OPERATING INSTRUCTIONS for the AUXILIARY IDLE CONTROL MODULE Exclusively for Ford Trucks with 7.3L DIT Diesel Engines Powertrain Control Systems Division Visteon Automotive Systems Copyright ©1998 Part No.
TABLE OF CONTENTS Subject Description Pages 1. System Description …………………………………………………. 1.1 Key and Display Description ………………………………. . 1.2 Guide through the Instruction Manual ……………………. . 2-3 2 3 2. Charge Protection Mode …………………………………………… 2.1 Basic Operation ……………………………………………… 2.2 Automatic Operation ………………………………………… 2.3 Remote Usage ……………………………………………….. 4-5 4 4 5 3. RPM Control Mode ………………………………………………….. 3.1 Basic Operation ……………………………………………… 3.2 Automatic Operation ………………………………………… 3.
Section 1 SYSTEM DESCRIPTION The Auxiliary Idle Control Module, also called Auxiliary Powertrain Control Module (APCM), is for use in Light Trucks equipped with 7.3L DIT Diesel engines. Each kit includes an Auxiliary Idle Control module, wiring harness, mounting bracket and hardware, operator's card, and this instruction booklet.
Section 1.2 GUIDE THROUGH THE INSTRUCTION MANUAL Refer to the following diagram as a guide through the manual. Each APCM function is listed along with the appropriate Section(s) where detailed information can be found. RPM CONTROL MODE CHARGE PROTECTION Section 3 Section 2 Module Power On/Off RPM CONTROL ACTIVATION Section 3 PTO Link: Section 4.4, 4.5 PTO & RPM CONTROL LINKED Section 4.4 Custom RPM: Section 4.
CHARGE PROTECT Section 2 CHARGE PROTECTION MODE Charge Protection is used for maintaining system voltage. In Charge Protection mode, the system (battery) voltage is monitored and the engine speed, in RPM, is increased so the voltage is maintained and battery charged as required. Charge Protection mode can be activated from incab, remotely, and can be programmed to activate automatically on engine start-up.
CHARGE PROTECT Step 2 Activate Automatic Charge Protection Mode. With Automatic Charge Protection programmed, the engine speed will be elevated within a few seconds after programming is exited and the vehicle's enabling conditions are met. It is not required to press any additional keys on the module for activation. To deactivate Automatic Charge Protection (until key off and key back on) ANY ONE of the following will exit Automatic Charge Protection and return engine to normal idle.
RPM CONTROL Section 3 RPM CONTROL MODE RPM Control is used for elevating idle speed. In RPM Control mode, the engine speed can be controlled between 1200 and 2500 RPM. There are four (4) RPM memory settings, manual (up/down) RPM Control, and "Power Up" or Automatic RPM Control. There are also two remote inputs available for on/off RPM Control and adjustable vernier RPM Control. Section 3.1 BASIC OPERATION - RPM CONTROL Step 1 Ensure all vehicle enabling conditions are met. 1. Parking brake is set 2.
RPM CONTROL Section 3.2 AUTOMATIC OPERATION - RPM CONTROL Note that Automatic or "Power-up" operation can function only in vehicles equipped with Automatic Transmissions. With Automatic RPM Control programmed, the engine speed will be elevated to Memory #1 within a few seconds after the vehicle's enabling conditions are met. Step 1 Program the module for Automatic RPM Control. 1. Go to main programming mode, press and hold [RPM CONTROL], [CHARGE PROTECT] & [FORD] keys 2.
Section 3.4 CUSTOM RPM CONTROL Custom RPM Control allows the user to elevate and adjust the engine speed from a remote location on the vehicle. Inputs are provided in the wiring harness for an electrical vernier potentiometer-type input. Correct installation and programming is required for proper operation. Before beginning Custom RPM Control, follow the instructions given in Section 6, "Remote Switch Installation and Usage" for the proper installation of the remote switches.
Section 3.5 AUTOMATIC OPERATION - CUSTOM RPM CONTROL Automatic Custom RPM Control allows the user to elevate the engine speed automatically, and also adjust the engine speed from a remote location on the vehicle. Inputs are provided in the wiring harness for an electrical vernier potentiometer-type input. Correct installation and programming is required for proper operation. Be sure to read and understand Custom RPM Control operation outlined in Section 3.4 before proceeding.
PTO CONTROL Section 4 PTO CONTROL MODE PTO Control is used for electrically actuating a 12V PTO solenoid. The PTO Control key activates a discrete high side driver in the APCM to power up an auxiliary load, such as a Power Take-Off, electric clutch, or other implement. When the application requires the PTO to turn on and run at an elevated engine speed, there is an option to do this called PTO/RPM LINKED.
Section 4.2 PTO CONTROL WITH MAXIMUM ENGAGEMENT PROTECTION "Maximum PTO clutch engagement protection" can be achieved by utilizing the PTO lower limit on the APCM. The PTO output driver will not be allowed to turn on whenever the actual engine speed exceeds the programmed lower limit. The default is 1000 RPM. Keep in mind the RPM values are engine speeds and proper conversion to PTO speed is necessary (refer to table below for 4R100 applications).
PTO CONTROL Section 4.3 PTO CONTROL WITH OVERSPEED PROTECTION "PTO overspeed protection" can be achieved by using the upper disabling engine limit on the APCM. The PTO output driver will be turned off whenever the actual engine RPM exceeds programmed upper limit. Keep in mind the RPM values are engine speeds and proper conversion to PTO speed is necessary (refer to table below). If the upper limit is programmed below normal engine idle speed (~650 RPM), the PTO output will not function.
Section 4.4 PTO LINKED WITH RPM CONTROL When PTO Control is linked with RPM Control (PTO/RPM LINKED), the PTO output is activated and engine speed is elevated in conjunction with each other. When the RPM Control is commanded off, the PTO output will also turn off. Conversely, when the PTO output is commanded off, the RPM Control is also turned off and the engine returns to normal idle speed. This feature requires programming.
Section 4.5 PTO LINKED WITH CUSTOM RPM CONTROL When PTO Control is linked with Custom RPM Control (PTO/CUSTOM RPM LINKED), the PTO and Custom RPM Control operate together. This feature requires programming and remote switch installation. This feature is useful for applications when it's necessary to turn on the PTO and elevate idle from a remote location on the vehicle. Additionally, with this function programmed, you can turn off the PTO, adjust the idle speed, and return to normal idle.
Section 5 PROGRAMMING THE APCM This section describes how the Auxiliary Powertrain Control Module can be programmed. Section 5.
APCM MAIN PROGRAMMING MODE DIAGRAM • • • • Press [RPM CONTROL], [CHARGE PROTECT], and [FORD] keys simultaneously for three (3) seconds to start programming Press [FORD] key to save and move to the next Menu Press any [ARROW] key to select options in each Menu To exit programming mode, complete all menus OR press and hold the [RPM CONTROL], [CHARGE PROTECT], and [FORD] keys for 3 seconds START Press & Hold 3 seconds RPM CONTROL CHARGE PROTECT MENU 1 MENU 2 AUTOMATIC CAPABILITY MENU 3 LINK RPM CONTRO
Section 5.3 RPM PROGRAMMING MODE Programmable engine speed ranges from a minimum of 1200 RPM to a maximum of 2500 RPM. The four RPM memories are preset at four intermediate values within the operating range. These memory presets can be changed in RPM Programming mode or while RPM Control is activated. Section 5.3.
Section 6 INSTALLATION This section describes the installation procedure for the additional remote circuits available on the Auxiliary Idle Control Module. The Installation Instruction sheet in the kit describes the set-up of this module to the vehicle, including mounting bracket. Locate the mating 4-pin connector under the driver's side instrument panel and connect. See Section 9.2 for connector pin-out. NOTE: 1) DO NOT CUT THE WIRING HARNESS to extend or shorten the harness length.
Section 6.1.2 Custom Switch Installation Custom Remote RPM Control requires a potentiometer type input. The potentiometer or other type of resistor network, is used to adjust the engine speed by providing a voltage between 0.5V and 4.5V to the module. For remote activation, it is recommended that a Remote FORD switch is installed as described above to activate and deactivate Custom RPM Control.
Section 6.
Section 7 DIAGNOSTICS AND TROUBLESHOOTING PROBLEM OR SYMPTOM ACTION 1) No backlight on [FORD] key or [POWER] key Check power and ground lines. 2) When trying to enter a mode, light next to RPM Control key or Charge Protect key blinks briefly but does not stay lit.
Section 8 FUNCTIONAL SUMMARY VEHICLE REQUIREMENTS Enablers required to activate high-idle modes - Parking brake engaged - Clutch engaged (foot off) or vehicle in PARK - Service brake off - Foot off accelerator - Brake lights connected and functional Disablers allowing multiple ways of returning to idle - Press brake or clutch pedal - Release parking brake - Take vehicle out of PARK - Deselect APCM function - Turn off power to APCM CHARGE PROTECTION MODE Adaptive "Charge Protection" - Remote activation -
Section 9.1 CUSTOM INPUT VOLTAGE TO OUTPUT SPEED Table 9.1.1: Custom Voltage to RPM Function Input Voltage (V) <0.5V 0.5V 1.0V 1.5V 2.0V 3.0V 4.5V >4.5V V = (RPM - 1037.5) / 325 Engine Speed (RPM) (normal idle) 1200 1360 1525 1685 2010 2500 (normal idle) RPM = 325 x V + 1037.5 RPM VS. VOLTAGE 3000 2000 1000 0 0 1 2 Vin 3 4 5 Section 9.2 APCM MODULE HARNESS CONNECTORS Vehicle Side: Ford Part No.
RPM programming mode allows the user to adjust two ramp rates. The default settings are appropriate for most idle control applications. Table 9.3.2 shows the rate of change in RPM for both ramp rates. The first is the initial ramp up rate (∧RMP), which is how fast the engine ramps up to the desired speed. For PTO applications, a slower initial ramp up rate may be beneficial for clutch durability.
