch to suit speed limiter

4874 Label

Technical Specifications

Weight: 250 g

Mounting Bracket: Yes

Input Voltage: 12–24 Vdc

Inputs: 0–5 V, PWM up to 24 V peak-to-peak

Standby Current Draw: 32 mA

Current Draw Normal Operation: 32 mA

Operating Temperature Range: −25 °C to +90 °C

Connection Types: Deutsch – DTM series

Circuit Protection: None

Enclosure Type: Thermoplastic

IP Rating: IP65

Programming Port: Via the speed limiter loom

Programming Lead Supplied: No

Quality Standards: C-Tick

Maximum Speed Input Frequency: 2000 Hz

Maximum Speed Input Amplitude: 32 V measured with an RMS voltmeter


Compliance and Standards

RCT has an obligation as a manufacturer to comply with the regulations as required by the relevant regulatory bodies, depending on the market and location.

This product currently complies with the following:

ACMA CISPR 22:2006 Class A procedures – Information technology equipment – Radio disturbance characteristics – Limits and methods of measurement

EU EMC Directive 2004/104/EC

RoHS Directive 2011/65/EU

FCC This device is exempt from FCC regulations under 47 CFR 15.103 Exempted devices.

IC This device is exempt from IC regulations under ICES-003 — Information Technology Equipment (ITE) — Limits and Methods of Measurement.

Troubleshooting

No. Fault Remedy

1. Vehicle throttle operates but does not speed limit.

■ Check connection of the speed sensor to the control unit.

■ Connect laptop computer to control unit and operate machine. Observe the speed window while the vehicle is being driven. The vehicle’s speed should be able to be viewed on the laptop. If there are no pulses, ensure the control unit has been set up correctly for the speed signal amplitude—refer to the Programming Information section of this manual.

■ Check all wiring, connections and the vehicle speedometer to ensure that the speed sensor is operating correctly. Re-save changes.

Note: This should be carried out using the wireless link with another person driving when testing single seat vehicles.

2. Vehicle throttle does not operate.

■ Check all electrical connectors and ensure the machine is powered up.

■ Has the engine management light on the instrument panel been observed to come on at any stage? If so, then recheck settings on the laptop as this would indicate that the settings entered are outside the OEM ECM parameters and will need to be increased or decreased accordingly.

3. Vehicle throttle operates but when speed limiting the vehicle throttle is unstable.

■ Refer to set up procedure in the Programming Information section of this document for setting absolute max speed to remove hunting and stabilise the speed limiting. Resave changes to the program as required.

Note: Some vehicles may still hunt and behave unstably at the desired speed even when the setup tips in the manual have been observed. In such cases, the ‘Absolute MAX speed setting’ and ‘Allow XX kph for XX sec’ will need to be slowly increased in value until the hunting is eliminated.

■ In some cases there will be a compromise between getting the speed limiting without hunting and the response time that the limiter will respond to the desired speed overshoot.

4. Vehicle does not reach full throttle.

■ Check all connections and ensure they are all secure.

■ Connect a laptop computer to the control unit, turn machine power on and check all settings. Operate pedal to make sure the input settings are correct. It may be that they are too low. Check output at idle and at full pedal movement, adjust as required.

■ Check the desired speed and absolute max speed are not the same, the system will not produce throttle if they are set to the same value.


No. Fault Remedy

5. Vehicle does not reach desired speed.

■ Check all connections and ensure they are all secure.

■ Connect laptop to the control unit turn machine power on and check all settings. Operate the pedal to make sure the input settings are correct. It may be that they are too low. Check output at idle and at full pedal movement, adjust as required.

■ Run through the calibrations to set the PPM in the Programming Information section of this manual to ensure the control unit is seeing the same speed as the vehicle.

6. Machine throttle operates but when speed limiting, it over shoots too far before returning to desired speed.

■ Refer to set up procedure in the Programming Information section of this document to remove over shooting of speed limiting. Adjust the absolute maximum speed and adjust the allowable time over shoot windows as required. Road test after all adjustments and resave changes before closing the program.

7. Sudden speed increases while driving or erratic speed control.

■ This may be because of a bad or lost speed signal. Check for faulty speed signal wiring and components.

8. Speed signal is ‘rolling’ yet machine is not moving.

■ Possible amplification of noise, check wiring and speed sensor.

9. Loss of throttle on engine crank.

■ Check actual voltage and specific gravity from battery. If the system pulls below 6 V for more than 300 ms it can cause a reset of the processor.

■ Check ignition circuit for proper wiring.

■ If battery and wiring are confirmed OK, refer to point below.

10. Vehicle ECU starts showing error codes and/or warning lights after fitting the system.

■ Adjust the PWM IN settings closer to the exact values. Do not exceed the actual value seen.

The Effect of a Speed Signal Spike

Figure 16 Screenshot – Speed signal spike

Drop in maximum allowable throttle output.

Momentary drop in actual output from the RSL control unit at high idle as a direct result of the spike as shown.

Spike in speed signal.

Note: This would

appear much clearer if the graph screen was maximised.

Whilst testing this truck, the speed signal had a large spike just as the transmission was shifting gears.


Appendix 1: Example of an Installation to VDJ Series Toyota LandCruiser

The following pictures are taken from an installation to a VDJ series Toyota LandCruiser to demonstrate a possible mounting method.

Figure 17 Possible mounting method to a VDJ series Toyota LandCruiser

Remove the glove box and using a 6 mm x 30

mm hex bolt and flat washer drop the bolt with

washer fitted into the top of this hole.

Fit the 11186 control unit to the 6 mm bolt and secure with washer and nyloc nut.

Plug the connectors on the 11068 loom into the 11186 control.

Lay in the loom behind the instrument panel so that the program port connector is easy to access. In this example, the program port exits into the ash tray compartment.

The tails of the 11068 loom will exit here behind the panel under the steering column. Tie the loom tails into place and connect into the TPS/ECM, ignition

and speed signal wiring as per drawing 476j in this manual.


Typical Wiring Diagram

Figure 18 Typical wiring diagram (reference drawing 477v)

1 2 3 4 5 6

TPS INPUT

1

2

3

4

5

6

1

2

3

4

5

6

TPS OUTPUT

BU

BU/RD

RD/BK

BU

(CONNECT TO THE PEDAL

SIDE OF THE TPS LOOM)

(CONNECT TO THE MACHINE


BU

BU

/WH

RD

/BK

BN

BN

/WH

TO OEM ECM

PART OF APN 11068 LOOM

REFER TO DRAWING 423m

BU

/RD

RD

BK

BK

E2

SPLICE3

SPLICE3

RDE1

RD

BK

BK

D2

SPLICE3

SPLICE3

RDD1

YL/BK

BK/WH

A10

A9

YL

WH

A4

A3

BU/RD

RD/BK

OEM

PEDAL

1 2 3 4 5 6

TPS INPUT

1

2

3

4

5

6

1

2

3

4

5

6

E

D

TPS OUTPUT

WH

BU/RD

RD/BK

WH

BU/RD

RD/BK

(CONNECT TO THE PEDAL


(CONNECT TO THE MACHINE


WH

BN

/WH

RD

/BK

BN

PU

OEM WIRING

HARNESS

TO OEM ECM

PART OF APN 11068 LOOM

REFER TO DRAWING 423m

BU

/RD

RD

BK

BK

E2

SPLICE3

SPLICE3

RDE1

RD

BK

BK

D2

SPLICE3

SPLICE3

RDD1

YL/BK

BK/WH

A10

A9

YL

WH

A4

A3

E

D

OEM WIRING

HARNESS

OEM

PEDAL

OEM WIRING PRIOR TO AUGUST 2016, AUSTRALIA PRODUCTION OEM WIRING AFTER AUGUST 2016, AUSTRALIA PRODUCTION

WIRE LEGEND

BK - BLACK PK - PINK

BU - BLUE PU - PURPLE

BN - BROWN RD - RED

GN - GREEN WH - WHITE

GY - GREY YL - YELLOW

OR - ORANGE TQ - TURQUOISE

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

B

A

C

D

E

F

G

H

B

A

C

D

E

F

G

H

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

A4

COPYRIGHT - ALL RIGHTS RESERVED

This drawing is the property of REMOTE

CONTROL TECHNOLOGIES PTY LTD (RCT),

and is not to be copied or used in whole or in

part for any purpose without the express

authority of RCT. The drawing is to be returned

to RCT, on demand.

TYPICAL TOYOTA

MODEL THROTTLE

POSITION SENSOR

(TPS) WIRING

SPLICED INTO TPS

INPUT AND OUTPUT

PLUGS OF 11068

LOOM

WIRING DIAGRAM

www.rct.net.au

UNCONTROLLED DOCUMENT

REV

2DWG No

477v

STATUS

NTSSCALE

Released

SHEET 1 of 1

BY SD

DRN CW DATE 17/05/13

APPD DH DATE 17/05/13

STOCK

CODE ----

PART

NO ----

3rd ANGLE

PROJECTION

ALL DIMENSIONS IN MILLIMETERS

REV ZONE DESCRIPTION BY DATE

1 G3, I3wiring changed at plug D

and EJB 30/08/16

2 Var.OEM wiring prior/after

addedJB 12/06/19

The VDJ series Toyota LandCruiser has a speed signal wire feeding into this point behind the radio. See green wire feeding into the scotch lock. Only the blue wire in the 3-pin Deutsch plug for the speed signal on the 11068 loom needs to be connected to this wire. The orange (ignition) and BU/WH (signal sensor 0 V) do not get connected to anything in this type of install to light vehicle.


Appendix 2: Caterpillar PWM Throttle RSL Applications

Figure 19 Screenshot – Caterpillar PWM throttle RSL applications

Note 2: – PWM values from the throttle

pedal for 0% throttle and 100% throttle need to be entered in both locations.

Note 1: – PowerMaster control unit type needs to be changed to Speed

limiter with PWM in.

Note 4 – Set frequency for the PWM outputs to 500 Hz.

Note 3 – Setting of Ch2 (PWM IN2) is not required and must be unselected.


Note 5 – Set 11186 option switches as per the table below:

Switch Bank 1 Switch Bank 2

Switch 1 Off Off

Switch 2 Off Off

Switch 3 Off Off

Switch 4 Off Off

Switch 5 On Off

Switch 6 On Off

Switch 7 On Off

Switch 8 On On

Switch 9 On Off

Switch 10 Off Off

Note 6 – Speed sensor connections should be connected to the OEM 2-wire transmission speed sensor whenever possible. For example, if a 2-wire sensor is fitted on the 777F series trucks, E900-WH should be connected to 11186 grey connector pin 11 and E901-GN should be connected to 11186 grey connector pin 1. Refer to the manual for 3-wire connection detail.

Note 7 – OEM pedal connections:

Figure 20 OEM pedal connections

OEM Electronic Control Module (ECM)

Machine Connector

Throttle pedal with pedal-

mounted sensor

WH - 3

BK - 3

RD - 3

Machine Connector

Pedal PWM signal output to 11186 grey connector Pin 43

11186 PWM output to ECM 11186 grey connector pin 9

Pedal Earth to 11186 grey connector pin 2


Appendix 3: Road Speed Limiter – Optional Torque Reduction

Overview

RCT has received feedback from mine sites that the new V8 Toyota LandCruisers are suffering from premature failure due to wear and tear caused by the effects of high torque. Trials have been carried out in which the free rpm has been limited to a maximum of 4000 using the Muirhead® Speed Limiter product to adjust the maximum throttle position output. When the throttle is set to a free rpm of 4000, the vehicle under load travelling at 30 km/h runs optimally at about 3600 rpm. This setting has proved to work well for some users.

The following instructions allow technicians to set the maximum free rpm to 4000 rpm. These instructions are based on the speed limiter having already had all other standard set points adjusted as per the speed limiter manual.

To apply the Muirhead® Speed Limiter torque reduction option, perform the following instructions.

Programming Information

1. Run the PowerMaster software. 2. Click Yes to all warnings and authority window messages.

Figure 21 Screenshot – Programming information

1) Com Port 1 is

selected Note: This many

need to be configured to the com port that the

programming lead is connected to.

2) Key 1 is set (default)

4) Road Speed Limiting is selected (default)

3) Address 1 is set (default)

5) Speed Limiter with Voltage in is

selected. This is selected for vehicles with 0-5 V throttle circuit (default)

5a) Speed Limiter with PWM in is selected.

This is selected for vehicles with PWM throttle circuit.

6) 0-100% PWM is selected

7) Force Zero is not selected

8) Freq is set to 4000 Hz

9) PWM Fast is

selected

10) Hi res is

selected.

Note:

Only selected for low speed

applications under 25 km/h


3. Depress the accelerator pedal until 4000 rpm is reached. Record the throttle maximum input voltage percentage coming from the pedal at 4000 rpm as indicated in the circle below for potentiometer 1.

Note

This ste

Documents

ROAD SPEED LIMITER...Appendix 2: Cat PWM Throttle RSL Applications 38 Appendix 3: Road Speed Limiter – Optional Torque Reduction 40 Overview 40 Programming Information 40 Example