KUSSMAUL 091-84-004 User manual

INSTRUCTION MANUAL
KUSSMAUL ELECTRONICS CO., INC.
170 CHERRY AVE., WEST SAYVILLE, N.Y. 11796
FILE: 091-84.P65 date: 06-02-99
TEL: in NY 631-567-0314 TOLL FREE: 800-346-0857 FAX: [phone]
ENGINE IDLER MODULE
PART OF A HIGH IDLE SYSTEM
3 YEAR WARRANTY
ENGINE IDLER
MODEL #091-84-005
VOLTGAE MONITOR
MODEL #091-84-004

INTRODUCTION
TheHighIdleSystemconsistsofamodel091-84-005EngineIdlerandamodel091-84-004
Voltage Monitor. The system permits a vehicle operator to increase engine RPM to obtain
morealternatoroutput.RPMmaybeincreasedmanuallyfromtheEngineIdlerorautomati-
callyfromtheVoltageMonitorwhenthesystemvoltagedropsbelowthethreshold.Inorder
to move the throttle mechanism or interface with electronic controlled engines additional
components are required.
ENGINE IDLER:
Thismoduleistheheartofthesystem.ItinterfaceswiththeBrakePedalSwitch,theVoltage
Monitor,NeutralSafetySwitchandtheoutputsolenoidvalveorrelay.TheEngineIdler 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.
VOLTAGEMONITOR:
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.Whenthebatteryvoltageisabove15.6voltsD.C.theHIGHindicatorisilluminated.
TheLOWbatteryvoltageindicator illuminates whenthebatteryvoltageisbelow12.5 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.
DESCRIPTION

INSTALLATION
Typicalinstallationsareillustratedinfigures1through4.Mountactuatorandsolenoidvalve
inanappropriatelocationandconnecttheactuatoroutputtothethrottlemechanism.(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).Becertainthattheballchainorothercouplingdoesnotrestrictthrottlemotion
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

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.Pressthe"ON"switchontheEngineIdler.TheLEDontheEngineIdlershouldturn
ON.
3. Move the transmission to Drive or Reverse. The LED on the Engine Idler should
turnOFF.
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.DepresstheON switch ontheEngineIdlerandadjust the couplingtotheactuator
andthestroketoobtainthedesiredengineRPM.RecheckbyturningtheunitONand
OFF a few times.
8. Load the electrical system by turning on the headlights, area lights or other
accessories.Notethatwhenthevoltagedropsbelow12.5volts,thefollowingoccur:
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.

FORD, in many installations uses a starter
solenoid which has one side of the coil
grounded.The neutral safety switch is then
placedinthesupplysideofthesolenoidcoil.
This configuration creates a considerable
voltage spike when the vehicle is started.
A diode must be placed across the starter
solenoidintheseinstallationstopreventdam-
age to the engine idler.
Seetheappropriatewiringdiagramfordiode
installationdetails.
FORDINSTALLATIONS
CAUTION

KUSSMAUL
ENGINE IDLER
ON
OFF
ENGINE IDLER INSTALLATION
BATTERY +
NEUTRAL
SAFETY SWITCH
CLOSE IN
NEUTRAL/PARK
BRAKE
LIGHT
DIODE
On some vehicles install diode to
prevent emergency flasher or
turn signals from turning off the
engine idler
To +12 volts
thru accessory
position of
Ignition switch
Figure 1
1 amp fuse
BRAKE SWITCH
IN
OUT
091-84-VV
SOLENOID
AIR VALVE
TO VACUUM
SOURCE
VACUUM
ACTUATOR
091-84-VA
Stroke adjust
CHAIN,
CONNECT TO
THROTTLE LINKAGE

KUSSMAUL
ENGINE IDLER
ON
OFF
ENGINE IDLER INSTALLATION
To +12 volts
thru accessory
position of
Ignition switch
Figure 2
1 amp fuse
IN
OUT
SOURCE
FOR ENGINES WITH NEUTRAL SAFETY SWITCH CONNECTED TO STARTER
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.
BATTERY +
BRAKE
LIGHT
DIODE
On some vehicles install diode to
prevent emergency flasher or
turn signals from turning off the
engine idler
BRAKE SWITCH
Starter
Solenoid
Connect 1N4004
as shown to suppress
starter solenoid transient
+12 volts from ignition switch
in "START" position
NEUTRAL
SAFETY SWITCH
CLOSED IN NEUTRAL OR PARK
SEE NOTE:
V
ACUUM
ACTUATOR
091-84-VA
Stroke adjust
CHAIN,
CONNECT TO
THROTTLE LINKAGE
091-84-VV
SOLENOID
AIR VALVE

KUSSMAUL KUSSMAUL
ENGINE IDLER
V
OLTAGE MONITOR
ON LOW
OFF HIGH
BATTERY +
NEUTRAL
SAFETY SWITCH
CLOSE IN
NEUTRAL/PARK
BRAKE
LIGHT
DIODE
On some vehicles install diode to
prevent emergency flasher or
turn signals from turning off the
engine idler
To +12 volts
thru accessory
position of
Ignition switch
Figure 3
1 amp fuse
VOLTAGE MONITOR & ENGINE IDLER
BRAKE SWITCH
INSTALLATION AND WIRING DIAGRAM
IN
OUT
SOURCE
VACUUM
ACTUATOR
091-84-VA
Stroke adjust
CHAIN,
CONNECT TO
THROTTLE LINKAGE
091-84-VV
SOLENOID
AIR VALVE

KUSSMAUL KUSSMAUL
ENGINE IDLER
V
OLTAGE MONITOR
ON LOW
OFF HIGH
INSTALLATION AND WIRING DIAGRAM
IN
OUT
SOURCE
BATTERY +
BRAKE
LIGHT
DIODE
On some vehicles install diode to
prevent emergency flasher or
turn signals from turning off the
engine idler
To +12 volts
thru accessory
position of
Ignition switch
Figure 4
1 amp fuse
V
OLTAGE MONITOR & ENGINE IDLER
BRAKE SWITCH
FOR ENGINES WITH NEUTRAL SAFETY SWITCH CONNECTED TO STARTER
Starter
Solenoid
Connect 1N4004
as shown to suppress
starter solenoid transient
+12 volts from ignition switch
in "START" position
NEUTRAL
SAFETY SWITCH
CLOSED IN NEUTRAL OR PARK
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
SEE NOTE:
VACUUM
ACTUATOR
091-84-VA
Stroke adjust
CHAIN,
CONNECT TO
THROTTLE LINKAGE
091-84-VV
SOLENOID
AIR VALVE

Bracket to support switch
Linkage to transmission
Transmission
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
To pin 4 Engine Idler
Ground
For vehicles that do not have a Neutral Safety Switch
or have a digital switch that does not connect to ground
.
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