Electronic Road Speed Limiter: Ersl Applications List

R
Electronic
Road Speed
Limiter
ERSL
Applications List
HOW TO NAVIGATE THE September 2008

APPLICATIONS LIST Issue F rev 2
HOW TO NAVIGATE THROUGH THE
100 ERSL APPLICATION LIST 100
95 95
75 75
25 25
Click on the “Bookmarks” tab
5 to open the navigation menu 5
0 0
Navigation menu opens. The selected fitting instructions open at the first page.
Click on the vehicle who’s Use the page scroll facility to browse the instructions.
fitting instructions you Referal to other pages are highlighted in blue text.
wish to view Click on the text to go to the refered page
100 100
95 95
75 Click on the “Return to fitting instructions” 75
text to return.
25 25
5 5
0 0
STURDY Europe
CONTENTS
1. Legal Requirements
Passenger Vehicles ............................................................................................................................... 1
More than 8 Passenger Seats ................................................................................................ 1
More than 16 Passenger Seats ............................................................................................. 1
Goods Vehicles ...................................................................................................................................... 2
2. Important Notes
ERSL Control Unit................................................................................................................................... 3
Speed Hold Utility .................................................................................................................................. 3
CANbus.................................................................................................................................................... 4
New Installation Sheet.......................................................................................................................... 5-6
3. Application Sheets
Aptec Williams
Aptec Williams Throttle Control .......................................................................................................... 7-8
Citroen
Relay ........................................................................................................................................................ 9 - 12
DAF
LF Series ................................................................................................................................................. 13 - 16
Ford
Focus 1.8D ............................................................................................................................................. 17 - 20
Ranger ..................................................................................................................................................... 21 - 24
Transit up to Nov 1997 ........................................................................................................................ 25 - 28
Transit from Nov 1997 ......................................................................................................................... 29 - 32
Transit from 2000 ................................................................................................................................. 33 - 36
Transit from 2005 ................................................................................................................................. 37 - 40
Isuzu
NPR .......................................................................................................................................................... 41 - 44
NQR .......................................................................................................................................................... 45 - 48
Iveco
Daily EDC .13 .......................................................................................................................................... 49 - 50
LDV
Convoy 2.4D ........................................................................................................................................... 51 - 54
Mercedes-Benz
Sprinter .................................................................................................................................................... 55 - 60
STURDY Europe
Mitsubishi
Canter ...................................................................................................................................................... 61- 64
Peugeot
Boxer ....................................................................................................................................................... 65 - 68
Renault
Master ..................................................................................................................................................... 69 - 72
Vauxhall
Astra ......................................................................................................................................................... 73 - 76
Combo CDTi ............................................................................................................................................ 77 - 80
Vivaro ....................................................................................................................................................... 81 - 84
Volkswagen
LT 35 and 46 .......................................................................................................................................... 85 - 90
Transporter T4 ........................................................................................................................................ 91 - 94
Transporter T5 ........................................................................................................................................ 95 - 98
4. Throttle Pedal Wiring Diagrams
Aptec Williams Throttle Control .......................................................................................................... iii

Citroen Relay .......................................................................................................................................... iv
DAF LF Series ......................................................................................................................................... v
Ford Focus 1.8D .................................................................................................................................... vi
Ford Ranger ............................................................................................................................................ vii
Ford Transit up to Nov 1997 ............................................................................................................... viii
Ford Transit from Nov 1997 ................................................................................................................ ix
Ford Transit from 2000 ........................................................................................................................ x
Ford Transit from 2005 ........................................................................................................................ xi
Isuzu NPR ................................................................................................................................................ xii
Isuzu NQR ............................................................................................................................................... xiii
Iveco Daily EDC .13 ................................................................................................................................ xiv
LDV Convoy 2.4D ................................................................................................................................... xv
Mercedes-Benz Sprinter ....................................................................................................................... xvi
Mitsubishi Canter .................................................................................................................................. xvii
Peugeot Boxer ........................................................................................................................................ xviii
Renault Master ...................................................................................................................................... xix
Vauxhall Astra ......................................................................................................................................... xx
Vauxhall Combo CDTi ............................................................................................................................ xxi
Volkswagen LT 35 and 46 .................................................................................................................... xxii
Volkswagen Transporter T4 .................................................................................................................. xxiii
Volkswagen Transporter T5 .................................................................................................................. xxiv
Vauxhall Vivaro CDTi ............................................................................................................................ xxv
STURDY Europe
A GUIDE TO SPEED LIMITER REQUIREMENTS
Passenger vehicles with more than 8 passenger seats (Bus)

Diesel / LPG / Natural Gas Petrol
Vehicle Size C &U reg 36A
(Gross Design Weight) paragraph First registered Use date Stabilised speed not to exceed date Stabilised speed not to exceed
not exceeding 5000 2B & 7 1 January 2005 and after International 1 January 2005 100 kph 1 January 2005 100 kph
National only 1 January 2008 100 kph 1 January 2008 100 kph
1 October 2001 to
2C & 7 31 December 2004 International 1 January 2006 100 kph Not Required
(Euro III or later engine) National only 1 January 2007 100 kph
5001 to 7500 2A & 7 1 January 2005 and after All 1 January 2005 100 kph 1 January 2005 100 kph
1 October 2001 to
2C & 7 31 December 2004 International 1 January 2006 100 kph Not Required
7501 to 10000
2&7 1 January 2005 and after All 1 January 2005 100 kph 1 January 2005 100 kph
1 October 2001 to 31
2&7 All 1 January 2005 100 kph 1 January 2005 100 kph
December 2004
1 January 1988 to 30
2 & 7A All existing requirement set speed of 100 kph existing requirement set speed of 100 kph
September 2001
10001 >
2&7 1 January 2005 and after All 1 January 2005 100 kph 1 January 2005 100 kph
December 2004
2 & 7A All existing requirement set speed of 100 kph existing requirement set speed of 100 kph
September 2001
Passenger vehicles with more than 16 passenger seats (Coach)

7501 to 10000
1 April 1974 to 31
1&6 All existing requirement set speed at 112 kph existing requirement set speed at 112 kph
December 1987
10001 >
1 April 1974 to 31
1&6 All existing requirement set speed at 112 kph existing requirement set speed at 112 kph
December 1987
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STURDY Europe
A GUIDE TO SPEED LIMITER REQUIREMENTS
Goods
3501 to 7500 1A & 9 1 January 2005 and after International 1 January 2005 90 kph 1 January 2005 90 kph
National only 1 January 2008 90 kph 1 January 2008 90 kph
1 October 2001 to
1B & 9 31 December 2004 International 1 January 2006 90 kph Not Required
7501 to 1200 1A & 9 1 January 2005 and after All 1 January 2005 90 kph 1 January 2005 90 kph
1 October 2001 to
1B & 8 All existing requirement 90 kph existing requirement 96 kph
31 December 2004
1 August 1992 to
1&8 All existing requirement 96 kph existing requirement 96 kph
31 December 2001
7501 to 10000
2&9 1 January 2005 and after All existing requirement 90 kph existing requirement 90 kph
December 2004
September 2001
1. The category of vehicle highlighted needs particular attention. These vehicles will need to have their current settings reduced in order to comply.
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Important Notes
ERSL Control Unit
It should be noted that, all ERSL control units supplied to the European aftermarket after
Januaryy 2008
Januar 2008, feature an optional Speed Hold facility.
Speed Hold
The speed hold utility enables the driver of a vehicle to set a limited speed for the vehicle
anywhere below the maximum set speed. To activate the speed hold the driver should stabalise
the vehicle at the speed at which limitation is required, then turn on the dash mounted speed
hold switch. The vehicle speed will now be limited to the selected speed until the speed hold
switch is turned off. When turned off the vehicle limited speed will return to the maximum set
speed.
To enable the speed hold facility the following steps should be taken:
1. Separate the Blue wire from the ERSL wiring loom and connect the wire to a dashboard
mounted single pole On/Off switch, the other connection to the switch should be a
permanent vehicle ground.
2. Using the link wire supplied, connect terminals 2 and 3 at the 18 pin ERSL wiring loom
connector.
3. Connect the ER01 programmer between the wiring loom connector and the control unit
and down load the limiter program details. Change the code for table 8 to 255 and
send the updated program to the limiter.
Note
Note: When reprogramming takes place the vehicle must be run at the maximum speed
setting of the vehicle, at full throttle, for 10 to 20 seconds on a flat road surface. This
allows the limiter to ‘re-learn’ the new settings.
The speed hold switch should be Off during this road test.
18 pin Wiring loom

connector
Single pole
On/Off switch
18 13
12 7
6 Dk Blue
Link
wire Vehicle
ground
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CANbus
Whilst some vehicles are equipped with an analogue speed signal that can be utilized for the
speed signal input to the ERSL, most new vehicles are now using CANbus.
Communication Area Network BUS is a high-speed data transmission network of binary vehicle
information transmitted through limited vehicle wiring, linking all major vehicle components
together.
The Sturdy Limiter at this time will only operate from an Analogue Speed signal. Therefore in
vehicles with no Analogue Speed output we must covert the ‘CAN’ signal to an Analogue
signal for the ERSL to use.
This is achieved by the use of the Spal Canbus interface which is inserted, at a strategic
point, into the Can network wiring of the vehicle.
The Spal CANbus unit is available from Time Instruments Ltd under Part No. 122000
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STURDY Europe
New Installations
As you are aware the light commercial vehicle sector is a constantly changing market in terms
of technical development. Vehicle manufacturers regularly introduce new models or update
existing models to keep pace with new technology.
From time to time you will be asked to install the Sturdy ERSL to a vehicle where no fitting
instructions are available or the instructions do not reflect equipment changes made by the
manufacturer.
Should you require assistance from the Sturdy technical team to carry out the fitting, would
you please photocopy the ‘New Installation’ sheet that follows this page, enter the detail
requested and fax it to the number at the bottom of the sheet.
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STURDY Europe
STURDY ELECTRONIC ROAD SPEED LIMITER
FITTING INSTRUCTIONS
FOR
Aptec Williams Throttle Control
APTEC WILLIAMS
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 before
attempting to install the ERSL.
Ensure that any security codes for Radios, Alarms, etc., are available before disconnecting
the battery.
Control Unit
Find a suitable position within the cab of the vehicle and secure the Control Unit, ensuring
that 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 200mm
from the connector, then using a butt splice supplied with the kit join 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 fuse
panel / rear of Tachograph / rear of electronic speedometer. Connect the Red wire from the
ERSL loom to an ignition switched positive. Connect the Black wire from the ERSL wiring
loom to a vehicle ground. Connect the Green wire from the ERSL loom to the wire carrying a
speed signal.
Route the other half of the ERSL wiring loom to the vehicle wiring harness that runs to the
throttle potentiometer.
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Wiring Loom cont’d

At a suitable position in the potentiometer wiring harness, separate and cut the Black wire.
Using a butt splice included in the kit, connect the Orange wire from the ERSL loom to the cut
wire from the throttle potentiometer.
Connect the Yellow wire from the ERSL loom to the cut wire that runs to the vehicle ECU.
ellow
Separate the Whit
White
e wire from the potentiometer harness and using a suitable connector,
splice the Pink wire from the ERSL loom to it.
Once the connections have been made wrap the looms with insulating tape to provide a neat
APTEC WILLIAMS
finish and reconnect the loom to the throttle potentiometer.
Calibration details
The Sturdy ERSL is supplied with generic calibration characteristics which may or may not be
suitable 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 speed
setting can be easily changed to suit the customers specific requirements using the Sturdy
ER-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 vehicle
be road tested to allow the Control 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 maximum throttle position should be maintained for a further 10-20 seconds whilst the
control unit learns the calibration settings, a reasonably flat road, clear of traffic, is required
to carry out this operation efefff iciently and safely
ely..
safely
8
STURDY Europe
FOR
CITROEN RELAY
MODELS: Diesel models from March 2007
ERSL KIT No: ER-07
CITROEN
the battery.
Control Unit
The control unit can be fitted in the area below the drivers side of the dash panel, using
suitable screws or adhesive.
Wiring Loom
Run the ERSL wiring loom containing 10 wires to the throttle pedal assembly.
Disconnect the wiring plug at the throttle position potentiometer, remove the protective plastic
sleeve and approximately 200mm of canvas wrap from the wiring loom to the potentiometer
plug.
Refering to the diagram on page iii, separate the Brown/black wire from the potentiometer
loom and cut the wire at a convenient position. Using the butt splices supplied in the ERSL kit,
connect the Green/yellow wire from the ERSL loom to the throttle pedal side of the cut
wire, then connect the Tan/red wire from the ERSL loom to the EMC side of the cut wire.
Separate the Blue/black wire from the potentiometer loom and again cut the wire at a
convenient position. Using the butt splices supplied connect the Orange wire from the ERSL
loom to the throttle pedal side of the cut wire, then connect the Yellow wire from the ERSL
ellow
loom to the EMC side of the cut wire.
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Connect the Pink wire from the ERSL loom, in series, to the Brown/white wire in the
potentiometer loom. Connect the Black/yellow wire from the ERSL loom, in series, with the
Purple/black wire in the potentiometer loom.
If engine rev limitation is required, the Blue wire from the ERSL wiring loom should be routed
to the alternator and connected to the W terminal.
To complete the wiring for the ERSL there are a further three connections to be made, these
being the Red, Black and Green wires from the ERSL wiring loom. Where these connections
should be made will depend on the vehicle having either a tachograph or an electronic
speedometer fitted.
Tachograph fitted
Select the ERSL loom containing three wires (Red, Black and Green) and run this to the rear
of the tachograph. At this point, using the butt splices supplied, connect the Black wire in
the ERSL loom to the tachograph negative (pin A5). The Red wire in the ERSL loom is connected
to the ignition switched positive (pin A3) and the Green wire to the road speed signal at
CITROEN
either pin B7 or pin D3.

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

At the rear of the speedometer can be found a Black plug containing an Green/grey wire,
the Green wire from the ERSL loom should be spliced to this wire to obtain a road speed
signal. The Red and Black wires from the ERSL loom should be routed to the Brake Pedal
Switch where the Black wire should be spliced to the Negative wire from the switch and the
Red wire spliced to the Ignition Positive wire to the switch.
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Calibration details
The Sturdy ERSL is supplied with a generic set of calibration characteristics. For the limiter to
operate correctly the characteristics listed below should be programmed into the ERSL Control
Unit.
TABLE PROGRAM CODE LEVEL
1 Speed setting Legal/customer requirement
2 Pole setting (x 1000imp) 13 7.5
3 Error gain 8 9
4 Response gain 176 12
5 % of WOT 8 52%
6 Not used
7 Not used
8 Engine rev setting
9 Eng.Sp Alternator poles 2.5
CITROEN
10 Eng.Sp Error gain 6
11 Eng.Sp Response gain 7
12 Eng.Sp % of WOT 50%
13 (L) Min. voltage 136 9%
13 (H) Max voltage (8+18) 93%
14 Not used
15 Not used

setting can be easily changed to suit the legal or customers specific requirements using the
Sturdy ER-01 programmer.
Refer to the ER-01 Programming manual for programming details.
Road Test
ely..
safely
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CITROEN STURDY Europe
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FOR
DAF LF Series
MODELS: All 45 models up to 7.5 tonnes
ERSL KIT No: ER-02
the battery.
DAF
Control Unit
Wiring Loom
Remove the steering column shroud to gain access to the throttle pedal potentiometer and
to enable the tachograph to be removed.
In the ERSL wiring loom, remove the Purple and Brown wires from their sheath and cut the
wires approximately 200mm from the connector, then using a butt splice supplied with the kit
join the cut ends of the wires together. Feed the joined wires back into the protective sheath.
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At a suitable position in the potentiometer wiring harness, separate and cut the Grey wire
4679. Using a butt splice included in the kit, connect the Orange wire from the
number 4679
ERSL loom to the cut Gre
Greyy wire from the throttle potentiometer.
Connect the Yellow wire from the ERSL loom to the cut Gre
ellow Greyy wire that runs to the vehicle
ECU.
Separate the Grey wire number 4680 from the potentiometer harness and using a suitable
connector, splice the Pink wire from the ERSL loom to it (see wiring diagram on page v).
Calibration details
Unit.
2 Pole setting (x 1000imp) 32 17
3 Error gain 5 6
5 % of WOT 4 38%
DAF
6 Not used
7 Not used
8 Engine rev setting Disabled
13 (H) Max voltage (8+128) 93%
14 Not used
15 Not used
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Road Test
ely..
safely
DAF
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DAF STURDY Europe
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STURDY Europe
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)
the 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 be
manufactured to allow the control unit to be fixed to an existing anchor point.
Wiring Loom
FORD
Run the ERSL wiring loom along the side of the vehicle ECM up to the vehicle wiring loom
carrying the throttle potentiometer control wires.
Referring to the schematic diagram on page vi, separate the White wire (pin 5) from the
potentiometer loom and cut the wire at a convenient position.
Using the butt splices supplied in the ERSL kit, connect the Purple wire from the ERSL loom
to the throttle pedal side of the cut wire. Then connect the Brown wire from the ERSL loom
to the ECM side of the cut wire.
Separate the White/red wire (pin 4) from the potentiometer loom, again cutting the wire at
a convenient position.
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Connect the Green/yellow wire from the ERSL loom to the pedal side of the cut wire and
the Tan/red wire from the ERSL loom to the ECM side of the cut wire.
Separate the White/blue wire (pin 7) from the potentiometer loom and cut the wire. Connect
the Orange wire from the ERSL loom to the pedal side of the cut wire and the Yello w wire
ellow
from the ERSL loom to the ECM side of the cut wire.
Connect the Pink wire from the ERSL loom in series with the Brown/blue wire (pin 2) in the
potentiometer loom.
Connect the Black/yellow wire from the ERSL loom in series with the Brown/red wire (pin
6) in the potentiometer loom.
Once the connections have been made, wrap the modified loom with insulating tape to provide
a neat finish, then reconnect the loom to the throttle potentiometer.
If the engine rev signal wire is required, this should be routed through a grommet in the
engine 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, Green
wire to road speed signal, Red wire to ignition positive and Black wire to negative.
A speed signal for the ERSL can be obtained by splicing the Green wire from the ERSL loom
to the Brown/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-hand
side of the battery. Disconnect the fly-lead and feed the lead back to the rear of the
transmission 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 Green and Blue wires from the ERSL loom as required.
FORD
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Calibration details
Unit.
1 Speed setting Legal/Customer Requirement
3 Error gain 5 6
5 % of WOT 4 38%
6 Not used
7 Not used
13 (L) Min voltage 136 9%
13 (H) Max voltage (8+128) 93%
14 Not used
15 Not used

ER-01 programmer.
FORD
Road Test
conditions.
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 the control unit
learns the calibration settings, a reasonably flat road, clear of traffic, is required to carry out
this operation efefff iciently and saf ely
ely..
safely
19
FORD STURDY Europe
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STURDY Europe
FOR
FORD RANGER
MODELS: All
ERSL KIT No: ER-06
KIT CONTENTS: 57D-03668 Control Unit
the battery.
Control Unit
The control unit can be fitted in the area below the drivers side dash panel or a suitable place
of your choosing, using suitable screws or adhesive.
Wiring Loom
FORD
Run the ERSL loom containing 10 wires down to the throttle pedal assembly.
plug.
Referring to the schematic diagram on page vii, separate the Pink wire (pin 6) from the
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Using the butt splices supplied in the ERSL kit, connect the Green/yellow wire from the
ERSL loom to the throttle pedal side of the cut wire. Then connect the Tan/red wire from the
ERSL loom to the ECM side of the cut wire.
Separate the Red wire (pin 3) from the potentiometer loom, again cutting the wire at a
convenient position.
Connect the Orange wire from the ERSL loom to the pedal side of the cut wire and the
Yellow wire from the ERSL loom to the ECM side of the cut wire.
ellow
Connect the Pink wire and the Black/yellow wire from the ERSL loom in series with the
Brown/black wire (pin 1) in the potentiometer loom.
Once the connections have been made wrap the loom with insulating tape to provide a neat
finish 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 routed
and connected to the ‘W’ terminal on the alternator.
wire 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 or
an electronic speedometer fitted.
Tachograph fitted
The ERSL loom containing the Green, Red and Black wires should be routed to the back of
the tachograph. Using an appropriate butt-splice, connect the Red wire to the tachograph
ignition positive (pin A3), connect the Black wire to the tachograph negative (pin A5). The
Green wire should be connected to either terminal B7 or D3 in the rear of the tachograph
casing.
These actions may result in the breaking of a tachograph seal, if the vehicle falls within the
category of vehicles governed by EC tachograph regulations, this seal must be replaced by a
Dpt of transport approved tachograph calibration centre.

In cases where an electronic speedometer is fitted to the vehicle, a speed signal for the ERSL
can be obtained at the rear of the speedometer.
At the rear of the speedometer is a Green plug containing an Orange wire ( pin 1). The
FORD
Green 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 Red wire is connected to an ignition switched positive and the Black wire connected
to a vehicle earth.
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Calibration details
Unit.

1 Speed setting Legal/Customer Spec
3 Error gain 7 8
5 % of WOT 8 52%
6 Not used
7 Not used
9 Eng.Sp Alternator poles
13 (H) Max voltage (8+128) 93%
14 Not used
15 Not used

The Sturdy ERSL is supplied with the operating speed set at 70 mph and the engine rev
limitation disabled, however the speed setting can be easily changed to suit the customers
FORD
specific requirements and the engine rev limiter enabled using the Sturdy ER-01 programmer.
Road Test
After installation or re-calibration it is essential that the vehicle is road tested to allow the
Control Unit to “learn” the calibration settings under road going conditions.
this operation efefff iciently and safely
safely
ely.
23
FORD STURDY Europe
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FOR
FORD TRANSIT
MODELS: Turbo Diesel up to NOV’97
ERSL KIT No: ER-02
the battery.
Control Unit
The control unit should be sited in a convenient position within the cab or engine compartment
of the vehicle.
Wiring Loom
Run the ERSL loom containing the purple, brown, orange, yellow and blue wires down to the
FORD
throttle pedal assembly.

Disconnect the vehicle wiring from the throttle position potentiometer, feed the wiring together
with plugs and grommet and the ERSL loom through the engine bay bulkhead where it will be
more convenient to work on.
Refer to the schematic diagram on page viii.
Separate the Grey wire (pin 3) from the potentiometer loom and cut the wire at a convenient
position.
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Separate the White wire from the potentiometer loom, again cutting the wire at a convenient
position.
ellow
Connect the Pink wire from the ERSL loom in series with the Brown wire (pin 4) in the
potentiometer 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-connect
the loom to the throttle potentiometer.
If the engine rev signal wire is required, this should be routed back through the potentiometer
loom grommet and then on to the alternator where it should be connected to the ‘W’ terminal
via the in-line fuse supplied.
wire to road speed signal, Red wire to ignition positive and Black wire to negative. Where
these connections should be made will depend on the vehicle having either a tachograph or
a mechanical speedometer fitted.
Tachograph fitted
the tachograph. Using an appropriate butt-splice connect the Red wire to the tachograph
casing.
These actions will normally result in the breaking of a tachograph seal, if the vehicle falls
within the category of vehicles governed by EC tachograph regulations, this seal must be
replaced 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 a
speed signal for the ERSL.
The ERSL loom containing the Green, Red and Black wires should be routed together with the
electrical lead from the speed sensor to the fuse board area below the dashboard. At this
FORD
point the Red wire from the ERSL loom and the Brown wire from the speed sensor should be
twinned together and connected to an ignition positive at the fuse board. The Black wire
from the ERSL and the Blue wire from the speed sensor should be twinned together and
connected to a vehicle negative. The Green wire from the ERSL loom should be spliced to
the Green/Y ello
Green/Yello
elloww wire from the speed sensor.
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Cable Clamp Gearbox Adaptor
Speedometer Drive Cable Speed Signal Generator
Calibration details
Unit.

3 Error gain 5 6
5 % of WOT 11 62%
6 Not used
7 Not used
9 Eng.Sp Alternator poles 17
FORD

13 (H) Max voltage (15+240) 100%
14 Not used
15 Not used
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The Sturdy ERSL is supplied with the operating speed set at 70 mph, however the speed
ER-01 programmer.
Road Test
this operation efefff iciently and saf ely
safely
ely.
FORD
28
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FOR
FORD TRANSIT
MODELS: Turbo Diesel from NOV’97
ERSL KIT No: ER-02
the battery.
Control Unit
The control unit can be fitted to the top of the glove box compartment using suitable screws
or adhesive. Access is achieved by removing the storage tray in the top of the dashboard in
front of the passenger seats.
Wiring Loom
FORD
Run the ERSL loom containing the purple, brown, orange, yellow and blue wires down to the
Disconnect the wiring plug and socket at the throttle position potentiometer, remove
approximately 200mm of canvas wrap from the wiring on the ECM side of the connector.
Referring to the schematic diagram on page ix, separate the Grey wire (pin 5) from the
29
STURDY Europe

Separate the White wire (pin 1) from the potentiometer loom, again cutting the wire at a
ellow
Connect the Pink wire from the ERSL loom in series with the Brown wire (pin 7) in the
potentiometer loom.
If the engine rev signal wire is required, this should be routed through a grommet in the
engine bulkhead and then on to the alternator where it should be connected to the ‘W’
terminal via the in-line fuse supplied.
Tachograph fitted
casing.

At the rear of the speedometer is a Black connector plug. Pin 5 (White/blue
White/blue) of this plug
White/blue
carries the speed signal from the gearbox transducer, the Green wire from the ERSL loom
should be spliced to this wire using an appropriate butt-splice.
FORD
30
STURDY Europe
Calibration details
Unit.
3 Error gain 5 6
5 % of WOT 11 62%
6 Not used
7 Not used
13 (H) Max voltage (15+240) 100%
14 Not used
15 Not used

The Sturdy ERSL is supplied with the operating speed set at 70 mph, however the speed
ER-01 programmer.
FORD
Road Test
safely
ely.
31
FORD STURDY Europe
32
STURDY Europe
FOR
FORD TRANSIT 2000
MODELS: Dura torque (2000)
ERSL KIT No: ER-06
the battery.
Control Unit
The control unit can be fitted in the area above the glove box compartment using suitable
screws or adhesive. Access is achieved by removing the storage tray in the top of the dashboard
in front of the passenger seats.
Wiring Loom
FORD
plug.
Referring to the schematic diagram on page x, separate the Grey/orange wire (pin 5) from
the potentiometer loom and cut the wire at a convenient position.
33
STURDY Europe

Separate the Blue/white wire (pin 7) from the potentiometer loom, again cutting the wire at
ellow
Separate the Grey/black (pin 4) wire from the potentiometer loom and cut the wire at a
convenient location.
Connect the Pink wire from the ERSL loom in series with the Grey/violet wire (pin 2) in the
potentiometer loom.
Connect the Black/yellow wire from the ERSL loom in series with the Grey/red wire (pin 6)
in the potentiometer loom.
If the engine rev limitation is required, the Blue wire from the ERSL loom should be routed to
the rear of the speedometer where it should be spliced to the White/black wire from the
large plug in the rear of the speedometer.
Tachograph fitted
casing.
FORD

At the rear of the speedometer is a small connector plug. The White/ violet wire in this plug
34
STURDY Europe
Calibration details
Unit.
3 Error gain 5 6
5 % of WOT 4 38%
6 Not used
7 Not used
13 (H) Max voltage (8+128) 93%
14 Not used
15 Not used

FORD
Road Test
safely
ely.
35
FORD STURDY Europe
36
STURDY Europe
FOR
FORD TRANSIT 2005
MODELS: From 2005
ERSL KIT No: ER-06
the battery.
Control Unit
The control unit can be fitted in the area above the glove box compartment using suitable
screws or adhesive. Access is achieved by removing the storage tray in the top of the dashboard
in front of the passenger seats.
Wiring Loom
FORD
plug.
Referring to the schematic diagram on page xi, separate the White wire (pin 5) from the
37
STURDY Europe

Separate the White/blue wire (pin 7) from the potentiometer loom, again cutting the wire at
ellow
Separate the White/red (pin 4) wire from the potentiometer loom and cut the wire at a
convenient location.
Connect the Pink wire from the ERSL loom in series with the Brown/blue wire (pin 2) in the
potentiometer loom.
Connect the Black/yellow wire from the ERSL loom in series with the Brown/red wire (pin
6) in the potentiometer loom.
the rear of the speedometer where it should be spliced to the White/black wire from the
large plug in the rear of the speedometer.
Tachograph fitted
casing.
FORD

At the rear of the speedometer is a small connector plug. The White/ violet wire in this plug
38
STURDY Europe
Calibration details
Unit.
3 Error gain 5 6
5 % of WOT 4 38%
6 Not used
7 Not used
13 (H) Max voltage (8+128) 93%
14 Not used
15 Not used

FORD
Road Test
safely
ely.
39
FORD STURDY Europe
40
STURDY Europe
FOR
ISUZU
MODELS: NPR
ERSL KIT No: ER-02
the battery.
Control Unit
The control unit can be fitted to the left-hand side of the glove box compartment using cable
ties. Access is achieved by removing the glove box from the dashboard in front of the passenger
seats.
Wiring Loom
Run the ERSL loom across the dashboard to a position behind the instrument cluster. At this
point separate the loom containing the yellow, orange and pink wires and run it down to the
Remove 2 x 12mm captive nuts that secure the throttle pedal assembly and remove the
assembly.
ISUZU
Referring to the schematic diagram on page xii, separate the Green/yellow wire from the
41
STURDY Europe

Using the butt splices supplied in the ERSL kit, connect the Orange wire from the ERSL loom
to the throttle pedal side of the cut wire. Then connect the Yellow wire from the ERSL loom
ellow
Connect the Pink wire from the ERSL loom in series with the Black/green wire in the
potentiometer loom.
finish and re-connect the loom to the throttle potentiometer and re-fit the throttle pedal
assembly.
wire to road speed signal, Red wire to ignition positive and Black wire to negative. These
connections can all be made at the rear of the instrument cluster.
the instrument cluster. Behind the instrument cluster you will find a spare tachograph wiring
connector (White mini-timer plug). Using an appropriate butt-splice connect the Red wire to
the tachograph ignition positive (pin A3), connect the Black wire to the tachograph negative
(pin A5).
The Green wire should be connected to the terminal post, marked SIG and positioned behind
the 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 to
the rear of the rev counter side of the instrument cluster where another terminal post marked
SIG will be found. Connect the Blue wire to this post using a suitable ring terminal.
ISUZU
42
STURDY Europe
Calibration details
Unit.
3 Error gain 6 7
5 % of WOT 8 52%
6 Not used
7 Not used
13 (H) Max voltage (8+128) 93%
14 Not used
15 Not used

The Sturdy ERSL can be supplied to the customers specification, however the speed setting
can be easily changed to suit new requirements using the Sturdy ER-01 programmer.
Road Test
safely
ely.
ISUZU
43
ISUZU STURDY Europe
44
STURDY Europe
FOR
ISUZU
MODELS: NQR
ERSL KIT No: ER-02
the battery.
Control Unit
The control unit can be fitted to the left-hand side of the glove box compartment using cable
ties. Access is achieved by removing the glove box from the dashboard in front of the passenger
seats.
Wiring Loom
Run the ERSL loom across the dashboard to a position behind the instrument cluster. At this
point separate the loom containing the yellow, orange, purple, brown and pink wires and run
it down to the throttle pedal assembly.
Referring to the schematic diagram on page xiii, separate the Blue/white wire from pin 5 in
ellow
ISUZU
Connect the Pink wire from the ERSL loom in series with the Black wire in pin 3 of the
potentiometer loom.
45
STURDY Europe

Separate the White wire from pin 2 in the potentiometer loom and cut the wire at a suitable
position.
finish and re-connect the loom to the throttle potentiometer and re-fit the throttle pedal
assembly.
wire to road speed signal, Red wire to ignition positive and Black wire to negative. These
connections can all be made at the rear of the instrument cluster.
the instrument cluster. Behind the instrument cluster you will find a spare tachograph wiring
connector (White mini-timer plug). Using an appropriate butt-splice connect the Red wire to
the tachograph ignition positive (pin A3), connect the Black wire to the tachograph negative
(pin A5).
The Green wire should be connected to the terminal post, marked SIG and positioned behind
the 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 to
the rear of the rev counter side of the instrument cluster where another terminal post marked
SIG will be found. Connect the Blue wire to this post using a suitable ring terminal.
ISUZU
46
STURDY Europe
Calibration details
Unit.
3 Error gain 6 7
5 % of WOT 8 52%
6 Not used
7 Not used
13 (H) Max voltage (8+128) 93%
14 Not used
15 Not used

The Sturdy ERSL can be supplied to the customers specification, however the speed setting
can be easily changed to suit new requirements using the Sturdy ER-01 programmer.
Road Test
safely
ely.
ISUZU
47
ISUZU STURDY Europe
48
STURDY Europe
IVECO
FOR
IVECO DAILY
MODELS: EDC .13
ERSL KIT No: ER-02
the battery.
Control Unit
Wiring Loom
speed signal.
49
STURDY Europe

At a suitable position in the potentiometer wiring harness, separate and cut the Orange
IVECO
(5157) wire connected to pin 5 of the Throttle Pedal Sensor. Using a butt splice included in
the kit, connect the Orange wire from the ERSL loom to the cut wire from the throttle
potentiometer (refer to wiring diagram on page xiv).
ellow
Separate the Br
Broown (0150) wire from pin 6 of the potentiometer harness and using a suitable
connector, splice the Pink wire from the ERSL loom to it.
Calibration details
The Sturdy ERSL is supplied with generic calibration characteristics which may or may not be
suitable for the vehicle.
For advise on the suitability of the calibration contact the Sturdy Europe Technical Department.

ER-01 programmer.
Road Test
ely..
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50
STURDY Europe
FOR
LDV Convoy
LDV
MODELS: Dura torque (2000)
ERSL KIT No: ER-06
the 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
plug.
Referring to the schematic diagram on page xv, separate the Whit
White/blue
e/blue wire (pin 5) from
Separate the Grey wire (pin 7) from the potentiometer loom, again cutting the wire at a
51
STURDY Europe

ellow
Separate the White (pin 4) wire from the potentiometer loom and cut the wire at a convenient
location.
Connect the Pink wire from the ERSL loom in series with the Purple/yellow wire (pin 2) in
the potentiometer loom.
Connect the Black/yellow wire from the ERSL loom in series with the Brown wire (pin 6) in
LDV
the potentiometer loom.

the rear of the speedometer were it should be spliced to the White/black wire from the
large ‘A’ block pin 10.
Tachograph fitted
casing.

At the rear of the speedometer is a large connector plug ‘A’. The wire in pin 7 of this plug
52
STURDY Europe
Calibration details
Unit.
3 Error gain 5 6
LDV
5 % of WOT 4 38%
6 Not used
7 Not used
13 (H) Max voltage (8+128) 93%
14 Not used
15 Not used

Road Test
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ely.
53
LDV STURDY Europe
54
STURDY Europe
FOR
MERCEDES-BENZ SPRINTER
MODELS: 210D, 212D, 310D, 312D, 410D, and 412D
ERSL KIT No: ER-02
KIT CONTENTS:
MERCEDES-BENZ
57D-02996 Control Unit (preset at 70 m.p.h.)
the battery.
Control Unit
To allow easy access when siting the ERSL Control Unit it is recommended that the near side
headlamp assembly be removed.
Using the Control Unit base plate as a template mark the positions of the four fixing holes
onto the flat panel between the nearside wheel arch and the front panel of the vehicle directly
below the headlamp.
Drill 4 x M6 clearance holes, and install the Control Unit using M6 bolts, spacing bushes, nuts
and washers (see diagram on page 58). The spacers are used to keep the control unit above
any water that may collect on the panel where it is fitted.
The Control Unit should be mounted with the electrical connection socket facing the near
side 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 and
Black wires.
If control of Engine revs is NOT required then cut the blue wire in such a position that it no
longer protrudes from it’s protective sheath (always tape the cut end).
55
STURDY Europe

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 Electronic
Control Module (ECM) until it reaches the point where the ECM loom splits. One part of the
ECM loom runs toward the throttle position potentiometer, the other part being routed through
the 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 this
through the bulkhead access port into the cab of the vehicle (a wire threader will be required
for this operation).
The other half of the ERSL wiring loom should follow the routing of the Throttle position
potentiometer wiring.
At the Throttle potentiometer, disconnect the vehicle wiring from the potentiometer and using
an appropriate tool remove approximately 150 mm of canvas wrap from the wiring loom.
MERCEDES-BENZ
Referring to the schematic diagram on page xvi, separate the White wire (pin 5) from the
ellow
Connect the Pink wire from the ERSL loom in series with the Yello
elloww wire (pin 6) in the
potentiometer loom.
Secure the ERSL loom to the vehicle wiring using cable ties.
The other half of the ERSL loom (Red, Black and Green wires) should now be routed behind
the dashboard (over the transmission tunnel and the steering column support struts), to the
wiring bundle situated behind the lower dashboard panel to the right of the steering column
(see diagram on page 59).
Crimp the ring terminal supplied to the Black (negative) lead in the ERSL loom and connect to
the 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 the
Green wire from the ERSL loom together with the signal wire (white white
white) from the generator
using the butt splice supplied and refit the two halves of the plug (see page 59).
white/red
Locate and separate from its wiring bundle the positive wire (white/red
white/red) to the brake lights,
splice the Red (positive) lead from the ERSL loom to this wire using the butt splice supplied.
56
STURDY Europe
Calibration details
Unit.
3 Error gain 6 7
5 % of WOT 8 52%
6 Not used
7 Not used
MERCEDES-BENZ
13 (H) Max voltage (8+128) 93%
14 Not used
15 Not used
When fitted to 310 and 410 models it will be necessary to engage the “ High Torque Option”.
See ER-01 Programming Manual for details.

ER-01 programmer.
Road Test
to carry out this operation efeffficiently and saf ely
ely..
safely
57
STURDY Europe
Sprinter Engine Bay

MERCEDES-BENZ
ERSL Control Module
FIG 1. ERSL Control Module position
58
STURDY Europe
Speed Generator Lead
MERCEDES-BENZ
B+ Ignition Pos
Green wire from ERSL loom
59
MERCEDES-BENZ STURDY Europe
60
STURDY Europe
FOR
MITSUBISHI CANTER
MODELS: Canter
ERSL KIT No: ER-06
MITSUBISHI
the battery.
Control Unit
Wiring Loom
speed signal.
61
STURDY Europe

At a suitable position in the potentiometer wiring harness, separate and cut the Green/blue
wire. Using a butt splice included in the kit, connect the Orange wire from the ERSL loom to
the cut wire from the throttle potentiometer (refer to wiring diagram on page xvii).
ellow
Separate and cut the Blue wire in the potentiometer harness. Using a butt splice included in
the kit, connect the Green/yellow wire from the ERSL loom to the cut wire from the throttle
potentiometer.
Connect the Tan/red wire from the ERSL loom to the cut wire that runs to the vehicle ECU.
Separate the Green/red wire from the potentiometer harness and using a suitable connector,
splice the Pink and Black/yellow wires from the ERSL loom to it.
Calibration details
Unit.
3 Error gain 6 7
MITSUBISHI

5 % of WOT 4 38%
6 Not used
7 Not used
9 Eng.Sp Alternator poles
10 Eng.Sp Error gain
11 Eng.Sp Response gain
12 Eng.Sp % of WOT
13 (H) Max voltage (8+128) 93%
14 Not used
15 Not used
62
STURDY Europe

ER-01 programmer.
Road Test
ely..
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MITSUBISHI
63
MITSUBISHI STURDY Europe
64
STURDY Europe
FOR
PEUGEOT BOXER
MODELS: SWB
ERSL KIT No: ER-07
the battery.
Control Unit
Wiring Loom
PEUGEOT
plug.
Refering to the diagram on page xviii, separate the Brown/black wire from the potentiometer
Separate the Blue/black wire from the potentiometer loom and again cut the wire at a
ellow
65
STURDY Europe

Connect the Pink wire from the ERSL loom, in series, to the Brown/white wire in the
Purple/black wire in the potentiometer loom.
If engine rev limitation is required, the Blue wire from the ERSL wiring loom should be routed
to the alternator and connected to the W terminal.
speedometer fitted.
Tachograph fitted

At the rear of the speedometer can be found a Black plug containing an Green/grey wire,
PEUGEOT
66
STURDY Europe
Calibration details
Unit.
3 Error gain 8 9
5 % of WOT 8 52%
6 Not used
7 Not used
13 (H) Max voltage (8+128) 93%
14 Not used
15 Not used

PEUGEOT
Road Test
ely..
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67
PEUGEOT STURDY Europe
68
STURDY Europe
FOR
RENAULT MASTER
MODELS: All models
ERSL KIT No: ER-07
the battery.
Control Unit
Wiring Loom
plug.
Refering to the diagram on page xix, separate the Yello
ellow
w wire (pin 6) from the potentiometer
RENA
RENAU
Separate the Pink wire (pin 3) from the potentiometer loom and again cut the wire at a
U LLT
T
69
STURDY Europe

Connect the Pink wire from the ERSL loom, in series, to the Purple wire (pin 1) in the
Brown wire (pin 2) in the potentiometer loom.
speedometer fitted.
Tachograph fitted

At the rear of the speedometer can be found a Green plug containing an Orange wire (pin 1)
RENAU
RENA U LLT
T
70
STURDY Europe
Calibration details
Unit.
3 Error gain 7 8
5 % of WOT 8 52%
6 Not used
7 Not used
13 (H) Max voltage (8+128) 93%
14 Not used
15 Not used

Road Test
ely..
safely
RENA
RENAUU LLT
T
71
RENAU
RENA U LLT
T STURDY Europe
72
STURDY Europe
V A UXHALL
FOR
VAUXHALL ASTRA
MODELS:
ERSL KIT No: ER-07
ADDITIONAL EQUIPMENT
122000 SPAL CAN Interface
the battery.
Control Unit
The control unit can be fitted inside of the transmission tunnel towards the front of the
vehicle.
CAN Interface
The interface is fitted next to the ODC connector housed in the transmission tunnel just
below the hand-brake lever.
Refer to the manufacturers fitting instructions (supplied with the CAN interface), for details
of the interface wiring.
The Ignition positive feed and the ground for the interface and the ERSL can be located next
to the ODC connector.
73
STURDY Europe
Wiring Loom
Remove the Purple and Brown wires from the ERSL wiring loom, cut the wires approximately
V A UXHALL
100mm from the connector then join the two wire together using one of the butt splices
supplied with the ERSL kit.
Disconnect the wiring plug at the throttle position potentiometer. Refering to the diagram on
page xx, separate the Yello w/whit
ellow/whit
w/whitee wire (pin 3) from the potentiometer loom and cut the
wire at a convenient position. Using the butt splices supplied in the ERSL kit, connect the
Orange wire from the ERSL loom to the throttle pedal side of the cut wire, then connect the
Yellow wire from the ERSL loom to the EMC side of the cut wire.
ellow
Separate the Green/white wire (pin 6) from the potentiometer loom and again cut the wire
at a convenient position. Using the butt splices supplied connect the Green/yellow wire
from the ERSL loom to the throttle pedal side of the cut wire, then connect the Tan/red wire
from the ERSL loom to the EMC side of the cut wire.
Connect the Pink and the Black/yellow wires from the ERSL loom, in series, to the Red/
brown wire (pin 2) in the potentiometer loom.
being the Red, Black and Green wires from the ERSL wiring loom.
The Green wire from the ERSL loom should be butt spliced to the Orange wire from the CAN
interface to obtain a road speed signal. The Red wire from the ERSL loom should be routed
to the Brake Pedal Switch and spliced to the Ignition Positive wire to the switch. The Black
wire should have a ring terminal fitted to it and anchored under one of the steering column
securing bolts.
74
STURDY Europe
Calibration details
V A UXHALL
Unit.
1 Speed setting Legal/customer requirement (less 3%)
3 Error gain 7 8
5 % of WOT 8 52%
6 Not used
7 Not used
8 Speed hold 0 Disabled
9 Not used 0
10 Eng.Sp Error gain 9 10
11 Eng.Sp Response gain 112 8
12 Eng.Sp % of WOT 8 36%
13 (H) Max voltage (8+128) 93%
14 Not used
15 Not used

Road Test
ely..
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75
V A UXHALL STURDY Europe
76
STURDY Europe
V A UXHALL
FOR
VAUXHALL COMBO
MODELS: CDTi
ERSL KIT No: ER-07
ADDITIONAL EQUIPMENT
122000 Spal CAN Interface
the battery.
Control Unit
The control unit can be fitted behind the dashboard to the right of the steering column, using
suitable screws, cable ties or adhesive.
CAN Interface
Remove the instrument cluster to gain access to the wiring plug at the rear of the cluster.
Refer to the manufacturers fitting instructions (supplied with the CAN interface), for details
of the interface wiring.
The Ignition positive feed for the interface and the ERSL positive feed are connected to the
positive to the brake light switch.The ground wires of the interface and the ERSL can be
twinned and connected to a securing bolt for the steering column.
77
STURDY Europe
Wiring Loom
V A UXHALL
page xxi, separate the Yello w/whit
ellow/whit
w/whitee wire (pin 3) from the potentiometer loom and cut the
wire at a convenient position. Using the butt splices supplied in the ERSL kit, connect the
Orange wire from the ERSL loom to the throttle pedal side of the cut wire, then connect the
Yellow wire from the ERSL loom to the EMC side of the cut wire.
ellow
Separate the Green/white wire (pin 6) from the potentiometer loom and again cut the wire
at a convenient position. Using the butt splices supplied connect the Green/yellow wire
from the ERSL loom to the throttle pedal side of the cut wire, then connect the Tan/red wire
from the ERSL loom to the EMC side of the cut wire.
Connect the Pink wire from the ERSL loom, in series, to the Blue/brown wire (pin 2) in the
Red/brown wire (pin 1) in the potentiometer loom.
The Green wire from the ERSL loom should be butt spliced to the Orange wire from the CAN
interface to obtain a road speed signal. The Red wire from the ERSL loom should be routed to
the Brake Pedal Switch and spliced to the Ignition Positive wire to the switch. The Black wire
should have a ring terminal fitted to it and anchored under one of the steering column securing
bolts.
78
STURDY Europe
Calibration details
V A UXHALL
Unit.
1 Speed setting Legal/customer requirement (less 3%)
3 Error gain 7 8
5 % of WOT 8 52%
6 Not used
7 Not used
9 Not used 0
13 (H) Max voltage (8+128) 93%
14 Not used
15 Not used

Road Test
ely..
safely
79
80
STURDY Europe
V A UXHALL
FOR
VAUXHALL VIVARO
MODELS: CDTi 1.9
ERSL KIT No: ER-07
the battery.
Control Unit
The control unit can be fitted behind the heater matrix in the centre of the vehicle dash panel.
Wiring Loom
page xxv, separate the Viole t/red wire (pin 3) from the potentiometer loom and cut the wire
Violet/red
at a convenient position. Using the butt splices supplied in the ERSL kit, connect the Orange
wire from the ERSL loom to the throttle pedal side of the cut wire, then connect the Yello w
ellow
wire from the ERSL loom to the EMC side of the cut wire.
Separate the Biege/red wire (pin 6) from the potentiometer loom and again cut the wire at
a convenient position. Using the butt splices supplied connect the Green/yellow wire from
the ERSL loom to the throttle pedal side of the cut wire, then connect the Tan/red wire from
the ERSL loom to the EMC side of the cut wire.
81
STURDY Europe

Connect the Pink wire from the ERSL loom, in series, to the White/orange wire (pin 2) in
V A UXHALL
the potentiometer loom. Connect the Black/yellow wire from the ERSL loom, in series, with
the Orange/red wire (pin 1) in the potentiometer loom.
To obtain a road speed signal, the Green wire from the ERSL loom should be butt spliced to
the Purple wire (pin 14) from the green connector plug at the rear of the instrument panel.
The Red wire from the ERSL loom should be routed to the Brake Pedal Switch and spliced to
the Ignition Positive wire to the switch. The Black wire should have a ring terminal fitted to it
and anchored to a chassis ground.
Calibration details
Unit.
3 Error gain 7 8
5 % of WOT 8 52%
6 Not used
7 Not used
9 Not used 0
13 (H) Max voltage (8+128) 93%
14 Not used
15 Not used
82
STURDY Europe
V A UXHALL
Road Test
ely..
safely
83
84
STURDY Europe
FOR
VOLKSWAGEN LT
VOLKSWAGEN
MODELS: LT35, LT46
ERSL KIT No: ER-02
KIT CONTENTS:
57D-02996 Control Unit (preset at 70 m.p.h.)
the battery.
Control Unit
To allow easy access when siting the ERSL Control Unit it is recommended that the near side
headlamp assembly be removed.
Using the Control Unit base plate as a template mark the positions of the four fixing holes
onto the flat panel between the nearside wheel arch and the front panel of the vehicle directly
below the headlamp.
Drill 4 x M6 clearance holes, and install the Control Unit using M6 bolts, spacing bushes, nuts
and washers (see diagram on page 88). The spacers are used to keep the control unit above
any water that may collect on the panel where it is fitted.
The Control Unit should be mounted with the electrical connection socket facing the near
side 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 and
Black wires.
If control of Engine revs is NOT required then cut the blue wire in such a position that it no
longer protrudes from it’s protective sheath (always tape the cut end).
85
STURDY Europe

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 Electronic
Control Module (ECM) until it reaches the point where the ECM loom splits. One part of the
ECM loom runs toward the throttle position potentiometer, the other part being routed through
the engine bulkhead into the cab of the vehicle following the main wiring bundle.
VOLKSWAGEN
Select the half of the ERSL loom containing three wires (Red, Black and Green) and run this
through the bulkhead access port into the cab of the vehicle (a wire threader will be required
for this operation).
The other half of the ERSL wiring loom should follow the routing of the Throttle position
potentiometer wiring.
At the Throttle potentiometer, disconnect the vehicle wiring from the potentiometer and using
an appropriate tool remove approximately 150 mm of canvas wrap from the wiring loom.
Referring to the schematic diagram on page xxii, separate the White wire (pin 5) from the
ellow
Connect the Pink wire from the ERSL loom in series with the Yello
elloww wire (pin 6) in the
potentiometer loom.
Secure the ERSL loom to the vehicle wiring using cable ties.
The other half of the ERSL loom (Red, Black and Green wires) should now be routed behind
the dashboard (over the transmission tunnel and the steering column support struts), to the
wiring bundle situated behind the lower dashboard panel to the right of the steering column
(see diagram on page 89).
Crimp the ring terminal supplied to the Black (negative) lead in the ERSL loom and connect to
the 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 the
Green wire from the ERSL loom together with the signal wire (white) from the generator using
the butt splice supplied and refit the two halves of the plug (see page 89).
Locate and separate from its wiring bundle the positive wire (white/red trace) to the brake
lights, splice the red (positive) lead from the ERSL loom to this wire using the butt splice
supplied.
86
STURDY Europe
Calibration details
Unit.
3 Error gain 6 7
VOLKSWAGEN
5 % of WOT 8 52%
6 Not used
7 Not used
13 (H) Max voltage (8+128) 93%
14 Not used
15 Not used
When fitted to LT46 it will be necessary to program the speed setting to 1 m.p.h. above the
required set speed. See ER-01 Programming Manual for details.

ER-01 programmer.
Road Test
to carry out this operation efeffficiently and saf ely
ely..
safely
87
STURDY Europe
LT series Engine Bay

VOLKSWAGEN
ERSL Control Module
FIG 1. ERSL Control Module position
88
STURDY Europe
VOLKSWAGEN
B+ Ignition Pos
Green wire from ERSL loom
89
VOLKSWAGEN STURDY Europe
90
STURDY Europe
FOR
VOLKSWAGEN TRANSPORTER TDI
VOLKSWAGEN
MODELS: T4
ERSL KIT No: ER-02
the battery.
Control Unit
Wiring Loom
panel / main connector bank (lower right hand side of dash). At this point connect the Black
wire in the ERSL loom to a vehicle negative, the Red wire in the ERSL loom to an ignition
Black/yellow
Black/yellow) and the Green wire to the White/blue wire from the hall
switched positive (Black/yellow
effect sender on the gearbox (G22).
91
STURDY Europe

At a suitable position in the potentiometer wiring harness, separate and cut the Grey wire.
Using a butt splice included in the kit, connect the Orange wire from the ERSL loom to the cut
Grey wire from the throttle potentiometer (refer to wiring diagram on page xxiii).
Connect the Yellow wire from the ERSL loom to the cut Gre
ellow Greyy wire that runs to the vehicle
ECU.
Separate the Brown/yellow wire from the potentiometer harness and using a suitable
connector, splice the Pink wire from the ERSL loom to it.
VOLKSWAGEN
Calibration details
Unit.
3 Error gain 6 7
5 % of WOT 1 28%
6 Not used
7 Not used
13 (H) Max voltage (8+0) 85%
14 Not used
15 Not used
92
STURDY Europe

ER-01 programmer.
Road Test
VOLKSWAGEN
ely..
safely
93
VOLKSWAGEN STURDY Europe
94
STURDY Europe
FOR
VOLKSWAGEN TRANSPORTER TDI
VOLKSWAGEN
MODELS: T5 (all engine varients)
ERSL KIT No: ER-02
the battery.
Remove the battery cover, disconnect and remove the battery and battery tray, then remove
the E-box cover (see Figures 1, 2 and 3).
Figure 1. Figure 2.
Figure 3.
95
STURDY Europe
Control Unit
Using double-sided tape fix the Control Unit to the

top of the vehicle ECM Unit (see Figure 4).
VOLKSWAGEN
Figure 4.
Wiring Loom
At the ERSL wiring loom, remove the Purple and Brown wires from their sheath and cut the
wires approximately 200mm from the connector, then using a butt splice supplied with the kit
join the cut ends of the wires together. Feed the joined wires back into the protective sheath.
Connect the Black lead from the ERSL loom to the

upper earthing point to the right of the E-box (see
Figure 5).
Figure 5.
Disconnect the Blue plug (T10d) from the E-box

coupling station (see Figure 6).
Refering to the wiring diagram on page xxiv, splice
the Pink wire from the ERSL loom to the Grey/red
(T10d/4) wire in the 10 pin connector plug.
Approximately 50mm from the Blue plug cut the
White/blue (T10d/5) wire. Using a supplied butt
splice, connect the Orange wire from the ERSL loom
to the Blue connector side of the cut wire.
Again using a butt splice as supplied, connect the
Yellow wire from the ERSL loom to the engine control
ellow
side of the cut wire. Figure 6.
96
STURDY Europe

At the top of the coupling station is a Beige connector (T10a), locate the White/lilac wire
(T10a/9) and splice the Green wire from the ERSL loom to it for the road speed signal.
An ignition switched positive can be found at the

battery fuse holder box at position SA15 (see Figure
7), connect the Red lead from the ERSL wiring loom
to the output side of this fuse (SA15). A 5amp in-line
fuse (not supplied) should be used to make this
VOLKSWAGEN
connection.
Wrap the modified looms with insulating tape for a
neat finish.
Figure 7.
If required ensure that the ERSL Control Unit has been programmed to the settings listed
below 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
Unit.
3 Error gain 6 7
5 % of WOT 1 28%
6 Not used
7 Not used
13 (H) Max voltage (8+0) 85%
14 Not used
15 Not used
97
STURDY Europe

ER-01 programmer.
Road Test
VOLKSWAGEN
ely..
safely
98
STURDY Europe
99
STURDY Europe
100
STURDY Europe
Throttle Pedal
Wiring Diagrams
Important Note:
Whilst all efforts are made to ensure that the informaton on the following pages are correct,
Sturdy Europe will not be held responsible for any errors that may occur due to technical
changes made by vehicle manufacturers.
i
STURDY Europe
ii
STURDY Europe
Throttle Position
Sensor
Red 4.94 v
Black 0.56 v to 3.88 v ECM
White 0v
Road Speed Signal 12 volt from Ignition Sw (B+)
Engine Speed Signal (revs) Ground
Orange
Yellow
Purple
Brown
Green
Black
Blue
Pink
Red
1 9 10 11 12 16 17 8 7
18 Pin ERSL module connector
Aptec Williams Throttle Control

Return to fitting
Wiring Detail instructions
iii
STURDY Europe
Throttle Position
Sensor
Brown/black
Purple/black
ECM
Blue/black
Brown/white
Green/yellow
Black/yellow
Tan/red
Orange
Yellow
Purple
Brown
Green
Black
Blue
Pink
Red
1 9 10 11 12 14 15 18 16 17 8 7
Citröen Relay
Return to fitting
iv
STURDY Europe
Throttle Position
Sensor
1
2
3
5 ECM
6 Grey 4679
4 Grey 4680
Orange
Yellow
Purple
Brown
Green
Black
Blue
Pink
Red
1 9 10 11 12 16 17 8 7
DAF LF Series
Return to fitting
v
STURDY Europe
Throttle Position
Sensor
1
7 White/blue
2 Brown/blue
4 White/red
ECM
5 White
6 Brown/red
Green/yellow
Black/yellow
Tan/red
Orange
Yellow
Purple
Brown
Green
Black
Blue
Pink
Red
1 9 10 11 12 14 15 18 16 17 8 7
Ford Focus 1.8D

Return to fitting
vi
STURDY Europe
Throttle Position
Sensor
1 Brown/black
2
3 Red
4 ECM
5
6 Pink
Green/yellow
Black/yellow
Tan/red
Orange
Yellow
Purple
Brown
Green
Black
Blue
Pink
Red
1 9 10 11 12 14 15 18 16 17 8 7
Ford Ranger
Return to fitting
vii
STURDY Europe
Throttle Position
Sensor
3
2
1 ECM
4
Orange
Yellow
Purple
Brown
Green
Black
Blue
Pink
Red
1 9 10 11 12 16 17 8 7
Ford Transit up to Nov 1997

Return to fitting
viii
STURDY Europe
Throttle Position
Sensor
5 Grey ECM
1 White
7 Brown
Orange
Yellow
Purple
Brown
Green
Black
Blue
Pink
Red
1 9 10 11 12 16 17 8 7
Ford Transit after Nov’97

Return to fitting
ix
STURDY Europe
Throttle Position
Sensor
1
5 Grey/orange
6 Grey/red
4 Grey/black ECM
7 Blue/white
2 Grey/violet
Green/yellow
Black/yellow
Tan/red
Orange
Yellow
Purple
Brown
Green
Black
Blue
Pink
Red
1 9 10 11 12 14 15 18 16 17 8 7
Ford Transit 2000

Return to fitting
x
STURDY Europe
Throttle Position
Sensor
1
5 White
6 Brown/red
4 White/red ECM
7 White/blue
2 Brown/blue
Green/yellow
Black/yellow
Orange
Tan/red
Yellow
Purple
Green
Brown
Black
Blue
Pink
Red
1 9 10 11 12 14 15 18 16 17 8 7
Ford Transit 2005

Return to fitting
xi
STURDY Europe
Throttle Position
Sensor
Green/yellow ECM
Black/green
Orange
Yellow
Purple
Brown
Green
Black
Blue
Pink
Red
1 9 10 11 12 16 17 8 7
Isuzu NPR
Return to fitting
xii
STURDY Europe
Throttle Position
Sensor
1 Red
2 White
3 Black
4 Blue/red ECM
5 Blue/white
6 Blue
Orange
Yellow
Purple
Brown
Green
Black
Blue
Pink
Red
1 9 10 11 12 16 17 8 7
Isuzu NQR
Return to fitting
xiii
STURDY Europe
Throttle Position
Sensor
1
2
3
4 ECM
5 Orange (5157)
6 Brown (0150)
Orange
Yellow
Purple
Brown
Green
Black
Blue
Pink
Red
1 9 10 11 12 16 17 8 7
Iveco Daily EDC .13

Return to fitting
xiv
STURDY Europe
Throttle Position
Sensor
1
5 White/blue
6 Brown
4 White ECM
7 Grey
2 Purple/yellow
Green/yellow
Black/yellow
Tan/red
Orange
Yellow
Purple
Brown
Green
Black
Blue
Pink
Red
1 9 10 11 12 14 15 18 16 17 8 7
LDV Convoy 2.4D Turbo (2000)

Return to fitting
xv
STURDY Europe
Throttle Position
Sensor
1
2
3
4 ECM
5 White
6 Yellow
Orange
Yellow
Purple
Brown
Green
Black
Blue
Pink
Red
1 9 10 11 12 16 17 8 7
Mercedes-Benz 210/2 D, 310/2 D. 410/2 D

Return to fitting
xvi
STURDY Europe
Throttle Position
Sensor
Blue
ECM
Green/blue
Green/red
Green/yellow
Black/yellow
Tan/red
Orange
Yellow
Purple
Brown
Green
Black
Blue
Pink
Red
1 9 10 11 12 14 15 18 16 17 8 7
Mitsubishi Canter
Return to fitting
xvii
STURDY Europe
Throttle Position
Sensor
Brown/black
Purple/black
ECM
Blue/black
Brown/white
Green/yellow
Black/yellow
Tan/red
Orange
Yellow
Purple
Brown
Green
Black
Blue
Pink
Red
1 9 10 11 12 14 15 18 16 17 8 7
Peugeot Boxer
Return to fitting
xviii
STURDY Europe
Throttle Position
Sensor
1 Purple
2 Brown
3 Pink
4 Orange ECM
5 White
6 Yellow
Green/yellow
Black/yellow
Tan/red
Orange
Yellow
Purple
Brown
Green
Black
Blue
Pink
Red
1 9 10 11 12 14 15 18 16 17 8 7
Renault Master
Return to fitting
xix
STURDY Europe
Throttle Position
Sensor
Red/brown
Yellow/white
ECM
Green/white
Speed Hold (ground via switch) Ground
Green/yellow
Black/yellow
Tan/red
Orange
Yellow
Purple
Brown
Green
Black
Blue
Pink
Red
1 9 10 11 12 14 15 18 16 17 8 7
Vauxhall Astra
Wiring Detail Return to fitting
instructions
xx
STURDY Europe
Throttle Position
Sensor
Red/brown
Blue/brown
Yellow/white
ECM
Green/white
Green/yellow
Black/yellow
Tan/red
Orange
Yellow
Purple
Brown
Green
Black
Blue
Pink
Red
1 9 10 11 12 14 15 18 16 17 8 7
Vauxhall Combo CDTI

Return to fitting
xxi
STURDY Europe
Throttle Position
Sensor
1
2
3
4 ECM
5 White
6 Yellow
Orange
Yellow
Purple
Brown
Green
Black
Blue
Pink
Red
1 9 10 11 12 16 17 8 7
Volkswagen LT35 & LT46

Return to fitting
xxii
STURDY Europe
Throttle Position
Sensor
1
2
3
4 ECM
5 Grey
6 Brown/yellow
Orange
Yellow
Purple
Brown
Green
Black
Blue
Pink
Red
1 9 10 11 12 16 17 8 7
Volkswagen Transporter T4
Return to fitting
xxiii
STURDY Europe
10-pin connector, Blue

E-box coupling station
ECM
White/blue (T10d/5) T94/83
Grey/red (T10d/4) T94/39
Orange
Yellow
Purple
Brown
Green
Black
Blue
Pink
Red
1 9 10 11 12 16 17 8 7
Volkswagen Transporter T5
Return to fitting
xxiv
STURDY Europe
Throttle Position
Sensor
1 Orange/red
2 White/orange
3 Violet/red
4
ECM
5
6 Biege/red
Green/yellow
Black/yellow
Tan/red
Orange
Yellow
Purple
Brown
Green
Black
Blue
Pink
Red
1 9 10 11 12 14 15 18 16 17 8 7
Vauxhall Vivaro
Return to fitting
xxv
STURDY Europe
xxvi
STURDY Europe
xxvii
STURDY Europe
xxviii

Electronic Road Speed Limiter: Ersl Applications List

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HOW TO NAVIGATE THE September 2008

75 Click on the “Return to fitting instructions” 75

4. Throttle Pedal Wiring Diagrams

Aptec Williams Throttle Control .......................................................................................................... iii

A GUIDE TO SPEED LIMITER REQUIREMENTS

Passenger vehicles with more than 8 passenger seats (Bus)

Passenger vehicles with more than 16 passenger seats (Coach)

A GUIDE TO SPEED LIMITER REQUIREMENTS

ERSL Control Unit

18 pin Wiring loom

STURDY ELECTRONIC ROAD SPEED LIMITER

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

Wiring Loom cont’d

finish and reconnect the loom to the throttle potentiometer.

Re-calibration / changing the set speed

STURDY ELECTRONIC ROAD SPEED LIMITER

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

Wiring Loom cont’d

either pin B7 or pin D3.

Electronic Speedometer fitted

Re-calibration / changing the set speed

STURDY ELECTRONIC ROAD SPEED LIMITER

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

Wiring Loom cont’d

Re-calibration / changing the set speed

STURDY ELECTRONIC ROAD SPEED LIMITER

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

Re-calibration / changing the set speed

STURDY ELECTRONIC ROAD SPEED LIMITER

ERSL KIT No: ER-06

KIT CONTENTS: 57D-03668 Control Unit

57C-03060-005 Wiring Loom

59A-03362 Fitting Accessories

Wiring Loom cont’d

Electronic Speedometer fitted

TABLE PROGRAM CODE LEVEL

Re-calibration / changing the set speed

STURDY ELECTRONIC ROAD SPEED LIMITER

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

throttle pedal assembly.

Wiring Loom cont’d

Mechanical Speedometer fitted

Cable Clamp Gearbox Adaptor

Speedometer Drive Cable Speed Signal Generator