Ford Transit Gardner Denver PTO Parameters

1 Document: Ford Transit Gardner Denver PTO Parameters Organisation: National Grid Reference: NG TSL 04/2010 Revision: 001 Date: 5/08/2010 Page 1 Ford Transit Gardner Denver PTO Parameters Contents 1 Overview .. 1 How to disconnect/reconnect the OBP .. 1 2 Setting PTO Parameters .. 2 What to do if the OBP is not operating correctly .. 2 How to set up the RPM Speed Controller in IDS .. 2 RPM Settings For vehicles fitted with a 5 speed gearbox and driven in 4th gear .. 3 RPM Settings For vehicles fitted with a 6 speed gearbox and driven in 6th gear .. 3 RPM settings For vehicles fitted with a 6 speed gearbox and driven in 5th gear.

2 4 3 How to Test that the onboard power is operating correctly .. 4 4 Things that will prevent RPM Controller from activating .. 5 5 Appendix .. 5 Transit Engine RPM Speed Controller ( ) .. 5 1 OVERVIEW A number of National Grid vehicles are fitted with the Gardner Denver Onboard Power system. This system uses the Engine RPM Speed Controller to allow the vehicle to run at elevated RPM speeds. This power is used to drive ancillary equipment which is fitted to the vehicle. This feature is built into the latest Powertrain Control Module (PCM) software on all diesel Transits. In order for the system to operate correctly, this feature must be enabled via the IDS Diagnostic System.

3 The RPM Speed Controller mode used for this application is : 3 Speed Mode HOW TO DISCONNECT/RECONNECT THE OBP The Gardner Denver OBP connection on the Ford wiring loom is located in the vehicles glove box. By disconnecting this plug, the onboard power is disconnected. To reconnect the OBP, simply reconnect the connection. (Fig 1) Document: Ford Transit Gardner Denver PTO Parameters Organisation: National Grid Reference: NG TSL 04/2010 Revision: 001 Date: 5/08/2010 Page 2 Fig 1 2 SETTING PTO Parameters WHAT TO DO IF THE OBP IS NOT OPERATING CORRECTLY If the OBP is not operating correctly, the root cause needs to be established.

4 This could be related to the Gardner Denver equipment or an issue with RPM Speed Controller in the PCM. In order to test the RPM Speed Controls, you will need to introduce a resistance ladder between the pins of the disconnected plug. Details can be found in the Body and Equipment Mounting Manual (BEMM) Appendix or approach Gardner Denver for a test unit. If the RPM Speed Control does function correctly, then Gardner Denver should be contacted on 01274 683 131 as there is a fault with their system, not the Transit . If the RPM Speed Control does not function when the resistance ladder is introduced and operated, then the issue lies within the vehicle and requires diagnostics via IDS.

5 HOW TO SET UP THE RPM SPEED CONTROLLER IN IDS In the event that the RPM speed Controller settings need to be re-enabled in IDS if the vehicle has a Revised Calibration, or has the AS Built Data reinstated. You must follow the following procedure: Document: Ford Transit Gardner Denver PTO Parameters Organisation: National Grid Reference: NG TSL 04/2010 Revision: 001 Date: 5/08/2010 Page 3 1. Connect IDS to the vehicle 2. To get to the RPM Speed Controller menu got to: Tool box tab Powertrain Service functions Powertrain Service functions Powertrain Control Module (PCM) RPM Controller 3.

6 The RPM controller mode will be shown. This must always be set to 3 speed mode. 4. You will be asked if you would like to change the RPM Controller mode or associated engine speeds. 5. Select YES 6. The current engine speeds are identified: Level 1, Level 2 and Level 3. 7. Please check that these are the correct settings for this vehicle. You can confirm these details through Gardner Denver directly on 01274 683 131 or see the details below. NOTE A fault code of P251A indicates PTO Enabled switch Circuit/Open. Gardner Denver has confirmed that this is normal and will always show in IDS DTC s.

7 The 3 speeds can be customized for any application. The settings required for the Gardner Denver National Grid set-up are as follows: RPM SETTINGS FOR VEHICLES FITTED WITH A 5 SPEED GEARBOX AND DRIVEN IN 4TH GEAR Engine speed with alternator is in the ON position: a) 1660 Engine speed with alternator in the OFF position with the air outlet closed: b) 1200 Engine speed with alternator in the OFF position with the air outlet open: c) 1990 RPM SETTINGS FOR VEHICLES FITTED WITH A 6 SPEED GEARBOX AND DRIVEN IN 6TH GEAR Engine speed with alternator is in the ON position: a) 1320 Engine speed with alternator in the OFF position with the air outlet closed: b) 1100 Engine speed with alternator in the OFF position with the air outlet open: c) 1650 Document: Ford Transit Gardner Denver PTO Parameters Organisation: National Grid Reference: NG TSL 04/2010 Revision: 001 Date: 5/08/2010 Page 4 RPM SETTINGS FOR VEHICLES FITTED WITH A 6 SPEED GEARBOX AND DRIVEN IN 5TH GEAR Engine speed with alternator is in the ON position: a) 1660 Engine speed with alternator in the OFF position with the air outlet closed.

8 B) 1200 Engine speed with alternator in the OFF position with the air outlet open: c) 1990 The above speed values also correspond to the required speed in the Ford PCM. Speed b) = RPM 1 Speed a) = RPM 2 Speed c) = RPM 3 3 HOW TO TEST THAT THE ONBOARD POWER IS OPERATING CORRECTLY Once any work is completed, please ensure that the OBP is operating correctly before the vehicle is returned to the customer. In order to test that the OBP is operating correctly, please carry out the following test. These instructions are located on the O/S sun visor in the vehicle or on the BT Fleet Portal.

9 Please ensure that you select the correct gear and check the RPM (dependant on vehicle) An example for a 6 speed gearbox being driven in 6th gear is detailed below: 1. Select 6th gear 2. Depress clutch 3. Start engine 4. Select compressor/alternator on PTO lever by handbrake 5. Slowly release clutch. Engine revs increase slowly to 1100rpm 6. Go to fuse box, just inside rear doors, turn switch to on. Engine revs increased slowly to 1650 RPM 7. Close air valve. Dip clutch, engine will cut out (this is normal). Disengage PTO lever, select neutral. NB: It is normal for the engine to cut out when the foot brake is applied with the PTO lever in compressor/alternator position.

10 Document: Ford Transit Gardner Denver PTO Parameters Organisation: National Grid Reference: NG TSL 04/2010 Revision: 001 Date: 5/08/2010 Page 5 4 THINGS THAT WILL PREVENT RPM CONTROLLER FROM ACTIVATING 1. Low fuel level if there is less than 5 litres of fuel left, RPM Controller is denied. 2. Brake or Clutch press indicated an incorrectly installed clutch or brake switch will send a pedal pressed signal. 3. Note: Diagnostics on switches take time to spot these errors 4. Accelerator pedal sensor fault 5. Brake pedal switch fault 6. Clutch pedal switch fault 7. CAN fault 8.