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Auto
Cool
www.autocool.co.il
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FIAT Ducato L2:L3:L4
PEUGEOT Boxer
CITROEN Jumper / Relay
8
7
PowerDoorAndStep.com
27
49
EL
888.928.8000
RA
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P.
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.B
x
09
46
ch
ta
e
P
a
ikv
-T
IS
AT
FI
ASD
LHD Automatic Sliding Door
PN: 015-0002-DL
Recommendation
Please print this instruction manual in color
01.04.15
FIAT Ducato
PEUGEOT Boxer
CITROEN Jumper / Relay
015-0002-DL
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Pneumatic safety strip
Operating switch
Signal light
AT
FI
Gear-motor
Buzzer
Door Limit Switch
Safety Pressure Switch
Control unit
Main Fuse
Remote control receiver
Wiring harness
Lock Actuator ASSY
Page 1. ASD System - Overview
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T
FIA
Supplied Template
Cut according to dimensions
60
380
Template N1
10
Drill Ø7 (x2)
Cut according to Template
Page 2. Cutting and Preparation
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FIA
Drill Ø4 according to detail (24)
19
12mm
A
12m
A
25
25
25
m
Step 1
Align chain slide strip 24 to the right
and bottom of the track.
Step 2
Mark & drill thru the right strip
hole 4 mm.
Step 3
Attach the right strip using screw M4x20
& nut M4
24
90
Step 4
Tightly pressed chain slide strip to the surface of track,
Mark & drill thru the left strip hole 4 mm.
Step 5
Attach the left strip using screw M4x20
& nut M4
A-A
19
Ø10
90
Chain Slide Strip 24
25
Ø4
Track
Step 6
Attach the left strip using screw M4x20
& nut M4 .
*Make sure the screw is entirely inside
Section A-A
25
Socket flat head screw M4x20 - 2
19
Lock nut M4
Page 3. Chain Slide Strip Installation
-2
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FIA
1
7
8
12
Original nuts (x3)
8
Hex head screw M6x16 - 1
7
Flange nut M6
12
Page 4. Gear-motor installation
Washer 6
- 1
- 1
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View-A
Lock nut M6
Wheel
Hex bolt M6x16
Lock nut M6
12
3
Nut M6
Hex bolt M6x30
8
8
9
7
15
11
View-A
12 8
2
7
14
8
8
8
15
10
7
13
7
8
Hex head bolt M6x16 - 7
3
Hex head bolt M6x25 - 2
7
Flange nut M6
11
Thick Washer 6 ( H=2.5mm)
12
13
14
15
Washer 6
6
-9
- 1
- 2
Hex head bolt M6x30 - 1
Nut M6
-1
Lock nut M6
-1
Page 5. Gear-motor Installation
14
8
FIAT Ducato
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T
FIA
m
Drill Ø7mm(x2)
20m
TE
LA
N2
P
EM
T
Cut according to
Template N2
70
20
Drill Ø7mm(x2)
7
16
53
13
23
18
17
8.5
18
FRONT
original cover
17
20
17
Socket button head screw M6x16 - 2
7
Flange nut M6
Page 6. Rear Idler Installation
-2
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19
Drill Ø4 mm
22
23
21
18
Drill Ø16mm
Using Template N4
TEMPLAT
18
Hex head screw M4x16
- 2
19
Lock nut M4
-2
E N4
Page 7. Roller Chain Installation
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Chain sealing rubber
113-15-001
6
22
A
9
Page 8. Roller Chain Installation
16
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Drill Ø12
29
28
Self-drill screw 8x1/2" Drill Ø3.5
30mm
170mm
Page 9. Door Limit Switch Installation
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FIA
36
34
c Door
Automati
Electric
L
AUTO COO
.
IND. LTD
Page 10. Electrical Connections
35
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VSS Connection
up to 2012
ACC “+”
Solder and isolate:
Original Black-Blue wire
On the BSI from the 52V Black connector
17-way Redundant vehicle speed signal
LN connector 17-way
52
40
17
1
13
White/Gray wire
52
40
to VSS Detector
17
1
13
Page 11. Wiring. VSS connection
FIAT Ducato
PEUGEOT Boxer
CITROEN Jumper / Relay
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VSS Connection
From 2013
AT
FI
3
VSS Connection
1
2
3
3
5
6
6
8
9
10
11
12
13
14
15
3
Green/brown
38
37
Fuse 30A
Page 12. Electrical Connections
FIAT Ducato
PEUGEOT Boxer
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015-0002-DL
Version length L2
PowerDoorAndStep.com
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39
AUTO
COOL
41
Side cover
48
42
Cut
Model L-2
Model L-2
Page 13. Gear-motor Covers Installation ( Model L- 2)
45
FIAT Ducato
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Version length L3
PowerDoorAndStep.com
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FIA
Sikaflex
43
Drain pan
39
AUTO
COOL
41
40
42
Covers Kit
Page 14. Gear-motor Covers Installation
PN: 151-00-0021
FIAT Ducato
PEUGEOT Boxer
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Parts list of ASD system
No
1
2
3
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
Designation
Gear Motor Support
Idler Wheel
Hex Bolt M6x25 DIN 933 8.8
Gear Motor ASSY
Hex flange nut M6 DIN 6923
Hex Bolt M6x16 DIN 933 8.8
Front Idler
Front Idler Support
Thick Washer 6 DIN 7349
Washer 6 DIN 735
Hex Bolt M6x30 DIN 933 8.8
Hex Nut M6 DIN 934 Cl6
Hex Lock Nut M6 DIN 985 Cl8
Rear Idler
Socket button bolt M6x16 ISO 7380 10.9
Hex Bolt M4x16 DIN 933 8.8
Hex Lock Nut M4 DIN 985 Cl8
Rear Idler Cover
Chain Holder
Roller Chain
Connecting link
Slide Strip
Flat socket head screw M4x20 DIN 799
Cable strap
Star washer 6
Limit Door Switch
Self-drill screw 8x1/2"
Part No
111-00-0021
107-11-004-1
632-06-025
111-00-013
601-06-006
632-06-016
111-02-017
128-08-018
600-32-061
600-12-080
632-06-030
601-02-006
602-02-006
111-02-003
614-06-016
632-04-016
602-02-004
153-01-0021
128-00-0021
178-00-002-1
900-01-072
134-01-002
613-04-020
125-10-015
600-04-061
124-00-039
647-08-003
Page 15. Part List
Unit
(183 links L-2936mm)
Qty
1
1
4
1
12
8
1
1
1
6
2
3
2
1
2
2
4
1
1
1
2
1
2
1
2
1
1
FIAT Ducato
PEUGEOT Boxer
CITROEN Jumper / Relay
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Parts list of ASD system
No
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
Designation
Part No
Pneumatic safety switch
Pneumatic safety switch ASSY
Philips Screw 6x3/8"
Pneumatic Safety Strip
Rubber Tube
Operating switch
Signal lamp
Decal
Fuse 30A
Hex flange nut M8
Gear Motor Cover
Side Cover L3
Flat socket head screw M6x20
Screw 8x3/4"
Drain pan
Rubber grommet
Side Cover L2
Page 16. Part List
122-10-047
160-10-042
646-08-017
112-06-109
113-06-067
124-00-018
124-10-069
125-00-018
125-10-084
601-08-008
153-00-0021
153-02-0021
613-06-020-1
646-08-024
153-04-0021
112-04-000
153-15-021
Quantity
1
2
2m
1
1
1
1
1
1
1
1
2
4
1
3
1
FIAT Ducato
PEUGEOT Boxer
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Electric Harness Fiat Ducato
116-15-002-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 17. Wiring
Remote Control Set
Latching relay 12v ASSY
1
1
PowerDoorAndStep.com
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FIAT Ducato
PEUGEOT Boxer
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1
4
ASD Fiat Ducato Original Door
latches mechanism & operation
with handles
160-15-201
7
6
5
3
2
ITEM NO.
1
2
3
4
5
6
7
PART NUMBER
111-15-201
125-10-014
125-10-016
601-06-006
125-10-005
646-08-020
DESCRIPTION
Fiat Ducato locker bracket ASSY
Cable strap 100mm
Cable strap 150mm
Hex flange nut M6 DIN 6923
Plastic clamp UC-2 3/8"
Phillips screw 6x3/8"
Socket flat head screw M6X16
613-06-016
QTY.
1
2
3
2
1
1
2
3
7
1
Fiat Ducato locker
ASSY
6
111-15-201
9
5
6
8
2
ITEM NO.
1
2
3
5
6
7
8
9
PART NUMBER
128-15-201
110-01-006-10
110-11-006
128-36-309
DESCRIPTION
Actuator bracket
Lock actuator ASSY
Actuator ASSY
V363: V408 Lock Actuator arm
Philips cross Screw 4.2
632-04-016
128-15-203
602-02-004
Page 18. Lock Actuator ASSY installation.
Hex bolt M4x16 , DIN933
Cables adapter
Lock nut M4 DIN985
QTY.
1
1
1
1
4
1
1
FIAT Ducato
PEUGEOT Boxer
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Cut
Internal door handle cables
External door handle cable
28
lower release cable
Cancel the lower latch
Page 19. Cable Diagram
PowerDoorAndStep.com
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Cut
Page 20. Lock Actuator ASSY installation.
PowerDoorAndStep.com
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FIAT Ducato
PEUGEOT Boxer
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Hex flange nut M6
Socket flat head screw M6X16
Page 21. Lock Actuator ASSY installation.
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PEUGEOT Boxer
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R
PE
SU
SU
R
G
PE
60 sec
E
UE
LU
GL
Lock Actuator ASSY.
15
Left Sliding Door edge
Safety strip
Close
Pneumatic Switch ASSY
Transmitter
PN:160-10-042
2
Safety Switch
Clean surface carefully with alcohol to insure
good contact of the pneumatic safety strip.
2
Pneumatic Safety Strip
PN: 112-06-109
37
SU
PE
R
GL
UE
Rubber tube 38
Drill hole for rubber tube
Page 22. Pneumatic Safety Strip & Pneumatic Switch Installation
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Pressure Safety Switch
Pneumatic rubber
Hex key
Nº 4mm
PN:160-10-042
Pneumatic Switch
PN:122-10-047
Sensitivity adjustment
Increase Sens
Decrease Sens
Page 23.
PN:160-10-042
FIAT Ducato
PEUGEOT Boxer
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Disconnect
C-Pillar
Sliding door
Beige yellow
Black
Red
Green
Blue
Green
Blue
Violet / black
Cut
OE pink wire- plug sliding door
OE red/black wire- plug sliding door
Cut off
Page 24. Wiring
FIAT Ducato
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Operating by OE handle + latch
Sliding door
Pressure switch
Green
Blue
Green
White/Blue
Red
Plug
Black
White
10
9
8
7
6
2
1
Con 5
5
4
3
Black
Blue
White
Buzzer
Black
Blue
Plug
Operating switch
Internal micro switch
Black
Green
Orange
locker
VSS
Pulse Detector
Black
Black
Black
White
Green
Red
Yellow
6
Red 1.5 mm
7
AK-105L
8
Orange
9
30
10
Blue
87
1
86 85
2
Green
3
Green
Black
Red
Red
latch Relay 12 V
Battery
12V
Blue
Green
5A
Black
Red
Blue
Green
Black
Red
Remote Control
(receiver)
1
Remote Control
(receiver)
2
Red
30A
Page 25. Wiring Diagram
Red 1.5 mm
30
Connect to VSS
Pulse
Green
86
+ACC
MOTOR 12V DC
87
Blue
Relay 12 V
85
Signal Lamp
4
OE pink wire- plug sliding door
Green
VSS
Buzzer Black
5
OE red/black wire- plug sliding door
Plug
Door limit swith
D1
ai
M
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fo
in
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o.
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oc
t
u
8
7
PowerDoorAndStep.com
27
49
L
888.928.8000
AE
h
ox
.B
O
P.
09
46
c
ta
Pe
a
ikv
-T
R
IS
AT
FI
ASD
Automatic Sliding Door
External emergency
door opening kit
PN: 111-03-013
Page 26
FIAT Ducato
PEUGEOT Boxer
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AT
FI
min 1000mm
Recommended Emergency door opening
system location
max 50
0mm
Page 27.
FIAT Ducato
PEUGEOT Boxer
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Gear-motor ASSY
Nut 6 ST
Nut 6 ST
External emergency
door opening KIT
PN: 111-03-013
Internal emergency handle
Spring
140-03-013
Bracket
128-03-013A
Emergency Door Handle
111-03-0131
Emergency Handle Cover
151-03-131
Socket head M5x12
Page 28.
FIAT Ducato
PEUGEOT Boxer
CITROEN Jumper / Relay
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Figure1
cut
Sikaflex-221
Install the external handle for emergency 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 29.
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PowerDoorAndStep.com
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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 30.
FIAT Ducato
PEUGEOT Boxer
CITROEN Jumper / Relay
015-0002-DL
EMERCENCY
E
M
E
R
G
E
N
C
Y
EMERCENCY
Emergency handle bracket
Emergency handle
PowerDoorAndStep.com
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Internal emergency door kit
PN: 160-15-000
FRONT
AUTO
COOL
EMERCE
N CY
1
Insert the emergency handle 1 . Move the handle to left
for manual operating
Page 31.
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Recommended Torques
[ newton meter]
8.8
TORQUE
TORQUE
[Nm]
[Nm]
M5
6.031
M5
8
M6
10.3
M6
10
M8
25.4
M8
13
Page 32
PowerDoorAndStep.com
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FIAT Ducato
PEUGEOT Boxer
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015-0002-DL
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 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 33
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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 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 – 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.
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 34