Introduction
This kit provides adaptive vehicle "Charge Protection," selectable fixed elevated idle operation, and/or "manual" RPM control. This kit is compatible with IN-CAB ONLY mounting of the operator interface Auxiliary Powertrain Control Module (APC) Module). A user programming option allows for deselection of any of the functions.
NOTE: If "power up" RPM control is programmed, elevated idle will occur within a few seconds after the below enabling interlocks are met.
Features Specifications/Display
Enabling interlocks Parking brake engaged
Clutch engaged (foot off) or vehicle in PARK
Service Brake off
Foot off accelerator
Brake lights connected and functional
Adaptive "Charge Protection" System voltage display
Minimum activation RPM for charge protection 1300 RPM
Maximum charge rate At 1747 RPM
Selectable idle operation with closed-loop engine speed control System RPM display
Programmable RPM memories 4
Programmable engine speed "up" ramps 4 (1 per RPM memory)
Minimum programmable PRM 1300 RPM
Maximum programmable RPM 2500 RPM
Manual RPM control Via slow and fast up and down switches
Multiple means of returning to idle Press brake or clutch pedal
Release parking brake
Take vehicle out of PARK
Deselect APC module function
Turn off power to APC module
System Checkout:
NOTE: If "power up" RPM control is programmed, elevated idle will occur within a few seconds after the below enabling interlocks are met.
Ensure That Enabling Conditions Are Met
Parking brake set
Manual transmission
Engage clutch (foot off clutch pedal)
Automatic transmission
Gearshift lever in PARK
Foot off brake
Foot off accelerator
Brake lights connected and functional
Power Supply Check
Start Engine
Observe brief display of "8's" followed by engine speed
Observe steady light next to POWER key and backlighting on keys
NOTE: See Diagnostic Section (Section IX) if any of the above are not observed.
Functionality Check
Stop engine
Restart engine
Observe brief display of "8's"
IMMEDIATELY press CHARGE PROTECT key if "Power Up" Charge Protection is not enabled
Observe flashing light next to CHARGE PROTECT key
If batteries are fully charged, no high current draw accessories are on, and engine is fully warmed, observe elevated engine speed sound equivalent to 1300 RPM
Observe display of nominal system voltage
NOTE: If engine is not fully warmed (glow plugs are on initially after start), very high electrical loads exist, or batteries are significantly discharged, engine speed will be greater than 1300 RPM. If electrical loads exceed maximum alternator output (normal with glow plug operation) a below normal system voltage will be displayed.
You have activated the "Charge Protection" function to do this check. To deactivate this function, do one of the following:
Press CHARGE PROTECT key
Light next to CHARGE PROTECT key goes out
Engine speed returns to vehicle idle
Current engine speed is displayed
Press brake or clutch pedal, take vehicle out of PARK, or release parking brake
Light next to CHARGE PROTECT key goes out
Engine speed returns to vehicle idle
Current engine speed is displayed
Press ACTIVATE/DEACTIVATE (FORD OVAL) key
Light next to CHARGE PROTECT key goes out
Engine speed returns to vehicle idle
Current engine speed is displayed
Press POWER key
All lights next to keys go out (system is off)
Enabling/Disabling Functions and Station Programming
This unit is shipped with "Charge Protection" Fixed Elevated Idle, and Manual RPM Control activated and "Power Up" Charge Protection and "Power Up" RPM control deactived. Any of these features can be selected or deselected, either with the engine running or with the key in the "on" position and the engine not running. NOTE: This kit provides single station operation only.
To Enable or Disable Functions:
Ensure that light next to POWER key is lit and engine speed is displayed. If not, press POWER key
Steady light shows next to POWER key
Current engine speed is displayed
Press ACTIVATE/DEACTIVATE (FORD OVAL), RPM CONTROL, and CHARGE PROTECT keys simultaneously for 3 seconds to activate programming mode
Display shows current station setting
NOTE: For this kit, this value will always be "1". It cannot be changed.
Decimal point flashes on display
"VRMP" and "/\RMP" are displayed if Manual RPM Control capability is enabled.
Press any arrow key to toggle Manual RPM Control function.
"VRMP" and "/\AMP" are disappear if they were previously displayed (Manual RPM Control will be disabled)
"VRMP" and "/\AMP" are displayed if they were not previously displayed (Manual RPM Control will be enabled)
Press ACTIVATE/DEACTIVATE (FORD OVAL) key to proceed to the next step in programming. (To exit this programming mode, see the last paragraph of this section.)
"V" flashes in upper right corner of display
"CHARGE" is displayed if Charge Protect capability is enabled
Press any arrow to toggle Charge Protect capability
"CHARGE" disappears if it was previously displayed (Charge Protect capability will be disabled)
"CHARGE" is displayed if it was not previously displayed (Charge Protect capability will be enabled)
Press ACTIVATE/DEACTIVATE (FORD OVAL) key to proceed to the next step in programming. (To exit this programming mode, see the last paragraph of this section.)
"RPM" flashes in lower left corner of display
"RPM" is displayed at upper right if Fixed RPM Control is enabled
Press any arrow key to toggle Fixed RPM Control capability
"RPM" disappears if it was previously displayed (FIXED RPM Control capability will be disabled)
"RPM" is displayed if it was not previously displayed (Fixed RPM Control capability will be enabled)
Press ACTIVATE/DEACTIVATE (FORD OVAL) key to proceed to the next step in programming. (To exit this programming mode, see the last paragraph of this section.)
NOTE: The "Power-up" modes function only for vehicles with automatic transmission.
NOTE: If either of the "Power-up" functions were canceled prior to entering station programming, and a change is made to Manual RPM Control, Charge Protect, or Fixed RPM Control enabling/disabling, "BASE" will be indicated on the display.
If neither Power-up mode is activated, "BASE" will be displayed
If Power-up Charge Protect mode is activated, "A CP" will be displayed
If Power-up RPM mode is activated, "A Sr" will be displayed
Press any arrow key to change to a different "Power-up" mode
If neither Power-up mode is activated, "BASE" will be displayed
If Power-up Charge Protect mode is activated, "A CP" will be displayed
If Power-up RPM mode is activated, "A Sr" will be displayed
CAUTION: SELECTION OF THE "POWER-UP" RPM OR "POWER-UP" CHARGE PROTECT FUNCTION WILL RESULT IN ELEVATED ENGINE RPM WITHIN A FEW SECONDS OF THE VEHICLE'S ENABLING INTERLOCKS BEING MET.
To Exit Station/Function Enable/Disable Programming Before Completing All Steps:
Press ACTIVATE/DEACTIVATE (FORD OVAL), RPM CONTROL, and CHARGE PROTECT keys simultaneously for 3 seconds.
Current engine speed is displayed
To Exit Station/Function Enable/Disable Programming After Completing All Steps:
Press and release ACTIVATE/DEACTIVATE (FORD OVAL)
Current engine speed is displayed after the final programming step
Press POWER key
All lights next to keys go out (system is off)
RPM Control Usage
The RPM Control function provides elevated (minimum 1300 RPM, maximum 2500 RPM) idle engine speed operation with closed-loop control. When the module is shipped, the four engine RPM memories are pre-set at four intermediate RPM values over the operating range, with a moderate "up" ramp rate. Manual RPM control is available by using the slow and fast up and down keys.
CAUTION: IF "POWER-UP" RPM CONTROL HAS BEEN PROGRAMMED, ELEVATED ENGINE RPM WILL OCCUR WITHIN A FEW SECONDS AFTER VEHICLE'S ENABLING INTERLOCK CONDITIONS ARE MET.
To Activate RPM Control (If "Power-up" RPM Control has not been programmed):
Start engine and ensure that vehicle enabling conditions are met
Steady light shows next to POWER key
Current engine speed is displayed
Press RPM CONTROL key
Steady light shows next to RPM CONTROL key
RPM stored in Memory #1 displayed
If any memory other than Memory #1 is desired, press one of the four arrow keys to recall the engine speed stored in that memory
RPM stored in memory selected is displayed
Press ACTIVATE/DEACTIVATE (FORD OVAL) key to change the engine speed
Light next to RPM CONTROL key blinks
Engine speed increases to RPM displayed
To Use Manual RPM Control:
Select and activate a pre-set engine speed in "To Activate RPM Control"
Press or hold a single arrow (slow) key or a double arrow (fast) key
Next engine speed is displayed
Light next to RPM CONTROL key blinks
When arrow key is released, engine speed displayed becomes a new temporary set point
To Exit RPM Control:
Press RPM CONTROL key
Light next to RPM CONTROL key goes out
Engine speed returns to vehicle idle
Current engine speed is displayed
"Power-up" RPM Control, if enabled, is canceled for the current ignition cycle
Press brake or clutch pedal, take vehicle out of PARK, or release parking brake
Light next to RPM CONTROL key becomes steady (system is still in RPM Control mode)
Engine speed returns to vehicle idle
Engine speed stored in most recently selected memory is displayed
"Power-up" RPM Control, if enabled, is NOT canceled. If vehicle enabling conditions are re-established, RPM Control will be re-engaged
Press ACTIVATE/DEACTIVATE (FORD OVAL) key
Light next to RPM CONTROL key becomes steady (system is still in RPM Control mode)
Engine speed returns to vehicle idle
Engine speed stored in most recently selected memory is displayed
"Power-up" RPM Control, if enabled, is canceled for the current ignition cycle
Press POWER key
All lights next to keys go out (system is off)
"Power-up" RPM Control, if enabled, is NOT canceled. If APC is repowered, and vehicle enabling conditions are met, RPM Control will be re-engaged
RPM Memory Re-Programming
Programmable engine speed is limited to a minimum of 1300 RPM and a maximum of 2500 RPM. The four RPM memories are pre-set at four intermediate values within the operating range. These setpoints can be changed with the engine running the following method.
To Re-Program An RPM Memory
Select and activate the memory you wish to re-program
Tap or hold a single arrow (slow) key or a double arrow (fast) key until desired engine speed is reached
New engine speed is displayed
Light next to RPM CONTROL key blinks
Press ACTIVATE/DEACTIVATE (FORD OVAL) key and top arrow key simultaneously
New engine speed is stored in memory
To Exit RPM Memory Re-Programming
Press RPM CONTROL key
Light next to RPM CONTROL key goes out
Engine speed returns to vehicle idle
Current engine speed is displayed
Press brake or clutch pedal, take vehicle out of PARK, or release parking brake
Light next to RPM CONTROL key becomes steady (system is still in RPM Control mode)
Engine speed returns to vehicle idle
Engine speed stored in most recently selected memory is displayed
Press ACTIVATE/DEACTIVATE (FORD OVAL) key
Light next to RPM CONTROL key becomes steady (system is still in RPM Control mode)
Engine speed returns to vehicle idle
Engine speed stored in most recently selected memory is displayed
Press POWER key
All lights next to keys go out (system is off)
Charge Protection Usage
CAUTION: IF "POWER-UP" CHARGE PROTECTION HAS BEEN PROGRAMMED, AUTOMATIC ELEVATED ENGINE RPM WILL OCCUR WITHIN A FEW SECONDS OF THE VEHICLE'S ENABLING INTERLOCK CONDITIONS BEING MET.
To Activate "Charge Protection" (If "Power-up" Charge Protection has not been programmed):
Start engine and ensure that vehicle's enabling interlock conditions have been met
Steady light shows next to POWER key
Current engine speed is displayed
Press CHARGE PROTECT key
Light next to CHARGE PROTECT key blinks
Engine speed increases
Battery voltage ramps up (if necessary) and is displayed
To Exit "Charge Protection":
Press CHARGE PROTECT key
Light next to CHARGE PROTECT key goes out
Engine speed returns to vehicle idle
Current engine speed is displayed
"Power-up" Charge Protection, if enabled, is canceled for the current ignition cycle
Press brake or clutch pedal, take vehicle out of PARK, or release parking brake
Light next to CHARGE PROTECT key goes out
Engine speed returns to vehicle idle
Current engine speed is displayed
"Power-up" Charge Protection, if enabled, is NOT canceled. If vehicle enabling conditions are re-established, Charge Protection will be re-engaged
Press ACTIVATE/DEACTIVATE (FORD OVAL) key
Light next to CHARGE PROTECT key goes out
Engine speed returns to vehicle idle
Current engine speed is displayed
"Power-up" Charge Protection, if enabled, is canceled for the current ignition cycle
Press POWER key
All lights next to keys go out (system is off)
"Power-up" Charge Protection, if enabled, is NOT canceled. IF APC module is repowered, and vehicle enabling conditions are met, Charge Protection will be re-engaged
Alternative RPM Memory Re-Programming and Ramp Rate Re-Programming
The engine speed setpoints stored in the four memories can be reset in one of two ways: (1) While in RPM Control mode with the engine running as described in this section either with the key on and the engine off or with the engine running. In addition, the ramp "up" rate for each memory can be reset. This is the rate at which engine speed will increase when a new setpoint is activated in RPM Control mode. The ramp "up" rate for each of the four memories is preset at 1/2 of the maximum allowable acceleration rate. NOTE: The ramp "down" rate cannot be reset.
To Re-Program RPM Memories and Ramp Rates:
Ensure that light next to POWER key is lit and current engine speed is displayed. If not, press POWER key
Steady light shows next to POWER key
Current engine speed is displayed
Press ACTIVATE/DEACTIVATE (FORD OVAL) and RPM CONTROL keys simultaneously for 3 seconds
Lights next to POWER and RPM CONTROL keys blink
"RPM" blinks in lower left corner of display
Engine speed stored in Memory #1 is displayed
Press ACTIVATE/DEACTIVATE (FORD OVAL) key and an arrow key simultaneously to select a memory other than Memory #1 to reprogram, i.e..
Second arrow key - Memory #2
Third arrow key - Memory #3
Bottom arrow key - Memory #4
Engine speed stored in selected memory is displayed
Press or hold an arrow key until desired engine speed setpoint is reached (single arrows provide slow changes; double arrows provide fast changes)
New engine speed is displayed
Press ACTIVATE/DEACTIVATE (FORD OVAL) key to set engine speed for selected memory and proceed to ramp rate programming
/\AMP blinks on display
Vertical and horzontal lines show degree of ramp
Press or hold arrow keys until desired engine speed ramp up rate is reached
Vertical and horizontal lines on display show engine speed ramp up rate (as the rate increases, more lines are displayed)
Press ACTIVATE/DEACTIVATE (FORD OVAL) key to set ramp up rate for selected memory
NOTE: The ramp "down" rate cannot be reset.
Press ACTIVATE/DEACTIVATE (FORD OVAL) key to return to RPM memory re-programming. Another memory can be selected and re-programmed if desired
To Exit RPM Memory and Ramp Re-Programming:
Press ACTIVATE/DEACTIVATE (FORD OVAL) and RPM CONTROL keys simultaneously for 3 seconds
Light next to RPM CONTROL key goes out
Light next to POWER key goes to steady state
Current engine speed is displayed
Press POWER key
All lights next to keys go out (system is off)
Diagnostics
Problem Action
APCM functions but control screen is blank Reprogram the APCM with the latest level calibration
No backlight on ACTIVATE/DEACTIVATE (FORD OVAL) key or POWER key Check power and ground lines
When trying to enter a mode, light next to RPM CONTROL key or CHARGE PROTECT key blinks briefly but does not stay lit Ensure that enabling conditions are met
Parking brake engaged
Clutch engaged (foot off) or vehicle in PARK
Service brake off
Foot off accelerator
Brake lights connected and functional
With APC module turned off, use NGS Tester to determine if there are any brake or clutch pedal fault codes
For non-speed control vehicles (1995 MY only):
PCM may be incorrect. For manual vehicles, processor catch-word must be SOD4 or later.
For F250/F350/E350 automatic vehicles, processor catch-word must be TEE5 or later
For Super Duty vehicles, processor catch-word must be PRY4 or later. The catch-word tag may be located on the vehicle "A" pillar or on the PCM itself.
Display reads CErr for 5 seconds before normal display activation Check communication lines
One may be open or shorted
Display reads CErr Check communications lines
Both may be open
Check vehicle model year
May be pre-1995 (module will not function in earlier model vehicles)
Display reads CrSd Check communication lines
If communication lines are OK, replace APC module
Display reads EErr APC component defective - Replace APC module
Display reads AErr APC component defective - Replace APC module
Installation Instructions For APCM Kit
Remove contents of box and examine contents for correct component qualities.
Using the four (4) screws provided (Item #11), attach the APC Module (Item #12) to the Module Bracket (Item #10). Torque screws to 1.6 - 2.0 Nm.
Snap U-nut (Item #9) onto one end of the Bracket (Item #10) with conical nut projection pointing toward the inside of the angle. (Refer to sketch.)
Attach the Rear Angle Brace (Item #8) to the Module Bracket Assembly using one of the Screws (Item #6) provided. Do not fully tighten at this time!
Place Clip (Item #5) around Instrument Panel Support (Item #3), with the flat part of the Clip tangent to the bottom side of the Instrument Panel Support. (Refer to sketch.)
Remove the two (2) Instrument Panel Attachment Screws (Item #4) as shown.
Place APC Module Assembly under Instrument Panel (Item #1) in position under Ash Receiver Door (Item #2) and attach to flange using the two (2) screws (Item #4) that were removed in Step F. Torque screws to 2.5 ± 0.4 Nm.
Making sure that the Clip (Item #5) is above the Brace (Item #8), attach the components using the Screw (Item #6) and the Nut and Washer (Item #7 as shown.
Tighten the M6 Fasteners (Item #6) to 12 ± 1.8 Nm.
Attach Wiring Connector (Item #13) to mating connector under Instrument Panel and attach the other end to the APC Module.
APC Module Usage
NOTE: IF SYSTEM IS PROGRAMMED FOR "POWER-UP" RPM OR "POWER-UP" CHARGE PROTECTION, FUNCTION WILL BE ACTIVE WHENEVER THE ENABLING CONDITIONS ARE MET.
To Deactivate "Charge Protect" or RPM Control:
Press lighted key for function in use
Press ACTIVATE/DEACTIVATE (FORD OVAL) key
Press POWER key
Press brake or clutch pedal, take vehicle out of PARK, or release parking brake
NOTE: To deactivate "Power-up" RPM Control or "Power-up" Charge Protection, use and of the above methods. However, note that pressing the lighted key for the function in use or the ACTIVATE/DEACTIVATE (FORD OVAL) key will necessitate a key-off/restart cycle to regain the "Power-up" function. Pressing the POWER key does not cancel the "Power-up" function. It will still be enabled if the POWER key is pressed again.
Enabling Conditions:
Parking brake set
Foot off clutch or gear shift lever in PARK
Foot off service brake
Foot off accelerator
Brake lights connected and functional
"Charge Protect" Activation (If "Power-up" Charge Protection has not been programmed):
Press CHARGE PROTEC key
Light next to CHARGE PROTECT key blinks
RPM increases
System voltage is displayed
Fixed Speed RPM Control Activation (If "Power-up" RPM Control has not been programmed):
Press RPM CONTROL key
Steady light next to RPM COTROL key
RPM stored in Memory #1 is displayed
If any memory other than Memory #1 is desired, press on the the four (4) arrow keys to recall the engine speed stored in that memory
RPM stored in memory selected is displayed
Press ACTIVATE/DEACTIVATE (FORD OVAL) key to activate
Light next to RPM CONTROL key blinks
Engine speed increases to RPM displayed
Manual RPM Control:
Select and activate a preset fixed engine speed
Press or hold "up" or "down" single arrow (slow) or double arrow (fast) key
New engine speed is displayed
Light next to RPM CONTROL blinks
When key is released, RPM displayed becomes new temporary setpoint
To save new setpoint, simultaneously press and hold top arrow key and ACTIVATE/DEACTIVATE (FORD OVAL) key for 2 seconds
