Door's adjustment
1.1 DOOR'S SYSTEM 1.1.1 INTRODUCTION - IRIZAR'S I6 DOOR SYSTEM The vehicle's door system is designed to open and close during normal and emergency operation. As being an electro-pneumatic system, it possess a sensibilization system, which is capable of avoiding any accident during the process of closure and opening. The pneumatic system has a lubrication and protection system with a separation valve between the chassis and body. This valve can be used for leaking diagnoses or air removal during the door's system maintenance process. The i6 door's system has the structure protected by aluminium plates. Isolating agents are also applied in the interior, to provide thermal and acoustic isolation. The sealing system is composed by a solid rubber, with no junctions on the edges or over the doorstop. Door's rubber shape Doorstop shape 1.1.2 DOOR'S SENSIBILIZATION SYSTEM The door's sensibilization system operates during the opening and closure of the door. During the closure the system operates when the electric system possess the +30 line, in other words, the main switch must be on. To opening, the system operates permanently, even when the +30 line isn't working, disconnected main switch. During the closure process, the micro-switches system acts under the door's solenoid, reverting the movement, in case of any obstacle interrupt the door's movement. During the opening process, the door has its movement protected, avoiding any collision with adjacents components, such as compartment cover. 2
Picture 1 - Sensibilization during closure Picture 2 - Adjacent compartment blocking the door from opening It is possible to adjust the performance of the sensibilization system by adjusting the aluminium cam. This cam turns with the door's movement, providing the protection during the closure. There are two micro-switches connected, on vertical and the other horizontal. When the cam reaches the horizontal micro-switch (at the end of the door's course), the cam disables the vertical micro-switch, canceling the sensibilization. In case of an obstacle during the closure, the cam won't reach the horizontal micro-switch. The force imposition against the closure makes the door to initiate a vertical movement. The movement elevates the plastic part, in shape of half moon, activating the micro-switch that sends an electric signal to the door's valve so the movement of closure is reversed, therefore openning the door. Cam Half moon Micro-switch horizontal Micro-switch horizontal Micro-switch Vertical Picture 3 - Door's sensibilization This way, the cam's position is related to the door's position, in order to provide the door's sensibilization. 3
1.1.3 DOOR SYSTEM ADJUSTMENT The vehicle's door must be considered misfit when: Presents excessive noise; Does not close adequately and allows water entrance and air seal problems ar; Presents problems while opening or closing; Time demanded to open or close is excessive; Open or close just with external help; Doesn't present sensibility to obstacles while closing. Mechanical adjustment points Doors system Door's upper bearing Arm's conection Door's bottom bearing Bottom bearing Door's guide rod Wedge 4
1.1.4 DOOR MOVEMENT Movements Function Illustration Parallel to the body. Propitiate seal during the correct closure. Perpendicular to the body. Propitiate seal and correct closure. Vertical This movement is responsible for fixing the door in the doorstop, conferring rigidity and seal. 1.1.5 DOOR ADJUSTMENT PARAMETERS parameter Function Illustration Geometric positioning The geometric positioning is related with the alignment of the door to with the doorstop, as shown on the right. This parameter is controlled by the wedge set and the positioning of the door's fixation bearing, both internal and external. Sealing The door's sealing is of extreme importance to avoid water entrances, dust and even noises originated by the air entrance. The superior wedge's set is responsible for bringing the door closer to the body, complementing the perpendicular movement. The 5
set of inferior wedges limits the vertical movement Seal and also seals the door. Excessive seal implicates in high forces applied to the wedges, which reduces it's lifetime and may cause damage to the door's doorstop. It's possible to obtain good seal when the door's surface is aligned with the body's surface. Parallelism with the body Open the door This parameter is defined through the guide arm, situated in the door's inferior part. The lenght of the guide arm defines the position in which the door will touch the doorstop during the door's perpendicular movement. The door's approximation with the doorstop must be parallel, and both sides must touch the doorstop at the moment of closure. The door must be aligned with the body's lateral lines, doorstop and with the doorstop's inferior part. This can be obtained through the adjustment of the inferior wedges. Guide arm Centralization The existent cracks between the doorstop and the door must approach on both sides equally. This parameter can be reached when combining all the factors mentioned before. Velocity of closure The complete movements of opening and closure must be concluded in 4 to 6 seconds. Faster movements might damage the trigger, doorstop and the door's structure. 6
20 mm 2 to 4 mm Instrução Técnica Instrucción Técnica Technical Instruction Closur e Ope ning The doors closure force The doors closure force must be set to attend the operational necessity. For example, if the car stops on a descent roadside, the force applied to close the door is bigger. Wedge's positioning The standard approximation between the wedge set must be within 2 to 4 mm. Door's external bearing adjustment The minimum distance between the nut and the locknut is of 20mm. 1.1.6 DOOR'S SENSIBILIZATION SYSTEM The opened door signal is generated by an horizontal microswitch, as picture 3-Door sensibilization. This opened door signal also send an electric signal to the green pilots of the retractable step. This way, when the cam touches the horizontal micro-switches, the green pilots of the retractable steps turns off. 7
Opened door, cam does not touch the microswitch, stair's illumination is activated. Half open door with a clearance of 50mm, notice that the cam doesn't touches the micro-switch, so the stair's illumination isn't activated. 50mm 8
The cam's correct positioning must have as reference the centerline of its fixation screws and the door's surface. The artifice above can be used to adjust the cam's positioning. 90 graus Picture 4 - Cam's positioning diagram To adjust the cam's position, release the Allen screw, then turn it to the right position. Screw Picture 5 - Allen screw positioning 9
1.1.7 DOOR'S SYSTEM PREVENTIVE MAINTENANCE Table of preventive maintenance - Door Action Frequency Standard value Check the contact of the wedge's screws. Every month 20 N.M Check the M10 screw's torque ( bar, actuator support, guide arm ) Every month 40 N.M Check the M14 screw's torque ( tension rod ) Every month 80 N.M Check the torque of the M16 screw thread ( torsion bar ) Every month 125 N.M Check the torque of the M16 screw thread Every month 125 N.M 10
Check the door's sensibilization system Every week 150N, an adult must prevent the door from closing, activating the sensibility system. 1.1.8 TIPS OF IRIZA'S AFTERSALE STAFF. Description Tips Illustration Door does not close aligned, problems with geometrical alignment. Misalignment usually might be caused by incorrect coupling of the wedges. This effect can be observed by lifting of the door's rubber after closed. Another possibility is the incorrect adjustment of the door's fixation rod. Incorrect coupling In case of geometric misalignment, an adjust of the door's fixation wedges might help. To adjust the external bearing, just release them, and then use a rubber hammer to adjust its positioning. Upper bearing adjustment 11
The door's edge first touches the doorstop, the wedges might not fit correctly. To avoid these problems, the guide arm must be adjusted correctly. There are two possibilities of adjustment: The first it's own lenght through the screws in the body; Another possibility is through the guide's fixation screws on the body with the holes, as shown on the right. With the door closed, it is possible to notice noises of air entrance on the door's bottom part, when the car is moving. In some cases, the door's rod is misaligned, creating a gap at the door's bottom part. The procedure to adjust the door's height can be executed by releasing the screws, indicated on the left. Using a rubber hammer, the arm's position can be modified with soft hits. Attention: Never release the fixation of both arms at the same time. BRAÇ O 2 BRAÇ O 1 12
During closing, the door slams against the doorstop and doesn't align the wedge's set correctly. During the process of adjustment, use the emergency valve to keep the door loose. This makes the procedure easier, because it's not necessary to use the service valve to remove the body's air when a test is necessary. In this case, adjust the door's final course speed. The movements of opening and closure must be concluded within 4 to 6 seconds. Faster movements might damage the wedge's set, doorstop and door's structure. The movement's speed might be adjusted through the valves in the actuator cylinder, as indicated on the left. - Course end ( closure ) Course end ( opening ) 13