Download Automatic Sliding Door Set
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PowerDoorAndStep.com 888.928.8000 V363 TRANSIT RWD/FWD Long Wheel Base ,Jumbo Automatic Sliding Door Set PN: 015-3631-DL Original Door latch mechanism & operation with handles V363 TRANSIT RWD/FWD Long Wheel Base PowerDoorAndStep.com 888.928.8000 Door lock mechanism C-pillar Fuse 30A B-pillar 2 AK105L Lock Actuator O.E. Door latch Page 1. General view of ASD system. V363 TRANSIT RWD/FWD Long Wheel Base PowerDoorAndStep.com 888.928.8000 100 5 440 110 60 65 130 Page 2. Cutting and preparation. V363 PowerDoorAndStep.com 888.928.8000 TRANSIT RWD/FWD Long Wheel Base V363 Gear Motor Support Kit 160-36-310 2 7 5 4 3 1 5 5 6 ITEM NO. PART NUMBER DESCRIPTION QTY. 1 111-36-310 V363 Gear Motor Support Right side 2 501-17-006 22x8.5x6 Spacer 3 3 600-12-080 Flat washer M6,thin DIN735 6 4 600-04-052 Spring Washer 6 6 5 632-06-016 Hex cap screw M6x15 6 601-06-006 7 107-11-004-1 Hex flange nut M6 DIN 6923 Idler Wheel Page 3. Gear motor installation 1 7 4 1 V363 PowerDoorAndStep.com 888.928.8000 drill hole 16mm for roller chain Template Original hole C-Pillar Page 4. Gear motor installation TRANSIT RWD/FWD Long Wheel Base V363 PowerDoorAndStep.com 888.928.8000 7 4 3 TRANSIT RWD/FWD Long Wheel Base V363 Front Idler Kit 160-36-320 2 5 ITEM NO. Hex cap screw M6x30 632-06-030 7 1 6 PART NUMBER DESCRIPTION QTY. 1 111-36-330 V363 Front Idler Kit 1 2 632-06-016 Hex cap screw M6x15 2 3 603-02-006 Rivet nut M6 3 4 600-12-080 Flat washer M6,thin DIN735 3 5 600-04-052 6 601-06-006 Hex flange nut M6 DIN 6923 2 7 632-06-020 Hex bolt M6x20 DIN933, 8.8 3 Spring Washer 6 3 V363 LHD Front idler upper holder 128-36-304 Hex nut M6 DIN 934 Cl.6 Sprocket ASSY 107-36-300 Hex nut M6 DIN 934 Cl.6 Idler wheel ASSY. 107-11-004-1 V363 LHD Front idler lower Support 128-36-305 Hex cap screw M6x30 632-06-030 Attach the front support to the gear-motor ASSY using the bolts M6X16(2), and Nuts M6. Mark the position of the holes in the back end of the mounting bracket on the vehicle body. Remove the front support. Drill 33 holes holes 9.5mm 9.5mm and and install install the the threaded threaded Drill inserts (QTY. (QTY. 3) 3) inserts Page 5. Front Idler Installation. V363 TRANSIT RWD/FWD Long Wheel Base PowerDoorAndStep.com 888.928.8000 Chain Slide Strip Kit 160-36-330 5 0. 8 1 1. 50 4 230 38 17.5 2 3 230 ITEM NO. PART NUMBER 1 134-36-301 2 601-06-006 3 134-36-302 4 613-06-020 DESCRIPTION Chain Slide Strip (Transit) Hex flange Nut M6 Chain Slide Strip front (Transit) Socket flat head screw M6X20 QTY. 1 1 1 Washer 6 5 Step1 2 1 Use original threaded hole M6, fasten slip strips using washer 6 and screw M6 . Press firmly both slip strips to the track and mark the position for hole . Surface of strip must be straight without waves. Step2 drill B-Pillar Inside Page 6. Chain Slide Strip Installation V363 TRANSIT RWD/FWD Long Wheel Base PowerDoorAndStep.com 888.928.8000 Rear Idler Kit 2 160-36-340 3 ITEM NO. 1 2 PART NUMBER 1 111-02-013-1 2 614-06-016 3 603-02-006 DESCRIPTION Rear idler Socket button head cap screw M6X16 Rivet nut M6 Sprocket ASSY 107-36-300 Cut Template Drill hole 6.5mm 70 Drill hole 9.5mm and install the threaded insert 70 Page 7. Rear Idler Installation. Exploded/QTY. 1 2 1 V363 TRANSIT RWD/FWD Long Wheel Base PowerDoorAndStep.com 888.928.8000 Roller chain route for installation Electrical position Page 8. Roller chain installation. V363 TRANSIT RWD/FWD Long Wheel Base PowerDoorAndStep.com 888.928.8000 Roller Chain Kit 160-36-350 4 2 3 5 ITEM NO. PART NUMBER DESCRIPTION Exploded/QTY. 1 111-36-320 2 178-36-300 3 900-01-072 Chain bracket Roller chain B05 L=3088 mm(192 Links ) Chain connecting link B05 4 134-36-303 V363 Slider 1 5 647-03-012 Screw M3x12 1 3 Page 9. Roller chain installation. 1 2 2 V363 PowerDoorAndStep.com 888.928.8000 Link 7 Link 1 Link 7 Page 10. Roller chain installation. TRANSIT RWD/FWD Long Wheel Base V363 PowerDoorAndStep.com 888.928.8000 Two stoppers rotate 180 degrees Page 11. TRANSIT RWD/FWD Long Wheel Base V363 Plus wire installation TRANSIT RWD/FWD Long Wheel Base PowerDoorAndStep.com 888.928.8000 Fuse 30 A O.E. Nut M6 “+” Battery 2 Signal Lamp ACC Operation Switch AK105L Chassis ground Page 12. Wiring V363 TRANSIT RWD/FWD Long Wheel Base PowerDoorAndStep.com 888.928.8000 Electrical Accessories Kit PN:160-36-300 Pneumatic safety strip Operating Switch PN;124-02-012-1 PN:113-65067 Signal Light PN:124-10-069 Pneumatic Plastic Tube c Door Automati Electric Decal PN:125-00-018 PN:113-26063 Rubber Tube PN:113-06-067 L AUTO COO . IND. LTD SU PE R Door Limit Switch PN:124-00-039 GL UE 100mm Fast Glue PN:144-30-007 Cable strap PN:125-10-016 Cable strap Pneumatic Safety Switch Assy PN:160-10-042 150mm Page 13. Electrical Accessories Kit PN:125-10-014 V363 TRANSIT RWD/FWD Long Wheel Base PowerDoorAndStep.com 888.928.8000 Drill 12mm hole 21mm 8mm O.E. Switch Door Limit Switch O.E. Switch Self drilling screw 8x1/2” Cap (Spacer) 151-15-428 Apply grease on surface of switch Door Limit Switch 124-00-039 Page 14. Door limit switch installation V363 SU PE R GL UE 60 sec 15 R PE SU Close G LU E 29 Safety strip Lock Actuator Clean surface carefully with alcohol to insure good contact of the pneumatic safety strip. Transmitter 2 Safety Switch Pneumatic Safety Strip PN: 112-06-109 2 SU PE R GL UE Rubber tube Drill hole for rubber tube Page 15. Pneumatic Safety Strip & Pneumatic Switch Installation Left Sliding Door edge PowerDoorAndStep.com 888.928.8000 TRANSIT RWD/FWD Long Wheel Base V363 TRANSIT RWD/FWD Long Wheel Base PowerDoorAndStep.com 888.928.8000 Door lock mechanism C-pillar B-pillar 2 Lock Actuator B-pillar O.E. Door latch Page 16. Actuator ASSY. installation. V363 TRANSIT RWD/FWD Long Wheel Base PowerDoorAndStep.com 888.928.8000 ASD V363 Ford Transit _Original Door latch mechanism & operation with handles 160-36-301 6 1 2 3 A 7 5 3 4 4 ITEM NO. 1 2 3 4 5 6 7 PART NUMBER 111-36-354 632-06-016 125-10-005 601-06-006 646-08-020 125-10-016 125-10-014 DESCRIPTION Lock Actuator bracket ASSY. Hex cap screw M6x15 Plastic clamp UC-2 3/8" Hex flange nut M6 DIN 6923 Phillips screw 6x3/8" Cable strap 100mm Cable strap 100mm Cut Internal door handle cables External door handle cable Remove the cap from the cable Return the cap lower release cable Page 17. Cable Diagram QTY. 1 2 1 2 1 3 2 V363 TRANSIT RWD/FWD Long Wheel Base PowerDoorAndStep.com 888.928.8000 Step 4 Step 3 Step1 Step 2 Step 2 Page 18. Rerouting Cable V363 PowerDoorAndStep.com 888.928.8000 3 TRANSIT RWD/FWD Long Wheel Base Lock Actuator ASSY. 4 111-36-354 Long sleeve 1 Short sleeve 2 1 5 ITEM NO. PART NUMBER 1 128-36-354-2 2 Use this hole for O.E. cables clamp 2 3 4 5 110-01-006-10 110-01-006-Screw#4 128-36-309 128-15-203 DESCRIPTION V363 Lock Actuator bracket QTY. 1 Lock Actuator ASSY V363: V408 Lock Actuator arm Cables adapter Use original hole Drill 6mm hole Page 19. Lock Actuator ASSY installation. 1 2 1 1 V363 PowerDoorAndStep.com 888.928.8000 Short Sleeve Long Sleeve Page 20. O.E. Cables installation. TRANSIT RWD/FWD Long Wheel Base V363 PowerDoorAndStep.com 888.928.8000 TRANSIT RWD/FWD Long Wheel Base V363 Electric Harness Ford Transit 116-36-301-DL 7 3 6 5 9 1 2 8 s vs 4 ITEM NO. PART NUMBER DESCRIPTION QTY. 1 128-17-116 Bracket 1 2 124-10-504 VSS detector 1 3 124-38332 Control unit AK-105L V1.913 1 4 124-02-006 LD-007-1 - Remote control kit 1 5 124-02-906 6 124-13-902 7 124-00-032 Buzzer 12v 1 8 124-10-052 Socket terminal relay 1 9 R2A4-124 Relay 1 Page 21. Wiring Remote Control Set Latching relay 12v ASSY 1 1 V363 TRANSIT RWD/FWD Long Wheel Base PowerDoorAndStep.com 888.928.8000 B- Pillar cut B- Pillar Central locking Close 4 3 2 1 B- Pillar EMPTY Violet/White Brown/Green Blue/Gray Sliding Door 4 3 2 1 EMPTY Violet/White Brown/Green Green (+) Lock Actuator Blue/Gray Blue (-) Lock Actuator 4 3 2 1 Page 22. Wiring Green (+) Lock Actuator Blue (-) Lock Actuator Black Red V363 TRANSIT RWD/FWD Long Wheel Base PowerDoorAndStep.com 888.928.8000 1 4 Under driver seat Gray DRIVING SPEED (VSS PULSE) ACC+ Sliding door Pressure switch Lock Actuator Front Blue Green Red White/Blue 4 8 3 7 6 2 1 VSS Pulse Detector Black Black O.E.Plug Red 7 6 Red 1.5 mm 8 AK-105L(250) 9 Orange 10 30 1 Blue 87 2 86 85 3 Green 4 Black 5 Green Red Red Green latch Relay 12 V Battery 12V Blue Green 5A Blue Green Black Red 2 Black Red Remote Control (receiver) 1 Remote Control (receiver) Red 1.5 mm Door limit swith Green Yellow 30 +ACC Green 86 Signal Lamp MOTOR 12V DC 87 Buzzer Black Blue Relay 12 V Green 85 pin1 Connect to VSS Green CUT White D1 O.E.Plug (B-Pilar) 4 3 21 VSS Black 4 3 21 OE wire brown/green from B-pilar plug 9 5 Con 5 2 OE wire Blue/gray from B-pilar plug 10 Gray Black Plug Black White Black Blue White Buzzer Green Blue Plug Operating switch Internal micro switch Black Green Orange VSS (Vehicle speed sensor) connection Red 30A Page 23. Wiring diagram 19.02.15 V363 PowerDoorAndStep.com 888.928.8000 PN: 128-05-012 PN: 151-15-000 PN: 151-36-301-Cover - Handle - Housing Phillips screw M6 Page 24. Cover installation. TRANSIT RWD/FWD Long Wheel Base V363 PowerDoorAndStep.com 888.928.8000 ASD Automatic Sliding Door External emergency door opening kit PN: 111-03-013 Option Page 25 TRANSIT RWD/FWD Long Wheel Base V363 PowerDoorAndStep.com 888.928.8000 TRANSIT RWD/FWD Long Wheel Base Gear-motor ASSY. Nut 6 ST Nut 6 ST Internal emergency handle Emergency door KIT PN: 111-03-013 Spring Bracket PN: 128-03-013A Emergency door handle PN: 111-03-0131 Emergency handle cover PN: 151-03-131 Socket head M5X16 Page 26 V363 TRANSIT RWD/FWD Long Wheel Base PowerDoorAndStep.com 888.928.8000 Figure1 cut Sikaflex-221 Install the external handle for emergency opening door Figure2 Nylock nut M5 Nut M6 To install the cable: Verify that the Internal emergency handle is on closed position. Insert the cable into the hole (see figure 2) fasten nuts M6 Page 27 V363 TRANSIT RWD/FWD Long Wheel Base PowerDoorAndStep.com 888.928.8000 1 Insert the emergency handle 1 . Move the handle to right for electrical operating 10 mm Install the cable Clamping lug Nylock Nut M5 Spring Washer 4 Washer 4 Bolt M4X8 Page 28 V363 TRANSIT RWD/FWD Long Wheel Base PowerDoorAndStep.com 888.928.8000 Pneumatic rubber tube PN:160-10-042 Pneumatic Switch PN:122-10-047 Sensitivity adjustment Increase Sens Decrease Sens Page 29 Hex key N 4mm V363 TRANSIT RWD/FWD Long Wheel Base PowerDoorAndStep.com 888.928.8000 ASD: Basic Troubleshooting 1. Door does not function. • Check main fuse. • Check connections of power terminals to the control unit, motor and operating switch. • Check Control units AK-105L • Check motor. 2. Door does not operate upon commencing the closing mode or when reaching the fully closed position 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 – AK105. 3. 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. If issue still persists, replace the remote control receiver and the 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 30 V363 TRANSIT RWD/FWD Long Wheel Base PowerDoorAndStep.com 888.928.8000 Automatic Sliding Door user’s Manual. The Automatic Sliding Door 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 2004/104/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 indicator 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, the 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 31 V363 PowerDoorAndStep.com 888.928.8000 TRANSIT RWD/FWD Long Wheel Base Tools required for installation ASD. AAD. STEP. ATG Air Reciprocating Saw Saw BLades or High speed threaded insert tool or 13mm Pneumatic Drill Heavy duty hand tool for field and low volume production use or Air Die Grinder Small hand tool for . prototype work and repairs Hand holding battery-powered electric drill Soldering-iron Flashlight or drop light Pencil or marker Safety Glasses Page 32. Masking Tape 50MM V363 TRANSIT RWD/FWD Long Wheel Base 90 PowerDoorAndStep.com 888.928.8000 Straight Flute HSS Step Drill diameter 4-30mm Drill Point Countersinks Straight Shank Twist Drill diameter 4mm / 5mm / 6mm/ 6.5mm / 7mm / 9.5mm 12mm T-Handle Set Heavy Duty Snap Blade Knives Hand Files Wire Stripper/Crimper Locking plier Combination Wrench Set Metric Plier Set 1/4" Drive Socket Set metric Screwdriver Set Page 33.