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Now named the AP300
& CM19. General
Notes * First
ensure that any work will not invalidate any warranty on the vehicle. * Solder
the joints where possible - more reliable. * Use cable ties to keep wiring
as tidy as possible and away from throttle actuating lever - safety implications.
* Legends on Control Module don't match instructions: where SET is mentioned,
use FIX/KM+ and for RES use MEM/KM-. * Use a multimeter to determine "live"
wires on brake switch etc. The colours mentioned in the text may not match those
on your vehicle. * Put any removed parts carefully to one side with their
screws. Tools
& miscellaneous parts * Set of blade and pozi-drive cross-point screwdrivers.
* Set of Torx drivers (up to size T40). * Soldering iron (25W minimum - 60W
temperature controlled preferred). * Hacksaw, drill, drill bits, files etc.
* Cable ties (Nylon ratchet 2.5 x 99 and 3.5 x 150 approx.). * Nuts, bolts
and washers. * Insulation tape * The fitting kit provides most other parts
required. Dashboard
removal * First remove lower steering column shroud - 4 self-tappers.
Then remove upper shroud - two concealed self-tappers right at the top - use a
torch! * Remove fuse-box cover and reach inside to the left to find latch
which unclips the diagnostic connector cover. Remove it. * Remove the right-hand
dashboard oddments tray to expose a concealed dashboard skirt section securing
screw. Remove the "skirt" section - total of 4 self-tappers and a Torx
plus clips and locating studs - it's a fiddle! Watch out for the screws hidden
behind the bonnet release and steering wheel adjustment levers.
* Removed headlight up-down adjustment cover panel and matching blank on the other
(driver's side) of the steering column. This reveals two hidden screws - remove
these plus the two behind the speedo/rev counter binnacle (behind the windscreen
on top of the dashboard). * Remove the binnacle and release and un-plug the
three connectors. Protect the binnacle with a cloth to prevent scratching. Throttle
actuator * Attach to power steering fluid reservoir mounting bracket using
two right-angled brackets under the reservoir fixing. * Fit the unit upright,
with vacuum connection at the top, to allow any moisture to drain out of the small
hole on the opposite side to the vacuum tube. The curved fixing provided with
the unit will require re-orientation to suit. * Run the Bowden and signal
cables through a hole in the bulkhead. There is an un-used grommeted hole above
right of brake servo when viewed from front. Temporarily remove nuts and rubber
cover from the end of the Bowden cable to ease the task. A drop of washing-up
liquid works wonders for lubrication! * Route the Bowden cable, in as big
an arc as possible, around under the dashboard to a point adjacent steering column
"box" bolt. Remember that, when the skirt is re-fitted, the housing
for the steering wheel adjustment release lever will occupy space in this area.
* Cut the vacuum tube to the brake servo using a knife, backed by (say) a wide
chisel blade. Don't saw in order to avoid contamination of the vacuum system with
plastic dust. Remove a length of tube to suit the adapter. The small white adapter,
supplied in the kit, is the best fit. Use cable ties or small clips to secure
the tubes. Clips are best on brake servo vacuum pipe as it is hard. Cable ties
can be used for tube to servo. Take great care here as a vacuum leak may affect
engine and, especially, brake performance. As vacuum connections are self-sealing
to some extent, a tight fit will probably render clips unnecessary. If you do
use clips, make sure that they don't ruck the pipe. Throttle
actuating lever * Use a length of steel strip approx. 210mm long by 20mm
wide by around 2 to 3mm thick for the lever. A short length of the same strip
may be used to make the angle bracket which prevents rotation of the lever in
relation to the accelerator pedal. The finished angle bracket should measure around
20x30mm when finished. Stud and angle bracket securing screw holes should be about
8mm from the lever ends and there should be around 25mm between the fixing hole
and angle-bracket securing holes. It may be possible to use the long strip supplied
with the kit or Conrad-Anderson will supply a ready-made lever assembly, at additional
cost, on request. A stroke of about 40mm is required at the point of attachment
of the throttle actuating Bowden cable. * Drill holes and fit the throttle
lever to allow as straight a run as possible for the Bowden cable inner. See sketch
supplied with the kit for more detail. * Remove accelerator pedal assembly
and release and unplug the electrical connector. Caution - don't switch on the
ignition whilst the accelerator is un-plugged. * Remove pedal fixing screw
and (preferably, using a new longer screw) attach the actuating lever. Offer up
the modified assembly to the vehicle and ensure that the full swing
of the lever and pedal are un-impeded by any vehicle parts (eg. wiring harness
- of which there are many!). It may be necessary to bend the lever to bring the
end of it into line with the Bowden cable fixing bracket hole. I found about 5
degrees to be necessary. Use as small an angle as possible. It may also be necessary
to elongate the lever bracket hole in order to adjust the position of the top
of the lever clear of any obstructions. Take time and care over this - it will
pay dividends. Remember that the cruise control has safety features but it can't
compensate for a jammed throttle actuating lever!! * Remove assembly and carefully
tighten all fixings. I used some thread-locking compound on the accelerator fixing
screw for added security and safety. * Refit the assembly and re-fit the wiring
connector. Operate the accelerator pedal over it's full travel and ensure free
and un-obstructed operation. * Use the kit parts to secure the Bowden mounting
below the securing bolt. Use washers each side of bracket and secure with another
nut in order to "stand-off" the bracket from the box/bolt. There is
no need to remove the original nut as it makes a good spacer and there is plenty
of spare thread. * Ensure that the cable is accurately aligned and then fit
the solderless nipple (it's a "fiddle" but makes sure that the allen
screw is really tight) ensuring that there is a little bit of slack and plenty
of adjustment both ways on the outer cable fixing. Adjust as necessary for minimum
slack then ensure that the lever operates freely leaving the Bowden cable inner
free to slide in the stud hole. Control
module * I used the right-hand "stalk" unit fitted to the upper
steering wheel column shroud above and behind the ignition switch. The fixing
hole may be conveniently drilled on the bench with the stroud removed from the
vehicle. * There is no need to drill a hole for the cable as it passes nicely
down through exiting gaps in the dashboard trim. * Carefully fit the 4 wires
into the 8-way connector ensuring that the colours match. You only get one chance
so "get it right" don't have to "put it right"! Ensure that
the pins are inserted correctly by observing the shape of the pin and pin housing.
* Tape back the linked 3-way connector unless using the memory control module. Cable
harness/electronics unit mounting * Fit connector and use cable ties to
steady the cable form. * Cut off the yellow (tacho) wire around 75mm from
the logic box (before suppressor) and insulate the bare end. * "Mount"
the electronics module among the wiring etc. on top of the drivers-side wheel
arch. Brake
switch wiring * Connect brown wire to switched side and brn/wht wire to
"live" side of switch. Both wires must be connected. Clutch
switch wiring * Connect mauve wire to grey/white wire on clutch switch.
Switch may be removed to ease this task as it has a bayonet action. I used an
IDC (Scotch-Lock) connector here owing to restricted space and little slack in
the cable. * Note that action of clutch signal is inverted compared to brake.
Signal is normally at nominal +12V DC and goes to 0V when clutch operated. This
doesn't matter - it's edge triggered. Speed
sense wiring * Join the blue wire of the blue/back pair onto pin 1 of
the middle connector behind speedo. Salmon/blue wire. Fold back and tape the un-used
black wire. * Don't be tempted to use the white wire on the back of the radio
- it may not be connected - mine wasn't. Supply
wiring * Fit green earth tag under screw lower right of dashboard.
* Join the look orange supply wire to the orange/white wire from the ignition
switch. Don't fit the fuse yet. Safety
* Ensure free operation of throttle actuating lever. Use cable ties to secure
adjacent wires in order to ensure that they cannot move to impede movement of
the accelerator etc. * Check that vacuum connection * Visually check all
wiring at this point before fitting the fuse in the holder in the orange supply
wire. Diagnostics
* After fitting the in-line fuse, put the system into diagnostic mode by switching
off the ignition, holding down the "FIX" button and then switching on
the ignition. Press the ACT/OFF button to illuminate the green LED. Release the
FIX button after switching on the ignition. * All functions (eg. brake operation)
will cause a short bleep if "seen" by the electronics unit. A long bleep
indicates a fault. Remember that the clutch signal is inverted and this will initially
cause a long "error" bleep - ignore it. * To test the vacuum servo,
first put the system into diagnostic mode but start the engine immediately after
switching on the ignition. Press FIX and hold it until engine speed increases.
Release to obtain constant speed then press MEM/KM- to reduce it. Press ACT/OFF
to disengage the cruise. Switch off the ignition to exit diagnostic mode.
* When in diagnostic mode the vehicle may be driven. Listen for bleeps as speed
signals are detected. The frequency will increase with increased road speed. Set-up
* Follow the instructions supplied with the kit for initial set-up etc. *
I found that it was only necessary to follow the initial set-up procedure to get
an instant result. * Re-instate the dashboard parts in reverse order. Conclusions
* Conrad-Anderson were extremely helpful in offering advice prior to the installation
and supplied the throttle actuating lever at additional cost. * The basic
instruction left something to be desired and were re-hash of those for an earlier
model. Initially the up-to-date wiring diagram wasn't supplied with the kit but
was quickly provided when the fact was pointed out. The set-up instructions were
very good apart from the minor problem of legend mis-match. * Conrad-Anderson
are currently sorting out the instructions and informed me that fitting is similar
on Mercedes and Ford vehicles. * On the road the unit works very well indeed
with good pick-up, smooth control and good, fiddle free, accuracy. * Result
- an enjoyable project with satisfactory results at reasonable cost - enjoy!! Reproduced
courtesy of: Motorhome Monthly, incorporating RV News - September 2003
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