John Gold GoldCruise GC55 User manual

Cruisecontrol GC55
Installation manual

Cruisecontrol GC55 Installation manual
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Cruisecontrol GC55 Installation manual
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Foreword
This installation manual was written for installers with knowledge of modern vehicle
technology and experience in working on these vehicles.
The GC55 GoldCruise is a modular product of John Gold International BV, that has been
designed and produced with great care and precision.
Read the installation and user manuals of all applied modules carefully. Always leave the
user manual (supplied separately with the command module) in the vehicle for the end
user after completing the installation.
In the text boxes the following safety instructions are printed:
i
Tip:
This symbol is used to make suggestions or advises in order to make certain
tasks easier to perform.
Note:
This symbol is used for an installation advise. Failing to comply with this
advice may cause damage to the vehicle or product.
Warning:
This symbol is used in a potentially dangerous situation. In a dangerous
situation there is potential for unsafe traffic situations, heavy or light
injuries or damage to product, vehicle or environment.

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Contents
Foreword..............................................................................................................................2
Contents...............................................................................................................................3
1Purpose, construction and operation of the GC55 ......................................................4
1.1 Purpose of the GC55...............................................................................................4
1.2 Construction ...........................................................................................................4
1.3 Operation................................................................................................................4
2Safety directions ...........................................................................................................5
3Installation and connections ........................................................................................7
3.1 Installation electronic module (EM) .......................................................................7
3.2 Wiring Diagram.......................................................................................................8
3.3 Wiring harness connections ...................................................................................9
3.4 Electric servo.........................................................................................................11
3.4.1 Assembly electric servo .................................................................................11
3.4.2 Mounting electric servo .................................................................................12
3.5 Servo cable linkage ...............................................................................................12
3.5.1 Adjusting servo cable travel...........................................................................14
4Set-up..........................................................................................................................15
4.1 Introduction set-up...............................................................................................15
4.2 Vehicle speed signal set-up GC55.........................................................................16
4.3 Test drive ..............................................................................................................17
4.4 Increase response time.........................................................................................18
4.5 Reduce response time ..........................................................................................19
4.6 Increase sensitivity ...............................................................................................20
4.7 Reduce sensitivity .................................................................................................21
5Diagnostics and trouble shoot....................................................................................22
5.1 Diagnostics 1: CM and clutch switch connection .................................................22
5.2 Diagnostics 2: Servo, vehicle speed signal............................................................23
5.3 Trouble shoot 1.....................................................................................................24
5.4 Trouble shoot 2.....................................................................................................24
5.5 Trouble shoot 3.....................................................................................................24
5.6 Trouble shoot 4.....................................................................................................25
5.7 Trouble shoot 5.....................................................................................................25
6Frequently Asked Questions (FAQ) ............................................................................26

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1Purpose, construction and operation of the GC55
1.1 Purpose of the GC55
The purpose of the GC55 is to automate your speed management.
1.2 Construction
The GC55 is part of a Cruisecontrol-kit that consists of the following universal and
specific components:
universal components:
electronic module (EM);
electric servo
command module (CM) (order separately);
universal wiring harness;
general installation manual;
user manual CM (included with CM);
installation manual CM (included with CM);
clutch switch (optional)
specific components:
servo cable
pulley
installation materials
Depending on the modular supplies or the vehicle, more or less components are
applicable. Contact your supplier for more information.
1.3 Operation
The GC55 GoldCruise consists of an electric servo and a compact EM. The EM receives
and handles the signals from the command module and the speed signal. With these
signals the EM controls the servo. The servo pulls the throttle by means of a (steel) cable
that controls the throttle valve position to maintain the set speed.

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2Safety directions
To ensure safety the GC55 complies with the following labels.
For the GC55 the following safety instructions apply, also printed in the item it concerns:
Only use the GC55 for the purpose as described in this installation manual.
The installer of the GC55 should have technical knowledge of modern cars
and be experienced in working on them.
Incorrect and/or ignorant installation, connection, adjustments and/or
diagnostics can lead to vehicle and/or GC55 malfunctions
and indirectly affect road safety.
Never alter or manipulate a GC55. Alterations or technical manipulations
made to the GoldCruise products can affect its safety adversely.
Inform the customer whenever no clutch protection is installed.
Point out that the GC55 will not disengage when depressing the clutch
pedal. John Gold advises always to install a clutch protection (if applicable).
Connect the twin cable with brown and brown/white wires in such a way
that, with the brake pedal released, one wire has +12V from the brake light
fuse and the other has ground through the brake lights.
Always check for a smooth operation of the throttle valve, throttle cable
and servo cable by operating the throttle by hand and by foot.
Make sure that they cannot jam in any way..
The servo cable has to point straight from the adjuster and pull in a straight
line.
Some cars hardly decelerate when the throttle valve remains slightly open.
Always allow for some free play in throttle released position.
Always solder the connections and insulate them with vulcanizing tape.

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Always install the EM in a position where heat, vibration and moisture are
minimized, such as underneath the dashboard.
Undo the negative battery terminal before working on the vehicle.
Loss of volatile data is possible (audio, board computer, clock, etcetera).
Always use a multimeter when measuring on the vehicle.
Cut wires to size, keep them as short as possible.
Use a fuse of up to 10 Amps.
The servo can be installed in both engine bay to the body, and underneath
the dashboard. Never mount the servo to the engine.
Mount the servo at least 30cm from sources of electrical interference and
heat sources.
The bends in the servo cable have to be at least 40 cm in diameter.
In case a stationary switch or kick-down switch is present on the accelerator
pedal, the cable linkage should be connected directly to the accelerator
pedal.
Possible travel for the cable linkage (see pictures § 3.5.1) depending on the
chosen pulley: red pulley = 31-38mm –yellow pulley = 18-24mm.
Adjust the servo cable with a warm engine, because of a possible cold-start
device.

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3Installation and connections
3.1 Installation electronic module (EM)
Always install the EM in a position where heat, vibration and moisture are minimized,
such as underneath the dashboard, never in the engine compartment.
The installation kit contains tie-wraps, double-sided tape and screws that can be used to
install the EM.
Always install the EM in a position where heat, vibration and moisture are
minimized, such as underneath the dashboard.

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3.2 Wiring Diagram

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3.3 Wiring harness connections
Undo the negative battery terminal before working on the vehicle.
Loss of volatile data is possible (audio, board computer, clock, etcetera).
Always use a multimeter when measuring on the vehicle.
Cut wires to size, keep them as short as possible.
Connect the universal wiring harness as follows:
orange
wire
connect to an ignition switched feed (+15), preferably directly after the
ignition switch;
Insert the fuse in the fuse holder of the orange wire
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For many European car-makes it is possible to connect the orange wire to
the feed wire of the brake lights (along with the brown/white wire).
This is only possible in case the brake lights only operate when the
ignition is switched ON.
green wire
connect to a solid ground;
brown wire
connect to the wire that is connected to ground via the brake
lights, this becomes 12V when the brake pedal is depressed.
In case a relay is used in the brake light system, connect to the wire
that is connected to the brake lights directly;
brown/
white wire
connect to the fused feed wire of the brake lights, before the
brake light switch;
violet wire
connect to the wire of the original clutch switch that switched to or
away from ground when depressing the clutch pedal
or connect to one of the two wires of the optional clutch switch and
connect the other wire of the optional clutch switch to ground;
yellow wire
do not use. Cut off at 10 cm from the connector and insulate, unless
indicated otherwise;

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Connect the twin cable with brown and brown/white wires in such a way
that, with the brake pedal released, one wire has +12V from the brake light
fuse and the other has ground through the brake lights.
2-pin wire
lint
(blue and
black)
option 1: connect the blue wire to the vehicle speed signal wire.
Refer to the wiring diagrams of the vehicle. Do not connect the black wire.
option 2: connect to an (optional) speed pulse generator on the drive shaft
or between the speedometer cable –connect the blue wire to the pulse
signal, connect the black wire to the speed pulse generator ground;
4-pin wire
lint
connect the waterproof connector to the servo, feed the wire lint through
the firewall to the EM, fit the 4 pins to colour (pink, blue, black, green) to
the supplied connector and connect to the EM;
8-pin
connector
connect to the 8-pin connector of the CM, also refer to the installation
manual CM
3-pin
connector
connect to the optional 3-speed memory CM (CM8).
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Re-connect the negative battery terminal and remember to set the lost
volatile data (audio, board computer, clock, etcetera).

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3.4 Electric servo
The servo can be installed in both engine bay to the body, and underneath
the dashboard. Never mount the servo to the engine.
Mount the servo at least 30cm from sources of electrical interference and
heat sources.
Before the servo can be installed, it has to be assembled first.
3.4.1 Assembly electric servo
Step
Action
Picture
1
Remove the red protection cap from the servo cam
2
Mount the appropriate pulley to the servo
The different travels are marked on the
pulleys. The visible text indicates the
applicable travel.
Red pulley = 31-38mm
Yellow pulley = 18-24mm
3
Secure the pulley with the M6 locking nut
4
Remove the servo inner cable
5
Shorten the servo outer cable if necessary by cutting it with sharp pliers on the
servo side of the cable
6
Place the outer cable in the ‘slope’
The colour of the pulley has to match
the colour of the dot on the slope. Also
check the printed travel on the slope,
this has to match the travel printed on
the pulley
7
Guide the servo inner cable through the outer cable and fit the end clamp into
the gap of the pulley
8
Fit the slope with the servo cable to the servo
9
Check that the servo cable runs between the edges of the pulley
10
Slide the cover over the servo and secure it with the 2 screws. Insert the long
screw on the outside edge. Fit the spring washer to the short screw

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3.4.2 Mounting electric servo
The servo can be mounted in both engine bay to the body, and underneath the
dashboard. To be able to mount the servo properly 2 mounting brackets are supplied
with the universal set. In specific sets a selection has been made.
Mount the servo as follows:
Step
Action
Picture
1
Fit the mounting bracket to the servo in the desired position.
2
Secure the bracket by placing both locking washers
between the bracket and the M10-nut, with the
serrated sides facing each other.
3.5 Servo cable linkage
The bends in the servo cable have to be at least 40 cm in diameter.
The minimal distance between the servo cable and moving parts and the
exhaust system is 30cm.
The servo cable has to point straight from the adjuster and pull in a straight
line.
Possible travel for the cable linkage (see pictures § 3.5.1) depending on the
chosen pulley: red pulley = 31-38mm –yellow pulley = 18-24mm.
Adjust the servo cable with a warm engine, because of a possible cold-start
device.
Some cars hardly decelerate when the throttle valve remains slightly open.
Always allow for some free play in throttle released position.
Always check for a smooth operation of the throttle valve, throttle cable
and servo cable by operating the throttle by hand and by foot.
Make sure that they cannot jam in any way.

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The throttle linkage can be made with the following parts:
In case a stationary switch or kick-down switch is present on the accelerator
pedal, the cable linkage has to be connected directly to the accelerator
pedal. (refer to Picture C).
Examples of throttle linkages:
Pic.A
Pic.B
Pic.C
Pic.D

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3.5.1 Adjusting servo cable travel
Possible travel for the cable linkage (see pictures § 3.5.1) depending on the
chosen pulley: red pulley = 31-38mm –yellow pulley = 18-24mm.
The actual travel of the servo, travel X, is
visibly printed on the pulley. Travel A, the
travel of the connection to the throttle,
has to be equal to or 2-3 mm longer than
the travel of the chosen pulley.
In case travel A is longer than travel X
+3mm, adjust the cable linkage as
displayed.
Alternatively apply a pulley with a longer
travel § 3.4.1 (if applicable).
In case travel A is shorter than travel X,
adjust the cable linkage as displayed.
Alternatively apply a pulley with a shorter
travel § 3.4.1 (if applicable).
Always check for a smooth operation of the throttle valve, throttle cable
and servo cable by operating the throttle by hand and by foot.
Make sure that they cannot jam in any way.
First learn the GC55 to the speed signal, before using the cruisecontrol. Refer to chapter
4.0 Set-up.

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4Set-up
4.1 Introduction set-up
These symbols are used for the command module:
i
action
Zeichen
function
up
SET /ACC
down
RES/DEC
push
ON/OFF
pull
CANCEL
First learn the GC55 to the speed signal, before using the Cruisecontrol:
refer to § 4.3 Vehicle speed signal set-up.
Check during the test drive (§ 4.3) the response time and sensitivity of the cruise control.
Only adjust the response time if the Cruisecontrol engages too slowly or too
aggressively:
refer to § 4.4 Increase response time;
refer to § 4.5 Reduce response time.
Only adjust the sensitivity if the Cruisecontrol reacts too forcefully or too slowly while
cruising:
refer to § 4.6 Increase sensitivity;
refer to § 4.7 Reduce sensitivity.

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4.2 Vehicle speed signal set-up GC55
Perform the following to learn the GC55 to the vehicle speed signal.
Step
Action
Confirmation
1
Switch the ignition OFF and ON.
2
Start the engine.
3
Switch the Cruisecontrol ON
4
Press and hold the brake pedal during the next 2 steps.
5
Operate 4 times
4 beeps
6
Operate once
1 beep
7
Release the brake pedal.
1 beep
8
Drive 70 km/h and operate once
Cruisecontrol
engages
9
Press the brake pedal once.
2 beeps,
Cruisecontrol
releases
10
Stop in a safe place.
11
Press and hold the brake pedal and operate 4 times
1 long beep
12
Release the brake pedal.
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Perform diagnostics if the Cruisecontrol does not engage at step 8. Refer to
chapter 5.0 Diagnostics and trouble shoot.

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4.3 Test drive
Step
Action
Confirmation
1
Switch the ignition OFF and ON.
2
Start the engine.
3
Switch the Cruisecontrol ON
CM-LED turns green
4
Drive 90 km/h (55 mph) on the highway and
operate and release the accelerator pedal
CM-LED turns orange
Cruise control engage and
maintains the speed
5
Press the brake pedal (brake lights light up)
CM-LED turns green
Cruise control instantly
releases
6
Drive 90 km/h (55 mph) on the highway and
operate once
CM-LED turns orange
Cruise control engage and
maintains the speed
7
Depress the clutch pedal briefly
CM-LED turns green
Cruise control instantly
releases
8
Drive 75 km/h (45 mph) and operate once
Cruise control engages and
accelerate exactly to last set
cruise speed (90 km/h(55
mph))
9
Operate long while cruising until the speed
reaches about 100 km/h (65 mph)
CM-LED turns orange
Vehicle accelerates
10
Operate long while cruising until the speed
reduces to about 95 km/h (60 mph)
CM-LED turns orange
Vehicle decelerates
11
Operate 5x brief while cruising
CM-LED turns orange
Vehicle accelerates 5 km/h
(3 mph)
12
Operate 5x brief while cruising
CM-LED turns orange
Vehicle decelerates 5 km/h
(3 mph)
Only adjust the response time if the Cruisecontrol engages too slowly or too
aggressively:
refer to § 4.4 Increase response time;
refer to § 4.5 Reduce response time.
Only adjust the sensitivity if the Cruisecontrol reacts too forcefully or too slowly while
cruising:
refer to § 4.6 Increase sensitivity;
refer to § 4.7 Reduce sensitivity.

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4.4 Increase response time
Perform the following steps to increase the response time.
Perform step 1-7 within 1 minute!
Step
Action
Confirmation
1
Switch the ignition OFF and ON.
2
Start the engine.
3
Switch the Cruisecontrol ON
4
Press and hold the brake pedal during the next 2 steps
5
Operate 4 times
4 beeps
6
Operate 3 times
3 beeps
7
Release the brake pedal
3 beeps
8
Drive at least 40 km/h (25 mph) and operate once
Cruisecontrol
engages
9
Operate
1 beep per
step
10
Press the brake pedal once.
2 beeps,
Cruisecontrol
releases
11
Drive at least 40 km/h (25 mph) and operate once
Cruisecontrol
engages
(determine the result. If necessary, repeat from step 8.)
12
Stop in a safe place.
13
Press and hold the brake pedal and operate 4 times
1 long beep
14
Release the brake pedal.

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4.5 Reduce response time
Perform the following steps to reduce the response time.
Perform step 1-7 within 1 minute!
Step
Action
Confirmation
1
Switch the ignition OFF and ON.
2
Start the engine.
3
Switch the Cruisecontrol ON
4
Press and hold the brake pedal during the next 2 steps
5
Operate 4 times
4 beeps
6
Operate 3 times
3 beeps
7
Release the brake pedal
3 beeps
8
Drive at least 40 km/h (25 mph) and operate once
Cruisecontrol
engages
9
Operate
1 beep per
step
10
Press the brake pedal once.
2 beeps,
Cruisecontrol
releases
11
Drive at least 40 km/h (25 mph) and operate once
Cruisecontrol
engages
(determine the result. If necessary, repeat from step 8.)
12
Stop in a safe place.
13
Press and hold the brake pedal and operate 4 times
1 long beep
14
Release the brake pedal.