2006 FORD TRANSIT service reset

NOTE: A power take off layout can only be
implemented on vehicles fitted with an ABS
braking system. Manual braking systems employ
a transmission speed sensor to determine vehicle
speed & the RPM speed control software
contains vehicle speed restrictions which prohibit
RPM speed control operation if vehicle speed is
detected above very low levels (approx 2.5 mph).
A vehicle fitted with an ABS braking system
derives vehicle speed via the vehicles wheel
speed sensors, so the transmission can operate
normally without effecting RPM speed control
operation.
3 Modes of Operation
There are 3 principle modes in which this feature
can operate, they are:
1.3 speed mode – this provides the end user a
choice of up to 3 preset RPM values to select
from. The end user cannot easily override
these values so there is minimal risk of damage
to ancillary equipment due to it being run at
speeds it was not designed for. Very limited
vehicle speed is allowable while in this mode
(up to 2.5mph approx)
2.Variable speed mode – this provides the end
user with RPM speed ramp up & down
buttons. The end user is free to select RPM
values between 1300-3000rpm in 25rpm
steps. A single press results in a 25 rpm jump.
If a ramp button is held depressed by the end
user then the rate of change is 250rpm/sec.
Very limited vehicle speed is allowable while in
this mode (up to 2.5mph approx)
3.Idle up speed – this mode allows the engines
normal idle to be increased to any value (in 25
rpm steps) in the range 900-1200rpm. There
is not a vehicle speed restriction in this mode
as the intended use is to raise the engine idle
to reduce the likelihood of engine stall when
ancillary equipment is being run from the
engine during normal drive operations. Eg
refrigerator units used to keep the cargo bay
cool.
NOTE: Items 1) & 2) will be available from Nov
2006, while item 3) should be available from Jan
2007. Any latest generation diesel Transit can be
updated to include item 3) Idle up speed with a
simple calibration update once it becomes
available.
System Availability
This feature is built into the latest Powertrain
Control Module (PCM) software on all diesel
engine variants.
By default the feature is not enabled unless the
vehicle is specifically ordered with the feature
from the factory.
Vehicles which have not been ordered with this
feature may have the feature enabled at a dealer
via the IDS diagnostics system. The dealer should
charge for this service.
How to control this feature
A loop of wire (green/white) is provided in the
main electrical loom to permit control of the RPM
Speed Control software. Cutting this loop will
provide two wires to connect a control box to the
PCM.
The control box needs to switch resistors into the
circuit across the two green/white wires which
formally formed the loop prior to being cut. This
sort of circuit is known as a resistance ladder. The
PCM software monitors the green/white wire
circuit & when certain resistances are detected
they are interpreted as various inputs which
control the feature. The switch box can be
located where it’s ideally required for the vehicle
conversion in question, rather than having to be
mounted on the Instrument Panel (IP). If the
converter chooses to locate the switch box in a
location which is subject to an adverse
environment then the converter should design
the switch box to withstand with these conditions.
How to locate the green/white loop
The main electrical loom enters the vehicle cab
from the engine bay on the left hand side of the
vehicle via a large diameter hole in the engine bay
/ cabin bulkhead. This hole is just above the left
hand front suspension turret. See following Figure
E88307
FordTransit 2006.5 (April 2006–)
Date of Publication: 12/2006
4 Electrical
158

The software in the PCM responds to the change
of state, so it is recommended that these 3
middle switches be non-latching push button
micro switches. When going from idle to an
elevated RPM the execution of the command
will occur as the button is released. When going
to idle the execution of the command occurs as
the button is pressed.
The final button (the one on the left in Fig. 4) acts
as an ‘emergency’ vehicle engine stop. It is
recommended that this be a red & oversize
non-latching micro switch button. The execution
of this command will occur as the button is
pressed.
All wiring connecting the PCM to the resistance
ladder control box should be shielded & twisted
(33 twists / m) to reduce EMC effects
All resistors should have a tolerance of +/- 5% or
better
Switch contact, connectors & loom (loom
between the green/white wires & the control
box) total resistance must be no greater than 5
ohm max.
The PCM to resister ladder control switch box
loom should not come within 100mm of any other
harness, especially any carrying heavy loads.
Designs which do not require all the button
switches must still have the complete resistor
network with the switches positioned correctly
within the network.
The resistance ladder is acting as a potential
divider
The 220 nF capacitor is used in the circuit to
reduce EMC effects on the system
A suitable two way quality connector should be
used to connect the control box to the two
green/white wires
How to change the default settings
By default, when the feature is first enabled
(either via factory order or via dealer IDS tools),
it will be set to the 3 speed mode of operation
with preset RPM values of 1100, 1600 & 2030rpm
for the 3 speeds.
There are two methods by which these defaults
can be modified:
1.via the IDS diagnostics system at a Ford dealer
(there may be a charge for this)
2.via an inbuilt vehicle ‘learn mode’
Via the IDS system the mode of operation can
freely be changed between any of the 3 modes
of operation, the feature can even be turn off
(disabled). The 3 default RPM speeds can also
be modified.
Via the vehicle ‘learn mode’ the 3 speed mode
& the variable speed mode can be freely
interchanged, however it is not possible to select
the idle up speed mode via the vehicle learn
mode. The 3 default RPM speeds can also be
modified via ‘learn mode’
It is not possible via either method above, to
change the step value of 25rpm per press or the
250 rpm per sec for a held down button, in the
variable rpm speed mode.
Via IDS The RPM Speed Controller menu is under
the tool box tab, then Powertrain, then service
functions, then PCM. The IDS on screen menus
will guide the dealer through the options & setup.
How to enter vehicle ‘Learn mode’
1.Make sure that the RPM Speed controller
switch box is connected but turned off (not
‘armed’)
2.Start the engine (vehicle out of gear & no foot
pedals being pressed, handbrake on)
3.Wait a couple of seconds for the instrument
panel start up diagnostic lights to extinguish
4.Press & release the clutch pedal
5.Press & release the brake pedal
6.Repeat steps 4) & 5) a further four times
(clutch & brake pressed a total of five times
sequentially each)
NOTE: Steps 4) to 6) have to be started within
10 seconds of the engine start
The vehicle should now be in ‘learn mode’
How to Select between modes
1.Enter ‘learn mode’ (see directions above)
2.Arm the RPM speed controller (turn the key
switch to ‘on’)
If the vehicle is already in 3 speed mode (the
initial default):
3.Press & release the brake pedal five times
The vehicle should now be in variable speed
mode. The new settings can be saved & learn
mode exited (see below)
Alternatively
4.Press & release the brake pedal once
The vehicle should now be in 3 speed mode.
The new settings can be saved & learn mode
exited (see below)
Using this method it is easy to change between
these two modes of operation for the RPM
speed controller
NOTE: If the engine stalls out at the initial brake
pedal input then the vehicle was not in, or has
dropped out of ‘learn mode’ & you will have to
restart the procedure.
FordTransit 2006.5 (April 2006–)
Date of Publication: 12/2006
4 Electrical
161