Product Service Bulletin

Transcription

1 MODEL: SUBJECT: C2 BODY ELECTRIC DOOR MECHANISM RETROFIT DATE: OCTOBER 20, 2008 INDEX: C2 2 PAGE: 1 OF 10 This service bulletin replaces Index C2 2, Bulletin 17 to correct the proper cam position statement in Figures 8 and 9. The correct position should state "OPEN". With the release of this service bulletin, Index C2 2, Bulletin 10 and Index C2 2, Bulletin 7R are obsolete. This bulletin will highlight a drop in retrofit to take the place of the existing door mechanism (pre-ag2). The new Electric Door Mechanism, #TBB is easier to maintain, and affects units with start of production dates of 12/1/03, body # through 5/14/07, body # IMPORTANT: READ ENTIRE PROCEDURE BEFORE BEGINNING. 1. Be sure that PSB Index C2 2, Bulletin 11R4, Hex Shaft Breakage has been completed before proceeding. If it has not, acquire the parts necessary for it, to be performed along with the this specific retrofit. 2. Remove mechanism cover. Retain fasteners for reinstallation. Figure 1 Remove fasteners and cover. Figure 1 3. If the old white nylon bearings are present, remove and discard. Replace with the Black Carbon Fiber Bearings, #TBB Figures 2 & 3 Product Service Bulletin

2 PAGE: 2 of 10 INDEX: C2 2 Remove White Nylon Bearing. New Black Bearing, #TBB Figure 2 Figure 3 4. Disconnect wire harnesses. Figure 4 5. Disconnect release cables and discard. Figure Remove the interior and exterior release cables. Remove Actuator Asm. Disconnect wire harness. Throttle cable & mount bracket Actuator Mount Bracket Remove Switch. Disconnect release cables. Figure 4 Figure 5 6. Disconnect door rod from the hex shafts and cams. Retain the rod and hardware to be reused. Figures 6 & 7 7. Be sure to mark the cams left and right as well as what was the top of the cam as it was before being removed. 7.1 If these are not in correct alignment you will not get the mechanism to engage the limit switches properly. Figures 8 & 9 8. Remove pins and other hardware holding actuator in place, and remove the actuator. Retain the hardware to be reused. Figures 4 & 7

3 PAGE: 3 of 10 INDEX: C2 2 Fasteners securing upper door seal. Disconnect lower door rod. Figure 6 Figure 7 Note and mark cam position before removal Note and mark cam position before removal Forward leaf in the "OPEN" position Rear leaf In the "OPEN" position Figure 8 Figure 9 9. Remove mounting bracket and switch bracket that remains on the tray. The tray should be completely devoid of all previous electric door actuator parts. Figure Some mounting brackets may be welded to the tray instead of bolted. If that is the case be sure to remove as much of this bracket as possible and remove all sharp edges after doing so. 10. Remove throttle cable and bracket used for the internal release. Discard these items. Figure Remove the door leafs and the old vertical door seals. Discard seals ONLY. 12. Install the new Seals, #TBB in the orientation described in PSB Index C2 2, Bulletin 4R3. Reinstall the door leafs. 13. Check to be sure there is a 25 amp fuse in the F18 location of the Body PDM located in the switch panel. 14. Install new Electric Door Mechanism, #TBB , utilizing the same connecting points as the tray is secured with the existing fasteners. Figures 10 & 11

4 PAGE: 4 of 10 INDEX: C2 2 Connection points forward on tray for mounting new mechanism. Connection points rear on tray for mounting new mechanism. Figure 10 Figure Attach the forward leaf rod to the hex shaft with the existing cams and new Spacers, #TBB and #TBB Figure The center to center dimension of the upper rod should be 16-7/8" nominal. Early versions this dimension is 15-7/8". Note: If there is interference between the lower rod and the fasteners securing the upper door seal, the rods can can be repositioned on top of and between the cams, or the spacer size can be altered. See Figure 7 for fasteners. 16. Reattach the existing rear leaf rod using the existing cams and new Spacers, #TBB and #TBB Figure 13 New Upper Rod with mechanism Existing lower rod reused with new mechanism Cams New Spacer, #TBB New Spacer, #TBB New Spacer, #TBB Lower Rod New Spacer, #TBB Figure 12 Figure If you had an exterior release cable, you will need to remove and modify the exterior release bracket. Once it is removed, clean it up. If it is bent, bend it back and add the new Shim, #TBB and Screw, #TBB as shown in Figure 14. The slot for the cable will need to be increased to 7/32" to allow for the new cable end. (Figure 15) Note: Be sure not to get slot too wide or cable will come out of slot.

5 PAGE: 5 of 10 INDEX: C2 2 Shim, #TBB Slot width 7/32" Screw, #TBB Open up to accept new cable end. Figure 14 Figure Install the new Exterior Release Cable, #TBB Figures 16 and 17 New Shim, #TBB in place Exterior Release Cable in place on mechanism Figure 16 Figure 17 Exterior Release Cable, #TBB in place in the exterior bracket 19. Reconnect the wire harnesses. Figures 18 and 19

6 PAGE: 6 of 10 INDEX: C2 2 Motor connector Rear connection P93 connector to Closed switch Forward connection P83 connector to Open switch Figure 18 Figure 19 Warning light connection P Operate door and check adjustment once everything is connected. Adjustments to the rods can be made as indicated in Figures 20 & 21 Note: In Figure 21, the top right switch of the stack is the Warning Light Activation and the bottom switch is the CLOSED Limit Switch. Rod adjustment location CLOSED Limit Switch & Warning Light Activation Rod adjustment location - jam nut OPEN Limit Switch Figure 20 Figure 21 Adjustment upper rod by hand or with a wrench If door does not operate or the interior release handle is difficult to release then check to make sure the small motor gear is flush with the top surface of the large gear as in Figure 22. If it is not then loosen the jam nut and turn the set screw counterclockwise to allow the small gear to move out flush with the large gear. Once it is set tighten the jam nut in that location.

7 PAGE: 7 of 10 INDEX: C2 2 These two gears should be flush or the small gear slightly above the surface of the large gear. Jam nut & set screw to set motor engagement with the large gear. Figure Refer to wiring schematic for troubleshooting the wire connections of the mechanism and body harness relationship. Figure 23

8 PAGE: 8 of 10 INDEX: C2 2 P83, P371 & P93 ARE TBB BODY HARNESS CONNECTIONS. P83 DOOR OPEN GROUND P371 DOOR SWITCH GROUND P93 DOOR CLOSED GROUND BROWN WHITE NC COM MS3 ALONE Motor side nearest you once installed MOTOR 1 Motor side near bus header once installed YELLOW GREEN BLUE RED NC NO COM MS1 TOP ORANGE BLACK NC COM MS2 BOTTOM P83 DOOR OPEN 490X_ D MOTOR 490Y_ D MOTOR P371 DOOR SWITCH P93 DOOR CLOSED NOTE 1 VIEW SHOWN IS SIDE OF MOTOR WITH TERMINAL PAD. Figure 23

9 PAGE: 9 of 10 INDEX: C Note the new release lever for the interior release. Figure A slot will need to be cut in the mechanism cover to account for the travel of the release handle. (Figure 25) Drill two holes 3/8" diameter at the dimensions specified. Then make two tangent lines from hole-to-hole to create the slot. Carefully cut out and file, or sand, rough edges Install Dome Plug, #TBB in the hole previously occupied by the old release handle Move handle toward rear of bus to disengage gears allowing you to manually move the door in any position. Move the handle back toward the front of the bus to re-engage the gears allowing you to again operate the door with the door switch. 22. Install the Instruction Label, #TBB (English) and/or Instruction Label, #TBB (French) centered just above the slot cut-out for the handle. These are activation labels for the mechanism. Interior release handle New Mechanism, #TBB " from center of hole to start of slot dia. 4" center to center Use Plug, #TBB /8" width of slot to fill hole. centered over handle Figure 24 Figure 25 Adjustment/Operating Procedure: Operating the new mechanism 1. To open and close the doors operate with the door switch as normal. 2. To release the doors from the inside of the bus either as an emergency or end of route to exit the bus push the release handle toward the rear of the bus. This will disengage the motor in any position and the door leafs will move freely. 3. To re-engage the motor push the release handle toward the front of the bus. The doors can now be operated with the door switch again. 3.1 You will get some resistance from the external release cable, so just move the handle as far as the cable will allow it to go forward. it will not click into position. 4. If you have a manual external release handle it is only to be used for emergency situations and not everyday use. However, it will disengage the doors from the outside of the bus allowing the door leafs to move freely. To re-engage the motor again push the interior release handle toward the front of the bus and operate with the door switch again. 4.1 You will get some resistance from the external release cable, so just move the handle as far as the cable will allow it to go forward. It will not click into position.

10 PAGE: 10 of 10 INDEX: C2 2 Adjusting the new mechanism 1. To adjust the front leaf more open or close see Figures 20 & 21. This should be done with the motor engaged and you will be able to see the forward leaf move in or out. 1.1 It will not take many rotations to make an adjustment. 1.2 Note the reference dimension for the forward drive rod in Step To adjust the rear leaf to gain more opening on that leaf adjust as pictured in Figure 20 by breaking loose both jam nuts and rotating the hex portion of the rod equally in or out to make your adjustment. 2.1 Remember that what you gain on the opening for this adjustment may have an adverse effect on the closing of the forward leaf. Opening needs to be a minimum of 24" while trying to achieve 26". 2.2 It is always best to adjust your forward leaf first to get the best closing position before making this adjustment to the rear leaf. 3. To adjust the motor engagement loosen the jam nut in Figure 22 and turn the set screw counterclockwise for better engagement as needed. This will also allow the interior release handle to move with little resistance. Note how the final result should look in Step 20.1 and Figure 22. Tighten the jam nut once setting is achieved. 4. If contact is not being made with the limit switches in either the open position or the closed position then first check your cam positions. If the cam positions are not correct the mechanism will be quite a distance from engaging either one or both the open and closed limit switches. If it is close but still not making contact with one of the limit switches they can be adjusted by loosening the screws holding the switches to the mounting bracket. It is slotted to make slight adjustments. MATERIALS REQUIRED: PART NUMBER QTY. DESCRIPTION TBB Bearing, Carbon Fiber, Flanged Spherical, Top Pivot, Front Entrance Door TBB Entrance Door Seal, Low Step, Extended TBB PVC Standoff,.500" TBB PVC Standoff,.875" TBB PVC Standoff,.750" TBB Electric Door Mechanism (Retro-fit Pre-AG2 Door) TBB Control Cable, Exterior, Manual Release TBB Shim Plate, Exterior Release Bracket TBB Dome Plug, Black, Head Diameter.921, Depth.406 TBB Instruction Label, Emergency Override English AND / OR (as needed) TBB Instruction Label, Emergency Override French WARRANTY STATUS: WITHIN PROVISIONS OF TBB WARRANTY - NINE (9) MONTHS FROM THE DATE OF THE ORIGINAL BULLETIN (07/08/08). WARRANTY CODE: 7515 SRT CODE: , TIME ALLOWANCE HRS. QC: X09 & V01