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INSTRUCTION MANUAL
ENGINE IDLER MODULE
PART OF A HIGH IDLE SYSTEM
10-19-96
ENGINE IDLER
MODEL #091-84-005
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
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INTRODUCTION
The 091-84-005 Engine Idler model is part of a high idle system that can be installed on
either gasoline or diesel engines. This device permits a vehicle operator to increase engine
RPM to obtain more alternator output. In order to move the throttle mechanism or interface
with electronic controlled engines additional components are required.
DESCRIPTION
This module interfaces with the Brake Pedal Switch, Park/Neutral Safety Switch, a solenoid
vacuum valve, a throttle actuator and in some installations a Voltage Monitor. It has 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.
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INSTALLATION
Typical installations on gasoline and diesel engines are illustrated in figures 1 and 2. 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.
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 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
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TEST PROCEDURE
1. With the transmission switch in PARK turn the ignition switch to 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.
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. Re-check the RPM by turning the
unit ON and OFF a few times.
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CAUTION
FORD INSTALLATIONS
FORD, in many installations uses a star ter
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 spik e when the v ehicle is started.
A diode must be placed across the starter
solenoid in these installations to prevent damage to the engine idler .
See the appropriate wiring diagram for diode
installation details.
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CHAIN,
CONNECT TO
THROTTLE LINKAGE
VACUUM
ACTUATOR
BRAKE
LIGHT
091-84-VA
Stroke adjust
TO VACUUM
SOURCE
T
N
I
U
O
091-84-VV
SOLENOID
AIR VALVE
BA TTERY +
BRAKE SWITCH
NEUTRAL
SAFETY SWITCH
CLOSE IN
NEUTRAL/PAR K
1 amp fu s e
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
KUSSMAUL
OFF
ON
ENGINE IDLER
ENGINE IDLER INSTALLATION
FOR GASOLINE ENGINES WITH A VACUUM SOURCE
Figure 1
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V
V
CHAIN,
CONNECT TO
THROTTLE LINKAGE
BRAKE
LIGHT
091-84-VA
Stroke adjust
TO VACUUM
SOURCE
T
N
I
U
O
VACUUM
ACTUATOR
BRAKE SWITCH
BA TTERY +
Starter
Solenoid
SEE NOTE:
Connect 1N4004
as shown to supp re ss
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 diod e
installed across the starter
solenoid as illustrated.
This is particularly true of
FORD products
KUSSMAUL
OFF
ON
HIGH
ENGINE IDLER
OLTAGE MONITOR
OLTAGE MONITOR & ENGINE IDLER
INST ALLATION AND WIRING DIAGRAM
FOR ENGINES WITH A VACUUM SOURCE
1 amp fu s e
KUSSMAUL
To +12 volts
thru accessory
position of
Ignition switch
LOW
Fig ure 2
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V
CONNECT TO THROTTLE
(PRESSURE PULLS THROTTLE)
PRESSURE
ACTUATOR
BRAKE
LIGHT
STROKE ADJ. SCREW
TO PRESSURE
SOURCE
IN
091-84-PV
OUT
SOLENOID
AIR VALVE
BRAKE SWITCH
BA TTER Y +
NEUTRAL
SAFETY SWITCH
CLOSE IN
NEUTRAL/PARK
DIODE
On some vehicles install diode to
prevent emergency flasher or
turn signals from turning off the
engine idler
1 amp fuse
To +12 volts
thru accessory
positio n of
Ignition switch
KUSSMAUL
OFF
ON
HIGH
KUSSMAUL
LOW
ENGINE IDLER
OL TAGE MONITOR
VOLTAGE MONITOR & ENGINE IDLER
INSTALLATION AND WIRING DIAGRAM
FOR DIESEL ENGINES WITH AIR PRESSURE AVAILABLE
Figu re 2
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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 repairing 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 damages of any kind to associated equipment arising from the installation and
/or use of the Kussmaul Electronics Company, Inc. products. The purchaser, 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
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