Installing the Throttle Commander Ford F250 F550 Super Duty

Transcription

1 Installing the Throttle Commander Ford F250 F550 Super Duty 7.3L Power Stroke Diesel 1996 up to T and T Preparing for Installation Installing the Throttle Controller T Connecting to the Green CMP Sensor Wire T Connecting to the White/Pink Wire Manual Transmission Automatic Transmission Completing and Testing the Installation Operational and Safety Test Auxiliary Equipment Connection Single Speed Control Multiple Speed Control Adjusting the Throttle Control Ordering Parts and Warranty...12 Fax:

2 Document Installation Manual for VMAC Throttle Commander T and T F250-F550 Super Duty 1996 up to L Power Stroke Diesel Changes and Revisions Version Revision Details Revised Approved Implemented 00 Original manual IB 23 Aug Revisions and reformat IB 19 Oct 2004 SC 19 Oct Oct 2004 a Wiring and control box IB 18 Jan 2005 SM 28 Jul Aug 2005 b ECN IB 24 July 2006 SM 27 July July 2006 Important Information The information in this manual is intended for certified VMAC installers who have been trained in installation procedures and for people with mechanical trade certification who have the tools and equipment to properly and safely perform the installation. Do not attempt this installation if you do not have the appropriate mechanical training, knowledge and experience. Follow all safety precautions and standard shop practices for mechanical work. These instructions are a general guide for installing this throttle control on standard production trucks and do not contain information for installation on non-standard trucks. If you have difficulty with the installation, contact VMAC. The VMAC warranty form is located at the back of this manual. This warranty form must be completed and mailed or faxed to VMAC at the time of installation for any subsequent warranty claim to be considered valid. To order parts, contact your VMAC dealer. Your dealer will ask for the VMAC serial number, part number, description and quantity. To locate your nearest dealer, call Copyright 2005 All trademarks used in this manual are the property of the respective copyright holder. The contents of this manual may not be reproduced in any form without the express written permission of VMAC, 1333 Kipp Road, Nanaimo, BC V9X 1R3. Printed in Canada 2 Fax:

3 FIREWALL Speed 1 Speed 2 Solder and seal to green CMP sensor wire. White Black Purple Red White Connect to accelerator pedal Throttle Controller OEM connectors from accelerator pedal Key switched 12 Volts See DDC Instructions Auto Trans Manual Trans Park brake switch 1A fuse To ground Green 1999 to (T500028) Fax:

4 FIREWALL Speed 1 Speed Solder and seal to white wire with pink stripe. White Black Purple Red White Connect to accelerator pedal Throttle Controller OEM connectors from accelerator pedal Key switched 12 Volts See DDC Instructions Auto Trans Manual Trans Park brake switch 1A fuse To ground Green 1996 to 1999 (T500011) 4 Fax:

5 1.0 Preparing for Installation Disconnect the vehicle battery terminals. Study the wiring diagrams and locate the wires on the components so that you are familiar with the connections. 2.0 Installing the Throttle Controller Fasten the throttle controller under the dash using nylon ties, to the right of the steering column and close enough to the foot pedal assembly so that the connectors will reach easily. Unplug the cable(s) from the foot pedal assembly and connect them to the matching connectors on the throttle controller. Connect the throttle controller cable(s) to the matching connectors on the foot pedal assembly. Leave the red wire inside the vehicle for operational testing. Once testing has been completed, connect it according to the wiring diagram for the specific application. 2.1 T Connecting to the Green CMP Sensor Wire Cut a short slit in the steering column boot on the right side of the column at the firewall and feed the white wire through the slit and into the engine compartment. Locate the green wire in the harness that goes to the cam position (CMP) sensor (Figure 1).! The green CMP sensor wire is critical. The engine will not run without it connected properly. Follow this procedure carefully. Cut the green wire and strip approximately 1/2 inch of insulation from both ends. Slide the melting-liner shrink tube over one end of the green wire and push it away from the joint. Fax:

6 Green wire Figure 1 Strip 1 inch of insulation from the end of the small white wire and twist it together with both stripped ends of green wire. Solder the joint using the supplied rosin core solder. Apply sufficient heat so that the solder will flow through the twisted wire bundle. Slide the shrink tube over the solder joint and shrink with a hot air gun until the meltable inner core extrudes slightly from each end (Figure 2). 6 Fax:

7 Green wire Cardboard or metal heat protector Shrink tube over the soldered joint White wire Figure 2 Do not overheat and be sure to protect the other nearby wires with a piece of cardboard or sheet metal. Push the green wire and splice back into the OEM plastic loom, install loom over the connection and insert it into the slit in the OEM loom. Secure the looms with a nylon tie or electrical tape. 2.2 T Connecting to the White/Pink Wire Cut a short slit in the steering column boot on the right side of the column at the firewall and feed the white wire through the slit and into the engine compartment. Locate the connector block on the engine side of the firewall next to the power brake assembly (Figure 3). Locate the wire that is white with a pink stripe at the connector block (Figure 3). Connect the white wire from the throttle controller to the white with pink stripe wire following the same soldering procedure as in the previous section. You cannot make this connection within the cab of the vehicle. The connection must be made according to instructions or the unit will not function correctly. Fax:

8 Connector detail Firewall Power brake assembly White wire from Throttle Commander Figure 3 White wire with pink stripe 2.3 Manual Transmission Remove the OEM connector from the park brake switch. Plug the black wire with the piggy-back connector from the throttle controller to the park brake switch. Plug the OEM connector onto the piggy-back connector. 2.4 Automatic Transmission! If the vehicle has an automatic transmission, the throttle control must be connected so that it will not function unless the transmission is in PARK or Neutral. FAILURE TO PROPERLY INSTALL AND VERIFY THE FUNCTION OF THIS SAFETY FEATURE CAN RESULT IN INJURY OR DEATH. If you require a safety interconnect to perform this task, order the VMAC Drive Disable Circuit part number Be sure to perform the safety test in the DDC installation instructions before proceeding. 8 Fax:

9 3.0 Completing and Testing the Installation Check all wiring to ensure that it will not contact any hot or moving components and will not interfere with the operation of the vehicle. Secure all wiring with nylon ties and loom. Connect the battery terminals and temporarily route an 18 gauge test wire from the positive battery terminal into the cab for testing. 3.1 Operational and Safety Test Place the vehicle in a safe operating position and block the wheels. Ensure that there are no people around the vehicle before beginning the test. Sit in the driver s position with the automatic transmission in Park, manual transmission in neutral and the park brake fully engaged. Start the vehicle engine and wait for the idle to stabilize. Engine temperature should be in the normal operating range. Test the operation of the throttle controller. Momentarily activate the throttle by quickly connecting and disconnecting the temporary wire from the battery positive post to the red wire on the Throttle Commander. The engine should start to idle up. Firmly apply the service brake pedal and hold it down. Release the park brake and momentarily activate the throttle as before. The engine should not idle up. Apply the park brake and shift the automatic transmission into gear with your foot on the service brake pedal. Momentarily activate the throttle as before. The engine should not idle up. Shift the transmission back into Park and shut down the engine.! If the vehicle fails the test, check the wiring connections. If you require additional assistance, contact your local VMAC dealer or call VMAC at or Fax:

10 4.0 Auxiliary Equipment Connection The throttle control has three possible speed settings by providing battery power to the red and purple wires. Default settings are: Speed Selection Red wire Purple wire Factory setting Off 0 Volts 0 Volts 0 RPM Speed 1 12 Volts 0 Volts 1,250 RPM Speed 2 0 Volts 12 Volts 1,800 RPM Speed 3 12 Volts 12 Volts approximate average of 1 & 2 Different methods for single speed connection are shown in Figure 4 (switched) and Figure 5 (relayed). Multiple speed connections are a duplicate of the single speed method. Key switched 12 Volts 1A fuse Body builder equipment switch To PTO circuit or other equipment Speed 2 Speed 1 This configuration uses a switch to turn on the throttle control at the same time as the body builder equipment. Figure 4 Throttle Controller Purple Red Key switched Volts 1A fuse 86 87a Body builder equipment switch To PTO circuit or other equipment Speed 2 Speed 1 This configuration uses a switch to activate a relay to turn on the throttle control at the same time as the body builder equipment. Figure 5 Throttle Controller Purple Red 10 Fax:

11 4.1 Single Speed Control Connect the red wire from the throttle control through a suitable switch to an ignition activated 12-volt power source using an 18 gauge or heavier wire. Coil and insulate the purple wire with tape. Install a 1-amp inline fuse between the switch and the red wire. 4.2 Multiple Speed Control Make the single speed connection using the red wire. Connect the purple wire from the throttle control through a second switch to an ignition activated 12-volt power source using 18 gauge or heavier wire. Install a 1-amp inline fuse between the switch and the wire. 5.0 Adjusting the Throttle Control Make sure that the switches or equipment supplying power to the throttle control are turned off. Start the engine. Allow the engine to reach normal operating temperature. Engine speed is adjusted by turning the screws on the throttle control. To increase the engine speed turn the screw clockwise, to decrease the engine speed turn the screw counter-clockwise. To adjust SPEED 1, activate the throttle control using the control that is connected to the red wire. Adjust the RPM by turning the RPM 1 screw. To adjust SPEED 2, activate the throttle control using the control that is connected to the purple wire. Adjust the RPM by turning the RPM 2 screw. SPEED 3 is an approximate average of SPEED 1 and SPEED 2. Fax:

12 ! Never use the park brake or the transmission as an ON- OFF switch. When the engine is OFF, the throttle switch must be OFF. Do not reactivate the throttle switch until the engine has been restarted and the RPM has stabilized. 6.0 Ordering Parts and Warranty To order parts, contact your nearest VMAC dealer. Please quote the part number, description and quantity required. The warranty form must be completed and mailed or faxed to VMAC at the time of installation for any subsequent warranty claim to be considered valid. 12 Fax: