Automatic Sliding Door Set
Contents
1. Page 9 Roller chain installation V363 ord TRANSIT Power Door amp RWD FWD Step Long Wheel Base PowerDoorAndStep com 888 928 8000 Page 10 Roller chain installation V363 Chord TRANSIT Power Door amp RWD FWD Step Long Wheel Base PowerDoorAndStep com 888 928 8000 V363 ord TRANSIT Power Door amp RWD FWD Step mm Plus wire installation Long Wheel Base PowerDoorAndStep com 888 928 8000 Batter Gear motor ASSY Pneumatic safety switch Pneumatic safety strip Door limit switch Signal Lamp Operation Switch Chassis ground H Page 12 Wiring Power V363 Chord TRANSIT Door amp RWD FWD Step Long Wheel Base PowerDoorAndStep com 888 928 8000 Electrical Accessories Kit PN 160 36 300 Operating Switch F Pneumatic safety strip PN 124 02 012 1 PN 113 65067 Signal Light PN 124 10 069 Pneumatic Plastic Tube Decal PN 113 26063 PN 125 00 018 Rubber Tube PN 113 06 067 Fast Glue Door Limit Switch PN 144 30 007 PN 124 00 039 Cable strap PN 125 10 016 Cable strap Pneumatic Safety Switch Assy PN 125 10 014 PN 160 10 042 Page 13 Electrical Accessories Kit Power V363 ord TRANSIT Door amp RWD FWD Step Long Wheel Base PowerDoorAndStep com 888 928 8000 Door Limit Switch Self drilling scr2. PowerDoorAndStep com 888 928 8000 mm Pneumatic rubber tube Hex key N 4mm PN 160 10 042 Pneumatic Switch PN 122 10 047 Sensitivity adjustment 9 Increase Sens Decrease Sens Page 29 Power V363 ord TRANSIT Door amp RWD FWD Step Long Wheel Base PowerDoorAndStep com 888 928 8000 ASD Basic Troubleshooting 1 Door does not function e Check main fuse Check connections of power terminals to the control unit motor and operating switch e Check Control units AK 105L e Check motor 2 Door does not operate upon commencing the closing mode or when reaching the fully closed position it reverses e Check the safety pneumatic pressure tube disconnect the plugs of pressure switch and close the door e If the issue is not solved try to regulate the sensitivity of the pressure switch e Check safety switch e Reset the system by extracting the fuse and returning it to its place e Check control unit AK105 3 Door does not close completely e Check voltage of battery if low start the engine 4 Door does not open although the electrical motor is engaged e 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 e Check safety pneumatic switch e Check pressure tube amp switch e Check control unit 6 Noise from the door s chain during opening and
3. or closing modes e Check installation and alignment of all wheel supports front and rear as well as the gear motor support e Very loose chain may also jump over and cause damage to the sprockets main motor e Check chain tension and if needed shorten it by removing one or two links 7 Remote control unit does not function e Check connection of power terminals e 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 e Check connections to the VSS unit e Check VSS unit 9 Buzzer does not operate during the closing mode e 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 Power V363 Jord TRANSIT Door amp RWD FWD Step 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 swit
4. 28 8000 V363 Ford TRANSIT RWD FWD Long Wheel Base ASD Automatic Sliding Door External emergency door opening kit PN 111 03 013 Option Page 25 Power V363 ord TRANSIT Door amp RWD FWD Step Long Wheel Base PowerDoorAndStep com 888 928 8000 Gear motor ASSY Nut 6 ST Na x_Internal emergency handle Emergency door KIT PN 111 03 013 Spring Bracket PN 128 03 013A Emergency door handle ee PN 111 03 0131 Socket head M5X16 Emergency handle cover PN 151 03 131 Page 26 V363 Ford TRANSIT RWD FWD Long Wheel Base Power Door amp Step PowerDoorAndStep com 888 928 8000 Figure1 Figure2 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 RWD FWD Long Wheel Base V363 Sord TRANSIT J Power Door amp step PowerDoorAndStep com 888 928 8000 Insert the emergency handle 7 Move the handle to right for electrical operating Install the cable 5 Clamping lug OE Washer 4 Aii f KL UCU AE Washer 4 Spring 8 Bolt M4X8 Nylock Nut M5 Page 28 Power V363 ord TRANSIT Door amp RWD FWD Step Long Wheel Base
5. 3 Ford TRANSIT RWD FWD Long Wheel Base J Power Door amp Step PowerDoorAndStep com 888 928 8000 Step 2 Step 2 Page 18 Rerouting Cable Power V363 Chord TRANSIT Door amp RWD FWD Step Long Wheel Base 388928 8000 ee Lock Actuator ASSY 111 36 354 Long sleeve 1 Short sleeve 2 ITEM NO PART NUMBER DESCRIPTION QTY 1 128 36 354 2 V363 Lock Actuator bracket 1 2 110 01 006 10 Lock Actuator ASSY 1 3 110 01 006 Screw 4 2 4 128 36 309 V363 V408 Lock Actuator arm 1 5 128 15 203 Cables adapter 1 Use original hole gt Use this hole for O E cables clamp Page 19 Lock Actuator ASSY installation V363 ord TRANSIT Power Door amp RWD FWD Step Long Wheel Base PowerDoorAndStep com 888 928 8000 Page 20 O E Cables installation Power Door amp Step PowerDoorAndStep com 888 928 8000 V363 Ford TRANSIT RWD FWD Long Wheel Base V363 Electric Harness Ford Transit 116 36 301 DL j EN A h S IN Y la Y ITEM NO PART NUMB
6. ER 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 Remote Control Set 1 6 124 13 902 Latching relay 12v ASSY 1 7 124 00 032 Buzzer 12v 1 8 124 10 052 Socket terminal relay 1 9 R2A4 124 Relay 1 Page 21 Wiring PowerDoorAndStep com 888 928 8000 Power V363 ord TRANSIT Door amp RWD FWD Step Long Wheel Base B Pillar B Pillar Central locking Close 4p EMPTY Violet White B Pillar Pneumatic safety strip Page 22 Wiring Power Door amp Step PowerDoorAndStep com 888 928 8000 O E Plug B Pilar 4321 Green gt CUT E eo gt Sia al ma F O E a gt 85 8 E g 7 Es 2 A D Ds x 86 30 S JE JF E eje BE u ii Red Ojo Black waa 0 latch Relay 12 V Battery 12V V363 Ford TRANSIT RWD FWD Long Wheel Base Under driver seat DRIVING SPEED VSS PULSE White Blue VSS Pulse Detector VSS White pin1 Connect to VSS Signal Lamp Red Remote Control receiver 2 i Remote Control receiver Page 23 Wiring diagram p V363 ord TRANSIT Power Door amp RWD FWD Step Long Wheel Base PowerDoorAndStep com 888 928 8000 Handle PN 151 36 301 Cover Phillips screw M6 Page 24 Cover installation Power Door amp Step PowerDoorAndStep com 888 9
7. PowerDoorAndStep com 888 928 8000 V363 Lord TRANSIT RWD FWD Long Wheel Base Jumbo Automatic Sliding Door Set PN 015 3631 DL Original Door latch mechanism amp operation with handles Power V363 Chord TRANSIT Door amp RWD FWD Step Long Wheel Base PowerDoorAndStep com 888 928 8000 Door lock mechanism Fuse 30A Operating Switch Control unit AK105L Door limit switch Main wiring harness O E Door latch Page 1 General view of ASD system Power V363 Ford TRANSIT Door amp RWD FWD Step Long Wheel Base PowerDoorAndStep com 888 928 8000 Page 2 Cutting and preparation Power V363 Chord TRANSIT Door amp RWD FWD Step Long Wheel Base PowerDoorAndStep com 888 928 8000 O V363 Gear Motor Support Kit 160 36 310 ITEM NO PART NUMBER DESCRIPTION QTY 1 111 36 310 V363 Gear Motor Support Right side 1 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 7 6 601 06 006 Hex flange nut M6 DIN 6923 4 7 107 11 004 1 Idler Wheel 1 Page 3 Gear motor installation Power V363 Chord TRANSIT Door amp RWD FWD Step Long Wheel Base PowerDoorAndStep com 888 928 8000 drill hole 16mm or roller chain Template H m
8. ch 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 vehicles 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 dev
9. ew 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 Power Door amp Step PowerDoorAndStep com 888 928 8000 V363 ord TRANSIT RWD FWD Long Wheel Base Lock Actuator Clean surface carefully with alcohol to insure good contact of the pneumatic safety strip Transmitter Pneumatic Safety Strip PN 112 06 109 Page 15 Pneumatic Safety Strip amp Pneumatic Switch Installation Safety strip Left Sliding Door edge Power V363 Chord TRANSIT Door amp RWD FWD Step Long Wheel Base PowerDoorAndStep com 888 928 8000 Door lock mechanism OE Door latch Page 16 Actuator ASSY installation Power V363 Jord TRANSIT Door amp RWD FWD te p Long Wheel Base PowerDoorAndStep com 888 928 8000 ASD V363 Ford Transit Original Door latch mechanism amp operation with handles 160 36 301 ITEM NO PART NUMBER DESCRIPTION QTY 1 111 36 354 Lock Actuator bracket ASSY 1 2 632 06 016 Hex cap screw M6x15 2 3 125 10 005 Plastic clamp UC 2 3 8 1 4 601 06 006 Hex flange nut M6 DIN 6923 2 5 646 08 020 Phillips screw 6x3 8 1 6 125 10 016 Cable strap 100mm 3 7 125 10 014 Cable strap 100mm 2 Internal door handle cables fF 7 SS UA lower release cable Page 17 Cable Diagram V36
10. front Transit 1 4 613 06 020 Socket flat head screw M6X20 2 5 Washer 6 1 Step1 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 Inside Page 6 Chain Slide Strip Installation Power V363 Chord TRANSIT Door amp RWD FWD Step Long Wheel Base PowerDoorAndStep com 888 928 8000 Rear Idler Kit 160 36 340 ITEM NO PART NUMBER DESCRIPTION Exploded QTY 1 111 02 013 1 Rear idler 1 2 614 06 016 Socket button head cap screw 2 3 603 02 006 Rivet nut M6 1 Sprocket ASSY 107 36 300 Drill hole 9 5mm and install the threaded GE Page Rear ldler Installation V363 ord TRANSIT Power Door amp RWD FWD Step Long Wheel Base PowerDoorAndStep com 888 928 8000 mm Roller chain route for installation mm Electrical position Page 8 Roller chain installation Power V363 ord TRANSIT Door amp RWD FWD Ste D Long Wheel Base PowerDoorAndStep com 888 928 8000 Roller Chain Kit 160 36 350 ITEM NO PART NUMBER DESCRIPTION Exploded QTY 1 111 36 320 Chain bracket 1 2 178 36 300 Roller chain T mm 192 2 3 900 01 072 Chain connecting link B05 2 4 134 36 303 V363 Slider 1 5 647 03 012 Screw M3x12 1
11. i CPikar SN in ZA Page 4 Gear motor installation wer V363 Chord TRANSIT Door amp RWD FWD Ste D Long Wheel Base PowerDoorAndStep com 888 928 8000 3 V363 Front Idler Kit 160 36 320 ITEM NO 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 Spring Washer 6 3 BO Hi 6 601 06 006 Hex flange nut M6 DIN 6923 2 cane 7 632 06 020 Hex bolt M6x20 DIN933 8 8 3 V363 LHD Front idler upper holder 128 36 304 Hex nut M6 DIN 934 Cl 6 Sprocket ASSY 107 36 300 Idler thes ore 107 11 004 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 3 holes 9 5mm and install the threaded inserts QTY 3 Page 5 Front Idler Installation Power Door amp Step PowerDoorAndStep com 888 928 8000 V363 Ford TRANSIT RWD FWD Long Wheel Base Chain Slide Strip Kit 160 36 330 ITEM NO PART NUMBER DESCRIPTION QTY 1 134 36 301 Chain Slide Strip Transit 1 2 601 06 006 Hex flange Nut M6 1 3 134 36 302 Chain Slide Strip
12. ice 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 Power V363 Chord TRANSIT Door amp RWD FWD Step Long Wheel Base PowerDoorAndStep com sic ana Tools required for installation ASD AAD STEP ATG SLIPS Saw BLades High speed threaded insert tool 13mm Pneumatic Drill Heavy duty hand tool for field and low volume production use or Air Die Grinder ME 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 Power V363 Chord TRANSIT Door amp RWD FWD Step Long Wheel Base PowerDoorAndStep com 888 928 8000 Straight Flute HSS Step Drill diameter 4 30mm Straight Shank Twist Drill diameter 4mm 5mm 6mm 6 5mm 7mm 9 5mm 12mm T Handle Set Hand Files Wire Stripper Crimper Plier Set 1 4 Drive Socket Set metric np Screwdriver Set Page 33
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