Audiovox CCS-100 User manual

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CCS-100CCS-100
CCS-100CCS-100
CCS-100
ELECTRELECTR
ELECTRELECTR
ELECTROO
OO
ONIC CRUISE CONIC CRUISE CO
NIC CRUISE CONIC CRUISE CO
NIC CRUISE CONTRNTR
NTRNTR
NTROLOL
OLOL
OL
INSTINST
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N MANUALANUAL
ANUALANUAL
ANUAL

MANUAL PREPARED AND PROVIDED BY LITEON AUTOMOTIVE CORPORATION
INDEX
1. Cruise Control Installation: .....................................................
PartsList ...........................................................................
Throttle Connections.........................................................
Wiring...............................................................................
2. Control Switch Installation......................................................
Troubleshooting ...............................................................
3. Magnet Kit Installation .............................................................
Speed Sensor Installation ................................................
4.Warranty ...................................................................................
Page
1
2
3
4
8
9
12
13
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HOW THE CRUISE WORKS
TheCruiseModulemakes"decisions"baseduponspeed,tachometer,andbrakesignalinformation. Thecontrol
circuitinterpretsdigitalspeedinformationfromthecar'senginecontrolmodule(VSS)orMagnetKitandignition
coil output. Brake information comes from the red and purple wires connected to the vehicle's brake switch.
Disengagementandno-engagementdecisionsarebasedonthemonitoredinformation.
An integral part of the cruise is the 'over rev.' protection circuit. It's function is to monitor engine R.P.M. and
disengage the cruise control when the clutch is applied or the transmission shift lever is moved in to neutral.
WhenasuddenriseinR.P.M.isdetected,thedecisiontodisengageismadefor'overrev'protection,theblue
wiremustbeattachedtothenegativesideoftheignitioncoil. Anoisesuppressor'inseries'withthebluewire
keepsexcessiveelectricalnoisefrom"fooling"thecruiseintodisengaging. Forthisreasonmakesureallcruise
controlwiringisatleast1ft.awayfromallelectromagneticsourcessuchas:ignitionwires,alternator,regulator,
and all high current carrying conductors.
NOTE : If your vehicle is not listed in the enclosed reference manual, the Magnet Kit must be utilized.
Additional available options: CCS-202 Vacuum Reservoir and CCS-204 Ford adaptor.
WARNING : WHEN TESTING WIRES, USE ONLY A LOGIC PROBE OR VOLT / OHM
METER. DO NOT USE A TEST LIGHT, AS THESE CAN CAUSE DAMAGE
TO THE ECM OR MAY ACTIVATE THE AIRBAG!
WARNING : DO NOT ATTEMPT TO ROAD TEST ON JACK STANDS OR A LIFT !
CAUTION : BEFORE DRILLING ANY HOLES, BE SURE THAT NO COMPONENTS
WILL BE DAMAGED AFTER THE DRILL PENETRATES THE SURFACE.
CAUTION: DONOTMOUNTORROUTEWIRINGHARNESSESORKITCOMPONENTS
ON OR NEAR ANY HOT, SHARP, OR MOVING SURFACES WITHIN THE
VEHICLE.
NOTE : IF YOU DO NOT FEEL CONFIDENT THAT YOU CAN SAFELY INSTALL THE
CRUISE CONTROL BY YOURSELF, THEN WE RECOMMEND THAT YOU
HAVE IT INSTALLED BY A QUALIFIED PROFESSIONAL.
Required Tools
It is important that you read and fully understand this entire instruction manual before proceeding with
theinstallation.Paycloseattentiontoallcautionsandwarningscontainedinthismanualforasafeand
trouble free installation.
4. Pliers
5. Side cutter pliers
6. Small wrench or socket set
1. Digital Volt OHM meter or logic probe
2. Drill with the following size bits : 1/4" & 1/2"
3. #2 Phillips screwdriver
-1-

CRUISE
CONTROL
M6 x 5/8" long
hex head bolt
( 3 )
Servo Assembly
( 1 ) Tie Straps
( 10 ) 1/2" rubber bulkhead
grommet
( 1 )
- 1 - - 4 - - 5 -
Convoluted tubing
( 1 ) Vacuum hose reducing
nipple
( 1 )
Assorted Vacuum
T - Connectors Vacuum Hose - Short ( 1 ) Vacuum Hose - Long
( 1 )
- 6 - - 7 - - 8 - - 9 - - 10 -
Main Wiring Harness
( 1 ) Fused wire with switch connector
( 1 )
Scotch lock connectors
( 4 ) Female T- tap terminal ( 1 ) “L” Bracket
( 1 )
- 11 - - 12 - - 13 - - 14 - - 15 -
Adjustable cable
mounting bracket assy.
( 1 )
Assorted tube clamps
(4) Parallel throttle cable clamps
( 1 )
GM style threaded
snap in cable anchor
( 1 )
Bead chain
( 1 )
- 16 - - 17 - - 18 - - 19 - - 20 -
Cotter pin
( 1 ) Ford snap on throttle adaptor
( 1 )
Bead chain coupling
sleeves
( 2 )
Bead chain coupling
( 2 ) Bead chain eyelet
connector
( 1 )
- 21 - - 22 - - 23 - - 24 - - 25 -
3 bead connector
( 1 )
GM throttle clip
( 1 ) Throttle mounting
bracket with locking
washer
( 1 )
Throttle wire loop
( 1 ) Barrel wire adaptor
( 1 )
- 26 - - 27 - - 28 - - 29 - - 30 -
M6 hex nuts
( 3 ) M6 x 3/4" long hex washer head sheet
metal screw
( 4 )
Slotted head shoulder
bolt with lock washer
and hex nut
( 1 )
M5 Phillips hex head
bolt with hex nut
( 1 )
- 35 -- 34 -- 33 -- 32 -- 31 -
Dash Mounted control switch
( 1 )
PARTS LIST
- 2 -
M6 external tooth
star washer
( 3 )
SET
RES
AUDIOVOX CST
ACC
OFF
- 3 -
ON
-2-

#1 - BROWN - IGNITION POWER
#2 - GREY - SPEED
#3 - RED - BRAKE
#4 - PURPLE - BRAKE
#5 - (NOT USED)
1 2 3 4 5 6 7
ON
OFF
JUMPER
LED
MANUAL / AUTOMATIC TRANSMISSION SELECT
WHEN INSTALLING THIS KIT INTO VEHICLES THAT HAVE A MANUAL TRANSMISSION, YOU MUST
REMOVE THE BLACK JUMPER CONNECTOR LOCATED TO THE LEFT SIDE OF DIP SWITCH #1.
NOTE: Ifthe vehicleisa manualtransmissionand does nothave a VSSwire, the cruisewill operate fromtach
signal only. Program dip switch #1 and #2 for 4000 PPM and move dip switch #3 to OFF position.
#10 - BLUE - TACH.
#9 - BLACK - GROUND
#8 - GREEN - SET
#7 - (NOT USED)
#6 - YELLOW - RESUME
* When changing dip switch setting, make sure the 10-pin connector is unplugged from module.
PROGRAMMING THE SERVO ASSEMBLY
To ensure that the cruise control operates smoothly and safely in your vehicle, the servo assembly must be
programmed.Inorder toproperly programtheservoassembly,you willneed toknowthenumberof cylinders,
thetypeoftransmission(manualorautomatic),ifyourvehicleisequippedwithaVehicleSpeedSensor(VSS),
and if so, the number of Pulses Per Mile ( PPM ), also if the cruise control switch is the open or closed circuit
style. The dash mount control switch supplied is the open circuit style switch. SW6 should be set to OFF.
Refer to the enclosed reference manual for information of VSS and PPM that applies to your vehicle. If there
is no VSS signal in your particular vehicle then the Magnet Kit must be used. Mount one magnet to the drive
shaft if the vehicle is rear wheel drive and set PPM to 2000. Mount 2 magnets to the drive shaft at 180° apart
ifthe vehicle is front wheeldriveand set PPM to 2000. Note: Whenusingmagnets set Dip Switch#3to "ON".
The sensitivity settings, control the amount of vacuum needed to keep the set speed constant. Remove the
( 2 ) screws securing the plastic cover on the back of the servo assembly to gain access to the dip switches.
DIPSWITCH PROGRAMMING TABLE:Followthechart belowtoprogramtheservo assembly.
SW1 SW2 SW3 SW4 SW5 SW6 SW7
PPM 2,000 OFF OFF
4,000 ON OFF
5,000 OFF ON
8,000 ON ON
SPEED SIGNAL
TACH ONLY OFF
VSS or MAGNETS ON
SENSITIVITY
LOW (LIGHT VEHICLES W/HIGH HORSE POWER) ON OFF
MEDIUM (MOST VEHICLES) OFF OFF
HIGH (LOW POWER VEHICLES/HEAVY VEHICLES) OFF ON
CONTROL SWITCH
NORM. CLOSED ON
NORM. OPEN OFF
TACH SOURCE SELECT
ECM OFF
COIL ON
-3-

Double fold to shorten
Crimpwithpliers
Bend to clear Throttle Cable
Throttle Arm
Throttle Cable Bead Chain
(#20)
3BeadConnector
(#27)
UNDER HOOD INSTALLATION
Connecting the Cruise Control Cable to the Throttle
NOTE: Prior to attaching servo cable to throttle, locate an accessible area to mount the cruise control servo,
butdonotmountit.Leavetheservointhisarea(unmounted)androutecabletothrottleattachmentarea.
CAUTION: Attach the cruise control cable so that it parallels the existing throttle cable as nearly as possible.
Chooseamountingmethodfromthe figures below:
Attachment area for
securing cable
Bead Chain
Coupling Sleeve (#23)
Bead Chain Coupling (#24)
3 BEAD CONNECTOR
FIG. 6 FIG. 7 FORD LINKAGE ADAPTOR
Rubber Ring
WIRE LOOP FOR PULLEY
Carburetor
Existing Snap-On Throttle Arm On Vehicle
FIG. 2 SNAP-ON THROTTLE ARM MOUNT FIG. 3 CLAMP-ON THROTTLE ARM MOUNT
Determine a suitable point on the throttle linkage to mount the cable connector. The mounting point chosen should have between
1-1/2" to 2" total linkage travel. It must operate smoothly by hand. There should be at least 5 beads between the throttle connector and
servo cable end. The cable must pull in a straight line from throttle linkage. Some vehicles that do not have enough total linkage travel
have to be connected at the accelerator pedal.
The bead chain and servo cable end must be
insertedintothebeadchainconnector.Thenthe
bead chain coupling sleeve must slide over
bead chain connector to insure that the end will
not hang in the connector.
FIG. 1
Cable
Bead Chain Eyelet
Connector (#25)
Pull off Throttle Arm and Insert Bead Chain Connector between it
andCarburetor Arm. Be sure additionalthicknessof adaptor does
not bind linkage.
20°
Bead Chain Eyelet
Connector (#25)
CableMust Bewithin20°of
sameangleasThrottleRod
Throttle Cable
Throttle Wire Loop
(#29)
Barrel Wire Adaptor
(#30)
WIRE BARREL FOR PULLEY
FIG. 5FIG. 4
Snap-on Throttle Adaptor (#22)
Cotter Pin (#21) locks Bead
Chain to Linkage Adaptor
Throttle Clip
(#26)
-4-

FIG. 8 FIG. 9
FIG. 10
Snap-inCableAnchor(#19)
ModuleCableMUSTextendpast Adaptor
Three Bead Connector
(#27)
Throttle Clip (#26)
Bead Chain (#20)
Hex Nut & Lockwasher
Bead Chain
Eyelet Connector
(#25)
Tube Clamp
Cable Anchor Point
PEDAL PULL
Carburetor
Existing
Sheet Metal
Bracket
ALTERNATE
FLEX CABLE MOUNTING TECHNIQUE
ALTERNATE
FLEX CABLE MOUNTING TECHNIQUE
FLEX CABLE CONDUIT MOUNTING
Select a location
which provides
1-3/4" travel
tomatchactuator.
Mounting Bracket used to
lock down carburetor end
of flexible cable (bend as
required).
4"R Min.
Bead Chain
Coupling Sleeve
(#23)
Connector
Bead Chain
FIG. 12
Tube Clamp
(#17)
Parallel Throttle Cable Clamps
(#18) used to lock cable end to
existing throttle housing
Slotted Head Shoulder Bolt
(#34)
Tube Clamp
(#17)
FIG. 11 THREADED SNAP-IN ADAPTOR
-5-

CAUTION!ATTACHTHECRUISECONTROLCABLESOTHATITPARALLELSTHEEXISTINGTHROTTLECABLEAS
NEARLYASPOSSIBLE.
WARNING!AFTERATTACHINGTHECRUISECONTROLCABLETOTHEVEHICLE’STHROTTLE, OPERATE THE
THROTTLEMANUALLY(FULLTRAVEL)FROMBOTHUNDERHOODANDACCELERATORPEDALTOBE
ABSOLUTELYSURETHATNONEOFTHECABLEATTACHMENTCOMPONENTSORBEADCHAINCAN
RESTRICTORINTERFEREWITHTHENORMALTHROTTLEOPERATION.
Mounting the Servo Assembly
1. Plugthe10pinconnectorfromthemainharnessintothematingconnectorontheservoassembly,arrange
the wires so that they do not cross over one another, and replace the plastic cover with the ( 2 ) screws
previously removed.
2. A) When selecting the location for the servo, make sure that the cable routing follows a smooth path, with
no sharp bends. You must also be sure that the cable is routed away from any hot, sharp, or moving
components within the engine compartment.
B) This unit has rapid response valves inside the servo which constantly operate during cruise operation.
TopreventnoisetransferringtoinsidethepassengercompartmentwestronglyrecommendthisunitNOT
be mounted to the fire wall.
3.Using(2)oftheM6x3/4"longhexwasherheadsheetmetalscrews,mounttheservototheselectedlocation.
Do Not mount servo on the engine !
4. Attach the eyelet terminal on the end of the Black wire to a solid chassis ground bolt within the engine
compartment.
Connecting the Vacuum Hose
1. Plug the vacuum hose onto the servo assembly.
2. Route the vacuum hose to an existing vacuum hose that has constant vacuum while the engine is running
at idle, trim the hose to length, and make the attachment using the appropriate size T connector from the
kit.
SeeDiagrams belowforcommonvacuumsourceconnection.
TubeVacuum
Tee-Tube
Vacuum Line
TubeVacuum
Reducer-Tube
Existing Vacuum Line
Factory Installed Tee
Remove cap and use
VacuumTeeforCruise
Controlvacuum
Manifold Vacuum Tree
Remove cap and
use vacuum port
forCruiseControl
vacuum
WARNING ! NEVER CUT OR ATTACH TO THE POWER BRAKE BOOSTER VACUUM HOSE.
VacuumTest
Look for the vacuum hose coming directly from the intake manifold.
Runtheengineatidle,andplaceyourfingerovertheselectedvacuumsource.Youshouldfeelastrongsuction
on your finger. Remove your finger and a noticeable change in engine RPM or engine smoothness should
result. Note: This vacuum source must maintain at least a minimum of 6 inches of mercury vacuum. If the
vacuum is lower than 6 inches while the pedal is depressed, then a vacuum canister must be used.
-6-

Routingthe Main WiringHarness
1.Locateyourvehiclebymake,model,andenginesizeintheincludedReferenceManualinordertoidentifythe
locationoftheVSSandTachconnectionlocations.Ifyourmakeandmodelcannotbelocated,thentheMagnet
Kit must be installed. Follow the installation instructions included in this manual.
In all cases, you will need to route the Brown, Green , Purple, Yellow, and Red wires through the bulkhead
to the passenger compartment of the vehicle.
TheBluewirewillneedtoberoutedtothetachlocation,andtheGrey&Blacktwinleadwillneedtoberouted
tothe VSSor magnetspeedsensor location.If eitherofthese locationsare in thepassenger compartment,
theywill needto berouted withtheBrown, Green, Purple,Yellow, andRed wires.
2. Route the wires that will pass through the bulkhead away from any hot or moving components within the
engine compartment, and be sure that they are routed to a point lower than the grommet that will be used
forentranceintothepassengercompartment.Thiswillpreventwater fromrunning alongthewiresandinto
the passenger compartment.
NOTE : FOR EASE OF INSTALLATION, YOU SHOULD USE AN EXISTING RUBBER GROMMET WHEN
PASSINGWIRESTHROUGHTHEBULKHEAD.IFANEXISTINGGROMMETISNOTAVAILABLE,
CAREFULLYDRILLA1/2"WIREENTRANCEHOLEINTHEBULKHEAD,ANDUSETHERUBBER
GROMMETSUPPLIED INTHEKIT.
WIRING CONNECTIONS
1. Blue Wire : Connect this wire to the vehicle’s negative side of the ignition coil using the blue Female T tap
terminal provided.
2.GreyandBlackPairWires:1)IfthevehiclehasVSSwirethenremovespadeterminalandconnectthegrey
wire to the vehicles VSS wire using the red scotch lock connector provided. The black wire is not used.
2) If the vehicle has no VSS wire then connect both the black spade terminal and the grey spade terminal
to the magnet speed sensor.
3.PurpleWire:Connectthiswiretothevehicle’sbrakelightwireatthebrakelightswitch.(Thisisthewirethat
turnsthebrakelightsonwhenthebrakepedalispressed).Thiswirewillshow+12voltswhenthebrakepedal
is pressed and 0 volts when released. See diagram below.
4. Red Wire : Connect this wire to the constant + 12 VDC battery source to the brake light switch. ( This is the
wire that remains at 12 volts whether the brake pedal is pressed or not ). See diagram below.
12V only when brake is depressed
PURPLE
4) Bend cover over
and snap shut
3) Squeeze tab into
connector with pliers
1) Press existing vehicle wire
into connector slot
2) Insert cruise control harness wire
to Stop - Must go past metal tab
Constant 12V
RED
-7-

1. Chooseaflatlocationonthedashboardthatisvisiblewhiledriving. Thelocationshouldbeveryaccessible
tothe driver, allowing easy activation of the switchwhileoperating the cruise control. A template has been
provided to confirm that there is adequate space for mounting the switch in the selected location. (Fig.1)
2. Afterthelocation isselected, checktheareabehindthe panelto besurethatthewires canbe routedto the
cruisecontrolharnessconnector. Youshouldalsomakesurethatthedrillwillnotdamageanycomponents
or wiring behind the panel, and it is always best to remove the panel before drilling.
3. Drill (2) 1/4" diameter holes in the location marked on the template. After drilling, use a file or razor knife
to remove the dash material between the (2) holes.
4. Clean the area of the dashboard where the switch will be mounted, and allow any cleaning fluids to dry
completely.
5. Passthewiresfromtheswitchthroughtheholeinthepanel,removethepaperliningfromthemountingpad
on the back of the switch, properly align the switch, and firmly press in place on the panel. (Fig.2)
6. Routethe6wiresfromtheswitchtothecontrolswitchconnectorfromthecruisecontrolmainwiringharness.
Be sure to avoid any sharp or moving surfaces when routing wires, and secure the wires along their path
using tie straps.
7. Plug the terminated ends of the Red, Brown, Green and Yellow wires into the color coded locations on the
connector. Be sure that the terminals click, and are fully seated in the connector. (Fig.3)
8. Plug the switch connector into the mating connector on the main cruise control harness.
9. Connect the Black wire from the switch to a known chassis ground source.
10. Connect the Grey wire from the switch to the parking light wire in the vehicle. When probed, the parking
light wire will read +12 VDC when the parking lights are on, and 0 VDC when the parking lights are off.
TheGreywirecontrolsthebacklightingof theswitch,and theswitchwill notilluminateiftheGreywireisleft
disconnected. You must connect all other wires from the switch, or the cruise control will not operate.
DASH MOUNTED (norDASH MOUNTED (nor
DASH MOUNTED (norDASH MOUNTED (nor
DASH MOUNTED (normally open)mally open)
mally open)mally open)
mally open)
CRUISE COCRUISE CO
CRUISE COCRUISE CO
CRUISE CONTRNTR
NTRNTR
NTROL SWITCHOL SWITCH
OL SWITCHOL SWITCH
OL SWITCH
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5.Locatethefusedwirewithswitchconnectorincludedinthekit,andloadtheBrown,Green,andYellowwires
fromthemainharnessintothe4pinswitchconnector.Besuretoloadthewiresaccordingtothecolorcoded
label on the connector, and press the terminals in fully until a click is heard.
6.OrangeWire:ConnecttheOrangewirefromthefuseholdertoawireinthevehiclethatshows+12VDCwhen
theignitionkeyisswitchedOnand0VDCwhilecrankingandwhenthekeyisswitchedOFF.Useabluescotch
lock connector to make this connection.