Post questions, comments, reviews or page errors in the comment box below.
PDF Content Summary:
****** Page 1 ****** FILE: 091-84.1365 date: 06-02-99 INSTRUCTION MANUAL ENGINE IDLER MODULE PART OF A HIGH IDLE SYSTEM IDLER ENGINE IDLER MODEL-#091-84-005 VOLTAGE VOLTGAE MONITOR MODEL#091-84-004 3 YEAR WARRANTY KUSSMAUL ELECTRONICS CO., INC- 170 CHERRY AVE. , WEST SAYVILLE, N.Y. 11796 TEL: in NY 631-567-0314 TOLL FREE: 800-346-0857 FAX: 631-567-5826
****** Page 2 ****** INTRODUCTION The High Idle System consists of a model 091-84-005 Engine Idler and a model 091-84-004 Voltage Monitor. The system permits a vehicle operator to increase engine RPM to obtain more alternator output. RPM may be increased manually from the Engine Idler or automati- cally from the Voltage Monitor when the system voltage drops below the threshold. In order to move the throttle mechanism or interface with electronic controlled engines additional components are required. DESCRIPTION ENGINE IDLER: This module is the heart ofthe system. It interfaces with the Brake Pedal Switch, the Voltage Monitor, Neutral Safety Switch and the output solenoid valve or relay. The Engine Idler has a High Idle “ON” and “OFF” pushbuttons on its front face allowing the operator to switch in and out of HIGH IDLE when the vehicle is in Park or Neutral. An LED indicator on the front face is illuminated when the engine is in HIGH IDLE. VOLTAGE MONITOR: This module interfaces with the Engine Idler module to activate the high idle system whenever the detected voltage drops. Three LED’s indicate High, Low or Normal battery voltage. When the battery voltage is above 15.6 volts D.C. the HIGH indicator is illuminated. The LOW battery voltage indicator illuminates when the battery voltage is below 12.5 volts. At this time a signal is sent to the Engine Idler module automatically placing it in high idle. This occurs only if the transmission is in Park or Neutral and the brake pedal is not depressed.
****** Page 3 ****** INSTALLATION Typical installations are illustrated in figures 1 through 4. Mount actuator and solenoid valve in an appropriate location and connect the actuator output to the throttle mechanism. (Note: The actuator and solenoid valve must be purchased seperately. Kits that simplify the actuator mounting and connection are available for several engines. Consult KECO sales Department). Be certain that the ball chain or other coupling does not restrict throttle motion at full closed throttle or wide-open throttle. Connect solenoid valve air lines and electrical wiring as illustrated. OPERATION The High Idler receives its power from the ignition switch and functions only when the ignition switch is either “ON” or in the ACC. position. High Idle is automatically disabled under any of the following conditions: 1 Operator depresses the “OFF” pushbutton on the Engine Idler 2. Operator depresses the brake pedal 3. Operator places the transmission into Drive or Reverse 4. Operator turns off the ignition switch
****** Page 4 ****** TEST PROCEDURE 1 . With the transmission switch in PARK turn the ignition switch the Accessory position. The LED on the Engine Idler should remain OFF. 2. Press the “ON” switch on the Engine Idler. The LED on the Engine Idler should turn ON. 3. Move the transmission to Drive or Reverse. The LED on the Engine Idler should turn OFF. 4. Place the transmission in PARK and press the “ON” switch to turn the LED ON again. 5. Depress the Brake Pedal. This should turn the LED OFF. NOTE: Steps 1 thru 5 are valid only if the battery voltage is greater than 12.5 volts. If less than 12.5 volts, the Voltage Monitor may turn on High Idle system. 6. Start the engine and allow it to warm up with the transmission in PARK mode. 7. Depress the ON switch on the Engine Idler and adjust the coupling to the actuator and the stroke to obtain the desired engine RPM. Recheck by turning the unit ON and OFF a few times. 8. Load the electrical system by turning on the headlights, area lights or other accessories. Note that when the voltage drops below 12.5 volts, the following occur: a. The Low indicator on the Voltage Monitor illuminates. b. The indicator on the Engine Idler illuminates. c. The High Idle System is active and the engine is speeded up.
****** Page 5 ****** CAUTION FORD INSTALLATIONS FORD, in many installations uses a starter solenoid which has one side of the coil grounded. The neutral safety switch is then placed in the supply side of the solenoid coil. This configuration creates a considerable voltage spike when the vehicle is started. A diode must be placed across the starter solenoid in these installations to prevent dam- age to the engine idler. See the appropriate wiring diagram for diode installation details.
****** Page 6 ****** CHAIN, CONNECT TO THROTTLE LINKAGE VACUUM ACTUATOR 091-84-VA Stroke adjust z TO VACUUM SOURCE z 5 O 091-84-vv SOLENOID AIR VALVE BRAKE LIGHT BRAKE SWITCH DIODE BATTERY + On some vehicles install diode to prevent emergency flasher or turn signals from turning off the engine idler NEUTRAL SAFETY SWITCH CLOSE IN NEUTRAL/PARK 1 amp fuse To +12 volts thru accessory position of Ignition switch 765432 KUSSMAUL OFFO O O ON ENGINE IDLER ENGINE IDLER INSTALLATION Figure 1
****** Page 7 ****** CHAIN, CONNECT TO THROTTLE LINKAGE VACUUM ACTUATOR 091-84-VA Stroke adjust SOURCE z 5 o 091-84-vv SOLENOID AIR VALVE NOTE: Some engines have one side of starter solenoid at ground and the neutral safety switch in the supply side. These must have a diode installed across the starter solenoid as illustrated. BRAKE LIGHT BRAKE SWITCH DIODE BATTERY + On some vehicles install diode to prevent emergency flasher or turn signals from turning off the engine idler +12 volts from ignition switch in “START” position Starter SEE NOTE: Solenoid NEUTRAL Connect IN4004 SAFETY SWITCH as shown to suppress CLOSED IN NEUTRAL OR PARK starter solenoid transient 1 amp fuse 7654321 KUSSMAUL OFF O O C) ON ENGINE IDLER ENGINE IDLER INSTALLATION To +12 volts thru accessory position of Ignition switch FOR ENGINES WITH NEUTRAL SAFETY SWITCH CONNECTED TO STARTER Figure 2
****** Page 8 ****** CHAIN, CONNECT TO THROTTLE LINKAGE VACUUM ACTUATOR 091-84-VA Stroke adjust SOURCE 5 o 091-84-vv SOLENOID AIR VALVE 765432 KUSSMAUL BRAKE LIGHT BRAKE SWITCH DIODE BATTERY + On some vehicles install diode to prevent emergency flasher or turn signals from turning off the engine idler NEUTRAL SAFETY SWITCH CLOSE IN NEUTRAL/PARK 1 amp fuse KUSSMAUL To +12 volts thru accessory position of Ignition switch OFF ENGINE IDLER HIGH O O O LOW VOLTAGE MONITOR VOLTAGE MONITOR & ENGINE IDLER INSTALLATION AND WIRING DIAGRAM Figure 3
****** Page 9 ****** CHAIN, CONNECT TO THROTTLE LINKAGE VACUUM ACTUATOR 091-84-VA Stroke adjust SOURCE z o BRAKE LIGHT BRAKE SWITCH BATTERY + Starter Solenoid SEE NOTE: Connect IN4004 as shown to suppress starter solenoid transient DIODE On some vehicles install diode to prevent emergency flasher or turn signals from turning off the engine idler +12 volts from ignition switch in “START” position NEUTRAL SAFETY SWITCH CLOSED IN NEUTRAL OR PARK 091-84-vv SOLENOID AIR VALVE NOTE: Some engines have one side of starter solenoid at ground and the neutral safety switch in the supply side. These must have a diode installed across the starter solenoid as illustrated. This is particularly true of FORD products 1 amp fuse 4321 KUSSMAUL To +12 volts thru accessory position of Ignition switch 7654321 KUSSMAUL OFF O O O ON ENGINE IDLER HIGH O O O LOW VOLTAGE MONITOR VOLTAGE MONITOR & ENGINE IDLER INSTALLATION AND WIRING DIAGRAM FOR ENGINES WITH NEUTRAL SAFETY SWITCH CONNECTED TO STARTER Figure 4
****** Page 10 ****** For vehicles that do not have a Neutral Safety Switch or have a digital switch that does not connect to ground Switch used to sense when vehicle is in park. This is a momentary switch that connects a ground to pin 4 on the Engine Idler Vehicle shown in park Linkage to transmission To pin 4 Engine Idler Ground Transmission Bracket to support switch Instructions Find a suitable momentary switch preferably watertight. Construct a bracket to mount the switch to the transmission. Use the oil pan to mount the bracket. Align the switch so when the vehicle is in park the switch will make a ground connection. Figure 5
****** Page 11 ****** INSTALLATION RECORD & WARRANTY Date Installed Installed By Vehicle Identification Vehicle Owner WARRANTY All product of Kussmaul Electronics Company Inc. are warranted to be free of defects of material or workmanship. Liability is limited to repair- ing or replacing at our factory, without charge, any material or defects which become apparent in normal use within 3 years from the date the equipment was shipped. Kussmaul Electronics Company, Inc. shall have no liability for dam- ages of any kind to associated equipment arising from the installation and /or use of the Kussmaul Electronics Company, Inc. products. The pur- chaser, by the acceptance of the equipment, assumes all liability for any damages which may result from its installation, use or misuse, by the purchaser, his or its
FREE ENGLISH PDF
USER GUIDE – USER MANUAL
OWNER GUIDE – OWNER MANUAL
REFERENCE GUIDE – REFERENCE MANUAL
INSTRUCTION GUIDE – INSTRUCTION MANUAL