ASD Automatic Sliding Door

Transcription

1 P.O.Box 4609 Petach-Tikva ISRAEL info@autocool.co.il VW ASD PN: DL Kombi standard (wheelbase-3.665) Kombi long and super long (wheelbase-4.325) Original Door latch mechanism & operation with handles Recommendation Please print this instruction manual in color

2 Gear-motor ASSY Pneumatic Safety Strip Signal Light Operating Switch VSS Plug K White 8 pins VSS Detector Buzzer Control Unit Remote Control Receiver Wiring Harness Pneumatic Safety Switch Door Limit Switch Main Fuse Lock Actuator ASSY Page. ASD System - Overview

3 Cut according to Template Drill 7 (x2) Supplied Template Cut according to dimensions Page 2. Cutting and Preparation

4 Drill 4.5 according to detail (25) 4.5mm AA-A Original bolt 2 3 Socket flat head screw M4X20 - Lock nut M4 - Page 3. Chain Slide Strip Installation

5 5 Thick washer 6 (H=3mm) 4 Original nuts (x3) Thick Washer 6-3 Hex head screw M6X6-7 Washer 6-8 Flange nut M6 - Page 4. Gear-Motor Bracket Installation

6 6 A 9 8 View-A 6 Hex head screw M6X6-6 8 Flange nut M6-6 6 Page 5. Gear-motor Installation

7 QTY Hex head screw M6X6-3 Washer 6-2 Flange nut M6-2 Hex head screw M6X30 - Nut M6 - Lock nut M6-3 Page 6. Front Idler Installation

8 Kombi standard (wheelbase-3.665) PN: Cut away opening for rear idler 5 Drill 7mm 6 Discard original cover FRONT This end slips in behind track & body in side of the vehicle This end mounts on outside of body panel Rear idler cover Combi standard PN: Socket button head screw M6X6 - Template FRONT Washer Lock nut M6-2 2 Hex head screw M6X30-4 Nut M These notches line up with the end of the track Nut s Plastic Cover - 24 Philips screw 5/8" - Page 7. Rear Idler Installation.

9 Kombi standard (wheelbase-3.665) PN: Drill 5 according to Template OPTION 2 2 Note Number of chain links is 96 ( for vehicles: Kombi standard wheelbase and Delivery van) Chain holder PN: Socket button head screw M5X6-22 Lock nut M5 - Page 8. Roller Chain Installation

10 STEP Drill 7mm Kombi long and super long (wheelbase-4.325) Discard original cover Cut away opening for rear idler 5 5mm These notches line up with the end of the track Template FRONT STEP 2 Cut away opening for rear idler installation Page 9. Rear Idler Installation.

11 Kombi long and super long (wheelbase-4.325) STEP 3 Remove this section and stud from tracking see pg 9 Remove 20mm Cut away opening for roller chain Cut away opening for rear idler 23 Having marked out template draw around this piece of plastic in situation.to ensure that there is enough room for fitting 24 Page 0. Rear Idler Installation.

12 Kombi long and super long (wheelbase-4.325) STEP 4 Side window Rear idler location Loosen tracking bolts to remove end cap Discard original cover Drill 7mm This end slips in behind track & body in side of the vehicle Cut away opening for roller chain 5mm 5 26 FRONT This end mounts on outside of body panel Socket button head screw M6X6-7 Washer Lock nut M6-2 2 Hex head screw M6X30-4 Nut M6-26 Nut s Plastic Cover - Page. Rear Idler Installation

13 Only Kombi long and super long (wheelbase-4.325) Original bolt Drill 8mm Drill 7mm 35mm Original holes Reinstall the door stoppers in new location Original bolt Flange nut M8-2 Flange nut M6-4 Hex head screw M6X25-4 Washer 6-4 Page 2. Door Stopper Installation

14 Kombi long and super long (wheelbase-4.325) Do not separate the cart from the door Drill the hole on the spot OPTION 2 OPTION Drill 5 Template Chain Support PN: Note Number of chain links is 89 For vehicle: Kombi wheelbase (4325mm) long and super long mm cut Link 89 (96 standard) 2 Socket button head screw M6X Lock nut M6-2 Page 3. Roller Chain Installation

15 Do not separate the cart from the door Drill the hole on the spot 8mm mm 8mm 5.5mm Page 4. Roller Chain Installation

16 Insert the emergency handle 45. Move the handle to left for manual operating 46 Chain Sealing Rubber Page 5. Roller Chain Installation

17 Drill 2 30 Door Limit Switch PN: mm 3mm Pneumatic Switch Set PN: Page 6. Door Limit Switch Installation

18 SUPER GLUE SUPER GLUE Close 60 sec 5 Safety Switch Clean surface carefully with alcohol to insure good contact of the pneumatic safety strip. 3 Pneumatic Safety Strip PN: SUPER GLUE Rubber tube 34 Drill hole for rubber tube Page 7. Pneumatic Safety Strip & Pneumatic Switch Installation

19 2 5 PowerDoorAndStep.com PLUG K White 8 pins pin N9 blue/red White Solder and isolate: Green 3 4 Black ( - Body) (ACC + ) Light (+) Drill 6 Solder 37 DOOR Discard Cut Original cover 35 Page 8. Electrical Connections

20 PLUG K White 8 pins pin N9 blue/red Page 9. VSS Connection

21 AUTO PowerDoorAndStep.com 37 COOL 38 Page 20. Gear-Motor Cover Installation

22 Parts list of ASD system No Designation Part No Quantity Chain Slide strip Flat Head Screw M4X Lock Nut M Gear-Motor Support Thick Washer Bolt M6X Washer Hex flange nut M Gear-Motor ASSY Front Idler Front Idler Support C Bolt M6X Idler Wheel Nut M Lock Nut M Rear Idler Socket button bolt M6x Chain Holder D or Roller Chain Connecting link Socket button bolt M5X Lock Nut M Cover Philips Screw 8X5/ Bolt M6X Nut Plastic Cover Rear Idler Cover Hex flange nut M Limit Door Switch Self Drill Screw 8-/ Pneumatic Safety Switch ( ) Rubber Grommet # Pneumatic Safety Strip m Rubber Tube Operating Switch Signal Light Gear-Motor Cover Flat Head Screw M6X Emergency Handle Page 2. Parts List

23 Internal door handle cables External door handle cable Lower release cable Cancel the lower latch Page 22. Cable Diagram

24 Figure. Remove original step Figure 2. Figure 3. Figure 4. Figure 5. Make marks position lower roller ASSY screws before disassembling Figure 6. Page 23. Lock Actuator ASSY installation.

25 Figure. Disconnect the cable and move him to a new location Figure 2. Figure 3. Cable strap 50mm Figure 4. Cancel the lower latch Page 24. Lock Actuator ASSY installation.

26 6 ASD MB Sprinter Original Door latches mechanism & operation with handles ITEM NO. PART NUMBER DESCRIPTION QTY MB Sprinter locker bracket ASSY Phillips screw 6x3/8" Cable strap 00mm Cable strap 50mm Plastic clamp UC-2 3/8" Hex flange nut M6 DIN Hex cap screw M6x MB Sprinter lockers ASSY ITEM NO. PART NUMBER DESCRIPTION QTY Actuator bracket Lock actuator ASSY Cables adapter V363: V408 Lock Actuator arm 5 Philips cross Screw Actuator ASSY Philips cross screw 4-5/8" Hex bolt M4x6, DIN Lock nut M4 DIN985 Page 25. Lock Actuator ASSY installation.

27 Pull off door latch mechanism Disconnect inner door handle cable Figure. Figure 2. Template Connect inner door handle cable to the new position Figure 3. Figure 4. Drill 6.5 mm two holes Figure 5. Figure 6. Figure 7. Page 26. Lock Actuator ASSY installation.

28 ITEM NO. PART NUMBER DESCRIPTION QTY Bracket 2 A-K-0 Control module CONNECTOR Latch RelayDS2V -60A 250VAC 8 24-R2A4 Page 27. Wiring

29 Front B-Pillar Sliding Door Door Limit Switch White Green Blue Cut off Discard Black Lockers ASSY C-Pillar Safety Pressure Switch White Black Green Brown O.E.Blue/Red O.E. Blue CUT OFF Pink/White Pink/Black Red Black Blue Cut off Blue Blue/Red Blue Green Gray Black 5 Operating Switch Green Signal Lamp Blue AAC+ Red White Fuse 30A Connect to VSS pulse 2 V DC - Solder and isolate: Page 28. Wiring

30 Pressure switch Sliding door locker Blue Black Plug Green Blue Black White Internal micro switch Operating switch Buzzer OE red/blue wire- plug sliding door OE blue wire- plug sliding door Black Red Timer.5 s. 2 V Black 85 Green Green Brown Brown 87 White Green Plug Plug Gray(Orange) White Green Green Green Door limit switch Blue Black Signal Lamp +ACC Blue Gray(Orange) AK-05L White/Blue Buzzer MOTOR 2V DC Yellow VSS Con Black Black Black White D Black Green Green Red Red Black Pulse Detector VSS Page 3 pin Connect to VSS Battery 2V 30 latch Relay 2 V 5A Red D Relay 2V a Blue Green Black Red 6 Remote Control (receiver) Red.5 mm Red.5 mm Red 30A Page 29. Wiring

31 Central Roller fix 2 C-PILLAR Upper lock Main lock SLIDING DOOR max B-PILLAR B B Sliding Side Door Guides CHECK 3 Adjustment. Adjust the sliding door. a. Loosen the 4 screws. see Picture. b. Move the door max c-pillar direction, relatively to the central roller. A Central Roller 2. Check Main lock and Upper lock Picture. Upper lock Main lock = = Page.30

32 3. Adjust the sliding door guides (parts on the sliding door). See pictures. B B B Page. 3

33 P.O.Box 4609 Petach-Tikva ISRAEL info@autocool.co.il ASD Emergency door opening kit PN: Page 32

34 Front m i n m m max 500mm Page 33

35 Gear-motor ASSY. Nut 6 ST Nut 6 ST Emergency door KIT Internal emergency handle Spring Bracket A Emergency door handle Socket head M5X6 Emergency handle cover Page 34

36 Sikaflex-22 Figure cut Install the external handle for emergency door Figure2 Nut M6 Nut M6 To install the cable: Insert the cable into the hole (see figure 2) fasten nuts M6 Page 35

37 Insert the emergency handle. Move the handle to right for automatic operating Install of the connection cable 0mm Nylock Nut M5 Clamping lug Washer 4 Spring Washer 4 Bolt M4X8 Page 36.

38 Em e r g e n c y handle bracket E m e r g e n c y h a n d l e AUTO PowerDoorAndStep.com 39 E M E R G E N C Y EMERCENCY FRONT COOL EMERCENCY Insert the emergency handle. Move the handle to left for manual operating EMERGENCY OPENING Page 37.

39 Pressure Safety Switch Sensitivity adjustment Allen N4 Increase Sens Decrease Sens Page 38

40 RECOMMENDED TORQUE FIGURES (In newton metres ) M5 M6 8.8 TORQUE TORQUE Nm mm Nm 6.3 M M6 0 M M8 3 Page. 39

41 user s Manual The system (ASD) manufactured by Auto Cool Ltd conforms with the requirements of the European regulations. The ASD is approved by the German TUV in Munich, it complies with the EEC DIRECTIVE 72/245EC and obtained the certificate of compliance No 2004/04/EC. Operation Instructions The door is operated by a switch located on the dashboard: To open press the switch shortly, door opens to the end of its range. To close - press the switch shortly, door closes and locks. To change its direction while in motion - press the switch shortly, the door will change direction. To control the opening range continuous pressure on the control switch will set the door in motion upon its release, the door will stop. Visual status indications when the vehicle s main ignition switch is on, the indication control light is visible. Dim light the door is closed. Bright light the door is open. Audio status indicators independently of the vehicle s main switch the vehicle s buzzer is always functioning whenever the door is in closing motion. Safety measures The system includes safety features to protect the passengers. Closing when encountering an obstruction, the controller automatically reverses the door direction to open all the way. In addition, a pneumatic switch is attached to the front side of door pillar, which upon sensing pressure performs the same function and retracts immediately. Opening - when encountering an obstruction, th e controller stops the door. ASD system is connected to the OE VSS device. The door operates only at speed of less than 5 km/h. Emergency facility The system has inside and outside (optional) emergency releasing handle. Operating one of them will result in disconnecting the ASD mechanism device and the door will function manually immediately. Please note: The system performs automatic reset after the ASD has been disconnected from the power either when replacing the fuse or by disconnecting the Battery. The system resets itself within two minutes. Please be patient. Page 40

42 ASD: Basic Troubleshooting. Door does not function. Check main fuse. Check connections of power terminals to the control unit, motor and operating switch. Check Control units AK-05L Check motor. 2. Door does not operate upon commencing the closing mode or when reaching the fully closed positions it reverses. Check the safety pneumatic pressure tube; disconnect the plugs of pressure switch and close the door. If the issue is not solved, try to regulate the sensitivity of the pressure switch. Check safety switch. Reset the system by extracting the fuse and returning it to its place. Check control unit AK Door does not close completely. Check voltage of battery, if low, start the engine. 4. Door does not open, although the electrical motor is engaged. Check position of the locker unit, which annuls the OEM locking system of the door. 5. Door does not automatically reverse when encountering an obstruction during the closing mode. Check safety pneumatic switch. Check pressure tube & switch. Check control unit. 6. Noise from the door's chain during opening and or closing modes. Check installation and alignment of all wheel supports, front and rear, as well as the gear motor support. Very loose chain may also jump over and cause damage to the sprocket s main motor. Check chain tension and if needed shorten it by removing one or two links. 7. Remote control unit does not function. Check connection of power terminals. Check battery of the key unit transmitter. It issue still persist replace remote control receiver with two transmitters 8. If equipped with VSS, the door operates although the vehicle is in motion over 5Km/h. Check connections to the VSS unit. Check VSS unit. 9. Buzzer does not operate during the closing mode. Check buzzer or replace it. Please note: The system performs automatic reset after the ASD has been disconnected from the power either when replacing the fuse or by disconnecting the Battery. The system resets itself within two minutes. Please be patient. Page. 4