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FILE: 091-84.P65 date: 06-02-99
INSTRUCTION MANUAL
ENGINE IDLER MODULE
PART OF A HIGH IDLE SYSTEM
ENGINE IDLER
MODEL #091-84-005
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
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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 automatically 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 of the 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.
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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 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.
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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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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 ENG INES 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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