Electronic Road Speed Limiter - timtach.com · Vauxhall Vivaro CDTi ... STURDY ELECTRONIC ROAD...

R

ElectronicRoad Speed

Limiter

ERSLApplications List

September 2008Issue F rev 2

HOW TO NAVIGATE THE

APPLICATIONS LIST

Click on the “Bookmarks” tabto open the navigation menu

Navigation menu opens.Click on the vehicle who’sfitting instructions youwish to view

HOW TO NAVIGATE THROUGH THEERSL APPLICATION LIST

The selected fitting instructions open at the first page.Use the page scroll facility to browse the instructions.Referal to other pages are highlighted in blue text.Click on the text to go to the refered page

Click on the “Return to fitting instructions”text to return.

0

5

25

75

95

100

0

5

25

75

95

100

0

5

25

75

95

100

0

5

25

75

95

100

STURDY Europe

1. Legal Requirements

Passenger Vehicles ............................................................................................................................... 1

More than 8 Passenger Seats ................................................................................................ 1

More than 16 Passenger Seats ............................................................................................. 1

Goods Vehicles ...................................................................................................................................... 2

2. Important Notes

ERSL Control Unit................................................................................................................................... 3

Speed Hold Utility .................................................................................................................................. 3

CANbus.................................................................................................................................................... 4

New Installation Sheet.......................................................................................................................... 5 - 6

3. Application Sheets

Aptec WilliamsAptec Williams Throttle Control .......................................................................................................... 7 - 8

Citroen

Relay ........................................................................................................................................................ 9 - 12

DAF

LF Series ................................................................................................................................................. 13 - 16

FordFocus 1.8D ............................................................................................................................................. 17 - 20

Ranger ..................................................................................................................................................... 21 - 24

Transit up to Nov 1997 ........................................................................................................................ 25 - 28

Transit from Nov 1997 ......................................................................................................................... 29 - 32

Transit from 2000 ................................................................................................................................. 33 - 36

Transit from 2005 ................................................................................................................................. 37 - 40

IsuzuNPR .......................................................................................................................................................... 41 - 44

NQR .......................................................................................................................................................... 45 - 48

Iveco

Daily EDC .13 .......................................................................................................................................... 49 - 50

LDV

Convoy 2.4D ........................................................................................................................................... 51 - 54

Mercedes-Benz

Sprinter .................................................................................................................................................... 55 - 60

CONTENTS

STURDY Europe

Mitsubishi

Canter ...................................................................................................................................................... 61- 64

PeugeotBoxer ....................................................................................................................................................... 65 - 68

Renault

Master ..................................................................................................................................................... 69 - 72

VauxhallAstra ......................................................................................................................................................... 73 - 76

Combo CDTi ............................................................................................................................................ 77 - 80

Vivaro ....................................................................................................................................................... 81 - 84

VolkswagenLT 35 and 46 .......................................................................................................................................... 85 - 90

Transporter T4 ........................................................................................................................................ 91 - 94

Transporter T5 ........................................................................................................................................ 95 - 98

4. Throttle Pedal Wiring Diagrams

Aptec Williams Throttle Control .......................................................................................................... iiiCitroen Relay .......................................................................................................................................... ivDAF LF Series ......................................................................................................................................... vFord Focus 1.8D .................................................................................................................................... viFord Ranger ............................................................................................................................................ viiFord Transit up to Nov 1997 ............................................................................................................... viiiFord Transit from Nov 1997 ................................................................................................................ ixFord Transit from 2000 ........................................................................................................................ xFord Transit from 2005 ........................................................................................................................ xiIsuzu NPR ................................................................................................................................................ xiiIsuzu NQR ............................................................................................................................................... xiiiIveco Daily EDC .13 ................................................................................................................................ xivLDV Convoy 2.4D ................................................................................................................................... xvMercedes-Benz Sprinter ....................................................................................................................... xviMitsubishi Canter .................................................................................................................................. xviiPeugeot Boxer ........................................................................................................................................ xviiiRenault Master ...................................................................................................................................... xixVauxhall Astra ......................................................................................................................................... xxVauxhall Combo CDTi ............................................................................................................................ xxiVolkswagen LT 35 and 46 .................................................................................................................... xxiiVolkswagen Transporter T4 .................................................................................................................. xxiiiVolkswagen Transporter T5 .................................................................................................................. xxivVauxhall Vivaro CDTi ............................................................................................................................ xxv

STURDY Europe

1

A GUIDE TO SPEED LIMITER REQUIREMENTS

Passenger vehicles with more than 8 passenger seats (Bus)

Diesel / LPG / Natural Gas Petrol

Vehicle Size C &U reg 36A

(Gross Design Weight) paragraph First registered Use date Stabilised speed not to exceed date Stabilised speed not to exceed

not exceeding 5000 2B & 7 1 January 2005 and after International 1 January 2005 100 kph 1 January 2005 100 kph

National only 1 January 2008 100 kph 1 January 2008 100 kph

1 October 2001 to

2C & 7 31 December 2004 International 1 January 2006 100 kph

(Euro III or later engine) National only 1 January 2007 100 kph

5001 to 7500 2A & 7 1 January 2005 and after All 1 January 2005 100 kph 1 January 2005 100 kph

1 October 2001 to

2C & 7 31 December 2004 International 1 January 2006 100 kph


7501 to 10000

2 & 7 1 January 2005 and after All 1 January 2005 100 kph 1 January 2005 100 kph

2 & 7

2 & 7A All existing requirement set speed of 100 kph existing requirement set speed of 100 kph

10001 >

2 & 7 1 January 2005 and after All 1 January 2005 100 kph 1 January 2005 100 kph

Passenger vehicles with more than 16 passenger seats (Coach)




7501 to 10000

1 & 6 All existing requirement set speed at 112 kph existing requirement set speed at 112 kph

10001 >

1 & 6 All existing requirement set speed at 112 kph existing requirement set speed at 112 kph

set speed of 100 kph

1 April 1974 to 31

December 1987

1 April 1974 to 31

December 1987

All existing requirement set speed of 100 kph existing requirement

1 January 1988 to 30

September 2001

1 October 2001 to 31

December 2004


September 2001

2 & 7A

Not Required

Not Required


December 2004All 1 January 2005 100 kph 1 January 2005 100 kph

STURDY Europe

2

A GUIDE TO SPEED LIMITER REQUIREMENTS

Goods




3501 to 7500 1A & 9 1 January 2005 and after International 1 January 2005 90 kph 1 January 2005 90 kph

National only 1 January 2008 90 kph 1 January 2008 90 kph

1 October 2001 to

1B & 9 31 December 2004 International 1 January 2006 90 kph


7501 to 1200 1A & 9 1 January 2005 and after All 1 January 2005 90 kph 1 January 2005 90 kph

1B & 8 All existing requirement 90 kph existing requirement 96 kph

1 & 8 All existing requirement 96 kph existing requirement 96 kph

7501 to 10000

2 & 9 1 January 2005 and after All existing requirement 90 kph existing requirement 90 kph

2 & 9 90 kph

2 & 9 All existing requirement 90 kph existing requirement 90 kph

Not Required


December 2004All existing requirement existing requirement 90 kph

1 October 2001 to

31 December 2004

1 August 1992 to

31 December 2001

1. The category of vehicle highlighted needs particular attention. These vehicles will need to have their current settings reduced in order to comply.


September 2001

STURDY Europe

3

Important Notes

ERSL Control Unit

It should be noted that, all ERSL control units supplied to the European aftermarket afterJanuarJanuarJanuarJanuarJanuary 2008y 2008y 2008y 2008y 2008, feature an optional Speed Hold facility.

Speed Hold

The speed hold utility enables the driver of a vehicle to set a limited speed for the vehicleanywhere below the maximum set speed. To activate the speed hold the driver should stabalisethe vehicle at the speed at which limitation is required, then turn on the dash mounted speedhold switch. The vehicle speed will now be limited to the selected speed until the speed holdswitch is turned off. When turned off the vehicle limited speed will return to the maximum setspeed.

To enable the speed hold facility the following steps should be taken:

1. Separate the Blue wire from the ERSL wiring loom and connect the wire to a dashboardmounted single pole On/Off switch, the other connection to the switch should be apermanent vehicle ground.

2. Using the link wire supplied, connect terminals 2 and 3 at the 18 pin ERSL wiring loomconnector.

3. Connect the ER01 programmer between the wiring loom connector and the control unitand down load the limiter program details. Change the code for table 8 to 255255255255255 andsend the updated program to the limiter.

NoteNoteNoteNoteNote: When reprogramming takes place the vehicle must be run at the maximum speedsetting of the vehicle, at full throttle, for 10 to 20 seconds on a flat road surface. Thisallows the limiter to ‘re-learn’ the new settings.The speed hold switch should be Off during this road test.

18 pin Wiring loom

connectorSingle pole

On/Off switch

Vehicle

ground

Link

wire

Dk Blue

7

6

12

1318

STURDY Europe

4

CANbus

Whilst some vehicles are equipped with an analogue speed signal that can be utilized for thespeed signal input to the ERSL, most new vehicles are now using CANbus.

Communication Area Network BUS is a high-speed data transmission network of binary vehicleinformation transmitted through limited vehicle wiring, linking all major vehicle componentstogether.

The Sturdy Limiter at this time will only operate from an Analogue Speed signal. Therefore invehicles with no Analogue Speed output we must covert the ‘CAN’ signal to an Analoguesignal for the ERSL to use.

This is achieved by the use of the Spal Canbus interface which is inserted, at a strategicpoint, into the Can network wiring of the vehicle.

The Spal CANbus unit is available from Time Instruments Ltd under Part No. 122000

STURDY Europe

5

New Installations

As you are aware the light commercial vehicle sector is a constantly changing market in termsof technical development. Vehicle manufacturers regularly introduce new models or updateexisting models to keep pace with new technology.

From time to time you will be asked to install the Sturdy ERSL to a vehicle where no fittinginstructions are available or the instructions do not reflect equipment changes made by themanufacturer.

Should you require assistance from the Sturdy technical team to carry out the fitting, wouldyou please photocopy the ‘New Installation’ sheet that follows this page, enter the detailrequested and fax it to the number at the bottom of the sheet.

STURDY Europe

6

STURDY Europe

7

STURDY ELECTRONIC ROAD SPEED LIMITER

FITTING INSTRUCTIONS

FOR

Aptec Williams Throttle Control

MODELS: Various

ERSL KIT No: ER-02

KIT CONTENTS: 57D-02996 Control Unit (preset at 70 m.p.h.)

57C-03060-002 Wiring Loom

59A-03115 Fitting Accessories

Fitting Instructions

In keeping with good workshop practices the vehicle battery should be disconnected beforeattempting to install the ERSL.

Ensure that any security codes for Radios, Alarms, etc., are available before disconnectingthe battery.

Control Unit

Find a suitable position within the cab of the vehicle and secure the Control Unit, ensuringthat the site is not directly in the air flow from any heater ducts.

Wiring Loom

Remove the Purple and Brown wires from their sheath and cut the wires approximately 200mmfrom the connector, then using a butt splice supplied with the kit join the cut ends of the wirestogether. Feed the joined wires back into the protective sheath.

Connect the ERSL wiring loom to the 18pin connector in the Control Unit.

Select the ERSL loom containing three wires (Red, Black and Green) and run this to the fusepanel / rear of Tachograph / rear of electronic speedometer. Connect the RRRRRededededed wire from theERSL loom to an ignition switched positive. Connect the BlackBlackBlackBlackBlack wire from the ERSL wiringloom to a vehicle ground. Connect the GreenGreenGreenGreenGreen wire from the ERSL loom to the wire carrying aspeed signal.

Route the other half of the ERSL wiring loom to the vehicle wiring harness that runs to thethrottle potentiometer.

APTEC WILLIAM

SAPTEC W

ILLIAMS

APTEC WILLIAM

SAPTEC W

ILLIAMS

APTEC WILLIAM

S

STURDY Europe

8

Wiring Loom cont’d

At a suitable position in the potentiometer wiring harness, separate and cut the BlackBlackBlackBlackBlack wire.Using a butt splice included in the kit, connect the OrangeOrangeOrangeOrangeOrange wire from the ERSL loom to the cutwire from the throttle potentiometer.

Connect the YYYYYelloelloelloelloellowwwww wire from the ERSL loom to the cut wire that runs to the vehicle ECU.

Separate the WhitWhitWhitWhitWhiteeeee wire from the potentiometer harness and using a suitable connector,splice the PinkPinkPinkPinkPink wire from the ERSL loom to it.

Once the connections have been made wrap the looms with insulating tape to provide a neatfinish and reconnect the loom to the throttle potentiometer.

Calibration details

The Sturdy ERSL is supplied with generic calibration characteristics which may or may not besuitable for the vehicle that the throttle control is fitted to.

For advise on the suitability of the calibration contact the Sturdy Europe Technical Department.

Re-calibration / changing the set speed

The Sturdy ERSL is supplied with the operating speed set at 70 m.p.h., however the speedsetting can be easily changed to suit the customers specific requirements using the SturdyER-01 programmer.

Refer to the ER-01 Programming manual for calibrating details.

Road Test

Although the ERSL is supplied fully calibrated it is essential that, after installation, the vehiclebe road tested to allow the Control Unit to “learn” the calibration settings under road goingconditions. The vehicle should be driven with maximum throttle until the set speed is attained.The maximum throttle position should be maintained for a further 10-20 seconds whilst thecontrol unit learns the calibration settings, a reasonably flat road, clear of traffic, is requiredto carry out this operation efefefefefffffficiently iciently iciently iciently iciently and saf saf saf saf safelyelyelyelyely.....

APTE

C W

ILLI

AMS

APTE

C W

ILLI

AMS

APTE

C W

ILLI

AMS

APTE

C W

ILLI

AMS

APTE

C W

ILLI

AMS

STURDY Europe

9



FOR

CITROEN RELAY

MODELS: Diesel models from March 2007

ERSL KIT No: ER-07







Control Unit

The control unit can be fitted in the area below the drivers side of the dash panel, usingsuitable screws or adhesive.

Wiring Loom


Run the ERSL wiring loom containing 10 wires to the throttle pedal assembly.

Disconnect the wiring plug at the throttle position potentiometer, remove the protective plasticsleeve and approximately 200mm of canvas wrap from the wiring loom to the potentiometerplug.

Refering to the diagram on page iii, separate the Brown/blackBrown/blackBrown/blackBrown/blackBrown/black wire from the potentiometerloom and cut the wire at a convenient position. Using the butt splices supplied in the ERSL kit,connect the Green/yellowGreen/yellowGreen/yellowGreen/yellowGreen/yellow wire from the ERSL loom to the throttle pedal side of the cutwire, then connect the TTTTTan/redan/redan/redan/redan/red wire from the ERSL loom to the EMC side of the cut wire.

Separate the Blue/blackBlue/blackBlue/blackBlue/blackBlue/black wire from the potentiometer loom and again cut the wire at aconvenient position. Using the butt splices supplied connect the OrangeOrangeOrangeOrangeOrange wire from the ERSLloom to the throttle pedal side of the cut wire, then connect the YYYYYelloelloelloelloellowwwww wire from the ERSLloom to the EMC side of the cut wire.

CITR

OEN

CITR

OEN

CITR

OEN

CITR

OEN

CITR

OEN

STURDY Europe

10


Connect the PinkPinkPinkPinkPink wire from the ERSL loom, in series, to the Brown/whiteBrown/whiteBrown/whiteBrown/whiteBrown/white wire in thepotentiometer loom. Connect the Black/yellowBlack/yellowBlack/yellowBlack/yellowBlack/yellow wire from the ERSL loom, in series, with thePurple/blackPurple/blackPurple/blackPurple/blackPurple/black wire in the potentiometer loom.


If engine rev limitation is required, the BlueBlueBlueBlueBlue wire from the ERSL wiring loom should be routedto the alternator and connected to the W terminal.

To complete the wiring for the ERSL there are a further three connections to be made, thesebeing the Red, Black and Green wires from the ERSL wiring loom. Where these connectionsshould be made will depend on the vehicle having either a tachograph or an electronicspeedometer fitted.

Tachograph fitted

Select the ERSL loom containing three wires (Red, Black and Green) and run this to the rearof the tachograph. At this point, using the butt splices supplied, connect the BlackBlackBlackBlackBlack wire inthe ERSL loom to the tachograph negative (pin A5). The RedRedRedRedRed wire in the ERSL loom is connectedto the ignition switched positive (pin A3) and the GreenGreenGreenGreenGreen wire to the road speed signal ateither pin B7 or pin D3.

If these actions result in the breaking of a tachograph seal, the seal must be replaced by aDepartment of Transport approved tachograph calibration centre.

Electronic Speedometer fitted

At the rear of the speedometer can be found a Black plug containing an Green/greyGreen/greyGreen/greyGreen/greyGreen/grey wire,the GreenGreenGreenGreenGreen wire from the ERSL loom should be spliced to this wire to obtain a road speedsignal. The Red and Black wires from the ERSL loom should be routed to the Brake PedalSwitch where the BlackBlackBlackBlackBlack wire should be spliced to the Negative wire from the switch and theRedRedRedRedRed wire spliced to the Ignition Positive wire to the switch.

CIT

RO

ENC

ITR

OEN

CIT

RO

ENC

ITR

OEN

CIT

RO

EN

STURDY Europe

11

Calibration details

The Sturdy ERSL is supplied with a generic set of calibration characteristics. For the limiter tooperate correctly the characteristics listed below should be programmed into the ERSL ControlUnit.

TABLE PROGRAM CODE LEVEL

1 Speed setting Legal/customer requirement

2 Pole setting (x 1000imp) 13 7.5

3 Error gain 8 9

4 Response gain 176 12

5 % of WOT 8 52%

6 Not used

7 Not used

8 Engine rev setting

9 Eng.Sp Alternator poles 2.5

10 Eng.Sp Error gain 6

11 Eng.Sp Response gain 7

12 Eng.Sp % of WOT 50%

13 (L) Min. voltage 136 9%

13 (H) Max voltage (8+18) 93%

14 Not used

15 Not used


The Sturdy ERSL is supplied with the operating speed set at 70 m.p.h., however the speedsetting can be easily changed to suit the legal or customers specific requirements using theSturdy ER-01 programmer.

Refer to the ER-01 Programming manual for programming details.

Road Test


CITR

OEN

CITR

OEN

CITR

OEN

CITR

OEN

CITR

OEN

STURDY Europe

12

CIT

RO

ENC

ITR

OEN

CIT

RO

ENC

ITR

OEN

CIT

RO

EN

STURDY Europe

13



FOR

DAF LF Series

MODELS: All 45 models up to 7.5 tonnes

ERSL KIT No: ER-02







Control Unit


Wiring Loom

Remove the steering column shroud to gain access to the throttle pedal potentiometer andto enable the tachograph to be removed.

In the ERSL wiring loom, remove the Purple and Brown wires from their sheath and cut thewires approximately 200mm from the connector, then using a butt splice supplied with the kitjoin the cut ends of the wires together. Feed the joined wires back into the protective sheath.




DAF

DAF

DAF

DAF

DAF

STURDY Europe

14



At a suitable position in the potentiometer wiring harness, separate and cut the GreyGreyGreyGreyGrey wirenumber 46794679467946794679. Using a butt splice included in the kit, connect the OrangeOrangeOrangeOrangeOrange wire from theERSL loom to the cut GreGreGreGreGreyyyyy wire from the throttle potentiometer.

Connect the YYYYYelloelloelloelloellowwwww wire from the ERSL loom to the cut GreGreGreGreGreyyyyy wire that runs to the vehicleECU.

Separate the Grey Grey Grey Grey Grey wire number 46804680468046804680 from the potentiometer harness and using a suitableconnector, splice the PinkPinkPinkPinkPink wire from the ERSL loom to it (see wiring diagram on page v).


Calibration details




2 Pole setting (x 1000imp) 32 17

3 Error gain 5 6


5 % of WOT 4 38%

6 Not used

7 Not used

8 Engine rev setting Disabled






13 (H) Max voltage (8+128) 93%

14 Not used

15 Not used

DAF

DAF

DAF

DAF

DAF

STURDY Europe

15




Road Test


DAF

DAF

DAF

DAF

DAF

STURDY Europe

16

DAF

DAF

DAF

DAF

DAF

STURDY Europe

17



FOR

FORD FOCUS 1.8D

MODELS: 1.8 DIESEL (2002)

ERSL KIT No: ER-06

KIT CONTENTS: 57D-03668 Control Unit (pre-set at 70 mph)






Control Unit

The control unit can be fitted inside the driver compartment, against the engine bulkhead,directly behind the throttle pedal position sensor. A mounting bracket will have to bemanufactured to allow the control unit to be fixed to an existing anchor point.

Wiring Loom


Run the ERSL wiring loom along the side of the vehicle ECM up to the vehicle wiring loomcarrying the throttle potentiometer control wires.

Referring to the schematic diagram on page vi, separate the WhiteWhiteWhiteWhiteWhite wire (pin 5) from thepotentiometer loom and cut the wire at a convenient position.

Using the butt splices supplied in the ERSL kit, connect the PurplePurplePurplePurplePurple wire from the ERSL loomto the throttle pedal side of the cut wire. Then connect the BrownBrownBrownBrownBrown wire from the ERSL loomto the ECM side of the cut wire.

Separate the White/redWhite/redWhite/redWhite/redWhite/red wire (pin 4) from the potentiometer loom, again cutting the wire ata convenient position.

FOR

DFO

RD

FOR

DFO

RD

FOR

D

18


Connect the Green/yellowGreen/yellowGreen/yellowGreen/yellowGreen/yellow wire from the ERSL loom to the pedal side of the cut wire andthe TTTTTan/redan/redan/redan/redan/red wire from the ERSL loom to the ECM side of the cut wire.

Separate the White/blueWhite/blueWhite/blueWhite/blueWhite/blue wire (pin 7) from the potentiometer loom and cut the wire. Connectthe OrangeOrangeOrangeOrangeOrange wire from the ERSL loom to the pedal side of the cut wire and the YYYYYelloelloelloelloellowwwww wirefrom the ERSL loom to the ECM side of the cut wire.

Connect the PinkPinkPinkPinkPink wire from the ERSL loom in series with the Brown/blueBrown/blueBrown/blueBrown/blueBrown/blue wire (pin 2) in thepotentiometer loom.

Connect the Black/yellowBlack/yellowBlack/yellowBlack/yellowBlack/yellow wire from the ERSL loom in series with the Brown/redBrown/redBrown/redBrown/redBrown/red wire (pin6) in the potentiometer loom.

Once the connections have been made, wrap the modified loom with insulating tape to providea neat finish, then reconnect the loom to the throttle potentiometer.

If the engine rev signal wire is required, this should be routed through a grommet in theengine bulkhead and then on to the alternator where it should be connected to the ‘W’terminal via the in-line fuse supplied.

To complete the wiring for the ERSL there are a further three connections to be made, GreenGreenGreenGreenGreenwire to road speed signal, RedRedRedRedRed wire to ignition positive and BlackBlackBlackBlackBlack wire to negative.

A speed signal for the ERSL can be obtained by splicing the GreenGreenGreenGreenGreen wire from the ERSL loomto the Brown/yellowBrown/yellowBrown/yellowBrown/yellowBrown/yellow wire in the vehicle speed sensor fly lead.

The fly lead can be located on top of the transverse gearbox housing, level with the left-handside of the battery. Disconnect the fly-lead and feed the lead back to the rear of thetransmission housing - access to the lead is easiest from underneath the vehicle.

To the right of the throttle pedal assy is an access hole through to the engine compartment,use this point to route the GreenGreenGreenGreenGreen and BlueBlueBlueBlueBlue wires from the ERSL loom as required.

FOR

DFO

RD

FOR

DFO

RD

FOR

D

19

Calibration details



1 Speed setting Legal/Customer Requirement


3 Error gain 5 6


5 % of WOT 4 38%

6 Not used

7 Not used






13 (L) Min voltage 136 9%

13 (H) Max voltage (8+128) 93%

14 Not used

15 Not used




Road Test

Although the ERSL is supplied fully calibrated it is essential that, after installation, the vehiclebe road tested to allow the Control Unit to “learn” the calibration settings under road goingconditions.

The vehicle should be driven with maximum throttle until the set speed is attained. The maximumthrottle position should be maintained for a further 10-20 seconds whilst the control unitlearns the calibration settings, a reasonably flat road, clear of traffic, is required to carry outthis operation efefefefefffffficiently iciently iciently iciently iciently and saf saf saf saf safelyelyelyelyely.....

FOR

DFO

RD

FOR

DFO

RD

FOR

D

STURDY Europe

20

FOR

DFO

RD

FOR

DFO

RD

FOR

D

STURDY Europe

21



FOR

FORD RANGER

MODELS: All

ERSL KIT No: ER-06

KIT CONTENTS: 57D-03668 Control Unit






Control Unit

The control unit can be fitted in the area below the drivers side dash panel or a suitable placeof your choosing, using suitable screws or adhesive.

Wiring Loom



Run the ERSL loom containing 10 wires down to the throttle pedal assembly.


Referring to the schematic diagram on page vii, separate the PinkPinkPinkPinkPink wire (pin 6) from thepotentiometer loom and cut the wire at a convenient position.

FOR

DFO

RD

FOR

DFO

RD

FOR

D

STURDY Europe

22


Using the butt splices supplied in the ERSL kit, connect the Green/yellowGreen/yellowGreen/yellowGreen/yellowGreen/yellow wire from theERSL loom to the throttle pedal side of the cut wire. Then connect the TTTTTan/redan/redan/redan/redan/red wire from theERSL loom to the ECM side of the cut wire.

Separate the RedRedRedRedRed wire (pin 3) from the potentiometer loom, again cutting the wire at aconvenient position.

Connect the OrangeOrangeOrangeOrangeOrange wire from the ERSL loom to the pedal side of the cut wire and theYYYYYelloelloelloelloellowwwww wire from the ERSL loom to the ECM side of the cut wire.

Connect the PinkPinkPinkPinkPink wire and the Black/yellowBlack/yellowBlack/yellowBlack/yellowBlack/yellow wire from the ERSL loom in series with theBrown/blackBrown/blackBrown/blackBrown/blackBrown/black wire (pin 1) in the potentiometer loom.

Once the connections have been made wrap the loom with insulating tape to provide a neatfinish and re-connect the loom to the throttle potentiometer.

If the engine rev limitation is required, the Blue wire from the ERSL loom should be routedand connected to the ‘W’ terminal on the alternator.

To complete the wiring for the ERSL there are a further three connections to be made, Greenwire to road speed signal, Red wire to ignition positive and Black wire to a vehicle negative.Where these connections are made will depend on the vehicle having either a tachograph oran electronic speedometer fitted.

Tachograph fitted

The ERSL loom containing the Green, Red and Black wires should be routed to the back ofthe tachograph. Using an appropriate butt-splice, connect the RedRedRedRedRed wire to the tachographignition positive (pin A3), connect the BlackBlackBlackBlackBlack wire to the tachograph negative (pin A5). TheGreenGreenGreenGreenGreen wire should be connected to either terminal B7 or D3 in the rear of the tachographcasing.

These actions may result in the breaking of a tachograph seal, if the vehicle falls within thecategory of vehicles governed by EC tachograph regulations, this seal must be replaced by aDpt of transport approved tachograph calibration centre.


In cases where an electronic speedometer is fitted to the vehicle, a speed signal for the ERSLcan be obtained at the rear of the speedometer.

At the rear of the speedometer is a Green plug containing an OrangeOrangeOrangeOrangeOrange wire ( pin 1). TheGreenGreenGreenGreenGreen wire from the ERSL loom should be spliced to this wire using an appropriate butt-splice.

The Black and Red wires from the ERSL loom should be routed to the Brake Light Switch,where the RedRedRedRedRed wire is connected to an ignition switched positive and the BlackBlackBlackBlackBlack wire connectedto a vehicle earth.

FOR

DFO

RD

FOR

DFO

RD

FOR

D

STURDY Europe

23

Calibration details



1 Speed setting Legal/Customer Spec


3 Error gain 7 8


5 % of WOT 8 52%

6 Not used

7 Not used


9 Eng.Sp Alternator poles





13 (H) Max voltage (8+128) 93%

14 Not used

15 Not used


The Sturdy ERSL is supplied with the operating speed set at 70 mph and the engine revlimitation disabled, however the speed setting can be easily changed to suit the customersspecific requirements and the engine rev limiter enabled using the Sturdy ER-01 programmer.


Road Test

After installation or re-calibration it is essential that the vehicle is road tested to allow theControl Unit to “learn” the calibration settings under road going conditions.

The vehicle should be driven with maximum throttle until the set speed is attained. The maximumthrottle position should be maintained for a further 10-20 seconds whilst the control unitlearns the calibration settings, a reasonably flat road, clear of traffic, is required to carry outthis operation efefefefefffffficientlyicientlyicientlyicientlyiciently and safsafsafsafsafelyelyelyelyely.

FOR

DFO

RD

FOR

DFO

RD

FOR

D

STURDY Europe

24

FOR

DFO

RD

FOR

DFO

RD

FOR

D

STURDY Europe

25



FOR

FORD TRANSIT

MODELS: Turbo Diesel up to NOV’97

ERSL KIT No: ER-02







Control Unit

The control unit should be sited in a convenient position within the cab or engine compartmentof the vehicle.

Wiring Loom


Run the ERSL loom containing the purple, brown, orange, yellow and blue wires down to thethrottle pedal assembly.

Disconnect the vehicle wiring from the throttle position potentiometer, feed the wiring togetherwith plugs and grommet and the ERSL loom through the engine bay bulkhead where it will bemore convenient to work on.

Refer to the schematic diagram on page viii.

Separate the GreyGreyGreyGreyGrey wire (pin 3) from the potentiometer loom and cut the wire at a convenientposition.


FOR

DFO

RD

FOR

DFO

RD

FOR

D

STURDY Europe

26


Separate the WhiteWhiteWhiteWhiteWhite wire from the potentiometer loom, again cutting the wire at a convenientposition.


Connect the Pink Pink Pink Pink Pink wire from the ERSL loom in series with the BrownBrownBrownBrownBrown wire (pin 4) in thepotentiometer loom.

Once the connections have been made wrap the looms with tape to provide a neat finish,feed the wiring loom back into the cab of the vehicle (re-seating the grommet) and re-connectthe loom to the throttle potentiometer.

If the engine rev signal wire is required, this should be routed back through the potentiometerloom grommet and then on to the alternator where it should be connected to the ‘W’ terminalvia the in-line fuse supplied.

To complete the wiring for the ERSL there are a further three connections to be made, GreenGreenGreenGreenGreenwire to road speed signal, RedRedRedRedRed wire to ignition positive and BlackBlackBlackBlackBlack wire to negative. Wherethese connections should be made will depend on the vehicle having either a tachograph ora mechanical speedometer fitted.

Tachograph fitted

The ERSL loom containing the Green, Red and Black wires should be routed to the back ofthe tachograph. Using an appropriate butt-splice connect the RedRedRedRedRed wire to the tachographignition positive (pin A3), connect the BlackBlackBlackBlackBlack wire to the tachograph negative (pin A5). TheGreenGreenGreenGreenGreen wire should be connected to either terminal B7 or D3 in the rear of the tachographcasing.

These actions will normally result in the breaking of a tachograph seal, if the vehicle fallswithin the category of vehicles governed by EC tachograph regulations, this seal must bereplaced by a Dpt of transport approved tachograph calibration centre.

Mechanical Speedometer fitted

In cases where a cable driven speedometer is fitted to the vehicle an in-line speed sensor(part no TIM4001-65H) and adapter (part no SXC-01374) must be installed to provide aspeed signal for the ERSL.

The ERSL loom containing the Green, Red and Black wires should be routed together with theelectrical lead from the speed sensor to the fuse board area below the dashboard. At thispoint the RedRedRedRedRed wire from the ERSL loom and the BrownBrownBrownBrownBrown wire from the speed sensor should betwinned together and connected to an ignition positive at the fuse board. The BlackBlackBlackBlackBlack wirefrom the ERSL and the BlueBlueBlueBlueBlue wire from the speed sensor should be twinned together andconnected to a vehicle negative. The GreenGreenGreenGreenGreen wire from the ERSL loom should be spliced tothe Green/YGreen/YGreen/YGreen/YGreen/Yelloelloelloelloellowwwww wire from the speed sensor.

FOR

DFO

RD

FOR

DFO

RD

FOR

D

STURDY Europe

27

Calibration details





3 Error gain 5 6


5 % of WOT 11 62%

6 Not used

7 Not used


9 Eng.Sp Alternator poles 17





13 (H) Max voltage (15+240) 100%

14 Not used

15 Not used

Cable Clamp Gearbox Adaptor

Speedometer Drive Cable Speed Signal Generator

FOR

DFO

RD

FOR

DFO

RD

FOR

D

STURDY Europe

28


The Sturdy ERSL is supplied with the operating speed set at 70 mph, however the speedsetting can be easily changed to suit the customers specific requirements using the SturdyER-01 programmer.


Road Test



FOR

DFO

RD

FOR

DFO

RD

FOR

D

STURDY Europe

29



FOR

FORD TRANSIT

MODELS: Turbo Diesel from NOV’97

ERSL KIT No: ER-02







Control Unit

The control unit can be fitted to the top of the glove box compartment using suitable screwsor adhesive. Access is achieved by removing the storage tray in the top of the dashboard infront of the passenger seats.

Wiring Loom


Run the ERSL loom containing the purple, brown, orange, yellow and blue wires down to thethrottle pedal assembly.

Disconnect the wiring plug and socket at the throttle position potentiometer, removeapproximately 200mm of canvas wrap from the wiring on the ECM side of the connector.

Referring to the schematic diagram on page ix, separate the GreyGreyGreyGreyGrey wire (pin 5) from thepotentiometer loom and cut the wire at a convenient position.


FOR

DFO

RD

FOR

DFO

RD

FOR

D

STURDY Europe

30


Separate the WhiteWhiteWhiteWhiteWhite wire (pin 1) from the potentiometer loom, again cutting the wire at aconvenient position.


Connect the PinkPinkPinkPinkPink wire from the ERSL loom in series with the BrownBrownBrownBrownBrown wire (pin 7) in thepotentiometer loom.

Once the connections have been made wrap the looms with insulating tape to provide a neatfinish and re-connect the loom to the throttle potentiometer.

If the engine rev signal wire is required, this should be routed through a grommet in theengine bulkhead and then on to the alternator where it should be connected to the ‘W’terminal via the in-line fuse supplied.

To complete the wiring for the ERSL there are a further three connections to be made, GreenGreenGreenGreenGreenwire to road speed signal, RedRedRedRedRed wire to ignition positive and BlackBlackBlackBlackBlack wire to negative. Wherethese connections should be made will depend on the vehicle having either a tachograph oran electronic speedometer fitted.

Tachograph fitted





At the rear of the speedometer is a Black connector plug. Pin 5 (White/blueWhite/blueWhite/blueWhite/blueWhite/blue) of this plugcarries the speed signal from the gearbox transducer, the GreenGreenGreenGreenGreen wire from the ERSL loomshould be spliced to this wire using an appropriate butt-splice.

FOR

DFO

RD

FOR

DFO

RD

FOR

D

STURDY Europe

31

Calibration details





3 Error gain 5 6


5 % of WOT 11 62%

6 Not used

7 Not used







13 (H) Max voltage (15+240) 100%

14 Not used

15 Not used


The Sturdy ERSL is supplied with the operating speed set at 70 mph, however the speedsetting can be easily changed to suit the customers specific requirements using the SturdyER-01 programmer.


Road Test



FOR

DFO

RD

FOR

DFO

RD

FOR

D

STURDY Europe

32

FOR

DFO

RD

FOR

DFO

RD

FOR

D

STURDY Europe

33



FOR

FORD TRANSIT 2000

MODELS: Dura torque (2000)

ERSL KIT No: ER-06







Control Unit

The control unit can be fitted in the area above the glove box compartment using suitablescrews or adhesive. Access is achieved by removing the storage tray in the top of the dashboardin front of the passenger seats.

Wiring Loom




Referring to the schematic diagram on page x, separate the Grey/orangeGrey/orangeGrey/orangeGrey/orangeGrey/orange wire (pin 5) fromthe potentiometer loom and cut the wire at a convenient position.


FOR

DFO

RD

FOR

DFO

RD

FOR

D

STURDY Europe

34


Separate the Blue/whiteBlue/whiteBlue/whiteBlue/whiteBlue/white wire (pin 7) from the potentiometer loom, again cutting the wire ata convenient position.


Separate the Grey/blackGrey/blackGrey/blackGrey/blackGrey/black (pin 4) wire from the potentiometer loom and cut the wire at aconvenient location.


Connect the PinkPinkPinkPinkPink wire from the ERSL loom in series with the Grey/violetGrey/violetGrey/violetGrey/violetGrey/violet wire (pin 2) in thepotentiometer loom.

Connect the Black/yellowBlack/yellowBlack/yellowBlack/yellowBlack/yellow wire from the ERSL loom in series with the Grey/redGrey/redGrey/redGrey/redGrey/red wire (pin 6)in the potentiometer loom.


If the engine rev limitation is required, the BlueBlueBlueBlueBlue wire from the ERSL loom should be routed tothe rear of the speedometer where it should be spliced to the White/blackWhite/blackWhite/blackWhite/blackWhite/black wire from thelarge plug in the rear of the speedometer.


Tachograph fitted





At the rear of the speedometer is a small connector plug. The White/ violetWhite/ violetWhite/ violetWhite/ violetWhite/ violet wire in this plugcarries the speed signal from the gearbox transducer, the GreenGreenGreenGreenGreen wire from the ERSL loomshould be spliced to this wire using an appropriate butt-splice.

FOR

DFO

RD

FOR

DFO

RD

FOR

D

STURDY Europe

35

Calibration details





3 Error gain 5 6


5 % of WOT 4 38%

6 Not used

7 Not used







13 (H) Max voltage (8+128) 93%

14 Not used

15 Not used




Road Test



FOR

DFO

RD

FOR

DFO

RD

FOR

D

STURDY Europe

36

FOR

DFO

RD

FOR

DFO

RD

FOR

D

STURDY Europe

37



FOR

FORD TRANSIT 2005

MODELS: From 2005

ERSL KIT No: ER-06







Control Unit

The control unit can be fitted in the area above the glove box compartment using suitablescrews or adhesive. Access is achieved by removing the storage tray in the top of the dashboardin front of the passenger seats.

Wiring Loom




Referring to the schematic diagram on page xi, separate the WhiteWhiteWhiteWhiteWhite wire (pin 5) from thepotentiometer loom and cut the wire at a convenient position.


FOR

DFO

RD

FOR

DFO

RD

FOR

D

STURDY Europe

38


Separate the White/blueWhite/blueWhite/blueWhite/blueWhite/blue wire (pin 7) from the potentiometer loom, again cutting the wire ata convenient position.


Separate the White/redWhite/redWhite/redWhite/redWhite/red (pin 4) wire from the potentiometer loom and cut the wire at aconvenient location.


Connect the PinkPinkPinkPinkPink wire from the ERSL loom in series with the Brown/blueBrown/blueBrown/blueBrown/blueBrown/blue wire (pin 2) in thepotentiometer loom.

Connect the Black/yellowBlack/yellowBlack/yellowBlack/yellowBlack/yellow wire from the ERSL loom in series with the Brown/redBrown/redBrown/redBrown/redBrown/red wire (pin6) in the potentiometer loom.


If the engine rev limitation is required, the BlueBlueBlueBlueBlue wire from the ERSL loom should be routed tothe rear of the speedometer where it should be spliced to the White/blackWhite/blackWhite/blackWhite/blackWhite/black wire from thelarge plug in the rear of the speedometer.


Tachograph fitted





At the rear of the speedometer is a small connector plug. The White/ violetWhite/ violetWhite/ violetWhite/ violetWhite/ violet wire in this plugcarries the speed signal from the gearbox transducer, the GreenGreenGreenGreenGreen wire from the ERSL loomshould be spliced to this wire using an appropriate butt-splice.

FOR

DFO

RD

FOR

DFO

RD

FOR

D

STURDY Europe

39

Calibration details





3 Error gain 5 6


5 % of WOT 4 38%

6 Not used

7 Not used







13 (H) Max voltage (8+128) 93%

14 Not used

15 Not used




Road Test



FOR

DFO

RD

FOR

DFO

RD

FOR

D

STURDY Europe

40

FOR

DFO

RD

FOR

DFO

RD

FOR

D

STURDY Europe

41



FOR

ISUZU

MODELS: NPR

ERSL KIT No: ER-02







Control Unit

The control unit can be fitted to the left-hand side of the glove box compartment using cableties. Access is achieved by removing the glove box from the dashboard in front of the passengerseats.

Wiring Loom



Run the ERSL loom across the dashboard to a position behind the instrument cluster. At thispoint separate the loom containing the yellow, orange and pink wires and run it down to thethrottle pedal assembly.

Remove 2 x 12mm captive nuts that secure the throttle pedal assembly and remove theassembly.

Referring to the schematic diagram on page xii, separate the Green/yellowGreen/yellowGreen/yellowGreen/yellowGreen/yellow wire from thepotentiometer loom and cut the wire at a convenient position.

ISU

ZUIS

UZU

ISU

ZUIS

UZU

ISU

ZU

STURDY Europe

42


Using the butt splices supplied in the ERSL kit, connect the OrangeOrangeOrangeOrangeOrange wire from the ERSL loomto the throttle pedal side of the cut wire. Then connect the YYYYYelloelloelloelloellowwwww wire from the ERSL loomto the ECM side of the cut wire.

Connect the PinkPinkPinkPinkPink wire from the ERSL loom in series with the Black/greenBlack/greenBlack/greenBlack/greenBlack/green wire in thepotentiometer loom.

Once the connections have been made wrap the looms with insulating tape to provide a neatfinish and re-connect the loom to the throttle potentiometer and re-fit the throttle pedalassembly.

To complete the wiring for the ERSL there are a further three connections to be made, Greenwire to road speed signal, Red wire to ignition positive and Black wire to negative. Theseconnections can all be made at the rear of the instrument cluster.

The ERSL loom containing the Green, Red and Black wires should be routed to the back ofthe instrument cluster. Behind the instrument cluster you will find a spare tachograph wiringconnector (White mini-timer plug). Using an appropriate butt-splice connect the RedRedRedRedRed wire tothe tachograph ignition positive (pin A3), connect the BlackBlackBlackBlackBlack wire to the tachograph negative(pin A5).

The GreenGreenGreenGreenGreen wire should be connected to the terminal post, marked SIG and positioned behindthe speedometer section of the cluster, using a suitable ring terminal.

If engine rev limitation is required then the Blue wire from the ERSL loom should be routed tothe rear of the rev counter side of the instrument cluster where another terminal post markedSIG will be found. Connect the BlueBlueBlueBlueBlue wire to this post using a suitable ring terminal.

ISU

ZUIS

UZU

ISU

ZUIS

UZU

ISU

ZU

STURDY Europe

43

Calibration details





3 Error gain 6 7


5 % of WOT 8 52%

6 Not used

7 Not used







13 (H) Max voltage (8+128) 93%

14 Not used

15 Not used


The Sturdy ERSL can be supplied to the customers specification, however the speed settingcan be easily changed to suit new requirements using the Sturdy ER-01 programmer.


Road Test


The vehicle should be driven with maximum throttle until the set speed is attained. The maximumthrottle position should be maintained for a further 10-20 seconds whilst the control unitlearns the calibration settings, a reasonably flat road, clear of traffic, is required to carry outthis operation efefefefefffffficientlyicientlyicientlyicientlyiciently and safsafsafsafsafelyelyelyelyely. IS

UZU

ISU

ZUIS

UZU

ISU

ZUIS

UZU

STURDY Europe

44

ISU

ZUIS

UZU

ISU

ZUIS

UZU

ISU

ZU

STURDY Europe

45



FOR

ISUZU

MODELS: NQR

ERSL KIT No: ER-02







Control Unit

The control unit can be fitted to the left-hand side of the glove box compartment using cableties. Access is achieved by removing the glove box from the dashboard in front of the passengerseats.

Wiring Loom


Run the ERSL loom across the dashboard to a position behind the instrument cluster. At thispoint separate the loom containing the yellow, orange, purple, brown and pink wires and runit down to the throttle pedal assembly.

Referring to the schematic diagram on page xiii, separate the Blue/whiteBlue/whiteBlue/whiteBlue/whiteBlue/white wire from pin 5 inthe potentiometer loom and cut the wire at a convenient position.


Connect the PinkPinkPinkPinkPink wire from the ERSL loom in series with the BlackBlackBlackBlackBlack wire in pin 3 of thepotentiometer loom.

ISU

ZUIS

UZU

ISU

ZUIS

UZU

ISU

ZU

STURDY Europe

46


Separate the WhiteWhiteWhiteWhiteWhite wire from pin 2 in the potentiometer loom and cut the wire at a suitableposition.


Once the connections have been made wrap the looms with insulating tape to provide a neatfinish and re-connect the loom to the throttle potentiometer and re-fit the throttle pedalassembly.

To complete the wiring for the ERSL there are a further three connections to be made, Greenwire to road speed signal, Red wire to ignition positive and Black wire to negative. Theseconnections can all be made at the rear of the instrument cluster.

The ERSL loom containing the Green, Red and Black wires should be routed to the back ofthe instrument cluster. Behind the instrument cluster you will find a spare tachograph wiringconnector (White mini-timer plug). Using an appropriate butt-splice connect the RedRedRedRedRed wire tothe tachograph ignition positive (pin A3), connect the BlackBlackBlackBlackBlack wire to the tachograph negative(pin A5).

The GreenGreenGreenGreenGreen wire should be connected to the terminal post, marked SIG and positioned behindthe speedometer section of the cluster, using a suitable ring terminal.

If engine rev limitation is required then the Blue wire from the ERSL loom should be routed tothe rear of the rev counter side of the instrument cluster where another terminal post markedSIG will be found. Connect the BlueBlueBlueBlueBlue wire to this post using a suitable ring terminal.

ISU

ZUIS

UZU

ISU

ZUIS

UZU

ISU

ZU

STURDY Europe

47

Calibration details





3 Error gain 6 7


5 % of WOT 8 52%

6 Not used

7 Not used







13 (H) Max voltage (8+128) 93%

14 Not used

15 Not used


The Sturdy ERSL can be supplied to the customers specification, however the speed settingcan be easily changed to suit new requirements using the Sturdy ER-01 programmer.


Road Test



ISU

ZUIS

UZU

ISU

ZUIS

UZU

ISU

ZU

STURDY Europe

48

ISU

ZUIS

UZU

ISU

ZUIS

UZU

ISU

ZU

STURDY Europe

49



FOR

IVECO DAILY

MODELS: EDC .13

ERSL KIT No: ER-02







Control Unit


Wiring Loom





IVECO

IVECO

IVECO

IVECO

IVECO

STURDY Europe

50


At a suitable position in the potentiometer wiring harness, separate and cut the OrangeOrangeOrangeOrangeOrange(5157) wire connected to pin 5 of the Throttle Pedal Sensor. Using a butt splice included inthe kit, connect the OrangeOrangeOrangeOrangeOrange wire from the ERSL loom to the cut wire from the throttlepotentiometer (refer to wiring diagram on page xiv).


Separate the BrBrBrBrBrooooownwnwnwnwn (0150) wire from pin 6 of the potentiometer harness and using a suitableconnector, splice the PinkPinkPinkPinkPink wire from the ERSL loom to it.


Calibration details

The Sturdy ERSL is supplied with generic calibration characteristics which may or may not besuitable for the vehicle.

For advise on the suitability of the calibration contact the Sturdy Europe Technical Department.




Road Test


IVEC

OIV

ECO

IVEC

OIV

ECO

IVEC

O

STURDY Europe

51



FOR

LDV Convoy

MODELS: Dura torque (2000)

ERSL KIT No: ER-06







Control Unit

The control unit can be fitted in the area above or below the stowage shelf in the lower,drivers side dash panel, using suitable screws or adhesive.

Wiring Loom




Referring to the schematic diagram on page xv, separate the WhitWhitWhitWhitWhite/bluee/bluee/bluee/bluee/blue wire (pin 5) fromthe potentiometer loom and cut the wire at a convenient position.


Separate the GreyGreyGreyGreyGrey wire (pin 7) from the potentiometer loom, again cutting the wire at aconvenient position.

LDV

LDV

LDV

LDV

LDV

STURDY Europe

52



Separate the WhiteWhiteWhiteWhiteWhite (pin 4) wire from the potentiometer loom and cut the wire at a convenientlocation.


Connect the PinkPinkPinkPinkPink wire from the ERSL loom in series with the Purple/yellowPurple/yellowPurple/yellowPurple/yellowPurple/yellow wire (pin 2) inthe potentiometer loom.

Connect the Black/yellowBlack/yellowBlack/yellowBlack/yellowBlack/yellow wire from the ERSL loom in series with the BrownBrownBrownBrownBrown wire (pin 6) inthe potentiometer loom.


If the engine rev limitation is required, the BlueBlueBlueBlueBlue wire from the ERSL loom should be routed tothe rear of the speedometer were it should be spliced to the White/blackWhite/blackWhite/blackWhite/blackWhite/black wire from thelarge ‘A’ block pin 10.


Tachograph fitted





At the rear of the speedometer is a large connector plug ‘A’. The wire in pin 7 of this plugcarries the speed signal from the gearbox transducer, the GreenGreenGreenGreenGreen wire from the ERSL loomshould be spliced to this wire using an appropriate butt-splice.

LDV

LDV

LDV

LDV

LDV

STURDY Europe

53

Calibration details





3 Error gain 5 6


5 % of WOT 4 38%

6 Not used

7 Not used







13 (H) Max voltage (8+128) 93%

14 Not used

15 Not used




Road Test



LDV

LDV

LDV

LDV

LDV

STURDY Europe

54

LDV

LDV

LDV

LDV

LDV

STURDY Europe

55



FOR

MERCEDES-BENZ SPRINTER

MODELS: 210D, 212D, 310D, 312D, 410D, and 412D

ERSL KIT No: ER-02

KIT CONTENTS:

57D-02996 Control Unit (preset at 70 m.p.h.)






Control Unit

To allow easy access when siting the ERSL Control Unit it is recommended that the near sideheadlamp assembly be removed.

Using the Control Unit base plate as a template mark the positions of the four fixing holesonto the flat panel between the nearside wheel arch and the front panel of the vehicle directlybelow the headlamp.

Drill 4 x M6 clearance holes, and install the Control Unit using M6 bolts, spacing bushes, nutsand washers (see diagram on page 58). The spacers are used to keep the control unit aboveany water that may collect on the panel where it is fitted.

The Control Unit should be mounted with the electrical connection socket facing the nearside wing of the vehicle.

Wiring Loom

Before connecting the wring loom to the ERSL Control Unit the loom must be modified.

Remove the Green wire from its sheath and install it into the sheath housing the Red andBlack wires.

If control of Engine revs is NOT required then cut the blue wire in such a position that it nolonger protrudes from it’s protective sheath (always tape the cut end).

MER

CED

ES-BEN

ZM

ERC

EDES-B

ENZ

MER

CED

ES-BEN

ZM

ERC

EDES-B

ENZ

MER

CED

ES-BEN

Z

STURDY Europe

56



Connect the ERSL wiring loom to the 18 pin connector in the Control Unit.

Run both sections of the ERSL loom along the main wiring loom for the vehicles ElectronicControl Module (ECM) until it reaches the point where the ECM loom splits. One part of theECM loom runs toward the throttle position potentiometer, the other part being routed throughthe engine bulkhead into the cab of the vehicle following the main wiring bundle.

Select the half of the ERSL loom containing three wires (Red, Black and Green) and run thisthrough the bulkhead access port into the cab of the vehicle (a wire threader will be requiredfor this operation).

The other half of the ERSL wiring loom should follow the routing of the Throttle positionpotentiometer wiring.

At the Throttle potentiometer, disconnect the vehicle wiring from the potentiometer and usingan appropriate tool remove approximately 150 mm of canvas wrap from the wiring loom.

Referring to the schematic diagram on page xvi, separate the WhiteWhiteWhiteWhiteWhite wire (pin 5) from thepotentiometer loom and cut the wire at a convenient position.


Connect the PinkPinkPinkPinkPink wire from the ERSL loom in series with the YYYYYelloelloelloelloellowwwww wire (pin 6) in thepotentiometer loom.


Secure the ERSL loom to the vehicle wiring using cable ties.

The other half of the ERSL loom (Red, Black and Green wires) should now be routed behindthe dashboard (over the transmission tunnel and the steering column support struts), to thewiring bundle situated behind the lower dashboard panel to the right of the steering column(see diagram on page 59).

Crimp the ring terminal supplied to the BlackBlackBlackBlackBlack (negative) lead in the ERSL loom and connect tothe cab earth point in the driver’s foot well.

Locate the speedometer signal generator lead and disconnect the two-pin plug.

Using a suitable tool remove approximately 200mm of the cable outer covering, splice theGreenGreenGreenGreenGreen wire from the ERSL loom together with the signal wire (whitewhitewhitewhitewhite) from the generatorusing the butt splice supplied and refit the two halves of the plug (see page 59).

Locate and separate from its wiring bundle the positive wire (white/redwhite/redwhite/redwhite/redwhite/red) to the brake lights,splice the RedRedRedRedRed (positive) lead from the ERSL loom to this wire using the butt splice supplied.

MER

CED

ES-B

ENZ

MER

CED

ES-B

ENZ

MER

CED

ES-B

ENZ

MER

CED

ES-B

ENZ

MER

CED

ES-B

ENZ

STURDY Europe

57

Calibration details





3 Error gain 6 7


5 % of WOT 8 52%

6 Not used

7 Not used







13 (H) Max voltage (8+128) 93%

14 Not used

15 Not used

When fitted to 310 and 410 models it will be necessary to engage the “ High Torque Option”.See ER-01 Programming Manual for details.




Road Test

Although the ERSL is supplied fully calibrated it is essential that, after installation, the vehiclebe road tested to allow the Control Unit to “learn” the calibration settings under road goingconditions. The vehicle should be driven with maximum throttle until the set speed is attained.The maximum throttle position should be maintained for a further 10-20 seconds whilst thecontrol unit learns the calibration settings, a reasonably flat road, clear of traffic, is requiredto carry out this operation efefefefefffffficiently and saficiently and saficiently and saficiently and saficiently and safelyelyelyelyely.....

MER

CED

ES-BEN

ZM

ERC

EDES-B

ENZ

MER

CED

ES-BEN

ZM

ERC

EDES-B

ENZ

MER

CED

ES-BEN

Z

STURDY Europe

58

ERSL Control Module

Sprinter Engine Bay

FIG 1. ERSL Control Module position

MER

CED

ES-B

ENZ

MER

CED

ES-B

ENZ

MER

CED

ES-B

ENZ

MER

CED

ES-B

ENZ

MER

CED

ES-B

ENZ

STURDY Europe

59

Speed Generator Lead


B+ Ignition Pos

Green wire from ERSL loom

MER

CED

ES-BEN

ZM

ERC

EDES-B

ENZ

MER

CED

ES-BEN

ZM

ERC

EDES-B

ENZ

MER

CED

ES-BEN

Z

STURDY Europe

60

MER

CED

ES-B

ENZ

MER

CED

ES-B

ENZ

MER

CED

ES-B

ENZ

MER

CED

ES-B

ENZ

MER

CED

ES-B

ENZ

STURDY Europe

61



FOR

MITSUBISHI CANTER

MODELS: Canter

ERSL KIT No: ER-06







Control Unit


Wiring Loom





MITSU

BISH

IM

ITSUB

ISHI

MITSU

BISH

IM

ITSUB

ISHI

MITSU

BISH

I

STURDY Europe

62


At a suitable position in the potentiometer wiring harness, separate and cut the Green/blueGreen/blueGreen/blueGreen/blueGreen/bluewire. Using a butt splice included in the kit, connect the OrangeOrangeOrangeOrangeOrange wire from the ERSL loom tothe cut wire from the throttle potentiometer (refer to wiring diagram on page xvii).


Separate and cut the BlueBlueBlueBlueBlue wire in the potentiometer harness. Using a butt splice included inthe kit, connect the Green/yellowGreen/yellowGreen/yellowGreen/yellowGreen/yellow wire from the ERSL loom to the cut wire from the throttlepotentiometer.

Connect the TTTTTan/redan/redan/redan/redan/red wire from the ERSL loom to the cut wire that runs to the vehicle ECU.

Separate the Green/redGreen/redGreen/redGreen/redGreen/red wire from the potentiometer harness and using a suitable connector,splice the PinkPinkPinkPinkPink and Black/yellowBlack/yellowBlack/yellowBlack/yellowBlack/yellow wires from the ERSL loom to it.


Calibration details





3 Error gain 6 7


5 % of WOT 4 38%

6 Not used

7 Not used


9 Eng.Sp Alternator poles

10 Eng.Sp Error gain

11 Eng.Sp Response gain

12 Eng.Sp % of WOT


13 (H) Max voltage (8+128) 93%

14 Not used

15 Not used

MIT

SUB

ISH

IM

ITSU

BIS

HI

MIT

SUB

ISH

IM

ITSU

BIS

HI

MIT

SUB

ISH

I

STURDY Europe

63




Road Test


MITSU

BISH

IM

ITSUB

ISHI

MITSU

BISH

IM

ITSUB

ISHI

MITSU

BISH

I

STURDY Europe

64

MIT

SUB

ISH

IM

ITSU

BIS

HI

MIT

SUB

ISH

IM

ITSU

BIS

HI

MIT

SUB

ISH

I

STURDY Europe

65



FOR

PEUGEOT BOXER

MODELS: SWB

ERSL KIT No: ER-07







Control Unit


Wiring Loom




Refering to the diagram on page xviii, separate the Brown/blackBrown/blackBrown/blackBrown/blackBrown/black wire from the potentiometerloom and cut the wire at a convenient position. Using the butt splices supplied in the ERSL kit,connect the Green/yellowGreen/yellowGreen/yellowGreen/yellowGreen/yellow wire from the ERSL loom to the throttle pedal side of the cutwire, then connect the TTTTTan/redan/redan/redan/redan/red wire from the ERSL loom to the EMC side of the cut wire.

Separate the Blue/blackBlue/blackBlue/blackBlue/blackBlue/black wire from the potentiometer loom and again cut the wire at aconvenient position. Using the butt splices supplied connect the OrangeOrangeOrangeOrangeOrange wire from the ERSLloom to the throttle pedal side of the cut wire, then connect the YYYYYelloelloelloelloellowwwww wire from the ERSLloom to the EMC side of the cut wire.

PEUG

EOT

PEUG

EOT

PEUG

EOT

PEUG

EOT

PEUG

EOT

STURDY Europe

66


Connect the PinkPinkPinkPinkPink wire from the ERSL loom, in series, to the Brown/whiteBrown/whiteBrown/whiteBrown/whiteBrown/white wire in thepotentiometer loom. Connect the Black/yellowBlack/yellowBlack/yellowBlack/yellowBlack/yellow wire from the ERSL loom, in series, with thePurple/blackPurple/blackPurple/blackPurple/blackPurple/black wire in the potentiometer loom.


If engine rev limitation is required, the BlueBlueBlueBlueBlue wire from the ERSL wiring loom should be routedto the alternator and connected to the W terminal.


Tachograph fitted




At the rear of the speedometer can be found a Black plug containing an Green/greyGreen/greyGreen/greyGreen/greyGreen/grey wire,the GreenGreenGreenGreenGreen wire from the ERSL loom should be spliced to this wire to obtain a road speedsignal. The Red and Black wires from the ERSL loom should be routed to the Brake PedalSwitch where the BlackBlackBlackBlackBlack wire should be spliced to the Negative wire from the switch and theRedRedRedRedRed wire spliced to the Ignition Positive wire to the switch.

PEU

GEO

TPE

UG

EOT

PEU

GEO

TPE

UG

EOT

PEU

GEO

T

STURDY Europe

67

Calibration details





3 Error gain 8 9


5 % of WOT 8 52%

6 Not used

7 Not used







13 (H) Max voltage (8+128) 93%

14 Not used

15 Not used




Road Test


PEUG

EOT

PEUG

EOT

PEUG

EOT

PEUG

EOT

PEUG

EOT

STURDY Europe

68

PEU

GEO

TPE

UG

EOT

PEU

GEO

TPE

UG

EOT

PEU

GEO

T

STURDY Europe

69



FOR

RENAULT MASTER

MODELS: All models

ERSL KIT No: ER-07







Control Unit


Wiring Loom




Refering to the diagram on page xix, separate the YYYYYelloelloelloelloellowwwww wire (pin 6) from the potentiometerloom and cut the wire at a convenient position. Using the butt splices supplied in the ERSL kit,connect the Green/yellowGreen/yellowGreen/yellowGreen/yellowGreen/yellow wire from the ERSL loom to the throttle pedal side of the cutwire, then connect the TTTTTan/redan/redan/redan/redan/red wire from the ERSL loom to the EMC side of the cut wire.

Separate the PinkPinkPinkPinkPink wire (pin 3) from the potentiometer loom and again cut the wire at aconvenient position. Using the butt splices supplied connect the OrangeOrangeOrangeOrangeOrange wire from the ERSLloom to the throttle pedal side of the cut wire, then connect the Yellow wire from the ERSLloom to the EMC side of the cut wire.

RE

NA

RE

NA

RE

NA

RE

NA

RE

NAU

LU

LU

LU

LU

LTT TTT

STURDY Europe

70


Connect the PinkPinkPinkPinkPink wire from the ERSL loom, in series, to the PurplePurplePurplePurplePurple wire (pin 1) in thepotentiometer loom. Connect the Black/yellowBlack/yellowBlack/yellowBlack/yellowBlack/yellow wire from the ERSL loom, in series, with theBrownBrownBrownBrownBrown wire (pin 2) in the potentiometer loom.



Tachograph fitted




At the rear of the speedometer can be found a Green plug containing an OrangeOrangeOrangeOrangeOrange wire (pin 1)the GreenGreenGreenGreenGreen wire from the ERSL loom should be spliced to this wire to obtain a road speedsignal. The Red and Black wires from the ERSL loom should be routed to the Brake PedalSwitch where the BlackBlackBlackBlackBlack wire should be spliced to the Negative wire from the switch and theRedRedRedRedRed wire spliced to the Ignition Positive wire to the switch.

RE

NA

RE

NA

RE

NA

RE

NA

RE

NA U

LU

LU

LU

LU

L TTTT T

STURDY Europe

71

Calibration details





3 Error gain 7 8


5 % of WOT 8 52%

6 Not used

7 Not used







13 (H) Max voltage (8+128) 93%

14 Not used

15 Not used




Road Test

Although the ERSL is supplied fully calibrated it is essential that, after installation, the vehiclebe road tested to allow the Control Unit to “learn” the calibration settings under road goingconditions. The vehicle should be driven with maximum throttle until the set speed is attained.The maximum throttle position should be maintained for a further 10-20 seconds whilst thecontrol unit learns the calibration settings, a reasonably flat road, clear of traffic, is requiredto carry out this operation efefefefefffffficiently iciently iciently iciently iciently and saf saf saf saf safelyelyelyelyely..... R

EN

AR

EN

AR

EN

AR

EN

AR

EN

AUL

UL

UL

UL

ULTT TTT

STURDY Europe

72

RE

NA

RE

NA

RE

NA

RE

NA

RE

NA U

LU

LU

LU

LU

L TTTT T

STURDY Europe

73

VV VVVAA AAAUXH

ALLU

XHALL

UXH

ALLU

XHALL

UXH

ALL



FOR

VAUXHALL ASTRA

MODELS:

ERSL KIT No: ER-07




ADDITIONAL EQUIPMENT

122000 SPAL CAN Interface




Control Unit

The control unit can be fitted inside of the transmission tunnel towards the front of thevehicle.

CAN Interface

The interface is fitted next to the ODC connector housed in the transmission tunnel justbelow the hand-brake lever.

Refer to the manufacturers fitting instructions (supplied with the CAN interface), for detailsof the interface wiring.

The Ignition positive feed and the ground for the interface and the ERSL can be located nextto the ODC connector.

STURDY Europe

74

Wiring Loom

Remove the Purple and Brown wires from the ERSL wiring loom, cut the wires approximately100mm from the connector then join the two wire together using one of the butt splicessupplied with the ERSL kit.

Disconnect the wiring plug at the throttle position potentiometer. Refering to the diagram onpage xx, separate the YYYYYelloelloelloelloellow/whitw/whitw/whitw/whitw/whiteeeee wire (pin 3) from the potentiometer loom and cut thewire at a convenient position. Using the butt splices supplied in the ERSL kit, connect theOrangeOrangeOrangeOrangeOrange wire from the ERSL loom to the throttle pedal side of the cut wire, then connect theYYYYYelloelloelloelloellowwwww wire from the ERSL loom to the EMC side of the cut wire.

Separate the Green/whiteGreen/whiteGreen/whiteGreen/whiteGreen/white wire (pin 6) from the potentiometer loom and again cut the wireat a convenient position. Using the butt splices supplied connect the Green/yellowGreen/yellowGreen/yellowGreen/yellowGreen/yellow wirefrom the ERSL loom to the throttle pedal side of the cut wire, then connect the TTTTTan/redan/redan/redan/redan/red wirefrom the ERSL loom to the EMC side of the cut wire.

Connect the PinkPinkPinkPinkPink and the Black/yellowBlack/yellowBlack/yellowBlack/yellowBlack/yellow wires from the ERSL loom, in series, to the Red/Red/Red/Red/Red/brownbrownbrownbrownbrown wire (pin 2) in the potentiometer loom.


To complete the wiring for the ERSL there are a further three connections to be made, thesebeing the Red, Black and Green wires from the ERSL wiring loom.

The GreenGreenGreenGreenGreen wire from the ERSL loom should be butt spliced to the OrangeOrangeOrangeOrangeOrange wire from the CANinterface to obtain a road speed signal. The RedRedRedRedRed wire from the ERSL loom should be routedto the Brake Pedal Switch and spliced to the Ignition Positive wire to the switch. The BlackBlackBlackBlackBlackwire should have a ring terminal fitted to it and anchored under one of the steering columnsecuring bolts.

VVVV V AAAA AU

XHAL

LU

XHAL

LU

XHAL

LU

XHAL

LU

XHAL

L

STURDY Europe

75

VV VVVAA AAAUXH

ALLU

XHALL

UXH

ALLU

XHALL

UXH

ALL

Calibration details



1 Speed setting Legal/customer requirement (less 3%)


3 Error gain 7 8


5 % of WOT 8 52%

6 Not used

7 Not used

8 Speed hold 0 Disabled

9 Not used 0

10 Eng.Sp Error gain 9 10

11 Eng.Sp Response gain 112 8

12 Eng.Sp % of WOT 8 36%


13 (H) Max voltage (8+128) 93%

14 Not used

15 Not used




Road Test


STURDY Europe

76

VVVV V AAAA AU

XHAL

LU

XHAL

LU

XHAL

LU

XHAL

LU

XHAL

L

STURDY Europe

77



FOR

VAUXHALL COMBO

MODELS: CDTi

ERSL KIT No: ER-07




ADDITIONAL EQUIPMENT

122000 Spal CAN Interface




Control Unit

The control unit can be fitted behind the dashboard to the right of the steering column, usingsuitable screws, cable ties or adhesive.

CAN Interface

Remove the instrument cluster to gain access to the wiring plug at the rear of the cluster.Refer to the manufacturers fitting instructions (supplied with the CAN interface), for detailsof the interface wiring.

The Ignition positive feed for the interface and the ERSL positive feed are connected to thepositive to the brake light switch.The ground wires of the interface and the ERSL can betwinned and connected to a securing bolt for the steering column.

VV VVVAA AAAUXH

ALLU

XHALL

UXH

ALLU

XHALL

UXH

ALL

STURDY Europe

78

Wiring Loom


Disconnect the wiring plug at the throttle position potentiometer. Refering to the diagram onpage xxi, separate the YYYYYelloelloelloelloellow/whitw/whitw/whitw/whitw/whiteeeee wire (pin 3) from the potentiometer loom and cut thewire at a convenient position. Using the butt splices supplied in the ERSL kit, connect theOrangeOrangeOrangeOrangeOrange wire from the ERSL loom to the throttle pedal side of the cut wire, then connect theYYYYYelloelloelloelloellowwwww wire from the ERSL loom to the EMC side of the cut wire.

Separate the Green/whiteGreen/whiteGreen/whiteGreen/whiteGreen/white wire (pin 6) from the potentiometer loom and again cut the wireat a convenient position. Using the butt splices supplied connect the Green/yellowGreen/yellowGreen/yellowGreen/yellowGreen/yellow wirefrom the ERSL loom to the throttle pedal side of the cut wire, then connect the TTTTTan/redan/redan/redan/redan/red wirefrom the ERSL loom to the EMC side of the cut wire.

Connect the PinkPinkPinkPinkPink wire from the ERSL loom, in series, to the Blue/brownBlue/brownBlue/brownBlue/brownBlue/brown wire (pin 2) in thepotentiometer loom. Connect the Black/yellowBlack/yellowBlack/yellowBlack/yellowBlack/yellow wire from the ERSL loom, in series, with theRed/brownRed/brownRed/brownRed/brownRed/brown wire (pin 1) in the potentiometer loom.



The GreenGreenGreenGreenGreen wire from the ERSL loom should be butt spliced to the OrangeOrangeOrangeOrangeOrange wire from the CANinterface to obtain a road speed signal. The Red wire from the ERSL loom should be routed tothe Brake Pedal Switch and spliced to the Ignition Positive wire to the switch. The BlackBlackBlackBlackBlack wireshould have a ring terminal fitted to it and anchored under one of the steering column securingbolts.

VVVV V AAAA AU

XHAL

LU

XHAL

LU

XHAL

LU

XHAL

LU

XHAL

L

STURDY Europe

79

Calibration details



1 Speed setting Legal/customer requirement (less 3%)


3 Error gain 7 8


5 % of WOT 8 52%

6 Not used

7 Not used


9 Not used 0





13 (H) Max voltage (8+128) 93%

14 Not used

15 Not used




Road Test


VV VVVAA AAAUXH

ALLU

XHALL

UXH

ALLU

XHALL

UXH

ALL

STURDY Europe

80

VVVV V AAAA AU

XHAL

LU

XHAL

LU

XHAL

LU

XHAL

LU

XHAL

L

STURDY Europe

81



FOR

VAUXHALL VIVARO

MODELS: CDTi 1.9

ERSL KIT No: ER-07







Control Unit

The control unit can be fitted behind the heater matrix in the centre of the vehicle dash panel.

Wiring Loom


Disconnect the wiring plug at the throttle position potentiometer. Refering to the diagram onpage xxv, separate the VioleVioleVioleVioleViolet/redt/redt/redt/redt/red wire (pin 3) from the potentiometer loom and cut the wireat a convenient position. Using the butt splices supplied in the ERSL kit, connect the OrangeOrangeOrangeOrangeOrangewire from the ERSL loom to the throttle pedal side of the cut wire, then connect the YYYYYelloelloelloelloellowwwwwwire from the ERSL loom to the EMC side of the cut wire.

Separate the Biege/redBiege/redBiege/redBiege/redBiege/red wire (pin 6) from the potentiometer loom and again cut the wire ata convenient position. Using the butt splices supplied connect the Green/yellowGreen/yellowGreen/yellowGreen/yellowGreen/yellow wire fromthe ERSL loom to the throttle pedal side of the cut wire, then connect the TTTTTan/redan/redan/redan/redan/red wire fromthe ERSL loom to the EMC side of the cut wire.

VV VVVAA AAAUXH

ALLU

XHALL

UXH

ALLU

XHALL

UXH

ALL

STURDY Europe

82


Connect the PinkPinkPinkPinkPink wire from the ERSL loom, in series, to the White/orangeWhite/orangeWhite/orangeWhite/orangeWhite/orange wire (pin 2) inthe potentiometer loom. Connect the Black/yellowBlack/yellowBlack/yellowBlack/yellowBlack/yellow wire from the ERSL loom, in series, withthe Orange/redOrange/redOrange/redOrange/redOrange/red wire (pin 1) in the potentiometer loom.



To obtain a road speed signal, the GreenGreenGreenGreenGreen wire from the ERSL loom should be butt spliced tothe PurplePurplePurplePurplePurple wire (pin 14) from the green connector plug at the rear of the instrument panel.The RedRedRedRedRed wire from the ERSL loom should be routed to the Brake Pedal Switch and spliced tothe Ignition Positive wire to the switch. The BlackBlackBlackBlackBlack wire should have a ring terminal fitted to itand anchored to a chassis ground.

Calibration details





3 Error gain 7 8


5 % of WOT 8 52%

6 Not used

7 Not used


9 Not used 0





13 (H) Max voltage (8+128) 93%

14 Not used

15 Not used

VVVV V AAAA AU

XHAL

LU

XHAL

LU

XHAL

LU

XHAL

LU

XHAL

L

STURDY Europe

83




Road Test


VV VVVAA AAAUXH

ALLU

XHALL

UXH

ALLU

XHALL

UXH

ALL

STURDY Europe

84

VVVV V AAAA AU

XHAL

LU

XHAL

LU

XHAL

LU

XHAL

LU

XHAL

L

STURDY Europe

85



FOR

VOLKSWAGEN LT

MODELS: LT35, LT46

ERSL KIT No: ER-02

KIT CONTENTS:

57D-02996 Control Unit (preset at 70 m.p.h.)






Control Unit

To allow easy access when siting the ERSL Control Unit it is recommended that the near sideheadlamp assembly be removed.

Using the Control Unit base plate as a template mark the positions of the four fixing holesonto the flat panel between the nearside wheel arch and the front panel of the vehicle directlybelow the headlamp.

Drill 4 x M6 clearance holes, and install the Control Unit using M6 bolts, spacing bushes, nutsand washers (see diagram on page 88). The spacers are used to keep the control unit aboveany water that may collect on the panel where it is fitted.

The Control Unit should be mounted with the electrical connection socket facing the nearside wing of the vehicle.

Wiring Loom

Before connecting the wring loom to the ERSL Control Unit the loom must be modified.

Remove the Green wire from its sheath and install it into the sheath housing the Red andBlack wires.

If control of Engine revs is NOT required then cut the blue wire in such a position that it nolonger protrudes from it’s protective sheath (always tape the cut end).

VOLK

SW

AGEN

VOLK

SW

AGEN

VOLK

SW

AGEN

VOLK

SW

AGEN

VOLK

SW

AGEN

STURDY Europe

86



Connect the ERSL wiring loom to the 18 pin connector in the Control Unit.

Run both sections of the ERSL loom along the main wiring loom for the vehicles ElectronicControl Module (ECM) until it reaches the point where the ECM loom splits. One part of theECM loom runs toward the throttle position potentiometer, the other part being routed throughthe engine bulkhead into the cab of the vehicle following the main wiring bundle.

Select the half of the ERSL loom containing three wires (Red, Black and Green) and run thisthrough the bulkhead access port into the cab of the vehicle (a wire threader will be requiredfor this operation).

The other half of the ERSL wiring loom should follow the routing of the Throttle positionpotentiometer wiring.

At the Throttle potentiometer, disconnect the vehicle wiring from the potentiometer and usingan appropriate tool remove approximately 150 mm of canvas wrap from the wiring loom.

Referring to the schematic diagram on page xxii, separate the WhiteWhiteWhiteWhiteWhite wire (pin 5) from thepotentiometer loom and cut the wire at a convenient position.


Connect the PinkPinkPinkPinkPink wire from the ERSL loom in series with the YYYYYelloelloelloelloellowwwww wire (pin 6) in thepotentiometer loom.


Secure the ERSL loom to the vehicle wiring using cable ties.

The other half of the ERSL loom (Red, Black and Green wires) should now be routed behindthe dashboard (over the transmission tunnel and the steering column support struts), to thewiring bundle situated behind the lower dashboard panel to the right of the steering column(see diagram on page 89).

Crimp the ring terminal supplied to the Black (negative) lead in the ERSL loom and connect tothe cab earth point in the driver’s foot well.

Locate the speedometer signal generator lead and disconnect the two-pin plug.

Using a suitable tool remove approximately 200mm of the cable outer covering, splice theGreen wire from the ERSL loom together with the signal wire (white) from the generator usingthe butt splice supplied and refit the two halves of the plug (see page 89).

Locate and separate from its wiring bundle the positive wire (white/red trace) to the brakelights, splice the red (positive) lead from the ERSL loom to this wire using the butt splicesupplied.

VOLK

SW

AGEN

VOLK

SW

AGEN

VOLK

SW

AGEN

VOLK

SW

AGEN

VOLK

SW

AGEN

STURDY Europe

87

Calibration details





3 Error gain 6 7


5 % of WOT 8 52%

6 Not used

7 Not used







13 (H) Max voltage (8+128) 93%

14 Not used

15 Not used

When fitted to LT46 it will be necessary to program the speed setting to 1 m.p.h. above therequired set speed. See ER-01 Programming Manual for details.




Road Test

Although the ERSL is supplied fully calibrated it is essential that, after installation, the vehiclebe road tested to allow the Control Unit to “learn” the calibration settings under road goingconditions. The vehicle should be driven with maximum throttle until the set speed is attained.The maximum throttle position should be maintained for a further 10-20 seconds whilst thecontrol unit learns the calibration settings, a reasonably flat road, clear of traffic, is requiredto carry out this operation efefefefefffffficiently and saficiently and saficiently and saficiently and saficiently and safelyelyelyelyely.....

VOLK

SW

AGEN

VOLK

SW

AGEN

VOLK

SW

AGEN

VOLK

SW

AGEN

VOLK

SW

AGEN

STURDY Europe

88

ERSL Control Module

LT series Engine Bay

FIG 1. ERSL Control Module position

VOLK

SW

AGEN

VOLK

SW

AGEN

VOLK

SW

AGEN

VOLK

SW

AGEN

VOLK

SW

AGEN

STURDY Europe

89



B+ Ignition Pos

Green wire from ERSL loom

VOLK

SW

AGEN

VOLK

SW

AGEN

VOLK

SW

AGEN

VOLK

SW

AGEN

VOLK

SW

AGEN

STURDY Europe

90

VOLK

SW

AGEN

VOLK

SW

AGEN

VOLK

SW

AGEN

VOLK

SW

AGEN

VOLK

SW

AGEN

STURDY Europe

91



FOR

VOLKSWAGEN TRANSPORTER TDI

MODELS: T4

ERSL KIT No: ER-02







Control Unit


Wiring Loom



Select the ERSL loom containing three wires (Red, Black and Green) and run this to the fusepanel / main connector bank (lower right hand side of dash). At this point connect the BlackBlackBlackBlackBlackwire in the ERSL loom to a vehicle negative, the RedRedRedRedRed wire in the ERSL loom to an ignitionswitched positive (Black/yellowBlack/yellowBlack/yellowBlack/yellowBlack/yellow) and the GreenGreenGreenGreenGreen wire to the White/blueWhite/blueWhite/blueWhite/blueWhite/blue wire from the halleffect sender on the gearbox (G22).


VOLK

SW

AGEN

VOLK

SW

AGEN

VOLK

SW

AGEN

VOLK

SW

AGEN

VOLK

SW

AGEN

STURDY Europe

92


At a suitable position in the potentiometer wiring harness, separate and cut the GreyGreyGreyGreyGrey wire.Using a butt splice included in the kit, connect the OrangeOrangeOrangeOrangeOrange wire from the ERSL loom to the cutGreyGreyGreyGreyGrey wire from the throttle potentiometer (refer to wiring diagram on page xxiii).

Connect the YYYYYelloelloelloelloellowwwww wire from the ERSL loom to the cut GreGreGreGreGreyyyyy wire that runs to the vehicleECU.

Separate the Brown/yellowBrown/yellowBrown/yellowBrown/yellowBrown/yellow wire from the potentiometer harness and using a suitableconnector, splice the PinkPinkPinkPinkPink wire from the ERSL loom to it.


Calibration details





3 Error gain 6 7


5 % of WOT 1 28%

6 Not used

7 Not used







13 (H) Max voltage (8+0) 85%

14 Not used

15 Not used

VOLK

SW

AGEN

VOLK

SW

AGEN

VOLK

SW

AGEN

VOLK

SW

AGEN

VOLK

SW

AGEN

STURDY Europe

93




Road Test


VOLK

SW

AGEN

VOLK

SW

AGEN

VOLK

SW

AGEN

VOLK

SW

AGEN

VOLK

SW

AGEN

STURDY Europe

94

VOLK

SW

AGEN

VOLK

SW

AGEN

VOLK

SW

AGEN

VOLK

SW

AGEN

VOLK

SW

AGEN

STURDY Europe

95



FOR

VOLKSWAGEN TRANSPORTER TDI

MODELS: T5 (all engine varients)

ERSL KIT No: ER-02






Remove the battery cover, disconnect and remove the battery and battery tray, then removethe E-box cover (see Figures 1, 2 and 3).

Figure 1. Figure 2.

Figure 3.

VOLK

SW

AGEN

VOLK

SW

AGEN

VOLK

SW

AGEN

VOLK

SW

AGEN

VOLK

SW

AGEN

STURDY Europe

96

Control Unit

Using double-sided tape fix the Control Unit to thetop of the vehicle ECM Unit (see Figure 4).

Wiring Loom

At the ERSL wiring loom, remove the Purple and Brown wires from their sheath and cut thewires approximately 200mm from the connector, then using a butt splice supplied with the kitjoin the cut ends of the wires together. Feed the joined wires back into the protective sheath.


Connect the BlackBlackBlackBlackBlack lead from the ERSL loom to theupper earthing point to the right of the E-box (seeFigure 5).

Disconnect the Blue plug (T10d) from the E-boxcoupling station (see Figure 6).

Refering to the wiring diagram on page xxiv, splicethe PinkPinkPinkPinkPink wire from the ERSL loom to the Grey/redGrey/redGrey/redGrey/redGrey/red(T10d/4) wire in the 10 pin connector plug.

Approximately 50mm from the Blue plug cut theWhite/blueWhite/blueWhite/blueWhite/blueWhite/blue (T10d/5) wire. Using a supplied buttsplice, connect the OrangeOrangeOrangeOrangeOrange wire from the ERSL loomto the Blue connector side of the cut wire.

Again using a butt splice as supplied, connect theYYYYYelloelloelloelloellowwwww wire from the ERSL loom to the engine controlside of the cut wire.

Figure 4.

Figure 5.

Figure 6.

VOLK

SW

AGEN

VOLK

SW

AGEN

VOLK

SW

AGEN

VOLK

SW

AGEN

VOLK

SW

AGEN

STURDY Europe

97


At the top of the coupling station is a Beige connector (T10a), locate the White/lilacWhite/lilacWhite/lilacWhite/lilacWhite/lilac wire(T10a/9) and splice the GreenGreenGreenGreenGreen wire from the ERSL loom to it for the road speed signal.

An ignition switched positive can be found at thebattery fuse holder box at position SA15 (see Figure7), connect the RedRedRedRedRed lead from the ERSL wiring loomto the output side of this fuse (SA15). A 5amp in-linefuse (not supplied) should be used to make thisconnection.

Wrap the modified looms with insulating tape for aneat finish.

If required ensure that the ERSL Control Unit has been programmed to the settings listedbelow before re-fitting the E-box cover, the battery tray and battery.

Re-connect the battery and fit the battery cover to finish the installation.

Calibration details





3 Error gain 6 7


5 % of WOT 1 28%

6 Not used

7 Not used







13 (H) Max voltage (8+0) 85%

14 Not used

15 Not used

Figure 7.

VOLK

SW

AGEN

VOLK

SW

AGEN

VOLK

SW

AGEN

VOLK

SW

AGEN

VOLK

SW

AGEN

STURDY Europe

98




Road Test


VOLK

SW

AGEN

VOLK

SW

AGEN

VOLK

SW

AGEN

VOLK

SW

AGEN

VOLK

SW

AGEN

STURDY Europe

99

STURDY Europe

100

STURDY Europe

i

Throttle Pedal

Wiring Diagrams

Important Note:Whilst all efforts are made to ensure that the informaton on the following pages are correct,

Sturdy Europe will not be held responsible for any errors that may occur due to technicalchanges made by vehicle manufacturers.

STURDY Europe

ii

STURDY Europe

iii

Aptec Williams Throttle ControlWiring Detail

E C M

Road Speed Signal 12 volt from Ignition Sw (B+)

GroundEngine Speed Signal (revs)

White

Black

Throttle PositionSensor

18 Pin ERSL module connector

10

Re

d

Bla

ck

Pu

rple

Bro

wn

Pin

k

Ora

ng

e

Ye

llow

Gre

en

Blu

e

11 1291 16 17 8 7

Red

0 v

0.56 v to 3.88 v

4.94 v

Return to fittingReturn to fittingReturn to fittingReturn to fittingReturn to fittinginstructionsinstructionsinstructionsinstructionsinstructions

STURDY Europe

iv

Citr en RelayWiring Detail

ö

E C M

Road Speed Signal

Engine Speed Signal (revs)

Brown/white

Blue/black



10

Ground

Bla

ck

12 volt from Ignition Sw (B+)

Red

Gre

en/y

ello

w

Tan/r

ed

Pin

k

Ora

nge

Yello

w

Gre

en

Blu

e

11 1291 16 17 8 7

Bro

wn

Purp

le

1514

Bla

ck/y

ello

w

18

Purple/black

Brown/black


STURDY Europe

v

1

2

356

4

DAF LF SeriesWiring Detail

E C M



Grey 4680

Grey 4679



10

Red

Bla

ck

Purp

le

Bro

wn

Pin

k

Ora

nge

Yello

w

Gre

en

Blu

e

11 1291 16 17 8 7


STURDY Europe

vi

17

245

6

E C M

Road Speed Signal


Brown/red

White



10

Ground

Bla

ck


Red

Gre

en/y

ello

w

Tan/r

ed

Pin

k

Ora

nge

Yello

w

Gre

en

Blu

e

11 1291 16 17 8 7

Bro

wn

Purp

le

1514

Bla

ck/y

ello

w

18

White/red

White/blue

Brown/blue

Ford Focus 1.8DWiring Detail


STURDY Europe

vii

1

2

345

6

Ford RangerWiring Detail

E C M

Road Speed Signal


Pink

Red



10

Ground

Bla

ck


Re

d

Gre

en

/ye

llow

Ta

n/r

ed

Pin

k

Ora

ng

e

Ye

llow

Gre

en

Blu

e

11 1291 16 17 8 7

Bro

wn

Pu

rple

1514

Bla

ck/y

ello

w

18

Brown/black


STURDY Europe

viii

321

4

Ford Transit up to Nov 1997Wiring Detail

E C M





10

Red

Bla

ck

Purp

le

Bro

wn

Pin

k

Ora

nge

Yello

w

Gre

en

Blu

e

11 1291 16 17 8 7


STURDY Europe

ix

51

7

Ford Transit after Nov’97Wiring Detail

E C M



Brown

White



10

Red

Bla

ck

Pu

rple

Bro

wn

Pin

k

Ora

ng

e

Ye

llow

Gre

en

Blu

e

11 1291 16 17 8 7

Grey


STURDY Europe

x

1

5

647

2

Ford Transit 2000Wiring Detail

E C M

Road Speed Signal


Grey/violet

Blue/white



10

Ground

Bla

ck


Red

Gre

en/y

ello

w

Tan/r

ed

Pin

k

Ora

nge

Yello

w

Gre

en

Blu

e

11 1291 16 17 8 7

Bro

wn

Purp

le

1514

Bla

ck/y

ello

w

18

Grey/orange

Grey/black

Grey/red


STURDY Europe

xi

1

5

647

2

Ford Transit 2005Wiring Detail

E C M

Road Speed Signal


Brown/blue

White/blue



10

Ground

Bla

ck


Red

Gre

en/y

ello

w

Tan/r

ed

Pin

k

Ora

nge

Yello

w

Gre

en

Blu

e

11 1291 16 17 8 7

Bro

wn

Purp

le

1514

Bla

ck/y

ello

w

18

White

White/red

Brown/red


STURDY Europe

xii

Isuzu NPRWiring Detail

E C M



Black/green

Green/yellow



10

Red

Bla

ck

Purp

le

Bro

wn

Pin

k

Ora

nge

Yello

w

Gre

en

Blu

e

11 1291 16 17 8 7


STURDY Europe

xiii

1

2

345

6

Isuzu NQRWiring Detail

E C M



Blue

Blue/white



10

Red

Bla

ck

Purp

le

Bro

wn

Pin

k

Ora

nge

Yello

w

Gre

en

Blu

e

11 1291 16 17 8 7

Red

White

Black

Blue/red


STURDY Europe

xiv

1

2

345

6

Iveco Daily EDC .13Wiring Detail

E C M



Brown (0150)

Orange (5157)



10

Red

Bla

ck

Purp

le

Bro

wn

Pin

k

Ora

nge

Yello

w

Gre

en

Blu

e

11 1291 16 17 8 7


STURDY Europe

xv

1

5

647

2

LDV Convoy 2.4D Turbo (2000)Wiring Detail

E C M

Road Speed Signal


Purple/yellow

Grey



10

Ground

Bla

ck


Red

Gre

en/y

ello

w

Tan/r

ed

Pin

k

Ora

nge

Yello

w

Gre

en

Blu

e

11 1291 16 17 8 7

Bro

wn

Purp

le

1514

Bla

ck/y

ello

w

18

White/blue

White

Brown


STURDY Europe

xvi

1

2

345

6

Mercedes-Benz 210/2 D, 310/2 D. 410/2 DWiring Detail

E C M



Yellow

White



10

Red

Bla

ck

Purp

le

Bro

wn

Pin

k

Ora

nge

Yello

w

Gre

en

Blu

e

11 1291 16 17 8 7


STURDY Europe

xvii

Mitsubishi CanterWiring Detail

E C M

Road Speed Signal


Green/red

Green/blue



10

Ground

Bla

ck


Red

Gre

en/y

ello

w

Tan/r

ed

Pin

k

Ora

nge

Yello

w

Gre

en

Blu

e

11 1291 16 17 8 7

Bro

wn

Purp

le

1514

Bla

ck/y

ello

w

18

Blue


STURDY Europe

xviii

Peugeot BoxerWiring Detail

E C M

Road Speed Signal


Brown/white

Blue/black



10

Ground

Bla

ck


Red

Gre

en/y

ello

w

Tan/r

ed

Pin

k

Ora

nge

Yello

w

Gre

en

Blu

e

11 1291 16 17 8 7

Bro

wn

Purp

le

1514

Bla

ck/y

ello

w

18

Purple/black

Brown/black


STURDY Europe

xix

1

2

345

6

Renault MasterWiring Detail

E C M

Road Speed Signal


Yellow

White



10

Ground

Bla

ck


Red

Gre

en/y

ello

w

Tan/r

ed

Pin

k

Ora

nge

Yello

w

Gre

en

Blu

e

11 1291 16 17 8 7

Bro

wn

Purp

le

1514

Bla

ck/y

ello

w

18

Brown

Purple

Pink

Orange


STURDY Europe

xx

Vauxhall AstraWiring Detail

E C M

Road Speed Signal

Speed Hold (ground via switch)

Green/white



10

Ground

Bla

ck


Red

Gre

en/y

ello

w

Tan/r

ed

Pin

k

Ora

nge

Yello

w

Gre

en

Blu

e

11 1291 16 17 8 7

Bro

wn

Purp

le

1514

Bla

ck/y

ello

w

18

Yellow/white

Red/brown


STURDY Europe

xxi

Vauxhall Combo CDTIWiring Detail

E C M

Road Speed Signal


Green/white



10

Ground

Bla

ck


Re

d

Gre

en

/ye

llow

Ta

n/r

ed

Pin

k

Ora

ng

e

Ye

llow

Gre

en

Blu

e

11 1291 16 17 8 7

Bro

wn

Pu

rple

1514

Bla

ck/y

ello

w

18

Blue/brown

Yellow/white

Red/brown


STURDY Europe

xxii

1

2

345

6

Volkswagen LT35 & LT46Wiring Detail

E C M



Yellow

White



10

Red

Bla

ck

Purp

le

Bro

wn

Pin

k

Ora

nge

Yello

w

Gre

en

Blu

e

11 1291 16 17 8 7


STURDY Europe

xxiii

1

2

345

6

Volkswagen Transporter T4Wiring Detail

E C M



Brown/yellow

Grey



10

Red

Bla

ck

Purp

le

Bro

wn

Pin

k

Ora

nge

Yello

w

Gre

en

Blu

e

11 1291 16 17 8 7


STURDY Europe

xxiv

Volkswagen Transporter T5Wiring Detail

E C M



White/blue (T10d/5)

Grey/red (T10d/4)

10-pin connector, BlueE-box coupling station


10

Red

Bla

ck

Purp

le

Bro

wn

Pin

k

Ora

nge

Yello

w

Gre

en

Blu

e

11 1291 16 17 8 7

T94/39

T94/83


STURDY Europe

xxv

Vauxhall VivaroWiring Detail

E C M

Road Speed Signal


Biege/red



10

Ground

Bla

ck


Re

d

Gre

en

/ye

llow

Ta

n/r

ed

Pin

k

Ora

ng

e

Ye

llow

Gre

en

Blu

e

11 1291 16 17 8 7

Bro

wn

Pu

rple

1514

Bla

ck/y

ello

w

18

Violet/red

Orange/red1

2

3

4

5

6

White/orange


STURDY Europe

xxvi

STURDY Europe

xxvii

STURDY Europe

xxviii

Date post:	01-Apr-2018
Category:	Documents
Upload:	vuongcong
View:	239 times
Download:	6 times

Electronic Road Speed Limiter - timtach.com · Vauxhall Vivaro CDTi ... STURDY ELECTRONIC ROAD...

Documents