Part 5

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Throttle # T500081 FORD 1999-2004 6.8L TRITON V10 F250-550 SUPER DUTY Manufactured by UNDERHOOD AIR COMPRESSORS 1333 KIPP ROAD NANAIMO B.C. V9X 1R3 TEL: (250)-740-3200 FAX: (250)-740-3201 TOLL FREE: 800-738-8622 Visit us at... www.throttlecommander.com TH E B EN C H M A R K I N I N N O V A TI O N Installation Manual T500081 Throttle Commander Throttle Control System Number T500081 Application: Ford 1999-2004 6.8L Triton V10 F250-550 SUPER DUTY Publication Date: November 2003 Origination Document: 1900656_b.doc Registered Trademarks: VR70, VMAC and Throttle Commander are registered trademarks of VMAC. Notice: Manuals and products are subject to change without notice. Copyright 2003 The contents of this manual may not be reproduced in any form without the express written permission of VMAC Part 1: Preparing For Installation 1. Locate a source for fused ignition switched 12volts. Mark this for later use. 2. Disconnect all negative battery terminals, then the positive ones. 3. Loosen the clamp on the plastic air duct at the joint to the throttle body. 4. Remove the plastic cover from the throttle body. 5. If the vehicle has an automatic transmission, the throttle must be connected so as to be inoperable unless the transmission is in Park or Neutral. If this important safety interconnect is not already provided, VMAC DDC “Drive Disable Circuit” Part Number 3550676 will accomplish this. Handle wires and harnesses carefully. All batteries must be fully disconnected while handling this or any other electronic module or damage could result. Page 4 Figure 2.1 – Main Circuit Diagram WIRE LABEL NOTE CHASSIS GROUND GROUND WHITE GREEN SEE APPROPRIATE INSTRUCTIONS IN MANUAL FOR TRANSMISSION TYPE SOLDER AND SEAL THIS CONNECTION OEM TACH WIRE SEE MANUAL FOR DETAILS TACH LINE WHITE WIRE Page 5 WHEN ENGINE OFF, 12V GOING TO THROTTLE MUST BE OFF. DO NOT REACTIVATE THROTTLE UNTIL ENGINE HAS RESTARTED AND RPM HAS STABILIZED. XXXX XXXX XXXX LEGEND CONTROL THROTTLE PARK BRAKE PURPLE YELLOW RED WHITE SPEED 2 SPEED 1 IGNITION SWITCHED 12 VOLTS Part 2: Installing The Throttle BLACK 2.1 Mounting the Throttle 1. Secure the throttle to the right hand radiator bulkhead and right hand forward coolant bottle bolt using OEM fasteners. See Figure 2.2. Figure 2.2 – Mounting location 2.2 Connecting the Cable 1. Disconnect the OEM cruise control throttle linkage if connected. 2. Fasten the throttle cable anchor bracket to the slot on the outside rear of the OEM throttle cable mounting bracket using the two (2) supplied socket head cap screws fitted through the slot in the OEM throttle bracket. Fit the supplied flat washers and nuts and tighten. Ensure that the top of the bracket is angled inward. See figure 2.3. Using the anchor bracket as a template, mark the third hole at the bottom and drill out the OEM throttle bracket using a 1/4 inch drill bit. Install the third supplied socket head cap screw with flat washer and nut and tighten. Drill the ¼” hole for the third screw Figure 2.3 – Mounting the anchor bracket Page 6 3. Route the throttle cable over the vehicle vacuum tank and insert the throttle cable end through the hole in the anchor bracket. Refit the cable outer nut and washers, and tighten the two cable nuts. See figure 2.4. Reinstall the rubber cable wiper (not shown). Figure 2.4 – Throttle cable mounting 4. Fit the supplied throttle pull bracket to the OEM throttle cam arm. See figure 2.5. 5. Using the bracket as a template, drill a 3/32” hole with a depth of 1/4” into the OEM throttle control cam. See figure 2.5. Figure 2.5 – Mounting the pull bracket 6. Use the self tapping screw (supplied) to secure the throttle pull bracket to the OEM throttle cam arm. See figure 2.6. 7. Pass the throttle cable through the collar on the pull bracket and allow the inner cable to sit between the intake manifold runners. Page 7 8. Tighten the set-screw in the cable nipple to the inner cable and leave approximately 1/8” of slack between the nipple and the pull bracket. Cut off the excess inner cable approximately 1/4” past the cable nipple. See figure 2.6. Self-tapping screw 1/4” 1/8” Figure 2.6 – Attaching the pull cable 9. Reconnect the cruise control cable if fitted. See figure 2.7. Check the operation of the vehicle throttle to ensure that the throttle cable doesn’t foul on any OEM linkage and slides freely up and down the throttle cable. Be sure to bend the OEM throttle return spring locating brackets to allow for unrestricted movement of the throttle pull cable. See figure 2.7. Figure 2.7 – Return spring detail Page 8 2.3 Connecting the Wiring Refer to figure 2.1 for wiring diagram. 1. Slit the steering column boot at the firewall and pass the black and the white throttle wires through the firewall and into the cab. 2.3.1 Connecting the Ground Wire 1. Attach the green ground wire from the throttle to the front right corner of the intake manifold using the OEM fastener or hook to ground strap on firewall (Figure 2.8). Figure 2.8 – Ground location Page 9 2.3.2 For 1999-2002 Models with Standard Transmissions 1. Remove the OEM connector from the park brake switch. See figure 2.9. 2. Plug the OEM wire connector onto the piggyback connector on the end of the black wire from the throttle. 3. Plug the black wire with the piggyback connector onto the park brake switch. Park Brake Connector Figure 2.9 – 1999-2002 Park brake connection 2.3.3 For 2003-2004 Models with Standard Transmissions 1. Locate the green with red stripe wire at the park brake switch (Figure 2.10). 2. Pull back the loom from the park brake wire and splice the black wire to the green/red park brake wire. Follow the generic instructions in Appendix A. Park Brake Wire – Green with Red Stripe Figure 2.10 – 2003-2004 Park brake connection Page 10 2.3.4 For Automatic Transmissions Follow the instructions for VMAC Drive Disable Circuit P/N: 3550676. Page 11 2.3.5 Connecting the Tach wire 2.3.5.1 For Model Years 1999-2001 1. Peel the tape away from the Z shaped plastic cover at the large wire bundle to the left of the steering column in the cab. 2. Remove the Z shaped plastic cover and find the white wire with the pink stripe. (Usually at the back of the wire bundle). 3. Solder the white wire from the throttle to the white wire with the pink stripe. See Figure 2.11. Greater reliability will be achieved by soldering this connection. A T-tap quick connect has been provided if this is not practical. 1999-2001 Tach Connection - White with Pink Stripe Figure 2.11 – 1999-2001 Tach connection Note: Make sure that you locate the white wire with the pink stripe. DO NOT use the white wire with the red stripe. The system will not function. 4. Tape the soldered joint, then reinstall and re-tape Z shaped plastic cover. Page 12 2.3.5.2 For Model Year 2002-2004 1. Locate the bundle of wires with sealed ends under the dash by the park brake. See figure 2.12. 2. Find the light green wire with a white stripe. 2002-2004 Tach Connection - Light Green with White Stripe Figure 2.12 – 2002-2004 Tach connection 3. Solder the white wire from the throttle to the light green wire with a white stripe. 4. Seal the soldered joint with the supplied heat shrink. Greater reliability will be achieved by soldering this connection. A T-tap quick connect has been provided if this is not practical. 2.3.6 Connecting The 12 Volt Power Wire 1. Connect the red wire from the throttle to the fused, key-switched 12 Volts power source found in the preparation section. Be sure to perform the safety circuit test before operating. Page 13 Part 3: Completing/Confirming 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 supplied loom as required. 3.1 Completing the Installation 1. Reconnect the batteries, positive first then the negative terminals. 2. Temporarily route an 18AWG test wire from the positive battery terminal to the throttle. This wire will be used to activate the throttle for the following tests. 3.2 Safety Circuit/Operational Test 1. For safety, place the vehicle in a safe operating position and block the vehicle’s wheels. Ensure that there are no people around the vehicle. 2. Sit in the driver’s position with the transmission in Park, and the park brake fully engaged. 3. Start the vehicle engine and wait for the idle to stabilize. The engine’s temperature should be in the normal operating range. 4. Test the operation of the throttle. Momentarily activate the throttle by quickly connecting and disconnecting the battery wire to the yellow “Speed 1” throttle wire. The engine should start to idle up. 5. Firmly apply the vehicle’s foot brake and hold it down. 6. Release the park brake and momentarily activate the throttle as before. The engine should not idle up. 7. Re-apply the park brake and shift the transmission into Reverse. Keeping your foot on the vehicle’s foot brake. Momentarily activate the throttle as before. The engine should not idle up. 8. Shift back into Park, and shut down the vehicle’s engine. If the vehicle fails the test, check your wiring to make sure that all the connections are correct and secure. If you require additional assistance, please contact your local VMAC dealer. Page 14 Part 4: Auxiliary Equipment Connection(s) The throttle may be operated at three (3) possible speed control settings by connecting the yellow SPEED 1 and purple SPEED 2 wires to a suitable switch or relay. Refer to figures 2.1 & 4.1&4.2 for suggested SPEED 1 and/or SPEED 2 connections. Table 4.1 shows the possible combinations. Standby mode SPEED 1 SPEED 2 SPEED 3 SPEED 1 (RED WIRE) 0V +12V NO CONNECTION +12V SPEED 2 (PURPLE WIRE) 0V NO CONNECTION +12V +12V FACTORY PRESETS N/A 1300 RPM 1600 RPM 1900 RPM Table 4.1 Power should be supplied to the customer-supplied switch/relay from an ignition-activated 12V source. The purpose of this is to isolate the throttle when the key is off to stop battery drain. Install 1-Amp inline fuses between the switches and the yellow and purple wires. Refer to figures 4.1 & 4.2 for example connections to auxiliary equipment like PTO’s, cranes, etc. Figure 4.3 shows how NOT to connect the ignition switched 12 volt wire. 4.1 Connecting The Control Switches For Single Speed Operation 1. If single speed operation is required, connect the yellow wire from the throttle through a suitable switch to an ignition-activated 12-volt power source or to the actuation switch for the auxiliary equipment. See Figures 2.1 & 4.1. 2. Cut or wrap the purple wire at the throttle and insulate end with tape. 3. Secure all wires using nylon ties supplied. 4.2 Connecting The Control Switches For Multiple Speed Operation 1. If multiple speed operation is required, connect both yellow the purple wires from the throttle through suitable switches to an ignition-activated 12 volt power source. See Figure 2.1. 2. Secure all wires using nylon ties supplied. Page 15 5 NOTE SPEED 2 WHEN ENGINE OFF, 12V GOING TO THROTTLE MUST BE OFF. DO NOT REACTIVATE THROTTLE UNTIL ENGINE HAS RESTARTED AND RPM HAS STABILIZED. THROTTLE CONTROL SPEED 1 IGNITION SWITCHED 12 VOLTS PURPLE YELLOW RED Figure 4.1 – Switch activation 5 5-PRONG RELAY (BOSCH TYPE) NOTE WHEN ENGINE OFF, 12V GOING TO THROTTLE MUST BE OFF. DO NOT REACTIVATE THROTTLE UNTIL ENGINE HAS RESTARTED AND RPM HAS STABILIZED. SPEED 2 THROTTLE CONTROL SPEED 1 IGNITION SWITCHED 12 VOLTS PURPLE YELLOW RED Figure 4.2 – Relay activation Page 16 4 NOTE WHEN ENGINE OFF, 12V GOING TO THROTTLE MUST BE OFF. DO NOT REACTIVATE THROTTLE UNTIL ENGINE HAS RESTARTED AND RPM HAS STABILIZED. SPEED 2 THROTTLE CONTROL SPEED 1 IGNITION SWITCHED 12 VOLTS PURPLE YELLOW RED Figure 4.3 – Incorrect connection Page 17 Part 5: Setting Up The Throttle WHEN ENGINE OFF, THROTTLE MUST BE OFF. DO NOT REACTIVATE THROTTLE UNTIL ENGINE HAS RESTARTED AND RPM HAS STABILIZED. 5.1 Preparing To Adjust The Throttle Speed 1. Turn off the equipment to be run. 2. Start the engine. Allow the engine to reach normal operating temperature. 3. Remove the weather-tight cover from the top of the throttle. See figure 5.1. 4. Plug the RPM setting tool securely into the socket as shown in Figure 5.1. Figure 5.1 – RPM Setting Tool Port The speeds can be adjusted between 1100 and 2600 RPM. 5.2 Changing Speed Setting #1 1. Activate the throttle using the “Speed 1” switch connected to the yellow wire. 2. To increase speed, firmly press the “+” button on the RPM Setting Tool and hold it for at least 1 second, the LED will turn off, then release, and the LED will turn back on. This will provide a 100RPM increase. Each time you repeat this process the speed will increase by 100RPM. 3. To decrease speed, firmly press the “-” button on the RPM Setting Tool and hold it for at least 1 second, the LED will turn off, then release, and the LED will turn back on. This will provide a 100RPM decrease. Each time you repeat this process the speed will decrease by 100RPM. Page 18 5.3 Changing Speed Setting #2 1. Activate the throttle using the “Speed 2” switch connected to the purple wire. 2. To increase speed, firmly press the “+” button on the RPM Setting Tool and hold it for at least 1 second, the LED will turn off, then release, and the LED will turn back on. This will provide a 100RPM increase. Each time you repeat this process the speed will increase by 100RPM. 3. To decrease speed, firmly press the “-” button on the RPM Setting Tool and hold it for at least 1 second, the LED will turn off, then release, and the LED will turn back on. This will provide a 100RPM decrease. Each time you repeat this process the speed will decrease by 100RPM. 5.4 Changing Speed Setting #3 1. Activate the throttle using both speed wires. 2. To increase speed, firmly press the “+” button on the RPM Setting Tool and hold it for at least 1 second, the LED will turn off, then release, and the LED will turn back on. This will provide a 100RPM increase. Each time you repeat this process the speed will increase by 100RPM. 3. To decrease speed, firmly press the “-” button on the RPM Setting Tool and hold it for at least 1 second, the LED will turn off, then release, and the LED will turn back on. This will provide a 100RPM decrease. Each time you repeat this process the speed will decrease by 100RPM. Page 19 Part 6: Flash Code Reference The green LED indicator lamp under the weather-tight cover provides throttle status indication. It can be very helpful in tracking down installation errors and solving operational problems. Table 6.1 provides a key to the interpretation of the flash code. LED Steady Off ON OFF 12V not applied to red wire &/or ground not applied to green wire(This is the Normal power off state with the engine shut off and key off). Throttle is powered up, has successfully completed initialization checks, & is in “standby” state ON OFF LED Steady On ON Throttle is active & controlling engine RPM. OFF “Single Flash” ON No tach signal on white wire, Throttle is ‘Home’ & awaiting proper tach signal OFF “Two Flash” ON OFF Three Flash ON Park brake not applied – (or if a DDC circuit is installed transmission is not in park). Throttle is home awaiting proper park brake & or transmission states to be met Over speed condition (3400RPM or higher)has been sensed. Throttle shuts down & cannot be restarted without powering down completely & restarting. OFF “Four Flash” ON The cable is at one of its limits of travel. OFF “Five Flash” ON OFF “Six Flash” ON Failure to find “home” limit switch. Caused by a failed motor, a failed limit switch or a seized capstan. Repeated failures of this kind requires factory service to throttle. Unit was powered up in the wrong order. See Figures 2.1 & 4.1-4.3. OFF Table 6.1 – Flash Code Key Page 20 Appendix A – Generic soldering instructions 1. Cut the OEM wire, and strip approx. 1/2” from each end and from the VMAC wire (Figure A1). Figure A1 2. Slide the heat shrink provided onto one OEM wire and the VMAC wire. Twist the 3 wires together (Figure A2). Figure A2 Page 21 3. Heat all 3 wires at the joint with a soldering gun/pen, then apply the provided solder. Ensure the solder “flows” into the joint to bond the wires together (Figure A3). Figure A3 4. Slide the heat shrink over the joint, and shrink onto the joint using a heat gun. Make sure the shrink is heated until the liner melts and makes a good seal (Figure A4). Figure A4 Page 22 Warranty Registration This form must be completed and returned to VMAC at the time of installation. Warranty will be void if this form is not received by VMAC within 30 days by mail or fax. Installer Information Company Name: Installer Name: City: State/Prov. Postal Code: Telephone: / Installation Date: day / month year Owner Information Owner Name: Address: City: State/Prov. Telephone: Postal Code: Purchase Date: / day / month year Purchased From: Application Vehicle Make: Year: Engine type/size: Vehicle Identification Number (VIN#): Product Information VMAC Part Number: Description: Product Serial Number (if applicable): VMAC Part Number: Description: Product Serial Number (if applicable): VMAC Part Number: Product Serial Number (if applicable): Description: UNDERHOOD AIR COMPRESSORS 1333 KIPP ROAD, NANAIMO, B.C. V9X 1R3 TEL: 250-740-3200 FAX: 250-740-3201 TOLL FREE: 800-738-8622