BENDIX ET-2 ELECTRONIC THROTTLE User manual

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®
8V
1
2
3
4
5
6
7
MACK
CAT
DETROIT
DIESEL
0V
DESCRIPTION
The ET-2™is an electronic throttle. On electronically
controlleddieselengines,theET-2™treadlefulfillsthesame
functionas aconventional mechanicalthrottle. The ET-2™
treadle controls engine speed by interacting with an
electronicfuelmanagementcontrolleronthe engine, rather
thantransmittinga mechanical force fromthethrottle pedal
totheenginegovernor.
The main components of the ET-2™throttle are a cast
aluminummountingbaseandtreadle,arubbertreadlecover,
a potentiometer (variable resistor), and a roller assembly.
Thepotentiometer is specificto each engine application.
OPERATION
TheET-2™treadleprovidessmooth,graduatedthrottlecontrol
throughthefunctionofitsvariableresistor,orpotentiometer.
TheET-2™treadlereceivesitssupplyvoltagefromtheengine
control unit. The lever shaft connects the roller assembly
to the potentiometer, so that any movement of the treadle
rotates the potentiometer. As the potentiometer rotates,
its resistance changes. This way, the potentiometer
communicates the throttle position to the fuel control
system by changing resistance, returning more or less of
thesuppliedvoltageback totheelectronicenginecontroller.
Ifthedriver does not requestenginepower, thethrottleis in
the idle (or “closed throttle”) position. In this state, the
potentiometer significantly reduces the amount of supply
voltage returned to the engine control unit (See Figure 2).
As the driver depresses the ET-2™treadle, output voltage
increases (see Figure 3). The potentiometer allows an
increasedamount ofitssupplyvoltagetoreturntotheengine
control unit, which in turn increases the engine’s speed.
In the full (or “open throttle”) position, the driver has fully
depressed the ET-2™treadle. This is the state of least
potentiometer resistance. The ET-2™treadle returns the
maximumpercentageofsupplyvoltagetotheenginecontrol
unit(see Figure 2).
SD-15-4106
Engine Idle Throttle Full Throttle
Manufacturer (Closed) (Open)
CAT 13 - 21% 79 - 89%
Cummins 8 - 18% 70 - 80%
Detroit Diesel 6 - 14% 86 - 94%
Mack 10 - 20% 70 - 85%
FIGURE 2 - ET-2™TREADLE OUTPUT VOLTAGE, AS A
PERCENTAGE OF SUPPLY VOLTAGE
FIGURE 3 - ET-2™TREADLE OUTPUT VOLTAGE
CLOSED THROTTLE OPEN THROTTLE
ET-2™
TREADLE
OUTPUT
VOLTAGE
○○○○○○○○○○○○○○○○○○○○○○○○○○○○
OR CUMMINS
Bendix®ET-2™Electronic Treadle
CONNECTOR
FIGURE 1 - ET-2™ELECTRONIC TREADLE
TREADLE
COVER
CABLE ASSEMBLY
ROLLER
MOUNTING BASE
DOUBLE RETURN
SPRING
PIVOT SPRING
POTENTIOMETER

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FIGURE 4 - EXPLODED VIEW
Figure3illustratestherelationshipbetweenthrottleposition
andengine RPM. Potentiometerperformance will vary for
eachengineapplication,thereforepotentiometers must not
beinterchanged.
WARNING! PLEASE READ AND FOLLOW
THESE INSTRUCTIONS TO AVOID
PERSONAL INJURYOR DEATH:
When working on or around a vehicle, the following
general precautions should be observed at all times.
1. Park the vehicle on a level surface, apply the
parking brakes, and always block the wheels.
Always wear safety glasses.
2. Stop the engine and remove ignition key when
working under or around the vehicle. When
working in the engine compartment, the engine
should be shut off and the ignition key should be
removed. Where circumstances require that the
enginebeinoperation, EXTREME CAUTION should
be used to prevent personal injury resulting from
contact with moving, rotating, leaking, heated or
electrically charged components.
3. Do not attempt to install, remove, disassemble or
assemble a component until you have read and
thoroughly understand the recommended
procedures. Useonlythepropertoolsandobserve
all precautions pertaining to use of those tools.
4. If the work is being performed on the vehicle’s air
brake system, or any auxiliary pressurized air
systems,make certain to draintheair pressure from
all reservoirs before beginning ANY work on the
vehicle. If the vehicle is equipped with an AD-IS™
air dryer system or a dryer reservoir module, be
sure to drain the purge reservoir.
5. Following the vehicle manufacturer’s
recommendedprocedures,deactivate the electrical
system in a manner that safely removes all
electrical power from the vehicle.
6. Never exceed manufacturer’s recommended
pressures.
7. Never connect or disconnect a hose or line
containing pressure; it may whip. Never remove a
component or plug unless you are certain all
system pressure has been depleted.
8. Use only genuine Bendix®replacement parts,
components and kits. Replacement hardware,
tubing, hose, fittings, etc. must be of equivalent
size, type and strength as original equipment and
be designed specifically for such applications and
systems.
9. Components with stripped threads or damaged
parts should be replaced rather than repaired. Do
not attempt repairs requiring machining or welding
unless specifically stated and approved by the
vehicle and component manufacturer.
10. Prior to returning the vehicle to service, make
certain all components and systems are restored
to their proper operating condition.
PREVENTIVE MAINTENANCE
GENERAL
Performthefollowing testsandinspectionsattheprescribed
intervals. IftheET-2™treadledoesnotfunctionasdescribed,
repair it or replace it with a new unit, available at any
authorizedBendixpartsoutlet. EVERY 3 MONTHS,25,000
MILES,OR900 OPERATING HOURS:
1. Remove any accumulated contaminants and visually
inspect the exterior of the ET-2™treadle for physical
damageor excessive corrosion.
2. Inspect electrical connections and cable assembly for
signsof corrosion, wear,or physical damage. Replace
as necessary.
3. Inspect springs (11, 12, 13) for signs of corrosion or
pitting. Replace as necessary.
4. Inspect bearings (10), washer (7), and snap rings (8)
for cracks or deterioration. Replace as necessary.
OPERATIONAL TEST
Perform these tests only if the vehicle’s throttle does not
appear to operate as expected.
Test 1: For Mack and DDC engines:
1. Unplug the cable assembly from the potentiometer’s
integral connector by lifting the lock tab and pulling
the connectors until they disengage. Inspect cable
assembly for loose terminals, frayed wires, corrosion,

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wear,or physical damage. Check end-to-endelectrical
continuity at terminals. NOTE: Potentiometer pin
locationswillremainconstant (see Figure 5). However,
cableassemblyconnectorpinoutmayvaryfromengine
to engine.
2. Removethe ET-2™treadle fromthe vehicle.
3. Secure the ET-2™treadle to a smooth, flat surface in
such a way that it does not twist the unit.
4. Connectthe potentiometer tothe volt meter and power
supply as shown in Figure 5. NOTE: Power supply
canbe a 12 VDC vehicle battery in good condition and
with known voltage output.
5. Verify that the closed throttle (idle) output voltage, as
apercentageof supply voltage, iswithinthe limits listed
in Figure 2.
6. Depress the treadle to its full throttle position. The
output voltage, as a percentage of supply voltage,
should be within the limits listed in Figure 2, e.g.
Testing a Detroit Diesel ET-2™Treadle Potentiometer:
Battery = 10 VDC. Full throttle = 9 VDC. 9/10 x 100 =
90%.
7. Make several full applications and record idle position
voltageeachtime. Verifythatidle position voltage does
not vary by more than .4% (.02 volts). If the ET-2™
treadle does not operate within its specified ranges,
service the unit, or replace it with a new ET-2™treadle,
available at your nearest Bendix parts outlet.
Test 2: For Cummins engines (featuring a separate
potentiometer and idle validation switch):
Totestthe potentiometer onthevehicle,usesteps1 through
8. Alternatively, instructions for carrying out a “bench test”
is covered in instructions 11 through 16.
1. Firstconstructthe“breakout”harness showninFigure6.
2. Insert connector X on the breakout harness into the
connector leading from the potentiometer. Then insert
connectorYonthebreakoutharness into the connector
leading from the dashboard wire harness.
3. Nextinsertpin1intothe ground position on avoltmeter.
Then insert pin 2 into the positive position on a volt
meter.
4. Disconnect the idle validation switch cable from the
dashboardwireharness. Connect anohmmeterto pins
A and B on the connector leading from the idle
validation switch. The positive lead should be
connected to pin A and the negative lead should be
connected to pin B.
5. Turn the vehicle’s ignition key to the “battery on”
position. This supplies a 5 volt input to the
potentiometer. Since the idle validation switch is no
longer connected, a fault code may be triggered on
some vehicles. This fault code will be reset at the end
of this test.
FIGURE 6 - ET-2™TREADLE ELECTRICALTEST
SCHEMATIC FOR THE CUMMINS CONNECTOR
PACKARD ELECTRIC
CONNECTOR12015793
(CONNECTOR Y)
C B A
PACKARD ELECTRIC
CONNECTOR12010717
(CONNECTOR X)
A B C
GROUND PIN 1
OUTPUT PIN 2
INPUT PIN 3
FIGURE 5 - ET-2™TREADLE ELECTRICAL TEST
SCHEMATIC FOR THE DETROIT DIESEL CONNECTOR
POTENTIOMETER
PC. NO. ON THIS
SURFACE
POWER
SUPPLY
(9-16 VDC)
RESISTOR
TEST LOAD
(47,000 OHM FOR
DETROIT DIESEL,
300,000OHM
FOR MACK)
DIGITAL
VOLT/
OHM
METER
PIN C
GROUND
PIN B
VOUT
(OUTPUT)
PIN A
VREF
(INPUT)
POTENTIOMETER

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6. Record the output voltage when the pedal is in the idle
position (V1). Then slowly depress the pedal. When
theohm meter shows that the resistance has changed
from“overload” to about.003 ohms (orfrom .003 ohms
to “overload”), stop depressing the pedal. Record the
voltage (Vx) registered with the pedal in this position.
Then press the pedal to the full throttle position and
record the output voltage (V2).
7. Calculatethe“switchpointpercentage”usingthe formula
below.
Switchpoint percentage =((Vx-V1)/(V2-V1))*100
Vx = Output voltage when the switch changed
V1= idle voltage
V2 = full throttle voltage
The following instructions are for a bench test for the
potentiometerused withCummins engines.
10. Unplug the cable assembly from the potentiometer’s
integralconnector by liftingthe lock tab and pullingthe
connectors until they disengage. Inspect cable
assembly for loose terminals, frayed wires, corrosion,
wear,orphysical damage. Check end-to-end electrical
continuity at terminals. NOTE: Potentiometer pin
locationswillremainconstant(see Figure 5). However,
cableassemblyconnector pin outmayvaryfromengine
toengine.
11. Removethe ET-2™treadlefromthe vehicle.
12. Secure the ET-2™treadle to a smooth, flat surface in
such a way that it does not twist the unit.
13. Connect thepotentiometer to the voltmeterand power
supply as shown in Figure 5. NOTE: Power supply
canbe a 12VDC vehiclebattery in goodcondition and
withknown voltage output.
14. Verify thatthe closed throttle (idle) outputvoltage,as a
percentage of supply voltage, is within the limits listed
in Figure 2.
15. Depress the treadle to its full throttle position. The
outputvoltage,asapercentageofsupplyvoltage,should
be within the limits listed in Figure 2. e.g. Testing a
DetroitDiesel ET-2™TreadlePotentiometer:Battery =
10 VDC. Full throttle = 9 VDC. 9/10 x 100 = 90%.
16. Make several full applications and record idle position
voltageeach time. Verifythatidlepositionvoltagedoes
not vary by more than .4% (.02 volts). If the ET-2™
treadle does not operate within its specified ranges,
servicethe unit, or replace itwith a new ET-2™treadle,
available at your nearest Bendix parts outlet.
Test 3: For Cummins engines (with integrated switch
andsensor (ISS): ForuseonlywiththeCumminsCelet
Plus and later editions of the ECU. This sensor can
not be used to replace the separate potentiometer &
idle validation switch. To do this a new ET-2™treadle
with the ISS must be purchased.
Test1: Where the set resistance and voltage is shown
on a label. The Cummins potentiometer on the ET-2™
treadlehas an integral idle validationswitch. It also has a
setresistancevaluemarkedonthe cover,whichneeds to
be used to properly install the potentiometer. The drive
slot in the potentiometer should engage with the drive
tang at the end of the drive shaft. Next rotate the
potentiometer until the hole in the metal sleeve matches
themounting holeson theactuator base. Looselyscrew
the potentiometer in place but do not tighten. Connect
anohmmeter topins 3 (APS output) and 4 (APS ground)
as shown in Figure 8. Now the installer should read the
set resistance value marked on the label. Rotate the
POTENTIOMETER
PC. NO. ON THIS
SURFACE
POWER
SUPPLY
(9-16 VDC)
RESISTOR
TEST LOAD
47,000OHM
DIGITAL
VOLT/
OHM
METER
PIN C
GROUND
PIN B
VOUT
(OUTPUT)
PIN A
VREF
(INPUT)
POTENTIOMETER
8. Theswitch point percentage should be between 3% to
10%. If it is not with in this range adjust the
potentiometer by loosening the mounting screws and
turning the potentiometer within the range allowed by
themounting holes. Repeat steps 1-7again. If you can
notobtain the proper switch point percentage, replace
with a new ET-2™treadle, available at your nearest
Bendix parts outlet.
9. After a successful test the vehicle may be returned to
service.
FIGURE 7 - ET-2™TREADLE ELECTRICALTEST
SCHEMATIC FOR THE CUMMINS CONNECTOR

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FIGURE 8 - ET-S™TREADLE ELECTRICAL TEST SCHEMATIC FOR THE CATERPILLAR CONNECTOR
PEDAL
POSITION
SENSOR
(PWM)
.001µF (CABLE)
POTENTIOMETER
47,000OHM±5%
RESISTOR
PIN C
GROUND
BLACK
2000OHM±5%
RESISTOR
PIN A VREF
(INPUT)
-8V
PINB
VOUT
(OUTPUT)
RED
Closed Throttle (open) Range: 10-20%
Open Throttle (full) Range: 75-90%
Caterpillar output voltage is Pulse Width Modulated
potentiometer until the ohmmeter reads the same
resistanceasshown on thelabel within ±10 Ohms. Next,
while holding the potentiometer at the set resistance
screw and lock the potentiometer in place (torque to 25
inch pounds ±5). The sleeves lock into the body of the
potentiometer for easy removal and reassembly.
Test 2: Where the potentiometer has no label, but
has engraved set voltage shown. The Cummins
potentiometer on the ET-2™treadle has an integral idle
validation switch. It also has a set voltage value marked
on the cover, which needs to be used to properly install
thepotentiometer.Thedriveslotinthepotentiometershould
engage with the drive tang at the end of the drive shaft.
Next rotate the potentiometer until the hole in the metal
sleevematchesthe mounting holesonthe actuator base.
Loosely screw the potentiometer in place but do not
tighten. Construct the test circuit following the circuit
diagram shown in Figure 8. To make the test circuit
connect the test load resistor (47,000 Ohms) and a
capacitor (.01 Microfarads) across pins 3 and 4 of the
potentiometer. Thenconnectavoltmetertothe lead ends
of the test circuit. Next connect a 5 volt power supply to
thepotentiometeratpin 4 (APS ground)andpin 5 (supply
voltage). Caution: Sensor may be damaged if supply
exceeds 5 volts. Now the installer should read the set
voltage value marked on the potentiometer. Rotate the
potentiometeruntil the voltmeter reads the same voltage
as shown on the potentiometer within ±.02 volts. Next
screw and lock the potentiometer in place (torque to 25
inch pounds ±5). The sleeves lock into the body of the
potentiometerfor easy removaland reassembly.
Test 4: For CAT engines:
1. Securely clamp the treadle Mounting Plate (6).
2. ForCaterpillarPotentiometers:Aligningthe drive slot,
thePotentiometer(1) engages the drivetangatthe end
ofthe Cam FollowerDrive Shaft (see Figure4). Rotate
the Potentiometer clockwise until the first set of
mounting holes align. Secure using two screws (2):
torque to 20 (±2) in. lbs.
To test the Caterpillar sensor construct the test circuit
shown in Figure 7. Connect both pin B and pin C into
avoltmeter. Setthe voltmeter tothe settings described
in Figure 7. Record the output values in Figure 2. If
the unit does not operate within the specified ranges,
service the unit or replace it with a new ET-2™treadle.
REMOVAL
1. Parkthevehicleonalevelsurfaceandblock the wheels
and/or hold the vehicle by means other than the air
brakes.
2. Drain the air pressure from all vehicle reservoirs.
3. Unplug the cable assembly at the opposite end of the
potentiometer. Disconnect by lifting the lock tab and
pulling the connectors until they disengage.
4. Removethe ET-2™treadle fromthe vehicle.
VOLTMETER (V => %)

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INSTALLATION
1. Installthe assembled ET-2™treadle onthe vehicle.
2. Reconnect the cable connector by plugging it into the
potentiometer’s integral connector and pushing until
the lock tab snaps into place.
DISASSEMBLY
The following instructions present a major disassembly of
the ET-2™treadle. They are included for reference only.
Several replacement parts and maintenance kits that do
notrequire full disassembly areavailable. The instructions
provided with those items should be followed in lieu of the
steps presented here. Refer to Figure 4 throughout the
procedures.
1. Remove the treadle cover (1).
2. Remove the pivot pin’s snap ring (8).
3. Remove the pivot pin (9) and the two nyliner bearings
(10) from the treadle’s exterior. Also remove the two
nyliner bearings (10) from the mounting base.
4. Remove the pivot spring (11).
5. Remove the screws (3) that secure the potentiometer
(2) to the treadle. Remove the potentiometer.
6. Remove the lever shaft’s snap ring (5).
7. Remove the lever shaft (4) and the washer (7). Then
remove the roller assembly (15), the inner washer (5),
and the nyliner bearing (6) from the treadle. Separate
the treadle from the mounting base.
8. The roller assembly consists of the lever, roller, two
springs (12 & 13), and a spring support (14). Remove
thesprings andthe springsupport fromthe lever.
CLEANING & INSPECTION
1. Usemineral spirits or an equivalent solvent to clean all
metal parts. Be sure to thoroughly dry the parts.
2. Inspect the treadle and mounting base for severe
corrosion, pitting, or cracks. Replace as necessary.
Superficialcorrosion and/orpitting isacceptable.
3. Inspect the cable assembly for loose or frayed wires,
physical damage, or any contaminants on the
connectors. Check end-tend electrical continuity at
terminals. Replace as necessary.
ASSEMBLY
Referto Figure 4 throughout theassembly procedure.
1. Install the four nyliner bearings (10) on the mounting
baseand treadle.
2. Place the treadle “ears” outside the mounting base
“ears” so that the holes line up.
3. Install the pivot spring (11) into the base and treadle.
Thecurved end ofthe spring fits into asmall hole inthe
treadle,and thestraight endfits intoa smallhole inthe
mountingbase.
4. The pivot pin (9) should slide through the holes in the
“ears” of the treadle and base assembly, then through
the center of the spring. Secure the pin with its snap
ring (8). Make sure the pivot spring is straight and is
seated in its holes.
FIGURE 8 - ET-2™TREADLE ELECTRICAL TEST SCHEMATIC FOR THE CUMMINS CONNECTOR
.01µF
TEST LOAD
47000 OHM
IDLE
VALIDATION
SWITCH
IVS
PEDAL
POSITION
SENSOR
PIN 3
PIN 4
PIN 5 Vs
SUPPLY
VOLTAGE
V1
(OUTPUT)
APS
GROUND
PIN 2
PIN 6
PIN 1
TEST
LOAD
470
OHM
TEST
LOAD
470
OHM
Vs
SUPPLY
VOLTAGE
DIODES Closed Throttle (open) Range: 5-17%
Open Throttle (full) Range: 70-81%
V3 (LOGIC HIGH AT IDLE)
V2 (LOGIC LOW AT IDLE)
IVS GROUND
3
V1
(OUTPUT) SIG1 2
(IVS) V 2
1
IVS GROUND
6
(IVS)
V 3
5
VS
(INPUT)
4
APS GROUND
POTENTIOMETER
SET VOLTAGE
AND PC. NO.
SHOWN
HERE
LOCK TAB
LOCK TAB

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5. The installation of the remaining components is much
easier if the inner and outer springs (12 & 13) are
compressedand caged. This can be donewith ashort
pieceof wire,or evena paperclip. The springsshould
be compressed so that their ends are approximately
one inch apart.
6. Place the spring support (14) inside the caged spring
assembly. Then insert the springs into the roller
assembly(15). The curved ends of the springs fit over
the small bar directly behind the roller.
7. Inorderto install the levershaft(4),the roller assembly,
with its springs and spring support, and the washers
(5 & 7) must be aligned. This can be done by resting
theET-2™treadle on itsside, withthe smaller ear of the
treadlefacingup. Insertthe washers as shown inFigure
4. Washer (5) has the larger diameter (.520"). While
holdingtherollerassemblyinplace,pushthelevershaft
throughthe treadleears.
8. Withthe ET-2™treadleonitsside, asmentionedabove,
thelever shaftshould protrudefrom the treadle with its
snapring groove visible. Securethe lever shaftwith its
snapring (8).
9. Turn the ET-2™treadleupright. Placethepotentiometer
(2)in the position shown in Figure 4, with its connector
facing the rear of ET-2™treadle. Secure the
potentiometer with its screws (3). Torque to 20 inch
pounds(+/-5).
10. Installthetreadlecover(1)andcableassemblyasshown
in Figure 4. Clip the wire from the spring assembly so
that the straight end of the springs rest against the
undersideof the treadle.
11. Makesure the ET-2™treadle hassmooth, even treadle
movement. Also, perform Operational Test steps 3-7
beforeinstallingtheET-2™treadle.
12. Install the ET-2™treadleon the vehicle.

8BW1650 © 2004 Bendix Commercial Vehicle Systems LLC All rights reserved. 6/2004 Printed in U.S.A.