AstroStart RS-504 User manual

REMOTE CONTROLLED ENGINE STARTER
WITH BUILT-IN
ALARM SYSTEM
MODEL RS-504
Designed for use in all manual
transmission , gasoline or diesel
powered, fuel injected vehicles
(Carbureted or throttle-assisted
vehicles require an optional
solenoid kit). Do not install
in vehicles equipped with
an automatic transmission.
Made in Canada by:
ASTROFLEX Inc.
Patents Pending
Patent No. U.S. 4.345.554
Patent No. CDN 1.130.426 193-504-121-00 4L25

193-504-121-00 4L25 PAGE 1
SYSTEM INSTALLATION............................................................................................................................................4
RUNNING WIRES INTO THE ENGINE COMPARTMENT............................................................................................ 4
PIN SWITCH INSTALLATION AND WIRING................................................................................................................ 4
TEMPERATURE SENSOR INSTALLATION .................................................................................................................. 5
TACH WIRE CONNECTION ...........................................................................................................................................6
IGNITION COIL TYPES & CONNECTION.....................................................................................................................6
A) STANDARD IGNITION COIL WITH SEPARATE DISTRIBUTOR............................................................................. 6
B) THE MULTICOIL DISTRIBUTORLESS SYSTEM..................................................................................................... 7
C) OTHER MULTICOIL SYSTEMS................................................................................................................................ 7
BRAKE PEDAL CONNECTION ......................................................................................................................................7
CLUTCH SWITCH OVERRIDING...................................................................................................................................8
STARTER WIRE SWITCHING .......................................................................................................................................8
STARTER RELAY WIRE SWITCHING...........................................................................................................................9
MAIN HARNESS CONNECTION.................................................................................................................................. 10
MAIN HARNESS TEST.................................................................................................................................................. 11
MAIN HARNESS TROUBLESHOOTING...................................................................................................................... 12
DISABLE SWITCH MOUNTING AND LOCATION ..................................................................................................... 13
INSTALLING THE RECEIVER...................................................................................................................................... 13
MODULE CONNECTION.............................................................................................................................................. 13
SND-1 MODULE INSTALLATION.............................................................................................................................14
HAND BRAKE ............................................................................................................................................................... 14
SENSOR INSTALLATION............................................................................................................................................. 15
RECEIVER INSTALLATION........................................................................................................................................ 15
TRANSMITTER INSTALLATION................................................................................................................................. 16
SENSOR ALIGNMENT................................................................................................................................................ 17
ALIGNMENT VERIFICATION..................................................................................................................................... 18
SYSTEM PROGRAMMING........................................................................................................................................19
PREPARING PRIOR STARTING ................................................................................................................................... 19
MAIN INSTALLATION TEST....................................................................................................................................... 20
TEST AFTER INSTALLATION..................................................................................................................................... 20
MODULE INSTALLATION ........................................................................................................................................... 21
TROUBLESHOOTING ................................................................................................................................................22
START FAIL CODES................................................................................................................................................... 23
RS-504 MODULE........................................................................................................................................................ 23
SND-1 MODULE......................................................................................................................................................... 23
ALARM SYSTEM RS-504............................................................................................................................................ 24
FACTORY DOOR SWITCH INTERFACE ..................................................................................................................... 24
SIREN INSTALLATION ................................................................................................................................................ 25
SHOCK SENSORS.......................................................................................................................................................... 26
INTEGRATED SHOCK SENSOR................................................................................................................................... 26
INTERNAL WARNING BUZZER .................................................................................................................................. 27
ADDITIONAL L.E.D...................................................................................................................................................... 27
OPTIONAL WIRING AND ACCESSORIES...............................................................................................................28
HORN CONNECTION.................................................................................................................................................... 28
REAR WINDOW DEFROSTER ACTIVATION ............................................................................................................. 29
PROTECT INPUT........................................................................................................................................................... 29
DOOR LOCK INTERFACE............................................................................................................................................ 30

PAGE 2193-504-121-00 4L25
SPECIAL APPLICATIONS.......................................................................................................................................... 31
CARBURETED OR THROTTLE ASSISTED VEHICLES.............................................................................................. 31
SECONDARY CIRCUITS............................................................................................................................................... 31
DUAL PARKING LIGHT CIRCUITS ............................................................................................................................. 32
OVERRIDING FACTORY/AFTERMARKET ANTI-TEFTH SYSTEMS ................................................................33
G.M PASS-KEY SYSTEMS............................................................................................................................................ 33
FACTORY & AFTERMARKET ALARM OVERRIDE................................................................................................... 34
STANDARD FACTORY SYSTEM................................................................................................................................. 34
AFTERMARKET ALARMS ........................................................................................................................................... 35
R.A.P SYSTEM (GM VEHICLES).................................................................................................................................. 36
CODE LEARNING OF ADDITIONAL TRANSMITTER..........................................................................................37
REPLACING A LOST TRANSMITTER..................................................................................................................... 37
GLOSSARY...................................................................................................................................................................38
CRANKING CYCLES................................................................................................................................................... 38
CARBURATOR TYPES................................................................................................................................................ 38
VATS AND PASSKEY SYSTEMS.................................................................................................................................. 38
CONTROL MODULE PROGRAMMING...................................................................................................................39
REMOTE CONTROL MODES.................................................................................................................................... 39
ENTERING THE USER PROGRAMMING MODE....................................................................................................... 39
ENTERING THE INSTALLER PROGRAMMING MODE:............................................................................................ 40
ENABLING THE VEHICLE TO RECEIVE INSTRUCTIONS........................................................................................ 40
EXITING THE INSTALLER PROGRAMMING MODE ................................................................................................ 40
RS-504 PROGRAMMING............................................................................................................................................ 41
INSTALLER PROGRAMMING CODES—CONFIDENTIAL......................................................................................... 42
SND-1 MODULE......................................................................................................................................................... 43
USER PROGRAMMING CODES RS-504 .................................................................................................................... 44
RS-504 RESPONSE CODES......................................................................................................................................... 45
CONTROL MODULE.................................................................................................................................................. 45
{SND-1 MODULE.................................................................................................................................................. 45
RS-504 ALARM INFRACTION CODES....................................................................................................................... 45
RS-504 COMMAND CODES........................................................................................................................................ 46
RS-504 REFECENCE CARD........................................................................................................................................ 47
RS-504 WIRING DIAGRAM........................................................................................................................................48
RS-504 WIRING CHART............................................................................................................................................. 48
PART LIST.................................................................................................................................................................... 49

193-504-121-00 4L25 PAGE 3
WARNINGWARNING
ASTROSTART™ RS-504 system is designed for use in all manual shift transmission, gasoline or diesel
powered, fuel injected vehicles.
Carbureted or throttle-assisted vehicles need an optional solenoid kit.(part #310-050-501)
Diesel vehicles need a Diesel Tach Sensor DTS-1 (part #310-066-500).
Do not install in vehicles equipped with a automatic transmission.
VEHICLEPRE-CHECKVEHICLEPRE-CHECK
Prior to installing the unit, go through this checklist carefully:
• Is the starter in good working condition?
• Is the battery fully charged?
• Does the climate control system work properly?
• Are the parking lights and horn functional?
• Are the hand brake, and the “BRAKE” indicator functional?
• Has the ASTROSTART™ switch been set to the OFF position prior to installation?
• Is the power door lock system (if used) working properly (some vehicles do not have a drivers door motor)?
BEFOREYOUBEGINBEFOREYOUBEGIN
Installing the ASTROSTART™ system is a simple step by step process. Take the time to review each step.
For a trouble free installation follow these guidelines:
• Carefully review the installation instructions and wiring diagrams.
• Solder all electrical connections.
• Probe and confirm every connection before soldering.
• Do not try to use the ASTROSTART™ before programming the unit properly.
• Do not cut or splice any of the ground wires. Use ring terminals to ground each wire to the chassis of the
vehicle.
• Probing unknown wires with a test light could damage the vehicles electrical system. To probe safely, use a
voltmeter or the ASTROSTART™ Multitest tool.
• Never disconnect any Air Bag circuits when probing wires at the steering column, serious damage can occur.
VEHICLEPREPARATIONVEHICLEPREPARATION
• You must first prepare the vehicle as follows:
• Leave the drivers door window open and remove the dome light fuse.
• Expose the under dash wiring on the drivers side by removing any panels blocking access.
• Find a suitable location under the dash for the ASTROSTART™ module. Do not locate close to any moving
parts (brake pedal, steering column, gas pedal, etc...).
• Make sure that the transmission shifter is in the “NEUTRAL” position.

PAGE 4193-504-121-00 4L25
SYSTEMINSTALLATIONSYSTEMINSTALLATION
STEP 1
RUNNINGWIRESINTOTHEENGINECOMPARTMENTRUNNINGWIRESINTOTHEENGINECOMPARTMENT
RUNTHEFOLLOWINGWIRESINTOTHEENGINECOMPARTMENT:RUNTHEFOLLOWINGWIRESINTOTHEENGINECOMPARTMENT:
• BLK/RED (harness #253) hood pin switch
• BLK/GRN (harness #252) ignition coil
• Temperature Sensor (harness #411)
WIREROUTINGPROCEDUREWIREROUTINGPROCEDURE
• Locate an existing rubber grommet on the firewall
• Run all wires through this grommet
• After you have made your connections (pin switch, tach, temp sensor) cover wires with split loom wire
conduit and secure using tie straps.
• Make sure that all your wiring is secured away from any moving parts or heat sources.
• Use Silicone to seal up the grommet opening.
• In the event that there is no available grommet in the firewall, carefully drill a hole and insert an appropriate
grommet.
STEP 2
PINSWITCHINSTALLATIONANDWIRINGPINSWITCHINSTALLATIONANDWIRING
HARNESS#253HARNESS#253
The Pin Switch is installed to prevent the vehicle from starting with the hood open. This important SAFETY
precaution prevents the possibility of the engine starting by mistake when the vehicle is being serviced. This
feature will also shut the engine off immediately if someone attempts to open the hood after the vehicle has
been started by remote.
PINSWITCHMOUNTINGPINSWITCHMOUNTING
• The switch must be mounted in contact with the chassis (ground) of the vehicle
• The switch must line up with the hood so that the hood pushes down on the switch (disconnects contact to
chassis of vehicle) when it closes.
• Connect the BLK/RED wire on harness #253 to the pin switch.

193-504-121-00 4L25 PAGE 5
PINSWITCHTESTINGPINSWITCHTESTING
• Close the hood.
• Set your voltage meter to the "Continuity" mode
• Attach one meter probe to the BLK/RED wire, attach the other meter probe to the chassis of the vehicle.
• With the hood closed there should be no indication of continuity to the chassis of the vehicle.
• Open the hood
• With the hood open the meter should indicate continuity to chassis ground.
• If the pin switch does not work exactly as outlined above you will have to readjust.
Caution: Advise your customer of the importance of maintaining this switch in good working
condition. Ask the customer to check switch operation at least once every month. by performing the
following tests;
Ø Start the vehicle by remote control,
Ø Than releasing the hood. The engine should shut off immediately,
Ø If this does not occur the customer should return to your installation facility immediately.
STEP 3
TEMPERATURESENSORINSTALLATIONTEMPERATURESENSORINSTALLATION
HARNESS#411HARNESS#411
The Temperature Sensor monitors the engine temperature at all times. When selected by remote control this
sensor will activate the ASTROSTART™ system when the temperature falls below a certain temperature. The
engine will automatically start and run for ten (10) minutes. This feature is used to maintain engine temperature
in times of extreme cold.
TEMPERATURESENSORMOUNTINGTEMPERATURESENSORMOUNTING
• Locate the engine heater hose (hose that connects to the heater core).
• Place the Temperature Sensor on the hose and secure with "Tie Straps".
5/16”

PAGE 6193-504-121-00 4L25
STEP 4
TACHWIRECONNECTIONTACHWIRECONNECTION
HARNESS#252HARNESS#252
This connection enables the ASTROSTART™ system to monitor engine R.P.M (Revolutions Per Minute). This
information is used to determine when to disengage the vehicles starter motor, and to shut the engine off when
the engine R.P.M becomes too high.
The RS-504 will display the tach pulses after enabling the function via the programming mode.
• 0,0 I1 C,B AND 0,0 U4 C,C
Or using the Multitest module will enable you to read the RPM via a digital readout.
IGNITIONCOILTYPES&CONNECTIONIGNITIONCOILTYPES&CONNECTION
• Refer to the "WIRE CODING SHEET" for vehicle "Tach" wire colour.
• Programming: - Program according to the number of cylinders (" # CYL" Installer Programming Mode).
• 5,1 I1 A,A TO 5,7 I1 C,A
A)STANDARDIGNITIONCOILWITHSEPARATEDISTRIBUTOR
This system incorporates a separate coil and distributor. The "Tach" wire is relatively easy to locate as the coil
itself is labeled with + & -. Connect the BLK/GRN to the NEGATIVE SIDE of the ignition coil.
-
+
BLACK/GREEN
DISTRIBUTOR
RED
IGNITION COIL

193-504-121-00 4L25 PAGE 7
B) THEMULTICOILDISTRIBUTORLESSSYSTEM
The multicoil distributorless system is similar to the one on the diagram below. Two, three or four coils are
located in the same control module with four, six, or eight spark plug wires exiting the module. Connect the
BLK/GRN wire to the PULSE INPUT wire at the module. (Wire that gives a tach signal)
In certain cases, there will be two white wires coming from the module. When tested using the MultiTest, both
wires will have a tach signal. Use the wire where the tach signal appears sooner while cranking the engine.
C)OTHERMULTICOILSYSTEMS
All other multicoil ignition systems have one, two, four or six cylinders per coil and each coil's negative terminal
is available for tach signal. This means that a three coil, six cylinder vehicle has three tach wires each
providing a tach signal for two cylinders. Connect the BLK/GRN wire to one (1) of the ignition coils.
• Program your ASTROSTART™ system to the setting corresponding with the number of cylinders that each
ignition coil services. eg. A three coil, six cylinder vehicle would be set for two (2) cylinders.
STEP 5
BRAKEPEDALCONNECTIONBRAKEPEDALCONNECTION
HARNESS#253HARNESS#253
This connection is made to enable the brake pedal to shut the engine off when started by remote control. This
prevents anyone from driving the vehicle without using the ignition key when it has been remote started.
CONNECTIONCONNECTION
• Locate the brake switch.
• Find the N.O. (Normally Open) brake switch wire (the wire that indicates +12V only when the pedal is
depressed.
• Connect the WHT/GRN wire on harness #253 to this wire.
Note: Some vehicles require the ignition to be ON in order for the brake lights to work. Keep this in
mind when locating the N.O. brake switch wire.
BLACK/GREEN
MULTICOIL DISTRIBUTORLESS IGNITION SYSTEM, TACH SIGNAL

PAGE 8193-504-121-00 4L25
STEP 6
CLUTCHSWITCHOVERRIDINGCLUTCHSWITCHOVERRIDING
In most manual shift transmission vehicle’s, the clutch must be held down to start the vehicle. Your remote
starter must simulate this operation. It is necessary to add a relay that shorts the clutch contacts only when
starting by remote.
WIRINGWIRING
• First, find the clutch switch located on top of the clutch pedal.
• Determine witch type of switching is used.
• Make connections according to the corresponding diagram below.
Following are the two types of switching most frequently used by vehicle manufacturers.
The clutch switch is used as a normally open contact to disable the starter by :
• Type # 1: cutting the starter circuit from ignition (see diagram # 1).
• Type # 2: cutting the wire that controls the starter relay from ground (see diagram # 2).
Never use a jumper to by-pass the clutch switch.
The clutch switch is the main security device featured by the manufacturer.
By-passing this switch could result in injuries to the user or its environment.
STARTERWIRESWITCHING
This type of circuit allows to connect the DK BLUE wire from harness #251 directly to the starter supply wire.
DIAGRAM # 1
STARTER
IGNITION KEY
CLUTCH PEDAL
SWITCH
DARK BLUE
LARGE GAGE WIRE
THAT SHOWS
+12VDC WHEN THE
KEY IS THE START
POSITION AND THE
CLUTCH PEDAL IS
PRESSED

193-504-121-00 4L25 PAGE 9
STARTERRELAYWIRESWITCHING
DIAGRAM # 2
If the special application is used for something else. It is possible to double this output , using a relay in parallel.
See diagram # 2 (dashed lines).
PROGRAMMING
The factory setting for this output is;
•• 6,1 IGNIT I2 A,A
When this output is doubled (see dashed lines in the previous diagram) the possible programming settings are;
• 6,1 IGNIT I2 A,A
• 6,3 CARB UNIV I2 A,C
• 6,4 CARB T.B.I I2 B,A
• 6,7 VATS I2 C,A
• 6,8 VATS 6s I2 C,B
• 6,9 VATS 1.5m I2 C,C
• 6,10 VATS 3.m I2 A
• 6,11 VATS 5m I2 B
CLUTCH PEDAL
SWITCH
STARTER
RELAY
IGNITION KEY
DARK BLUE
+12vdc
STARTER
87
86 87A 85
30
87
86 87A 85
30
BLACK
BROWN
2 ND relay for special applications.
Eg: alarm overriding,
carburetor solenoid, etc....
+12vdc
+12vdc