Installing the Throttle Commander
Ford F250 – F550 Super Duty
T500106 2005-2007 6.0L Diesel
T500116 2008-2010 6.4L Diesel
1.0 Preparing for Installation ...........................................................5
2.0 Installing the Throttle Control ...................................................5
2.1 2005-2007 T500106 Connecting the Wiring .............................5
2.1.1 Automatic Transmission.........................................................6
2.1.2 Manual transmission ..............................................................6
2.2 2008-2010 T500116 Connecting the wiring..............................8
2.2.1 Automatic transmission..........................................................8
2.2.2 Manual transmission ..............................................................8
2.3 Remote Pendant Connections ..................................................8
3.0 Completing and Testing the Installation ..................................9
4.0 Operating the Pendant Controls .............................................10
4.1 Turning the Throttle On...........................................................10
4.2 Turning the Throttle Off...........................................................10
5.0 Troubleshooting .......................................................................11
6.0 Ordering Parts and Warranty ..................................................11
VMAC – Vehicle Mounted Air Compressors
Toll Free: 1-800-738-8622
Fax: 1-250-740-3201
1
Document 1930085
Installation Manual for VMAC Throttle Commander
Ford F250-F550 Super Duty
T500106 – 2005-2007 6.0L Diesel
T500116 – 2008-2010 6.4L Diesel
Changes and Revisions
Version
00
01
A
B
C
Revision Details
Original manual
Revisions and reformat
ECN 06-144 MY change
ECN 07-051 add 2008
ECN 09-114
Revised
IB 23 Aug 2004
IB 7 Feb 2005
IB 30 June 2006
IB 14 Mar 2006
SL 24 Nov 2009
Approved
SM 5 Oct 2004
SM 11 Feb 2005
SM 30 June 2006
SM 19 Mar 2007
SM 24 Nov 2009
Implemented
5 Oct 2004
14 Feb 2005
01 July 2006
24 Mar 2007
30 Nov 2009
Important Information
The information in this manual is intended for certified VMAC
installers who have been trained in installation procedures and for
people with mechanical trade certification who have the tools and
equipment to properly and safely perform the installation. Do not
attempt this installation if you do not have the appropriate
mechanical training, knowledge and experience.
Follow all safety precautions and standard shop practices for
mechanical work.
These instructions are a general guide for installing this throttle
control on standard production trucks and do not contain information
for installation on non-standard trucks. If you have difficulty with the
installation, contact VMAC.
The VMAC warranty form is located at the back of this manual. This
warranty form must be completed and mailed or faxed to VMAC at
the time of installation for any subsequent warranty claim to be
considered valid.
To order parts, contact your VMAC dealer. Your dealer will ask for
the VMAC serial number, part number, description and quantity. To
locate your nearest dealer, call 1-800-738-8622.
Copyright 2009
All trademarks used in this manual are the property of the respective copyright holder.
The contents of this manual may not be reproduced in any form without the express
written permission of VMAC, 1333 Kipp Road, Nanaimo, BC V9X 1R3.
Printed in Canada
2
VMAC – Vehicle Mounted Air Compressors
Toll Free: 1-800-738-8622
Fax: 1-250-740-3201
Wiring diagram 2005-2007 T500106
VMAC – Vehicle Mounted Air Compressors
Toll Free: 1-800-738-8622
Fax: 1-250-740-3201
3
THROTTLE
Throttle
Controller
Throttle
Controller
Blue
Connect to OEM circuit 76 green wire with white stripe clean tach out
Do not use short blue wire with
crimp connector
Blue
Blue
Connect the blue wires
Connect long blue wire to yellow
wire with a white stripe at the
blunt-cut harness
Blue
MANUAL TRANSMISSION
AUTOMATIC TRANSMISSION
Connect to light green wire with red stripe at the park brake switch
Connect to OEM white wire with light blue stripe key switched 12 volts
OFF
ON
COMMANDER
RPM
Green
Blue
BROWN
GREEN
WHITE
RED
BLACK
Blue
Black
Red
OEM Connector from
accelerator pedal
Throttle
Controller
BROWN
GREEN
WHITE
RED
BLACK
Connect to accelerator pedal
To ground
WALL OR
FLOOR OF CAB
GROMMET
White
Wiring diagram 2008-2010 T500116
4
VMAC – Vehicle Mounted Air Compressors
Toll Free: 1-800-738-8622
Fax: 1-250-740-3201
THROTTLE
Throttle
Controller
Blue
Throttle
Controller
RPM
Connect to OEM CE913 blue wire clean tach out (CTO) at the blunt cut harness
Do not use short blue wire with
crimp connector
Blue
Blue
Connect the blue wires
Connect long blue wire to CL505
blue wire with grey stripe
at the blunt-cut harness
Blue
MANUAL TRANSMISSION
AUTOMATIC TRANSMISSION
Connect to white wire with purple stripe at the park brake switch
Connect to OEM CBP44 purple wire key switched 12 volts
OFF
ON
COMMANDER
Green
Blue
BROWN
GREEN
WHITE
RED
BLACK
Blue
Black
Red
OEM Connector from
accelerator pedal
Throttle
Controller
BROWN
GREEN
WHITE
RED
BLACK
Connect to accelerator pedal
To ground
WALL OR
FLOOR OF CAB
GROMMET
White
1.0 Preparing for Installation
□ Disconnect the vehicle batteries.
□ Study
the wiring diagrams and locate the wires on the
components so that you are familiar with the connections.
2.0 Installing the Throttle Control
□ Remove
the dash panel below the steering column and tie-wrap
the throttle control box to the dash support bracket to the right of
the steering column, behind the diagnostic connector (Figure 1)
with the adjusting screws facing out.
Throttle pedal
connector
Diagnostic
connector
Tie-wrap to this bracket
Figure 1
2.1 2005-2007 T500106 Connecting the Wiring
□ Unplug
the cable(s) from the foot pedal assembly and connect
them to the matching connectors from the throttle control box.
□ Connect
the throttle control box cable(s) to the matching
connectors on the foot pedal assembly.
□ Connect
the red wire to the key-switched 12V OEM white with
blue stripe wire under the dash (Ford CCT #294) located near
the OEM diagnostic connector (Figure 2).
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□ Attach
the green wire with the ring connector to the OEM ground
above the diagnostic connector (Figure 2).
Dash
e
St
er
g
in
m
lu
co
n
White wire with a
light blue stripe
OEM ground
OEM diagnostic connector
Figure 2
□ Solder
and seal the white wire to the OEM light green with white
stripe Clean Tach Out (CTO - Ford CCT #76) wire located in the
bundle of blunt cut wires near the park brake (Figure 3).
2.1.1 Automatic Transmission
□ Solder
and seal the long blue wire form the throttle control box to
the yellow wire with a white stripe (PARK - Ford CCT 1857) in
the bundle of blunt cut wires beside the park brake under the
dash. Do not use the short blue wire with the butt connector.
2.1.2 Manual transmission
□ Cut
the long blue wire to about six inches, strip the end and
crimp it to the short blue wire with the butt connector.
□ Solder
and seal the black wire from the throttle control box to the
green with red stripe wire at the park brake (Figure 4).
6
VMAC – Vehicle Mounted Air Compressors
Toll Free: 1-800-738-8622
Fax: 1-250-740-3201
Blue wire (T500116)
Purple wire (T500116)
Blue wire with a grey stripe (T500116)
Light green wire with a white stripe (T500106)
Yellow wire with a white stripe (T500106)
HOOD
Figure 3
Green wire with a red stripe (T500106)
White wire with a purple stripe (T500116)
Figure 4
VMAC – Vehicle Mounted Air Compressors
Toll Free: 1-800-738-8622
Fax: 1-250-740-3201
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2.2 2008-2010 T500116 Connecting the wiring
□ Unplug
the cables from the foot pedal assembly and connect
them to the matching connectors from the throttle control box.
□ Connect
the throttle control box cables to the matching
connectors from the foot pedal assembly.
□ Connect
the red wire to the key switched 12V OEM purple wire
(Ford CCT CBP44) located in the bundle of blunt cut wires near
the park brake (Figure 3).
□ Attach the green wire with the ring connector to the OEM ground.
□ Solder
and seal the white wire to the OEM blue wire (Clean Tach
Out CTO-Ford CCT CE913) located in the bundle of blunt cut
wires near the park brake (Figure 3).
□ Solder
and seal the black wire from the throttle control box to the
white wire with purple stripe at the park brake (figure4)
2.2.1 Automatic transmission
□ Solder
and seal the long blue wire form the throttle control box to
the blue wire with grey stripe (PARK - Ford CCT CL505) in the
bundle of blunt cut wires beside the park brake under the dash.
Do not use the short blue wire with the butt connector.
2.2.2 Manual transmission
□ Cut
the long blue wire to about six inches, strip the end and
crimp it to the short blue wire with the butt connector.
2.3 Remote Pendant Connections
□ Route
the remote pendant cable into the cab through a suitable
opening.
□ Connect
the five colored wires on the pendant cable to the
matching colored wires in the heavy cable from the throttle
control box. Make sure that the bullet connectors are pushed
together securely to make a good connection.
8
VMAC – Vehicle Mounted Air Compressors
Toll Free: 1-800-738-8622
Fax: 1-250-740-3201
3.0 Completing and Testing 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 the supplied
loom as required.
□ Connect
the batteries. Place the vehicle in a safe operating
position and block the wheels. Ensure that there are no people
near the vehicle before beginning the test.
□ Place
the automatic transmission in PARK or manual
transmission in neutral and engage the park brake. Start the
vehicle engine and wait for the idle to stabilize and for engine
temperature to reach normal operating range.
□ Make
sure that the “RPM” knob is turned down counterclockwise, turn on the switch on the remote pendant, then slowly
turn up the “RPM” knob clockwise. The engine should begin to
idle up.
□ Turn
the knob fully counter-clockwise. The engine should idle
down.
□ Firmly apply the service brake pedal and hold it down.
□ Release
the park brake and activate as before. The engine
should not idle up.
□ Apply
the park brake and shift the automatic transmission into
reverse with your foot on the service brake pedal and activate as
before. The engine should not idle up. Repeat the test in all
forward gears.
□ Shift the transmission into Park and shut down the engine.
!
If the vehicle fails the test, check the wiring
connections. If you require additional assistance,
contact your local VMAC dealer or call VMAC at
1-800-738-8622 or 250-740-3200.
VMAC – Vehicle Mounted Air Compressors
Toll Free: 1-800-738-8622
Fax: 1-250-740-3201
9
4.0 Operating the Pendant Controls
4.1 Turning the Throttle On
□ Make
sure that the “RPM” knob is turned down counterclockwise before turning the throttle on to ensure the engine
doesn’t rev past the desired operating speed.
□ With
the engine running and the truck in “Park” with the park
brake on, turn on the switch on the remote pendant.
□ Slowly
turn up the “RPM” knob clockwise until the engine is at
the desired speed.
4.2 Turning the Throttle Off
□ Turn the “RPM” knob fully counter-clockwise.
□ Turn off the switch on the remote pendant.
□ Shut off the engine.
10
VMAC – Vehicle Mounted Air Compressors
Toll Free: 1-800-738-8622
Fax: 1-250-740-3201
5.0 Troubleshooting
Problem
Engine RPM climbs to
red line when Throttle
Commander is activated
Engine stays at base idle
(600 RPM) and
accelerator pedal
continues to have
authority over engine
speed
Engine RPM will not
adjust below 1200 RPM
Engine stays at pre-set
RPM even with Throttle
Commander switched
off
“Check Engine” light
comes on
Possible Causes
White wire not
connected properly
RPM knob turned fully
clockwise
Park brake not on
Black wire not
connected properly, if
automatic
transmission, DDC not
connected properly
Proper operation of
Throttle Commander
being disrupted by
PTO circuit
Proper operation of
Throttle Commander
being overridden by
PTO circuit
Bad plug connection at
the Throttle
Commander or foot
pedal assembly
Corrective Action
Check connections
Turn RPM knob
counterclockwise
Set park brake
With park brake on, check
electrical continuity from
black wire to chassis ground.
If no continuity, check
connection of black wire to
park brake switch. If
connection is good but still
no continuity to ground,
replace park brake switch
Disconnect all wires running
to Ford CCT 322 (blue/yellow
wire near data link connector
at lower center of dash)
Disconnect all wires running
to Ford CCT 322 (blue/yellow
wire near data link connector
at lower center of dash)
Make sure all plugs are
properly engaged
and fully seated and latched
If you are unable to effectively troubleshoot operational
problems, call your local VMAC dealer for technical
support. To locate your nearest dealer call:
1-800-738-8622 or 250-740-3200.
6.0 Ordering Parts and Warranty
To order parts, contact your nearest VMAC dealer. Please quote the
VMAC part number, the description and the quantity.
The VMAC warranty form must be completed and mailed or faxed to
VMAC at the time of installation for any subsequent warranty claim to
be considered valid.
VMAC – Vehicle Mounted Air Compressors
Toll Free: 1-800-738-8622
Fax: 1-250-740-3201
11