KUSSMAUL 091-84-005 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
Typicalinstallationsongasolineanddieselenginesareillustratedin figures1and2. Mount
actuatorandsolenoidvalveinanappropriatelocationandconnecttheactuatoroutputtothe
throttlemechanism.(Note:Theactuatorandsolenoidvalvemustbepurchasedseperately.
Becertainthat the ball chain orothercoupling does not restrict throttlemotionat full closed
throttle or wide-open throttle. Connect solenoid valve input to a source of vacuum for
gasoline engines or pressure for diesel engines. Pipe the solenoid valve output to the
actuator as illustrated in figure 1 or figure 2. Install wiring as shown.
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 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 2
1 amp fuse
VOLTAGE MONITOR & ENGINE IDLER
BRAKE SWITCH
INSTALLATION AND WIRING DIAGRAM
FOR DIESEL ENGINES WITH AIR PRESSURE AVAILABLE
091-84-PV
SOLENOID
AIR VALVE
TO PRESSURE
SOURCE
PRESSURE
ACTUATOR
OUT
IN
CONNECT TO THROTTLE
(PRESSURE PULLS THROTTLE)
STROKE ADJ. SCREW

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