sturdy applications list issue d
Post on 28-Mar-2016
247 Views
Preview:
DESCRIPTION
TRANSCRIPT
ElectronicRoad Speed
Limiter
ERSLApplications List
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
Legal RequirementsPassenger Vehicles ............................................................................................................................... 1
More than 8 Passenger Seats ................................................................................................ 1
More than 16 Passenger Seats ............................................................................................. 1
Goods Vehicles ...................................................................................................................................... 2
Aptec WilliamsAptec Williams Throttle Control .......................................................................................................... 3 - 5
Citroen
Relay ........................................................................................................................................................ 6 - 9
DAF
LF Series ................................................................................................................................................. 10 - 13
FordFocus 1.8D ............................................................................................................................................. 14 - 17
Ranger ..................................................................................................................................................... 18 - 21
Transit up to Nov 1997 ........................................................................................................................ 22 - 26
Transit from Nov 1997 ......................................................................................................................... 27 - 30
Transit from 2000 ................................................................................................................................. 31 - 34
Transit from 2005 ................................................................................................................................. 35 - 38
IsuzuNPR .......................................................................................................................................................... 39 - 42
NQR .......................................................................................................................................................... 43 - 46
Iveco
Daily EDC .13 .......................................................................................................................................... 47 - 49
LDV
Convoy 2.4D ........................................................................................................................................... 50 - 53
Mercedes-Benz
Sprinter .................................................................................................................................................... 54 - 59
Mitsubishi
Canter ...................................................................................................................................................... 60 - 62
PeugeotBoxer ....................................................................................................................................................... 63 - 66
Renault
Master ..................................................................................................................................................... 67 - 70
VolkswagenLT 35 and 46 .......................................................................................................................................... 71 - 76
Transporter T4 ........................................................................................................................................ 77 - 80
Transporter T5 ........................................................................................................................................ 81 - 85
CONTENTS
A GUIDE TO SPEED LIMITER REQUIREMENTS
Passenger vehicles with more than 8 passenger seats (Bus)Diesel / LPG / Natural Gas Petrol
Vehicle Size (Gross Design Weight)
C&U reg 36A 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 kphNational only 1 January 2008 100 kph 1 January 2008 100 kph
2C & 7 International 1 January 2006 100 kphNational 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
2C & 7 International 1 January 2006 100 kphNational only 1 January 2007 100 kph
7501 to 100002 & 7 1 January 2005 and after All 1 January 2005 100 kph 1 January 2005 100 kph
2 & 7 All 1 January 2005 100 kph 1 January 2005 100 kph
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)Diesel / LPG / Natural Gas Petrol
Vehicle Size (Gross Design Weight)
C&U reg 36A paragraph First registered Use date Stabilised speed not to exceed date Stabilised speed not to exceed
7501 to 100001 & 6 All existing requirement speed set at 112 kph existing requirement speed set at 112 kph
10001 >1 & 6 All existing requirement speed set at 112 kph existing requirement speed set at 112 kph
GoodsDiesel / LPG / Natural Gas Petrol
Vehicle Size (Gross Design Weight)
C&U reg 36B paragraph First registered Use date Stabilised speed not to exceed date Stabilised speed not to exceed
3501 to 7500 1A & 9 1 January 2005 and after International 1 January 2005 90 kph 1 January 2005 90 kphNational only 1 January 2008 90 kph 1 January 2008 90 kph
1B & 9 International 1 January 2006 90 kphNational only 1 January 2007 90 kph
7501 to 120001A & 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
12001 >2 & 9 1 January 2005 and after All existing requirement 90 kph existing requirement 90 kph
2 & 9 All existing requirement 90 kph existing requirement 90 kph
2 & 9 All existing requirement 90 kph existing requirement 90 kph
Please Note: 1.
set speed of 100 kph
1 October 2001 to 31 December 2004
The category of vehicle highlighted needs particular attention. These vehicles will need to have their current settings reduced in order to comply.
1 October 2001 to 31 December 2004 (Euro III or later engine)
1 April 1974 to 31 December 1987
1 October 2001 to 31 December 2004
1 January 1988 to 30 September 2001
1 Aug 1992 to 30 September 2001
1 April 1974 to 31 December 1987
1 January 1988 to 30 September 2001
1 January 1988 to 30 September 2001
1 October 2001 to 31 December 2004
2 & 7A All
1 October 2001 to 31 December 2004
Not Required
existing requirementset speed of 100 kphexisting requirement
1 October 2001 to 31 December 2004 (Euro III or later engine)
Not Required
1 October 2001 to 31 December 2004 (Euro III or later engine)
Not Required
1
A GUIDE TO SPEED LIMITER REQUIREMENTS
Passenger vehicles with more than 8 passenger seats (Bus)Diesel / LPG / Natural Gas Petrol
Vehicle Size (Gross Design Weight)
C&U reg 36A 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 kphNational only 1 January 2008 100 kph 1 January 2008 100 kph
2C & 7 International 1 January 2006 100 kphNational 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
2C & 7 International 1 January 2006 100 kphNational only 1 January 2007 100 kph
7501 to 100002 & 7 1 January 2005 and after All 1 January 2005 100 kph 1 January 2005 100 kph
2 & 7 All 1 January 2005 100 kph 1 January 2005 100 kph
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)Diesel / LPG / Natural Gas Petrol
Vehicle Size (Gross Design Weight)
C&U reg 36A paragraph First registered Use date Stabilised speed not to exceed date Stabilised speed not to exceed
7501 to 100001 & 6 All existing requirement speed set at 112 kph existing requirement speed set at 112 kph
10001 >1 & 6 All existing requirement speed set at 112 kph existing requirement speed set at 112 kph
GoodsDiesel / LPG / Natural Gas Petrol
Vehicle Size (Gross Design Weight)
C&U reg 36B paragraph First registered Use date Stabilised speed not to exceed date Stabilised speed not to exceed
3501 to 7500 1A & 9 1 January 2005 and after International 1 January 2005 90 kph 1 January 2005 90 kphNational only 1 January 2008 90 kph 1 January 2008 90 kph
1B & 9 International 1 January 2006 90 kphNational only 1 January 2007 90 kph
7501 to 120001A & 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
12001 >2 & 9 1 January 2005 and after All existing requirement 90 kph existing requirement 90 kph
2 & 9 All existing requirement 90 kph existing requirement 90 kph
2 & 9 All existing requirement 90 kph existing requirement 90 kph
Please Note: 1.
set speed of 100 kph
1 October 2001 to 31 December 2004
The category of vehicle highlighted needs particular attention. These vehicles will need to have their current settings reduced in order to comply.
1 October 2001 to 31 December 2004 (Euro III or later engine)
1 April 1974 to 31 December 1987
1 October 2001 to 31 December 2004
1 January 1988 to 30 September 2001
1 Aug 1992 to 30 September 2001
1 April 1974 to 31 December 1987
1 January 1988 to 30 September 2001
1 January 1988 to 30 September 2001
1 October 2001 to 31 December 2004
2 & 7A All
1 October 2001 to 31 December 2004
Not Required
existing requirementset speed of 100 kphexisting requirement
1 October 2001 to 31 December 2004 (Euro III or later engine)
Not Required
1 October 2001 to 31 December 2004 (Euro III or later engine)
Not Required
2
STURDY Europe
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 Red wire from theERSL loom to an ignition switched positive. Connect the Black wire from the ERSL wiring loomto a vehicle ground. Connect the Green wire from the ERSL loom tothe wire carrying a speedsignal.
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
3
STURDY Europe
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
4
Aptec Williams Throttle Control Wiring Detail
E C M
Road Speed Signal 12 volt from Ignition Sw (B+)
Ground Engine 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 12 9 1 16 17 8 7
Red
0 v
0.56 v to 3.88 v
4.94 v
50
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
6
CITR
OEN
CITR
OEN
CITR
OEN
CITR
OEN
CITR
OEN
STURDY ELECTRONIC ROAD SPEED LIMITER
FITTING INSTRUCTIONS
FOR
CITROEN RELAY
MODELS: Diesel models from March 2007
ERSL KIT No: ER-07
KIT CONTENTS: 57D-03668 Control Unit (preset at 70 m.p.h.)
57C-03060-005 Wiring Loom
59A-03386 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
The control unit can be fitted in the area below the drivers side of the dash panel, usingsuitable screws or adhesive.
Wiring Loom
Connect the ERSL wiring loom to the 18pin connector in the Control Unit.
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 9, 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.
STURDY EuropeC
ITR
OEN
CIT
RO
ENC
ITR
OEN
CIT
RO
ENC
ITR
OEN
7
Wiring Loom cont’d
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.
Once the connections have been made wrap the looms with insulating tape to provide a neatfinish and reconnect the loom to the throttle potentiometer.
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.
STURDY EuropeC
ITRO
ENC
ITRO
ENC
ITRO
ENC
ITRO
ENC
ITRO
EN
8
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 LEVEL
1 Speed setting Legal/customer requirement
2 Pole setting (x 1000imp) 7.5
3 Error gain 9
4 Response gain 12
5 % of WOT 52%
6 Not used
7 Not used
8 Engine rev setting Disabled
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 9%
13 (H) Max voltage 93%
14 Not used
15 Not used
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 legal or customers specific requirements using theSturdy ER-01 programmer.
Refer to the ER-01 Programming manual for programming 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.....
Citr en Relay Wiring Detail
ö
E C M
Road Speed Signal
Engine Speed Signal (revs)
Brown/white
Blue/black
Throttle PositionSensor
18 Pin ERSL module connector
10
Ground
Bla
ck
12 volt from Ignition Sw (B+)
Re
d
Gre
en
/ye
llow
Tan
/re
d
Pin
k
Ora
ng
e
Ye
llow
Gre
en
Blu
e
11 12 9 1 16 17 8 7
9
Bro
wn
Pu
rple
15 14
Bla
ck/y
ello
w
18
Blue/black
Brown/black
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 EuropeD
AFD
AFD
AFD
AFD
AF
STURDY ELECTRONIC ROAD SPEED LIMITER
FITTING INSTRUCTIONS
FOR
DAF LF Series
MODELS: All 45 models up to 7.5 tonnes
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 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.
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 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.
10
STURDY Europe
Wiring Loom cont’d
Route the other half of the ERSL wiring loom to the vehicle wiring harness that runs to thethrottle potentiometer.
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.
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 a generic set of calibration characteristics. For the limiter tooperate correctly the characteristics listed below should be programmed into the ERSL ControlUnit.
TABLE PROGRAM LEVEL
1 Speed setting Legal/customer requirement
2 Pole setting (x 1000imp) 17
3 Error gain 6
4 Response gain 10
5 % of WOT 38%
6 Not used
7 Not used
8 Engine rev setting Disabled
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 9%
13 (H) Max voltage 93%
14 Not used
15 Not used
DAF
DAF
DAF
DAF
DAF
11
STURDY Europe
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 legal or customers specific requirements using theSturdy ER-01 programmer.
Refer to the ER-01 Programming manual for programming 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.....
DAF
DAF
DAF
DAF
DAF
12
123564
DAF LF Series Wiring Detail
E C M
Road Speed Signal 12 volt from Ignition Sw (B+)
Ground Engine Speed Signal (revs)
Grey 4680
Grey 4679
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 12 9 1 16 17 8 7
130
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
STURDY ELECTRONIC ROAD SPEED LIMITER
FITTING INSTRUCTIONS
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)
57C-0306-005 Wiring Loom
59A-03362 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
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
Connect the ERSL wiring loom to the 18pin connector in the Control Unit.
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 17, separate the WhitWhitWhitWhitWhiteeeee 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
14
STURDY Europe
Wiring Loom cont’d
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 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.
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
15
STURDY Europe
Calibration details
The Sturdy ERSL is supplied with a top speed setting of 70mph and calibration characteristicsto suit the Mercedes-Benz Sprinter.
The ERSL must be re-calibrated to the settings in the following table when fitting to the FordFocus.
TABLE PROGRAM LEVEL
1 Speed setting Customer Spec
2 Pole setting (x 1000imp) 7.5
3 Error gain 6
4 Response gain 10
5 % of WOT 38%
6 Not used
7 Not used
8 Engine rev setting Customer Spec
9 Eng.Sp Alternator poles 12.5
10 Eng.Sp Error gain 6
11 Eng.Sp Response gain 7
12 Eng.Sp % of WOT 50%
13 (L) Min voltage 9%
13 (H) Max voltage 93%
14 Not used
15 Not used
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 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
16
172456
E C M
Road Speed Signal
Engine Speed Signal (revs)
Brown/red
White
Throttle PositionSensor
18 Pin ERSL module connector
10
Ground
Bla
ck
12 volt from Ignition Sw (B+)
Re
d
Gre
en
/ye
llow
Tan
/re
d
Pin
k
Ora
ng
e
Ye
llow
Gre
en
Blu
e
11 12 9 1 16 17 8 7
Bro
wn
Pu
rple
15 14
Bla
ck/y
ello
w
18
White/red
White/blue
Brown/blue
Ford Focus 1.8D Wiring Detail
170
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
STURDY ELECTRONIC ROAD SPEED LIMITER
FITTING INSTRUCTIONS
FOR
FORD RANGER
MODELS: All
ERSL KIT No: ER-06
KIT CONTENTS: 57D-03668 Control Unit
57C-03060-005 Wiring Loom
59A-03362 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
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
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.
Run the ERSL loom containing 10 wires down 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.
Referring to the schematic diagram, separate the PinkPinkPinkPinkPink wire (pin 6) from the potentiometerloom and cut the wire at a convenient position.
18
FOR
DFO
RD
FOR
DFO
RD
FOR
D
STURDY Europe
Wiring Loom cont’d
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.
Electronic Speedometer fitted
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.
19
FOR
DFO
RD
FOR
DFO
RD
FOR
D
STURDY Europe
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 LEVEL
1 Speed setting Legal/Customer Spec
2 Pole setting (x 1000imp) 7
3 Error gain 8
4 Response gain 11
5 % of WOT 52%
6 Not used
7 Not used
8 Engine rev setting Customer Spec
9 Eng.Sp Alternator poles
10 Eng.Sp Error gain 6
11 Eng.Sp Response gain 7
12 Eng.Sp % of WOT 50%
13 (L) Min voltage 9%
13 (H) Max voltage 93%
14 Not used
15 Not used
Re-calibration / changing the set speed
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.
Refer to the ER-01 Programming manual for calibrating details.
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.
20
FOR
DFO
RD
FOR
DFO
RD
FOR
D
123456
Ford Ranger Wiring Detail
E C M
Road Speed Signal
Engine Speed Signal (revs)
Pink
Red
Throttle PositionSensor
18 Pin ERSL module connector
10
Ground
Bla
ck
12 volt from Ignition Sw (B+)
Re
d
Gre
en
/ye
llow
Tan
/re
d
Pin
k
Ora
ng
e
Ye
llow
Gre
en
Blu
e
11 12 9 1 16 17 8 7
Bro
wn
Pu
rple
15 14
Bla
ck/y
ello
w
18
Brown/black
210
5
25
75
95
100
0
5
25
75
95
100
0
5
25
75
95
100
0
5
25
75
95
100
STURDY EuropeFO
RD
FOR
DFO
RD
FOR
DFO
RD
STURDY ELECTRONIC ROAD SPEED LIMITER
FITTING INSTRUCTIONS
FOR
FORD TRANSIT
MODELS: Turbo Diesel up to NOV’97
ERSL KIT No: ER-02
KIT CONTENTS: 57D-02996 Control Unit (pre-set at 70 mph)
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
The control unit should be sited in a convenient position within the cab or engine compartmentof the vehicle.
Wiring Loom
Connect the ERSL wiring loom to the 18pin connector in the Control Unit.
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 26.
Separate the GreyGreyGreyGreyGrey wire (pin 3) from the potentiometer loom and cut the wire at a convenientposition.
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.
22
STURDY Europe
Wiring Loom cont’d
Separate the WhiteWhiteWhiteWhiteWhite wire from the potentiometer loom, again cutting the wire at a convenientposition.
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 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
23
STURDY Europe
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 LEVEL
1 Speed setting Legal/customer requirement
2 Pole setting (x 1000imp) 8
3 Error gain 6
4 Response gain 10
5 % of WOT 62%
6 Not used
7 Not used
8 Engine rev setting Customer Spec
9 Eng.Sp Alternator poles 17
10 Eng.Sp Error gain 6
11 Eng.Sp Response gain 7
12 Eng.Sp % of WOT 50%
13 (L) Min voltage 16%
13 (H) Max voltage 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
24
STURDY Europe
Re-calibration / changing the set speed
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.
Refer to the ER-01 Programming manual for calibrating details.
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
25
3214
Ford Transit up to Nov 1997 Wiring Detail
E C M
Road Speed Signal 12 volt from Ignition Sw (B+)
Ground Engine Speed Signal (revs)
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 12 9 1 16 17 8 7
260
5
25
75
95
100
0
5
25
75
95
100
0
5
25
75
95
100
0
5
25
75
95
100
STURDY EuropeFO
RD
FOR
DFO
RD
FOR
DFO
RD
STURDY ELECTRONIC ROAD SPEED LIMITER
FITTING INSTRUCTIONS
FOR
FORD TRANSIT
MODELS: Turbo Diesel from NOV’97
ERSL KIT No: ER-02
KIT CONTENTS: 57D-02996 Control Unit (pre-set at 70 mph)
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
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
Connect the ERSL wiring loom to the 18pin connector in the Control Unit.
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 30, separate the GreyGreyGreyGreyGrey 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.
27
STURDY Europe
Wiring Loom cont’d
Separate the WhiteWhiteWhiteWhiteWhite wire (pin 1) 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 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
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.
Electronic Speedometer fitted
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 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
28
STURDY Europe
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 LEVEL
1 Speed setting Legal/customer requirement
2 Pole setting (x 1000imp) 7.5
3 Error gain 6
4 Response gain 10
5 % of WOT 62%
6 Not used
7 Not used
8 Engine rev setting Customer Spec
9 Eng.Sp Alternator poles 12.5
10 Eng.Sp Error gain 6
11 Eng.Sp Response gain 7
12 Eng.Sp % of WOT 50%
13 (L) Min voltage 16%
13 (H) Max voltage 100%
14 Not used
15 Not used
Re-calibration / changing the set speed
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.
Refer to the ER-01 Programming manual for calibrating details.
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
29
517
Ford Transit after Nov’97 Wiring Detail
E C M
Road Speed Signal 12 volt from Ignition Sw (B+)
Ground Engine Speed Signal (revs)
Brown
White
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 12 9 1 16 17 8 7
Grey
300
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
STURDY ELECTRONIC ROAD SPEED LIMITER
FITTING INSTRUCTIONS
FOR
FORD TRANSIT 2000
MODELS: Dura torque (2000)
ERSL KIT No: ER-06
KIT CONTENTS: 57D-03668 Control Unit (pre-set at 70 mph)
57C-03060-005 Wiring Loom
59A-03362 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
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
Connect the ERSL wiring loom to the 18pin connector in the Control Unit.
Run the ERSL loom containing 10 wires down 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.
Referring to the schematic diagram on page 34, separate the Grey/orangeGrey/orangeGrey/orangeGrey/orangeGrey/orange wire (pin 5) fromthe potentiometer 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.
FOR
DFO
RD
FOR
DFO
RD
FOR
D
31
STURDY Europe
Wiring Loom cont’d
Separate the Blue/whiteBlue/whiteBlue/whiteBlue/whiteBlue/white wire (pin 7) from the potentiometer loom, again cutting the wire ata convenient 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.
Separate the Grey/blackGrey/blackGrey/blackGrey/blackGrey/black (pin 4) wire from the potentiometer loom and cut the wire at aconvenient location.
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.
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.
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 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.
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
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.
Electronic Speedometer fitted
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 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
32
STURDY Europe
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 LEVEL
1 Speed setting Legal/customer requirement
2 Pole setting (x 1000imp) 7.5
3 Error gain 6
4 Response gain 10
5 % of WOT 38%
6 Not used
7 Not used
8 Engine rev setting Customer Spec
9 Eng.Sp Alternator poles 12.5
10 Eng.Sp Error gain 6
11 Eng.Sp Response gain 7
12 Eng.Sp % of WOT 50%
13 (L) Min voltage 9%
13 (H) Max voltage 93%
14 Not used
15 Not used
Re-calibration / changing the set speed
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.
Refer to the ER-01 Programming manual for calibrating details.
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
33
156472
Ford Transit 2000Wiring Detail
E C M
Road Speed Signal
Engine Speed Signal (revs)
Grey/violet
Blue/white
Throttle PositionSensor
18 Pin ERSL module connector
10
Ground
Bla
ck
12 volt from Ignition Sw (B+)
Re
d
Gre
en
/ye
llow
Tan
/re
d
Pin
k
Ora
ng
e
Ye
llow
Gre
en
Blu
e
11 12 9 1 16 17 8 7
Bro
wn
Pu
rple
15 14
Bla
ck/y
ello
w
18
Grey/orange
Grey/black
Grey/red
340
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
STURDY ELECTRONIC ROAD SPEED LIMITER
FITTING INSTRUCTIONS
FOR
FORD TRANSIT 2005
MODELS: From 2005
ERSL KIT No: ER-06
KIT CONTENTS: 57D-03668 Control Unit (pre-set at 70 mph)
57C-03060-005 Wiring Loom
59A-03362 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
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
Connect the ERSL wiring loom to the 18pin connector in the Control Unit.
Run the ERSL loom containing 10 wires down 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.
Referring to the schematic diagram on page 38, 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.
FOR
DFO
RD
FOR
DFO
RD
FOR
D
35
STURDY Europe
Wiring Loom cont’d
Separate the White/blueWhite/blueWhite/blueWhite/blueWhite/blue wire (pin 7) from the potentiometer loom, again cutting the wire ata convenient 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.
Separate the White/redWhite/redWhite/redWhite/redWhite/red (pin 4) wire from the potentiometer loom and cut the wire at aconvenient location.
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.
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 looms with insulating tape to provide a neatfinish and re-connect the loom to the throttle potentiometer.
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.
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
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.
Electronic Speedometer fitted
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 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
36
STURDY Europe
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 LEVEL
1 Speed setting Legal/customer requirement
2 Pole setting (x 1000imp) 7.5
3 Error gain 6
4 Response gain 10
5 % of WOT 38%
6 Not used
7 Not used
8 Engine rev setting Customer Spec
9 Eng.Sp Alternator poles 12.5
10 Eng.Sp Error gain 6
11 Eng.Sp Response gain 7
12 Eng.Sp % of WOT 50%
13 (L) Min voltage 9%
13 (H) Max voltage 93%
14 Not used
15 Not used
Re-calibration / changing the set speed
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.
Refer to the ER-01 Programming manual for calibrating details.
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
37
156472
Ford Transit 2005Wiring Detail
E C M
Road Speed Signal
Engine Speed Signal (revs)
Brown/blue
White/blue
Throttle PositionSensor
18 Pin ERSL module connector
10
Ground
Bla
ck
12 volt from Ignition Sw (B+)
Re
d
Gre
en
/ye
llow
Tan
/re
d
Pin
k
Ora
ng
e
Ye
llow
Gre
en
Blu
e
11 12 9 1 16 17 8 7
Bro
wn
Pu
rple
15 14
Bla
ck/y
ello
w
18
White
White/red
Brown/red
380
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
STURDY ELECTRONIC ROAD SPEED LIMITER
FITTING INSTRUCTIONS
FOR
ISUZU
MODELS: NPR
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
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
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.
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 42, 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
39
STURDY Europe
Wiring Loom cont’d
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
40
STURDY Europe
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 LEVEL
1 Speed setting Legal/customer requirement
2 Pole setting (x 1000imp) 4
3 Error gain 7
4 Response gain 10
5 % of WOT 52%
6 Not used
7 Not used
8 Engine rev setting Customer Spec
9 Eng.Sp Alternator poles 5
10 Eng.Sp Error gain 7
11 Eng.Sp Response gain 10
12 Eng.Sp % of WOT 50%
13 (L) Min voltage 9%
13 (H) Max voltage 93%
14 Not used
15 Not used
Re-calibration / changing the set speed
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.
Refer to the ER-01 Programming manual for calibrating details.
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. IS
UZU
ISU
ZUIS
UZU
ISU
ZUIS
UZU
41
Isuzu NPRWiring Detail
E C M
Road Speed Signal 12 volt from Ignition Sw (B+)
Ground Engine Speed Signal (revs)
Black/green
Green/yellow
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 12 9 1 16 17 8 7
420
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
STURDY ELECTRONIC ROAD SPEED LIMITER
FITTING INSTRUCTIONS
FOR
ISUZU
MODELS: NQR
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
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
Connect the ERSL wiring loom to the 18pin connector in the Control Unit.
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 run itdown to the throttle pedal assembly.
Referring to the schematic diagram on page 46, separate the Blue/whiteBlue/whiteBlue/whiteBlue/whiteBlue/white wire from pin 5 inthe potentiometer loom and cut the wire at a convenient position.
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 BlackBlackBlackBlackBlack wire in pin 3 of thepotentiometer loom.
ISU
ZUIS
UZU
ISU
ZUIS
UZU
ISU
ZU
43
STURDY Europe
Wiring Loom cont’d
Separate the WhiteWhiteWhiteWhiteWhite wire from pin 2 in the potentiometer loom and cut the wire at a suitableposition.
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.
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
44
STURDY Europe
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 LEVEL
1 Speed setting Legal/customer requirement
2 Pole setting (x 1000imp) 4
3 Error gain 7
4 Response gain 10
5 % of WOT 52%
6 Not used
7 Not used
8 Engine rev setting Customer Spec
9 Eng.Sp Alternator poles 5
10 Eng.Sp Error gain 7
11 Eng.Sp Response gain 10
12 Eng.Sp % of WOT 50%
13 (L) Min voltage 9%
13 (H) Max voltage 93%
14 Not used
15 Not used
Re-calibration / changing the set speed
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.
Refer to the ER-01 Programming manual for calibrating details.
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.
ISU
ZUIS
UZU
ISU
ZUIS
UZU
ISU
ZU
45
123456
Isuzu NQR Wiring Detail
E C M
Road Speed Signal 12 volt from Ignition Sw (B+)
Ground Engine Speed Signal (revs)
Blue
Blue/white
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 12 9 1 16 17 8 7
Red
White
Black
Blue/red
460
5
25
75
95
100
0
5
25
75
95
100
0
5
25
75
95
100
0
5
25
75
95
100
STURDY EuropeIVEC
OIVEC
OIVEC
OIVEC
OIVEC
O
STURDY ELECTRONIC ROAD SPEED LIMITER
FITTING INSTRUCTIONS
FOR
IVECO DAILY
MODELS: EDC .13
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.
47
STURDY EuropeIV
ECO
IVEC
OIV
ECO
IVEC
OIV
ECO
Wiring Loom cont’d
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.
Connect the YYYYYelloelloelloelloellowwwww wire from the ERSL loom to the cut wire that runs to the vehicle ECU.
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.
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.
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.....
48
123456
Iveco Daily EDC .13Wiring Detail
E C M
Road Speed Signal 12 volt from Ignition Sw (B+)
Ground Engine Speed Signal (revs)
Brown (0150)
Orange (5157)
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 12 9 1 16 17 8 7
490
5
25
75
95
100
0
5
25
75
95
100
0
5
25
75
95
100
0
5
25
75
95
100
STURDY EuropeLD
VLD
VLD
VLD
VLD
V
STURDY ELECTRONIC ROAD SPEED LIMITER
FITTING INSTRUCTIONS
FOR
LDV Convoy
MODELS: Dura torque (2000)
ERSL KIT No: ER-06
KIT CONTENTS: 57D-03668 Control Unit (pre-set at 70 mph)
57C-03060-005 Wiring Loom
59A-03386 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
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
Connect the ERSL wiring loom to the 18pin connector in the Control Unit.
Run the ERSL loom containing 10 wires down 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.
Referring to the schematic diagram on page 53, separate the White/blueWhite/blueWhite/blueWhite/blueWhite/blue wire (pin 5) fromthe potentiometer 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 GreyGreyGreyGreyGrey wire (pin 7) from the potentiometer loom, again cutting the wire at aconvenient position.
50
STURDY EuropeLD
VLD
VLD
VLD
VLD
V
Wiring Loom cont’d
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.
Separate the WhiteWhiteWhiteWhiteWhite (pin 4) wire from the potentiometer loom and cut the wire at a convenientlocation.
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.
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.
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 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.
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
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.
Electronic Speedometer fitted
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 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.
51
STURDY Europe
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 LEVEL
1 Speed setting Legal/customer requirement
2 Pole setting (x 1000imp) 7.5
3 Error gain 6
4 Response gain 10
5 % of WOT 38%
6 Not used
7 Not used
8 Engine rev setting Customer Spec
9 Eng.Sp Alternator poles 12.5
10 Eng.Sp Error gain 6
11 Eng.Sp Response gain 7
12 Eng.Sp % of WOT 50%
13 (L) Min voltage 9%
13 (H) Max voltage 93%
14 Not used
15 Not used
Re-calibration / changing the set speed
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.
Refer to the ER-01 Programming manual for calibrating details.
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.
LDV
LDV
LDV
LDV
LDV
52
156472
LDV Convoy 2.4D Turbo (2000) Wiring Detail
E C M
Road Speed Signal
Engine Speed Signal (revs)
Purple/yellow
Grey
Throttle PositionSensor
18 Pin ERSL module connector
10
Ground
Bla
ck
12 volt from Ignition Sw (B+)
Re
d
Gre
en
/ye
llow
Tan
/re
d
Pin
k
Ora
ng
e
Ye
llow
Gre
en
Blu
e
11 12 9 1 16 17 8 7
Bro
wn
Pu
rple
15 14
Bla
ck/y
ello
w
18
White/blue
White
Brown
530
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
STURDY ELECTRONIC ROAD SPEED LIMITER
FITTING INSTRUCTIONS
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.)
57C-03060-002 Wiring Loom
59A-03386 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
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 57). 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
54
STURDY Europe
Wiring Loom cont’d
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 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 59, 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 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 YYYYYelloelloelloelloellowwwww wire (pin 6) in thepotentiometer loom.
Once the connections have been made wrap the looms with insulating tape to provide a neatfinish and reconnect the loom to the throttle potentiometer.
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 58).
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 58).
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
55
STURDY Europe
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 LEVEL
1 Speed setting Legal/customer requirement
2 Pole setting (x 1000imp) 13
3 Error gain 7
4 Response gain 10
5 % of WOT 52%
6 Not used
7 Not used
8 Engine rev setting Disabled
9 Eng.Sp Alternator poles 17
10 Eng.Sp Error gain 9
11 Eng.Sp Response gain 1
12 Eng.Sp % of WOT 36%
13 (L) Min. voltage 9%
13 (H) Max voltage 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.
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 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
56
STURDY Europe
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
57
STURDY Europe
Speed Generator Lead
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
58
123456
Mercedes-Benz 210/2 D, 310/2 D. 410/2 D Wiring Detail
E C M
Road Speed Signal 12 volt from Ignition Sw (B+)
Ground Engine Speed Signal (revs)
Yellow
White
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 12 9 1 16 17 8 7
590
5
25
75
95
100
0
5
25
75
95
100
0
5
25
75
95
100
0
5
25
75
95
100
STURDY EuropeM
ITSUB
ISHI
MITSU
BISH
IM
ITSUB
ISHI
MITSU
BISH
IM
ITSUB
ISHI
STURDY ELECTRONIC ROAD SPEED LIMITER
FITTING INSTRUCTIONS
FOR
MITSUBISHI CANTER
MODELS: Canter
ERSL KIT No: ER-06
KIT CONTENTS: 57D-03668 Control Unit (preset at 70 m.p.h.)
57C-03060-005 Wiring Loom
59A-03386 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.
60
STURDY Europe
Wiring Loom cont’d
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.
Connect the YYYYYelloelloelloelloellowwwww wire from the ERSL loom to the cut wire that runs to the vehicle ECU.
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.
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.
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.....
MIT
SUB
ISH
IM
ITSU
BIS
HI
MIT
SUB
ISH
IM
ITSU
BIS
HI
MIT
SUB
ISH
I
61
Mitsubishi Canter Wiring Detail
E C M
Road Speed Signal
Engine Speed Signal (revs)
Green/red
Green/blue
Throttle PositionSensor
18 Pin ERSL module connector
10
Ground
Bla
ck
12 volt from Ignition Sw (B+)
Re
d
Gre
en
/ye
llow
Tan
/re
d
Pin
k
Ora
ng
e
Ye
llow
Gre
en
Blu
e
11 12 9 1 16 17 8 7
Bro
wn
Pu
rple
15 14
Bla
ck/y
ello
w
18
Blue
620
5
25
75
95
100
0
5
25
75
95
100
0
5
25
75
95
100
0
5
25
75
95
100
STURDY EuropePEU
GEO
TPEU
GEO
TPEU
GEO
TPEU
GEO
TPEU
GEO
T
63
STURDY ELECTRONIC ROAD SPEED LIMITER
FITTING INSTRUCTIONS
FOR
PEUGEOT BOXER
MODELS: SWB
ERSL KIT No: ER-07
KIT CONTENTS: 57D-03668 Control Unit (preset at 70 m.p.h.)
57C-03060-005 Wiring Loom
59A-03386 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
The control unit can be fitted in the area below the drivers side of the dash panel, usingsuitable screws or adhesive.
Wiring Loom
Connect the ERSL wiring loom to the 18pin connector in the Control Unit.
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 66, 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.
STURDY Europe
Wiring Loom cont’d
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.
Once the connections have been made wrap the looms with insulating tape to provide a neatfinish and reconnect the loom to the throttle potentiometer.
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.
64
PEU
GEO
TPE
UG
EOT
PEU
GEO
TPE
UG
EOT
PEU
GEO
T
STURDY Europe
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 LEVEL
1 Speed setting Legal/customer requirement
2 Pole setting (x 1000imp) 7.5
3 Error gain 9
4 Response gain 12
5 % of WOT 52%
6 Not used
7 Not used
8 Engine rev setting Disabled
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 9%
13 (H) Max voltage 93%
14 Not used
15 Not used
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 legal or customers specific requirements using theSturdy ER-01 programmer.
Refer to the ER-01 Programming manual for programming 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.....
65
PEUG
EOT
PEUG
EOT
PEUG
EOT
PEUG
EOT
PEUG
EOT
Peugeot Boxer Wiring Detail
E C M
Road Speed Signal
Engine Speed Signal (revs)
Brown/white
Blue/black
Throttle PositionSensor
18 Pin ERSL module connector
10
Ground
Bla
ck
12 volt from Ignition Sw (B+)
Re
d
Gre
en
/ye
llow
Tan
/re
d
Pin
k
Ora
ng
e
Ye
llow
Gre
en
Blu
e
11 12 9 1 16 17 8 7
66
Bro
wn
Pu
rple
15 14
Bla
ck/y
ello
w
18
Blue/black
Brown/black
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
STURDY ELECTRONIC ROAD SPEED LIMITER
FITTING INSTRUCTIONS
FOR
RENAULT MASTER
MODELS: All models
ERSL KIT No: ER-07
KIT CONTENTS: 57D-03668 Control Unit (preset at 70 m.p.h.)
57C-03060-005 Wiring Loom
59A-03386 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
The control unit can be fitted in the area below the drivers side of the dash panel, usingsuitable screws or adhesive.
Wiring Loom
Connect the ERSL wiring loom to the 18pin connector in the Control Unit.
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 70, 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.
67
RE
NA
RE
NA
RE
NA
RE
NA
RE
NAU
LU
LU
LU
LU
LTT TTT
STURDY Europe
Wiring Loom cont’d
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.
Once the connections have been made wrap the looms with insulating tape to provide a neatfinish and reconnect the loom to the throttle potentiometer.
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 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
68
STURDY Europe
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 LEVEL
1 Speed setting Legal/customer requirement
2 Pole setting (x 1000imp) 7.5
3 Error gain 8
4 Response gain 11
5 % of WOT 52%
6 Not used
7 Not used
8 Engine rev setting Disabled
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 9%
13 (H) Max voltage 93%
14 Not used
15 Not used
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 legal or customers specific requirements using theSturdy ER-01 programmer.
Refer to the ER-01 Programming manual for programming 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..... R
EN
AR
EN
AR
EN
AR
EN
AR
EN
AUL
UL
UL
UL
ULTT TTT
69
123456
Renault Master Wiring Detail
E C M
Road Speed Signal
Engine Speed Signal (revs)
Yellow
White
Throttle PositionSensor
18 Pin ERSL module connector
10
Ground
Bla
ck
12 volt from Ignition Sw (B+)
Re
d
Gre
en
/ye
llow
Tan
/re
d
Pin
k
Ora
ng
e
Ye
llow
Gre
en
Blu
e
11 12 9 1 16 17 8 7
Bro
wn
Pu
rple
15 14
Bla
ck/y
ello
w
18
Brown
Purple
PinkOrange
70
STURDY EuropeVO
LKS
WAG
ENVO
LKS
WAG
ENVO
LKS
WAG
ENVO
LKS
WAG
ENVO
LKS
WAG
EN
STURDY ELECTRONIC ROAD SPEED LIMITER
FITTING INSTRUCTIONS
FOR
VOLKSWAGEN LT
MODELS: LT35, LT46
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
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 74). 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).
71
STURDY EuropeVO
LKS
WAG
ENVO
LKS
WAG
ENVO
LKS
WAG
ENVO
LKS
WAG
ENVO
LKS
WAG
EN
Wiring Loom cont’d
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 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 76, separate the WhitWhitWhitWhitWhiteeeee 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 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 YYYYYelloelloelloelloellowwwww wire (pin 6) in thepotentiometer loom.
Once the connections have been made wrap the looms with insulating tape to provide a neatfinish and reconnect the loom to the throttle potentiometer.
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 75).
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 75).
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.
72
STURDY EuropeVO
LKS
WAG
ENVO
LKS
WAG
ENVO
LKS
WAG
ENVO
LKS
WAG
ENVO
LKS
WAG
EN
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 LEVEL
1 Speed setting Legal/customer requirement
2 Pole setting (x 1000imp) 13
3 Error gain 7
4 Response gain 10
5 % of WOT 52%
6 Not used
7 Not used
8 Engine rev setting Disabled
9 Eng.Sp Alternator poles 17
10 Eng.Sp Error gain 9
11 Eng.Sp Response gain 1
12 Eng.Sp % of WOT 36%
13 (L) Min. voltage 9%
13 (H) Max voltage 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.
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 and saficiently and saficiently and saficiently and saficiently and safelyelyelyelyely.....
73
STURDY EuropeVO
LKS
WAG
ENVO
LKS
WAG
ENVO
LKS
WAG
ENVO
LKS
WAG
ENVO
LKS
WAG
EN
ERSL Control Module
LT series Engine Bay
FIG 1. ERSL Control Module position
74
STURDY EuropeVO
LKS
WAG
ENVO
LKS
WAG
ENVO
LKS
WAG
ENVO
LKS
WAG
ENVO
LKS
WAG
EN
Speed Generator Lead
Speed Generator Lead
B+ Ignition Pos
Green wire from ERSL loom
75
123456
Volkswagen LT35 & LT46 Wiring Detail
E C M
Road Speed Signal 12 volt from Ignition Sw (B+)
Ground Engine Speed Signal (revs)
Yellow
White
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 12 9 1 16 17 8 7
760
5
25
75
95
100
0
5
25
75
95
100
0
5
25
75
95
100
0
5
25
75
95
100
STURDY EuropeVO
LKS
WAG
ENVO
LKS
WAG
ENVO
LKS
WAG
ENVO
LKS
WAG
ENVO
LKS
WAG
EN
STURDY ELECTRONIC ROAD SPEED LIMITER
FITTING INSTRUCTIONS
FOR
VOLKSWAGEN TRANSPORTER TDI
MODELS: T4
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 / 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).
Route the other half of the ERSL wiring loom to the vehicle wiring harness that runs to thethrottle potentiometer.
77
STURDY EuropeVO
LKS
WAG
ENVO
LKS
WAG
ENVO
LKS
WAG
ENVO
LKS
WAG
ENVO
LKS
WAG
EN
Wiring Loom cont’d
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 cutGreGreGreGreGreyyyyy 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 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.
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 a generic set of calibration characteristics. For the limiter tooperate correctly the characteristics listed below should be programmed into the ERSL ControlUnit.
TABLE PROGRAM LEVEL
1 Speed setting Legal/customer requirement
2 Pole setting (x 1000imp) 5
3 Error gain 7
4 Response gain 13
5 % of WOT 28%
6 Not used
7 Not used
8 Engine rev setting Disabled
9 Eng.Sp Alternator poles 2.5
10 Eng.Sp Error gain 3
11 Eng.Sp Response gain 6
12 Eng.Sp % of WOT 22%
13 (L) Min. voltage 9%
13 (H) Max voltage 85%
14 Not used
15 Not used
78
STURDY EuropeVO
LKS
WAG
ENVO
LKS
WAG
ENVO
LKS
WAG
ENVO
LKS
WAG
ENVO
LKS
WAG
EN
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.....
79
123456
Volkswagen Transporter T4 Wiring Detail
E C M
Road Speed Signal 12 volt from Ignition Sw (B+)
Ground Engine Speed Signal (revs)
Brown/yellow
Grey
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 12 9 1 16 17 8 7
800
5
25
75
95
100
0
5
25
75
95
100
0
5
25
75
95
100
0
5
25
75
95
100
STURDY EuropeVO
LKS
WAG
ENVO
LKS
WAG
ENVO
LKS
WAG
ENVO
LKS
WAG
ENVO
LKS
WAG
EN
STURDY ELECTRONIC ROAD SPEED LIMITER
FITTING INSTRUCTIONS
FOR
VOLKSWAGEN TRANSPORTER TDI
MODELS: T5 (all engine varients)
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
Ensure that any security codes for Radios, Alarms, etc., are available before disconnectingthe battery.
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.
81
STURDY Europe
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 ERSL wiring loom to the 18pin connector in the Control Unit.
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).
Using a suitable connector, splice the PinkPinkPinkPinkPink wire fromthe ERSL loom to the Grey/redGrey/redGrey/redGrey/redGrey/red (T10d/4) wire in the10 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.
VOLK
SW
AGEN
VOLK
SW
AGEN
VOLK
SW
AGEN
VOLK
SW
AGEN
VOLK
SW
AGEN
Figure 4.
Figure 5.
Figure 6.
82
STURDY Europe
Wiring Loom cont’d
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
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 LEVEL
1 Speed setting Legal/customer requirement
2 Pole setting (x 1000imp) 5
3 Error gain 7
4 Response gain 13
5 % of WOT 28%
6 Not used
7 Not used
8 Engine rev setting Disabled
9 Eng.Sp Alternator poles 2.5
10 Eng.Sp Error gain 3
11 Eng.Sp Response gain 6
12 Eng.Sp % of WOT 22%
13 (L) Min. voltage 9%
13 (H) Max voltage 85%
14 Not used
15 Not used
VOLK
SW
AGEN
VOLK
SW
AGEN
VOLK
SW
AGEN
VOLK
SW
AGEN
VOLK
SW
AGEN
Figure 7.
83
STURDY Europe
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.....
VOLK
SW
AGEN
VOLK
SW
AGEN
VOLK
SW
AGEN
VOLK
SW
AGEN
VOLK
SW
AGEN
84
Volkswagen Transporter T5 Wiring Detail
E C M
Road Speed Signal 12 volt from Ignition Sw (B+)
Ground Engine Speed Signal (revs)
White/blue (T10d/5)
Grey/red (T10d/4)
10-pin connector, BlueE-box coupling station
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 12 9 1 16 17 8 7
T94/39
T94/83
850
5
25
75
95
100
0
5
25
75
95
100
0
5
25
75
95
100
0
5
25
75
95
100
top related