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Rostra World Cruisell Manual 2-2000

1. Figure 27 Page 15 INSTALLATION IV ANCHORING CRUISE CABLE continuep INSULATION ON FLAG NUT CRUISE CABLE MUST EXTEND CAUTION PAST FLAG NUT When using the FLAG Nut on the CRulseE CABLE the Adjustable Sleeve MUST be REMOVED Oss When using a TUBE CLAMP on the CRUISE CABLE the adjustable sleeve MUST be USED to prevent slippage or binding of cable LOCKWASHER NUT C FLAG Nut Figure 28 1 Before using the FLAG Nur it will be necessary to form threads on the end of the BEAD CHAIN CRUISE CABLE This is easily accomplished by CONNECTOR placing the LOCKWASHER NutT on the end of the i CRUISE CABLE with your fingers Then use an 11mm box end wrench and turn clockwise A until the desired amount of threads have been q CONNECTOR formed Figure 20 Page 14 COVER 2 After the threads have been formed screw the FLAG Nut onto the Cruise CABLE Figure 28 3 The FLAG Nut may be used to anchor the Figure 29 CRUISE CABLE to the existing throttle cable bracket Figure 29 In some cases there is an existing hole in other cases you can drill a PORNECTOR 5mm 20 hole in the bracket A a pe ll 4 The FLAG Nut may also be used to anchor the A 5 e n CRUISE CABLE using the CABLE BRACKET le G Figure 30 MN F t lt CABLE Oo lt i BRACHET m rh a SELF THREAD pr A Tao Mil Figure 30 WARNING Failure to follow the instruction manual could not only cause the WorldCruise to work improperly
2. Under the fender Under the vehicle Directly to the engine With the cable pointed down Near sharp hot or moving objects Near ignition coil No closer than 255mm 10 In the passenger compartment Noise Where it will interfere with service checks A Select a possible location to mount your Cruise MODULE set the Cruise MODULE unmounted in that area The reason for leaving gt 00000 00000 the Cruise MODULE unmounted is to make sure a the CRUISE HARNESS will reach the passenger compartment and the CRUISE CABLE will reach the throttle attaching point B Once you have selected a location install the MopuLE BRACKET to the bottom of the CRUISE MoDULE with the two 2 MopuLE BOLTs provided It may be necessary to cut and bend the MODULE BRACKET to achieve a custom fit Figure 2 NOTE DO NOT OVERTIGHTEN DAMAGE TO THE CRUISE MODULE WILL OCCUR IF THE BOLTS ARE OVERTIGHTENED C Mount the Cruise MoDuLE in the spot you have selected using two 2 of the SELF THREADING BoLTS provided in the kit Be sure to set the programming switches located underneath the rubber grommet on top of the Cruise MODULE See Page 7 before mounting the WorldCruise Figure 3 WARNING Failure to follow the instruction manual could not only cause the WorldCruise to work improperly but could cause the throttle to hang up possibly causing damage to your vehicle and injury and or death to you and your passengers
3. Page 8 INSTALLATION Il MEASURING THROTTLE CABLE TRAVEL THROTTLE IDLE THIS IS A VERY IMPORTANT STEP FAILURE TO POSITION A DETERMINE THROTTLE CABLE TRAVEL COULD CAUSE DAMAGE TO YOUR VEHICLE AND OR WorldCruise MEASURE ONLY WITH THE ENGINE OFF The Cruise CABLE moves 41mm 1 5 8 To measure throttle travel measure the distance from Position A Idle to Position B Wide Open Throttle A Make a mark on the throttle cable when the throttle is in the idle position Figure 4 THROTTLE WIDE OPEN B Depress accelerator pedal and make a mark on the ces Te throttle cable when the throttle is in the wide open position Figure 5 C Measure the Distance C between the two marks Figure 6 If the distance is greater than 41mm 1 5 8 go to Page 9 If it is less go to Step D D If the throttle travel is less than 41mm 1 5 8 you must add length to the CRUISE CABLE to provide slack NOTE Slack is the distance the CRUISE CABLE moves before the throttle starts to move THROTTLE TRAVEL DISTANCE C E Slide a CONNECTOR COVER on the throttle Loop CABLE and on the CRUISE CABLE Install a BEAD CHAIN CONNECTOR on the end of the Loop CABLE and on the end of the CRUISE CABLE The BEAD CHAIN CONNECTOR may need to be spread slightly for cable to enter F Install the end bead of the BEAD CHAIN in each BEAD CHAIN CONNECTOR with a bead or beads between them to add additional length The
4. but could cause the throttle to hang up possibly causing damage to your vehicle and injury and or death to you and your passengers Page 16 INSTALLATION V CRUISE HARNESS A Push Rubber Grommet securely into place on the cover of CRUISE MODULE the Cruise MoDuLE Figure 31 B Straighten the CRUISE HARNESS and find the 2 8 4 pin mating connectors Seperate the 2 amp 4 pin connectors A small screwdriver may be needed See K in Figure 34 C CRUISE HARNESS needs a 19mm 75 hole to pass through bulkhead You may find one nearby such as the speedometer cable hole or a small one you can file larger If you find the right size hole in the right place remove vehicle grommet If not drill saw or punch a 19mm hole in bulkhead A hole a le A few millimeters to the left or slightly higher than the steering column is usually a good place Figure 32 NOTE Check inside before drilling sawing or filing so you don t damage anything l Omm HOLE D From engine side pass the 2 amp 4 pin connectors through IN PULEHEAD hole If you do not hook up the Dark Blue TACH wire and the Gray VSS wire under the hood pass them through to if the inside of the vehicle also pp LERURE HARNESS E Reattach the 2 amp 4 pin mating connectors and make the necessary wire connections See Page 18 for wiring A Mo VEHICLE instructions m GROMMET VI SEALING BULKHEAD Seal hole in bulkhead with SEALING PuTTY as shown i
5. Check power to the Red Brake Positive wire cC Check power to the Cruise MODULE if none of the diagnostic commands are functioning d Check Brake Switch Connector and wiring to brake switch a Vehicle s own computer as VSS source Roll the vehicle at least two 2 meters forward or backward the LED should flash and continue to flash at the same rate If so continue to Step 9 if not go to Step 8al i Check steps to entering Diagnostic Mode and test again ii Check Programming Switch 10 It should be ON for Square Weve Input If set incorrectly reset and reenter Diagnostic Mode iii Some vehicles need to be pushed more than two 2 meters In that case raise one 1 of the vehicle drive wheels both drive wheels on a limited slip differential and block the non drive wheels Use a support stand for safety Spin the drive wheel by hand as fast as possible The LED should flash and continue to flash at the same rate If so continue to Step 9 if not go to Step 8aiv iv Either your VSS wire is incorrect or your connection is bad Inpect your VSS connection and reenter Self Diagnostic Mode TROUBLESHOOTING b Auxiliary Speed Sensor SIGNAL GENERATOR or MAGNET amp Coit Pick Up Kit Kir 250 41065 Raise one 1 of the vehicle drive wheels both drive wheels on a limited slip differential and block the non drive wheels Use a support stand for safety Spin the drive wheel by hand as fast as possible You must spin the wheel at
6. POWER SPEED i WorldCruise System SENSOR 3 1 GRAY CL BLACK AME ES 8 DARK BLUE TACH SIGNAL 7 DARK GREEN SET COAST a BRO IENICI N EA DARK GREEN ARK GREEN 5 BROWN IGNITION POWER BROWN BROWN AAA 4 YELLOW RESUME ACCEL YELLOW YELLOW 3 BLACK GROUND RED BROWN RED BROWN 2 VIOLET NEGATIVE BRAKE 1 RED BROWN POSITIVE BRAKE a eT T BLACK BLACK ES VIOLET VIOLET RED VIOLET BLACK BRAKE BRAKE GROUND DARK COLD BLUE RESUME ACCEL ON OFF TACH RED BROWN RED BROWN DARK GREEN DARK GREEN YELLOW YELLOW BLACK LIGHT BLUE POWER GROUND CONNECTOR RED BROWN DARK GREEN YELLOW NORMALLY CLOSED CONTROL SWITCH ON OFF SET RESUME f Figure 36 NORMALLY OPEN CONTROL SWITCH Page 21 TROUBLESHOOTING XI CONTROL SWITCH TESTING PROCEDURE Utilize the following continuity charts to test your control switch if you suspect that it is not functioning properly You need to unplug the 8 pin connector from the Cruise MODULE to perform these tests 1 Ground the test light lead and verify that the light works by probing a known power source 2 Follow the test charts below using the appropriate chart for your control switch Your control switch is a Closed Circuit Control Switch if 1 Its ROSTRA part number is 250 3002 250 3018 250 3020 250 3021 250 3026 250 3032 250 3084 250 3091 250 3100 250 3120 250 3125 250 3126 250 3127 250 3133 250 3167 250 3168 250 3169 250 3175 250 3180 250 3194 250 3304
7. beads inside the BEAD CHAIN CONNECTORS do not add length NOTE Each bead of the BEAD CHAIN added between the BEAD es CHAIN CONNECTORS will give you 7mm 28 of slack CONNECTOR LIN OPC LLY ERK i _ ie et ie ICIH a a fy i o SOE LORE E Y CRUISE LEIP CAILE i i Tani CARE fot ta Example If your throttle travels 35mm 1 3 8 you will need to add one 1 bead between connectors Figure 7 G After the BEAD CHAIN is installed lightly crimp the BEAD CHAIN CONNECTORS without pinching the cables and center the CONNECTOR COVERS over the BEAD CHAIN CONNECTORS NOTE You must always use the CONNECTOR COVERS Figure 7 After determining your throttle cable travel continue to Section III WARNING Failure to follow the instruction manual could not only cause the WorldCruise to work improperly but could cause the throttle to hang up possibly causing damage to your vehicle and injury and or death to you and your passengers Page 9 INSTALLATION lil ATTACHING CRUISE CABLE TO THROTTLE This section will cover the proper ways to use the hardware available Each method contains sample illustrations showing how the connector is used in THREE BEAD an actual installation It must be noted however that you should have an CONNECTOR understanding of how each attachment method works so that a proper installation is achieved There are five 5 different types of throttle connections A Pulley Assembly Using Th
8. 10 C STUD CLIP W CABLE C 250 2261 1 00 25MM 10 250 4255B 1 25 32MM 10 250 4242 2 40 61MM 10 250 2260 2 80 71MM 10 D THROTTLE COUPLERS D 250 4291 M6 10 250 4292 M8 10 E TUBE CLAMPS E 250 2255 3 16 5MM 10 250 2256 1 4 6mm 10 250 2257 5 16 8MM 10 aay Sa 250 2258 3 8 10mm 10 tt y 250 2259 1 2 13MM 10 MISCELLANEOUS F E F 250 3440 GM _ HATCLIP 10 G 250 2262 PEDAL BRACKET ASSEMBLY 1 de The THROTTLE COUPLER Sets 250 4291 and 250 4292 come complete with THROTTLE COUPLER STUD CAP and ELASTOMER RETAINER The PEDAL BRACKET ASSEMBLY 250 2262 comes complete with a PEDAL BRACKET a SELF LOCKING PIN an M5 8 x 12 BoLT an M5 Nurt and two 2 PLAIN WASHERS Page 6 The Cruise MoDULE must be programmed for the vehicle on which it The twelve 12 programming switches are located under is installed The twelve 12 programming switches must be set the Black rubber grommet on top of the Cruise MoDuULE according to the chart below in order for the WorldCruise to operate properly Figure 1 NOTE 1 Both the VSS Gray and TACH Dark Blue wires must be connected If the Gray wire is not used an auxiliary road speed source must be used See Page 18 NOTE 2 If using an Open Circuit control switch with the WorldCruise Switch number seven 7 will have to be OFF If you are unsure as to whether the control switch is Open Circuit or Closed Figure 1 represents the t
9. 250 3328 250 3421 250 3446 OR 2 You must push the control button to the left for the RESUME ACCEL function Your control switch is an Open Circuit Control Switch if 1 Its ROSTRA part number is 250 3357 250 3358 250 3443 250 3444 250 3592 250 3593 250 3632 250 3633 250 3594 250 3595 250 3742 250 3743 OR 2 You must push the control button to the right for the RESUME ACCEL function OR 3 It has a Green LED Indicator Light OR 4 It is a ROSTRA Radio Frequency RF control switch CLOSED CIRCUIT CONTROL SWITCH IGNITION CONTROL RED WIRE DARK GREEN YELLOW WIRE BROWN WIRE SWITCH SWITCH WIRE POSITION POSITION ON press and hold RESUME ACCEL IGNITION CONTROL SWITCH SWITCH POSITION POSITION ON press and hold RESUME ACCEL The CRANK or START IGNITION SWITCH POSITION refers to the momentary state when the key starts the engine just before it returns to the RUN IGNITION SWITCH POSITION Page 22 OPERATING INSTRUCTIONS XII WorldCruise OPERATING INSTRUCTIONS ON To operate the WorldCruise turn the power button ON Green LED Indicator will light if equipped Wait three 3 seconds before setting speed SET SPEED To engage system drive at any speed above 50 KPH 33 MPH press SET COAST or press RESUME ACCEL and release then remove your foot from the accelerator pedal Automatic control will be at the speed of the vehicle when the button is released plus or minus 3 KPH 1 1 2 MPH Press
10. 5 Attach the T BAR ADAPTER to the BEAD CHAIN CONNECTOR Make sure to slide the CONNECTOR COVER over the BEAD CHAIN CONNECTOR Figure 12 C Pedal Attachment DUAL PULLEY 1 Select a TUBE CLAMP that fits around the top of the accelerator pedal shaft Make sure the tabs of the TUBE CLAMP point away from the bulkhead 15mm 25mm 2 Attach the BEAD CHAIN to the CRUISE CABLE with a BEAD CHAIN CONNECTOR Make sure to use a CONNECTOR COVER 3 After you determine the length of BEAD CHAIN needed to attach to the accelerator pedal shaft cut BEAD CHAIN and attach to the EYELET CONNECTOR Make sure to use a CONNECTOR COVER 4 Put M5 BoLT through the holes in the TUBE CLAMP Slide the EYELET CONNECTOR over the bolt Thread LockNuT onto the bolt and tighten Figure 13 5J CA REL PL MS EXILI ce FFEIT p i nr t 4 A AQUI AATIOA PEDAL SAAFI WARNING Failure to follow the instruction manual could not only cause the WorldCruise to work improperly but could cause the throttle to hang up possibly causing damage to your vehicle and injury and or death to you and your passengers Figure 13 Page 11 INSTALLATION Ill ATTACHING CRUISE CABLE TO THROTTLE Continued D Ford Throttle MS ie l Select a TUBE CLAMP that fits the throttle cable Make sure the tabs of the TUBE CLAMP point away from the carburetor or air throttle this will prevent TUBE ULA THROTTLE CABLE zm y the throttle from hanging Figu
11. ISE CABLE will be anchored this is necessary so that CRUISE CABLE and throttle cable will not cross 4 The THREE BEAD CONNECTOR may need to be bent so E that it clears the throttle cable Figure 18 Use the Figure 17 TIE STRAP 102mm to hold the THREE BEAD CONNECTOR to the sleeve of the throttle cable Figure 18 5 When the THREE BEAD CONNECTOR is properly used the following parts will be required eo BRAD CHAIN CONNECTOR READ CHAIN COVER CRUISE LABLE THREE BEAD CONNECTOR THREE BEAD CONNECTOR CRUISE CONNECTOR COVER BEAD CHAIN CONNECTOR BEAD CHAIN See Figure 19 Figure 18 NOTE After the CRUISE CABLE has been attached manually move the throttle to assure the Cruise CABLE does not hang up on any part of the vehicle HEAD CHAIN THREE DL AL CONNECTOR WARNING Failure to follow the instruction manual could not only cause the WorldCruise to work improperly Figure 19 but could cause the throttle to hang up possibly causing damage to your vehicle and injury and or death to you and your passengers e CABLE ARRAN CHAIN CRUISE CONNECTOR CABLE r GEAL CILALN CONNECTOR COVER Page 13 INSTALLATION IV ANCHORING CRUISE CABLE llmm BOX There are three 3 types of connectors used to anchor the END WRENCH LOCKWASHER NUT CRUISE CABLE A SNAP IN ADAPTER B General Motors Blank Anchor FORMED THREADS C FLAG Nut nn ATINA DU gt A SNAP IN ADAPTER 35mm 38
12. ISO 9001 Made in the U S A
13. M x 16MM SEALING PUTTY 1 2 3 4 5 6 T 8 9 RD NR RB Re re oo BNW Use CLUTCH DISENGAGEMENT SWITCH Kit 250 4206 for manual transmission vehicle when the Dark Blue TACH wire cannot be obtained from vehicle or fails to disengage the WorldCruise Service Parts are available to replace any part in this kit See Service Part Numbers above Additional Hardware is available on Page 6 Page 4 WARNING PARTS DIAGRAM A El Gl a G3 G4 65 G6 G7 i tl G2 K Mh e G8 eg 0 711 G12 G13 E Gi6 G17 i qa j fad I Pue a TF f E i G14 G15 q men Gril G19 C20 G 22 SF Failure to follow the instruction manual could not only cause the WorldCruise to work improperly but could cause the throttle to hang up possibly causing damage to your vehicle And injury and or death to you and your passengers Page 5 SUPPLEMENTAL PARTS The following parts are available for your convenience and may simplify the installation of your WorldCru use Contact your local dealer or ROSTRA representative for details SERVICE ITEM PART DESCRIPTION QTY A LOOP CABLES A 250 2248 1 83 47MM 10 250 3089 2 62 67MM 10 250 2250 2 91 74MM 10 Se 250 2249 3 20 81mm 10 250 2251 3 81 97MM 10 B T BAR ADAPTERS B 250 2252 1 65 42mm 10 250 2247 2 74 70MM 10 250 2253 3 03 77MM 10 250 2254 3 53 90MM 10 250 4248 5 93 151mm
14. TACH wire is not hooked up the cruise control will function however the TACH over rev safety feature will be inactive this is dangerous and not recommended ROSTRA PRECISION CONTROLS INC always recommends the attachment of the TACH wire Page 18 INSTALLATION E Dark Blue Tachometer TACH Wire CONTINUED On a vehicle with a manual transmission the TACH wire connection is not required only when CLUTCH DISENGAGEMENT SWITCH Kit 250 4206 has been installed this will take into acount the TACH over rev safety feature The TACH wire should be grounded when using a clutch disengagement switch to ensure that the wire does not introduce trashy signals into the system In order to locate the TACH signal consult a Vehicle Shop Manual our Vehicle Technical Guide ROSTRA Form 2482 try our Fax Back System at 910 610 4191 call our Technical Service Department at 910 277 1828 Fax us at 910 276 3759 USA or visit us on the web at www rostra com F Gray Vehicle Speed Sensor VSS Wire The Gray Vehicle Speed Signal VSS wire is how the WorldCruise knows how fast the vehicle is moving The Pulses Per Mile Kilometer PPM PPK are a characteristic of the vehicle and must be set accordingly See Page 7 If VSS cannot be located on the vehicle then an auxiliary road speed sensor must be used SIGNAL GENERATOR or MAGNET 82 Co1 Pick Up Kir KiTt 250 4165 If you use an auxiliary speed sensor plug it into auxiliary s
15. WorldCruise ELECTRIC CRUISE CONTROL Kit 250 1311 INSTALLATION amp OWNER S MANUAL CONTENTS Sale A 2 as cre hres eee eee eee Fete bp lade EIS aa E ha Ura aA MD RO AMER HD cr Amy Uae Re ate hye Pre Be Ra eae Batista AeA een ete Supplements eee eee OWIE E OS a PrOUlbleS MOO A O Operatine Instruclons ias panal Loa a BLES 618 Form 2976 Rev B 2 00 SAFETY PROCEDURES The WorldCruise is a microprocessor based Cruise Control It is designed for ease of installation and can be used with most cars light trucks and vans Carefully follow the installation procedures in this manual for best results DO NOT INSTALL THIS SYSTEM ON A DIESEL POWERED VEHICLE WHICH HAS A MANUAL TRANSMISSION WITHOUT A DISENGAGE MENT SWITCH Kit 250 4206 ON THE CLUTCH PEDAL ASSEMBLY Your vehicle must have a VSS Vehicle Speed Signal wire or an available signal generator for installation of the WorldCruise Please consult vendor s application guide Throughout the instructions there are WARNINGS CAUTIONS AND NOTES that are meant to make it easier for you to install the WorldCruiseon your vehicle and make it safer to use We have gathered these tips from people across the country who have informed us of their problems and solutions Even with all these reports from the field we cannot cover every condi tion which you might encounter there are just too many different vehicle makes and models We do our best to tell you how to handle most ve
16. accelerator and speed will increase release accelerator and you will return to set speed NOTE The RESUME ACCEL button will SET the WorldCruise without pressing the SET button first COAST Press and Hold the SET COAST button and your speed will decrease Release button and speed of vehicle at time button is released will be new set speed if above 50 KPH 33 MPH ACCEL Press and hold the RESUME ACCEL button and your speed will increase Release button and you will have a new higher set speed TAP UP You can gradually increase your speed by quickly pressing and releasing the RESUME ACCEL button Each time you press and release the button your speed will increase by 1 1 2 to 5 KPH 2 to 3 MPH TAP DOWN You can gradually decrease your speed by quickly pressing and releasing the SET COAST button Each time you press and release the button your speed will decrease by 1 1 2 to 5 KPH 2 to 3 MPH DISENGAGE Depress brake pedal slightly automatic speed control will cease but set speed will stay in the system s memory Also you can disengage by pressing button to OFF position but this erases the memory To get the RESUME feature to work again you must first set a speed Turning OFF the ignition also clears the system s memory RESUME After disengaging system with brake or clutch return to SET speed by driving above 50 KPH 33 MPH Then press RESUME ACCEL button and release it If acceleration rate i
17. all times it will not function NOTE Do not use the engine as a grounding point Do not use the cable bracket as a gounding point NOTE To find a place to get electrical power you will need to ground one lead of your test light or volt ohmmeter Find electrical ground by turning ON the ignition switch and touching one lead to a Hot fused terminal at fuse panel touch other lead to unpainted metal part of vehicle The metal you touch if it makes continuity is ground The bracket for the parking brake lever is usually a good ground Turn the ignition OFF B Brown Accessory Power Find a fuse at the fuse panel that supplies power to one of the vehicles accessories It should be 12 volts when the key is ON and zero 0 volts when the key is OFF or in the START CRANK position C Red Brake Positive Hot side of brake switch Use the wire at the brake switch connector with constant 12 volts D Violet Brake Negative Cold side of brake switch Use the wire at the brake switch connector with zero O resistance when brake is not pressed and 12 volts or open resistance when brake is pressed E Dark Blue Tachometer TACH Wire The TACH function is a safety feature of the WorldCruise If a vehicle with an automatic transmission is accidentally knocked into neutral while the vehicle is in motion and the WorldCruiseis active the TACH wire when connected will disengage the WorldCruise before engine over rev If the
18. e Loop CABLE B Pulley Assembly Using T BAR ADAPTER See Page 6 C Pedal Attachment D Ford Throttle E General Motors and Chrysler Throttle Using THREE BEAD CONNECTOR LOOP CABLE NOTE When using the BEAD CHAIN CONNECTOR to connect the BEAD CHAIN to the CRUISE CABLE you must always use the CONNECTOR COVER Figure 8 Failure to use the CONNECTOR COVER could possibly cause the BEAD CHAIN or CRUISE CABLE to hang in the BEAD CHAIN CONNECTOR causing the throttle to be held in a partially open position This condition may even occur when the cruise control is not being used Figure 8 A Pulley Assembly Using The Loop CABLE 1 On some vehicles it may be necessary to remove the air cleaner to access the throttle pulley segment 2 Set the pulley segment in an OPEN throttle position and remove the throttle cable from the pulley 3 Hold the Loop CABLE between the holes in each side of the pulley Slide the barrel at the end of the throttle cable through the slotted hole then through the Loop CABLE and into the second hole i CONNECTOR Figure 9 COVER 4 Connect the Loop CABLE to the CRUISE CABLE using the BEAD CHAIN CONNECTOR as follows BEAD CHAIN CRUISE CONNECTOR CABLE Slide a CONNECTOR COVER on the Loop CABLE Install a BEAD CHAIN CONNECTOR onto the Loop CABLE and then onto the CRUISE CABLE BEAD CHAIN CONNECTOR may need to be spread slightly for cables to enter After the BEAD CHAIN CONNECTOR is installed l
19. ehicle needs a Throttle Adapter before you install the WorldCruise If an adapter is listed it must be used with that application Target Group and Qualified Installation This description is intended for those persons who install the product in the motor vehicle In order to be able to operate properly the WorldCruise must be correctly installed The system may therefore be installed and wired by persons who know and have understood the installation instructions of this manual and are familiar with automotive electrical and mechanical systems Installation by nonqualified personnel can lead to injury to the driver or third parties or damage to property or the environment Modifications to the product The WorldCruise is designed manufactured and tested with due regard to safety and reliability Modifying or tampering with the product can affect its safety This can lead to death serious or slight injury to the driver or third parties or damage to property or the environment For this reason the product must not be modified or tampered with Inform the user Hand the Operating Manual for the cruise to the user The Operation Manual is an integral part of the product If the cruise has not been fitted with a clutch switch Please inform the user that the engine speed briefly increases when the function is switched off via the clutch WARNING The information in this manual has been carefully compiled through actual vehicle testing and manufacturers
20. hicles but we must Depend on Your Good J udgement for dealing with the rest Therefore we believe you can understand why we strongly urge you to think carefully about what could happen to you your passengers and your vehicle if you use any tools parts fastening methods routing or procedures which are not described in this manual There is NO drain on the battery if the control switch is left on The WorldCruise needs no regular service WARNING Failure to follow the instruction manual could not only cause the WorldCruise to work improperly but could cause the throttle to hang up possibly causing damage to your vehicle and injury and or death to you and your passengers WARNING If you question the applications of the WorldCruise please consult the applicable application guide Only install on approved applications The product described in this manual was developed manufactured and tested in line with recognized technical standards and is in compliance with the fundamental safety requirements Nevertheless there are residual risks It is therefore important to read this manual before installing and connecting the product Keep the manual in a place that is readily accessible at all times Throttle Adapter In order to cover certain vehicles with a universal cruise control we have designed throttle adapters for performance and safety Consult current Application Guides and Vehicle Technical Information Guides to see if your v
21. ightly crimp the connector without pinching the cables Then slide the CONNECTOR COVER over the center of the BEAD CHAIN CONNECTOR CONNECTOR COVER LOOP NOTE You must always use the CONNECTOR COVER Failure to do so could possibly cause the Loop CABLE or the CRUISE CABLE to hang in the BEAD CHAIN CONNECTOR causing the throttle to be held in a partially open position 5 To secure the Loop CABLE to the throttle cable punch a small hole in the CONNECTOR COVER and slide the TIE STRAP 102mm through the hole and secure to the throttle cable Figure 10 NOTE Firmly tighten the TIE STRAP 102mm and remove excess to prevent possible throttle interference Fi gure 10 WARNING If the Loop CABLE is not secured to the existing throttle cable it could come out of the pulley segment possibly Page 10 causing the throttle to be held in a partially open position INSTALLATION lil ATTACHING CRUISE CABLE TO THROTTLE Continued B Pulley Assembly Dual Using The T BAR ADAPTER 1 Remove air cleaner to expose the dual pulley segments TOP PULLEY 2 Find the blank anchor that is located above the throttle oe anchor Follow the instructions for anchoring the CRUISE CABLE See Page 14 CONNECTOR COVER 3 Attach a BEAD CHAIN CONNECTOR onto the CRUISE CABLE BEAD CHAIN Figure 11 CONNECTOR 4 Attach the T BAR ADAPTER to the top pulley segment Slide the CONNECTOR COVER onto the T BAR ADAPTER Figure 11
22. ive battery cable However remember that some vehicles retain power to the airbag system when battery is disconnected 4 REMOVAL OF NEGATIVE BATTERY CABLE Disconnect the negative battery cable before installing the WorldCruise for safety precautions Remember to reconnect the cable after installation Figure C 5 ACCESSORY POWER When installing the special terminal into the fuse panel of vehicle See Figure D WARNING Failure to follow the instruction manual could not only cause the WorldCruise to work improperly but could cause the throttle to hang up possibly causing damage to your vehicle and injury and or death to you and your passengers Figure B Figure C INSERT Figure D IMA AMA EL FUSED BROWN WIRE WITH BLADE TERMINAL FROM CRUISE HARNESS Page 3 PARTS LIST SERVICE PART DESCRIPTION 250 3779 CRUISE MODULE 250 3695 CRUISE HARNESS 250 3607 CRUISE CABLE 250 3702 MODULE BRACKET 250 3700 CABLE BRACKET 250 3425 CONVOLUTED TUBING 58 250 3947 HARDWARE PACKAGE MODULE BOLT SELF THREADING BoLT M6 x 19 BEAD CHAIN BEAD CHAIN CONNECTOR CONNECTOR COVER Loop CABLE 67MM Loop CABLE 81MM THREE BEAD CONNECTOR EYELET CONNECTOR TIE STRAP 102mm TIE STRAP 190mm TUBE CLAMP 10MM FLAG NUT THREADED TUBE CLAMP M5 Bott M5 8 x 10 M5 Bott M5 8 x 20 M5 Nut LOCKNUT NYLON INSERT M5 8 LOCKWASHER NUT 1 4 20 PLAIN WASHER SNAP IN ADAPTER COTTER PIN 2M
23. least 4 8 KPH 3 MPH or faster in order to test an auxiliary speed signal The LED should flash and continue to flash at the same rate If so continue to Step 9 if not go to Step 8bi I Check steps to entering Diagnostic Mode and test again ii Check Programming Switch 10 It should be OFF for Sine Wave Input If set incorrectly reset and reenter Diagnostic Mode Step 9 Your WorldCruise has successfully passed the Self Diagnostic Testing Procedure If it still does not function test your TACH signal X TACH SIGNAL TESTING PROCEDURE Step 1 Turn the cruise control switch OFF Step 2 Turn the ignition to the OFF position Step 3 Closed Circuit Control Switch See Page 22 Press and hold the RESUME ACCEL button while you turn the ignition switch to the ON position and start the engine Now release the the RESUME ACCEL slide switch Open Circuit Control Switch See Page 22 Turn the ignition switch to the ON position and start the engine hold the RESUME ACCEL button down while you turn the cruise control switch to the ON position Step 4 The Diagnostic LED should be flashing Rev the engine the LED should flash faster at higher RPM s If so your TACH signal is valid if not go to Step 4a a Check steps to entering Diagnostic Mode and test again b Either your TACH wire is incorrect or your connection is bad Inspect your TACH connection and reenter Self Diagnostic Mode General Wiring Diagram OPTIONAL BROWN IGNITION
24. mm 1 Before using the SNAP IN ADAPTER remove the Adjustable Sleeve from the CRUISE CABLE To use the SNAP IN ADAPTER it will be necessary to form threads on the end of the CRUISE CABLE This is easily accomplished by placing the LOCKWASHER NuT Figure 20 on the end of the Cruise CABLE with your fingers INSULATION ON i CRUISE CABLE Then using an 11mm box end wrench and turning MUST EXTEND clockwise until the desired amount of threads have PAST ADAPTER been formed Figure 20 2 After the threads have been formed screw the SNAP IN ADAPTER onto the CRUISE CABLE Figure 21 Figure 21 NOTE Insulation on the CRUISE CABLE must extend past CABLE ARACKET ERA y Ne r Pell the end of the SNaAP IN ADAPTER on all applications z J e i 7 3 The SNAP IN ADAPTER snaps into the square hole of the CABLE BRACKET Figure 22 or snaps into an existing square hole on the vehicle common on GM vehicles Figure 23 SNAP IN ADAPTER WARNING Failure to follow the instruction manual could not only cause the WorldCruise to work improperly but could cause the throttle to hang up possibly causing damage to your vehicle and injury and or death to you and your passengers Page 14 Figure 23 INSTALLATION IV ANCHORING CRUISE CABLE continuep B General Motors Blank Anchor DRILL 6 4mm 1 To locate the blank anchor on General Motors FROM THIS SIDE vehicles it is necessary to remove
25. n Figure 32 Vil CONTROL SWITCH INSTALLATION If your cruise control switch is the type which clamps on the turn Figure 32 signal lever requires cutting the turn signal lever or is mounted on the instrument panel follow the instructions packaged with it If you have a switch which replaces the complete original equipment turn signal lever remove the existing lever and install the cruise control switch and lever assembly as instructed in the vehicle shop service manual WARNING Failure to follow the instruction manual could not only cause the WorldCruise to work improperly but could cause the throttle to hang up possibly causing damage to your vehicle and injury and or death to you and your passengers PLL Figure 33 Page 17 INSTALLATION VIII WIRING ATTACHMENTS TO VEHICLE CAUTION a te Before making any wiring connections be sure to disconnect Utilize Figure 34 to make the necessary wiring vee h ti i hicl your vehicle s negative battery cable to avoid electrical shock O en eg and or damage to the the vehicle s electrical system all ee A p E E aWv vb Ni C TO CONTROL SWITCH 16 PIN E E AAA ae A _ __ __R RQR e AL Ce i Lo CA OPTIONAL av OT El SIGNAL GENERATOR 1 B A Black Ground Wire In order to find a good ground for the cruise system find a vehicle ground point which is a clean unpainted metal surface If the cruise control does not see ground at
26. peed sensor connector G in Figure 34 and trim the Gray VSS wire as not to pick up any stray signals In order to locate the VSS signal consult a Vehicle Shop Manual our Vehicle Technical Guide ROSTRA Form 2482 try our Fax Back System at 910 610 4191 call our Technical Service Department at 910 277 1828 Fax us at 910 276 3759 USA or visit us on the web at www rostra com G Auxiliary Speed Sensor Connector This connector is utilized when the Gray VSS wire is not used as the vehicle speed source Both ROSTRA SIGNAL GENERATOR and MAGNET amp Cor Pick Up Kir Kir 250 4165 have a mating connector which plugs right into the wiring harness H 4 Pin Switch Connector This connector is utilized by the control switch All ROSTRA control switches contain a mating connector which plugs right into the main wiring harness J 2 Pin Switch Connector This connector is used in conjunction with the 4 Pin Switch Connector H in Figure 34 The 2 Pin Switch Connector J in Figure 34 is utilized by control switches which require an additional power and ground source such as those containing an LED indicator light or ROSTRA Radio Frequency RF models K Bulkhead Connectors These connectors simplify the installation of the wiring harness through the engine bulkhead firewall Simply disconnect the connectors run them through any 19mm 75 hole in the firewall preferably near the steering column and reconnect them once inside the pa
27. re 14 2 Attach CRUISE CABLE to the EYELET CONNECTOR NOTE Use the CONNECTOR COVER EYELET DLR N ELU POH a 3 CRUISE 3 Put the M5 BoLT through the holes in the TUBE CABLE CLAMP Slide the EYELET CONNECTOR over the bolt Thread the LOCKNUT onto the bolt and tighten Figure 14 4 Figure 15 is an example of a Ford Throttle connection using the TUBE CLAMP E General Motors and Chrysler Throttle using THREE BEAD CONNECTOR 1 Most General Motors vehicles and many Chrysler vehicles can use the THREE BEAD CONNECTOR to attach the CRUISE CABLE Figure 16 WARNING Failure to follow the instruction manual could not only cause the WorldCruise to work improperly but could cause the throttle to hang up possibly causing damage to your vehicle and injury and or death to you and your passengers Page 12 LIM MR R DONNE TOR COVER Figure 14 Ll HL TSF rani Figure 15 GENERAL MOTORS amp gt HATCLIP E BEAD CHAIN CHRYSLER Figure 16 INSTALLATION lil ATTACHING CRUISE CABLE TO THROTTLE Continued HEAD CHAIN E General Motors and Chrysler Throttle using THREE BEAD CONNECTOR Continued 2 Attach the BEAD CHAIN to the THREE BEAD CONNECTOR DEAD Secure beads by folding the metal tabs Figure 17 CONNECTOR 3 Remove clip or pin which retains throttle cable and washer if provided and install THREE BEAD CONNECTOR on the same side of throttle cable that the CRU
28. s faster or slower than you like drive to within a few KPH MPH of your set speed then press and release the RESUME ACCEL button THINGS YOU SHOULD KNOW ABOUT YOUR WorldCruise The performance of the WorldCruise is dependent upon the condition of the engine its size and even by the type of emission control equipment it has Driving at higher alti tudes will have an effect on WorldCruise performance Under normal conditions and with proper switch settings speed should be controlled within plus or minus 3 KPH 1 1 2 MPH There may be situations however which make it seem as if the WorldCruise is not capable of func tioning accurately such as an extra heavy load a very steep hill or a severe headwind CAUTION Do not use the WorldCruise on a slippery road nor in heavy traffic CAUTION Manual Transmission While driving with the WorldCruise ON do not shift to neutral without depressing the clutch pedal as this may cause engine racing or overreving If this happens depress the clutch pedal or turn OFF the main Cruise Control Switch immediately OUR QUALIFIED EXPERT TECHNICAL SERVICE DEPARTMENT IS READY TO ASSIST YOU WITH ANY QUESTIONS OR PROBLEMS THAT YOU MAY HAVE ABOUT OUR PRODUCT CONTACT US VIA PHONE AT 910 277 1828 USA OR FAX AT 910 276 3759 USA Page 23 Rostra Precision Controls Inc Global Automotive Accessories Group 2519 Dana Drive Laurinburg NC 28352 4000 www rostra com Certified QS 9000
29. s time You are now in Self Diagnostic Mode Continue to follow the procedures below to test your cruise control switch brake switch connections and VSS signal Step 5 Step 6 Step 7 Step 8 Page 20 Press and Release the SET COAST button The LED should light each time the button is pressed and go out when it is released If so continue to Step 6 if not go to Step 5a a Check steps to entering Diagnostic Mode and test again b Check Programming Switch 12 It should be ON for a Normally Closed Circuit Control Switch and OFF for a Normally Open Circuit Control Switch See Page 22 If set incorrectly reset and reenter Diagnostic Mode c Check power to the Cruise MoDULE if none of the diagnostic commands are functioning d Check Cruise Control Switch See Page 22 Press and release the RESUME ACCEL button The LED should light each time the button is pressed and go out when it is released If so continue to Step 7 if not go to Step 6a a Check steps to entering Diagnostic Mode and test again b Check power to the Cruise MODULE if none of the diagnostic commands are functioning c Check Cruise Control Switch See Page 22 You will need a second person to help you perform this test Press and release the Brake Pedal The LED should light each time the brake is pressed and go out when it is released If so continue to Step 8 if not go to Step 7a a Check steps to entering Diagnostic Mode and test again b
30. service manual research and to the best of our ability is accurate However we do not warrant the accuracy of this information against changes in vehicle design the use or misuse of this information or typographical errors It is the responsibility of the installer to verify the signal and color on the wire attachments prior to and after the installation of the WorldCruise to assure proper operation We do not accept any responsibility for damage to the vehicle or injury to its occupants caused by the use of this information Improper installation and or connection to the incorrect wires could cause WorldCruise or vehicle malfunction component damage and or personal injury for you and or your passengers Page 2 HELPFUL HINTS 1 BEFORE STARTING INSTALLATION Familiarize yourself with the Installation Instructions and WorldCruise components 2 MATING CONNECTORS A When disconnecting hold connector and press the lock downward while pulling connectors apart Figure A CAUTION Do not pull on wires B When inserting push mating connectors together until locking mechanisms are firmly locked together Figure B 3 AIRBAG AND ANTI THEFT RADIO A If vehicle is equipped with an Anti Theft Radio the radio code must be written down prior to disconnecting battery cable The code must be reentered when the negative battery cable is reinstalled B If vehicle is equipped with an Airbag SRS it is advisable to disconnect the negat
31. ssenger compartment WARNING Failure to follow the instruction manual could not only cause the WorldCruise to work improperly but could cause the throttle to hang up possibly causing damage to your vehicle and injury and or death to you and your passengers Page 19 TROUBLESHOOTING IX SELF DIAGNOSTIC TESTING PROCEDURE The WorldCruise is equipped with a Self Diagnostic Light Emitting Diode LED located underneath the rubber grommet on top of the Cruse MopDuLE Utilize the following Self Diagnostic Procedure to troubleshoot your cruise control if it does not function properly once installed DIAGNOSTIC LED The twelve 12 programming switches and diagnostic LED are located under the Black rubber grommet on top of the Cruise MODULE FIGURE 35 Carefully follow the procedures below to enter your cruise control into Self Diagnostic Mode Step 1 Step 2 Step 3 Step 4 Turn the cruise control switch OFF Turn the ignition to the OFF position Closed Circuit Control Switch See Page 22 Press and hold the RESUME ACCEL button while you turn the ignition switch to the ON position without starting the engine Now release the the RESUME ACCEL slide switch Open Circuit Control Switch See Page 22 Turn the ignition switch to the ON position without starting the engine hold the RESUME ACCEL button down while you turn the cruise control switch to the ON position The Diagnostic LED should be OFF at thi
32. the air cleaner The blank anchor is located above the throttle anchor Figure 24 2 This anchor is hollow except at one end Use a 6 4mm 25 bit drill as shown in Figure 24 3 Before using the LOCKWASHER Nur remove the Adjustable sleeve from the CRUISE CABLE Then use the LOCKWASHER NutT to form threads on the end of the CRUISE CABLE This is easily accomplished by URBE placing the LOCKWASHER Nur on the end of the CRUISE MUST EXTEND LOCKWASHER NUT CABLE with your fingers Then use an 11mm box end PAST ADAPTER wrench and turn clockwise until the desired amount of threads have been formed Figure 20 Page 14 Figure 25 4 Insert the CRUISE CABLE through the blank anchor and thread the other LOCKWASHER NUT in place Figure 25 DUAL PULLEY NOTE If you do not use the other LOCKWASHER NUT install a TUBE CLAMP 152mm 178mm from the anchor point Figure 26 This will keep the CRUISE CABLE from backing out of the anchor 5 The LOCKWASHER NutT can also be used if there is a pre existing 6 4mm hole in a bracket on the vehicle or if it is possible to drill a 6 4mm hole in a bracket Figure 26 on the vehicle LOCKWASHER NUT WARNING Failure to follow the instruction manual could 6 4mm HOLE CABLE not only cause the WorldCruise to work improperly OR DRILL TO USE EXISTING CRUISE 6 4mm but could cause the throttle to hang up possibly causing damage to your vehicle and injury and or death to you and your passengers
33. welve 12 programming Circuit look at the label of the packaging in which the switch came switches for a vehicle characterized by or See Page 22 Switch 1 amp 2 High Gain Switch 3 4 11 amp 12 4000 PPM NOTE 3 If any of the twelve 12 switches need to be changed after Switch 5 amp 6 4 Cylinder Low Switch 10 Square Wave Input installation of the WorldCruise the control switch and the vehicle Saar eee i nes aoe Switch 9 Manual Transmission ignition must be in the OFF position this is to allow the WorldCruise Switch 8 High Set Up Timer and to RESET Switch 7 Closed Circuit Control Switch Programming Functions 1 2 3 4 5 6 7 8 9 M u i2 Gain Sensitivity Pulses Mile Pulses Kilometer 1250 2000 2500 3750 4000 5000 6000 10000 6250 12000 7500 12870 8000 16090 10000 18000 11250 19300 12000 24000 15000 28960 18000 38600 24000 Engine Auto Transmission 4 Cyl HI 7200RPM 4 Cyl LO 5500RPM 6 Cyl HI 5200RPM 6 Cyl LO 4800RPM 8 Cyl HI 4800RPM 8 Cyl LO 4000RPM Man Transmission 4 Cyl 6 Cyl 8 Cyl Control Switch Closed Circuit ON Open Circuit OFF Centering Set Up _ High ON Low OFF Transmission Automatic ON wom EE ET ET fore M VSS Source Vehicle s Own VSS Aux VSS Source Sig Gen Mag INSTALLATION CRUISE MODULE MOUNTING NOTE DO NOT MOUNT THE CRUISE MODULE IN THE FOLLOWING AREAS

Rostra World Cruisell Manual 2-2000

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