INNOVATION IN MOBILITY™
Contents
1. INNOVATION IN MOBILITY RDO2500 Series Power Sliding Door Operator PRINT Service Manual 02 14 02 3200002 1992 02 RICON CORPORATION All Rights Reserved U S Patent Nos 5 794 381 Other U S and foreign patents n Printed in the Un of Ameri This service manual is for use by qualified service technicians and is not intended for use by non professionals do it yourselfers The manual provides es sential instructions and reference information which sup ports qualified technicians in the correct installation and maintenance of Ricon products Qualified service technicians have the training and knowl edge to perform maintenance work properly and safely For the location of a Ricon authorized service technician in your area call Ricon Product Support at 1 800 322 2884 Customer i Installing Dealer gt Date Instaled Serial Number REVISION RECORD REV PAGES DESCRIPTION OF CHANGE ECR ECO 3200002 All New release in two book format 3882 4864 A END OF LIST TABLE OF CONTENTS Chapter Page INTRODUCTION eR m 1 1 A ONE YEAR LIMITED WARRANTY iiie tuts er Eh Perte 1 1 SHIPMENT INFORMATION ces 1 3 C GENERAL SAFETY 12. one of the following locations Ricon Corporation 7900 Nelson Road Panorama City CA 91402 Outside 818 Area Code World Wide Website Ricon U K Ltd E SEIN ENG 818 267 3000 800 322 2884 daaa MEI E www riconcorp com Littlemoss Business Park Littlemoss Road Droylsden Manchester United Kingdom M43 7EF nn 44 161 301 6000 A RICON ONE YEAR LIMITED WARRANTY refer to following page RICON CORPORATION ONE YEAR LIMITED WARRANTY Ricon Corporation Ricon warrants to original purchaser of this product that Ricon will repair or replace at its option any part that fails due to defective material or workmanship as follows Repair or replace parts for a period of one year from date of purchase If you need to return a product Return this Ricon product to your installing dealer Please give as much advance notice as possible and allow a reasonable amount of time for repairs If you are traveling All authorized Ricon dealers honor this warranty Consult telephone directory or call our Product Support department for the name of the nearest authorized Ricon dealer This warranty does not cover Labor or service charges these may be covered separately by the installing dealer Malfunction or damage to product parts caused by accident misuse lack of proper maintenance neglect improper adjustment modification alteration the mecha
3. 1 This page intentionally left blank INTRODUCTION signed to operate most full size vans and works in conjunction with Ricon S Series Spirit and UNI lite T he RICON RDO2500 Series Power Sliding Door Operator opens and closes sliding van doors It has been de Wheelchair Lifts The power door operator is electrically connected to and is operated with the controls of the wheelchair lift or ramp As the lift is activated to DE PLOY extend from the vehicle the power door operator automatically opens the vehicle door to allow the lift to deploy The door operator auto matically closes the vehicle door after the platform has been retracted into the vehicle This manual contains installation maintenance instructions and spare parts for the power door operator The installation instructions must be fol lowed exactly no steps should be eliminated nor should the product be modified It is important to user safety that the installation is thorough and correct It is equally important that the Ricon sales service staff be com pletely familiar with the Operators manual to demonstrate and explain the proper use of the product to the user Once the door operator is installed itis very important that it be properly maintained by following the Ricon recommended cleaning lubrication and inspection instructions If there are questions about this manual or additional copies are needed please contact Ricon Product Support at
4. 3 D COMPONENT TERMINOLOGY aaar 1 4 IM ae 2 1 uel pe NUI NE qus TE 2 1 11 VAN PREPARATION tides E E MIL ET 2 1 2 DOOR OPERATOR 5 2 1 3 FORWARD DOOR BRACKET 2 1 4 CHAIN HOOK 5 2 1 5 55 acct re 2 2 B ELECTRICAL INSTALLATION rete rire tear e e east tate tut erben 2 2 C INSTALU COVER qe 2 2 D VERIFY INSTALLATION aaa anaa a 2 2 E CUSTOMER ORIENTATION a E 2 2 1 MAINTENANCE Ec 3 1 A MAINTENANCE SCHEDULE 3 1 TROUBLESHOO TING 3 2 C ELECTRICAL WIRING 1 dre qn 3 3 1 DIAGRAM LEGEND 2 bededduhed 3 3 2 WIRING DIAGRAM s t esas rts dente ees amc a 3 5 IV PARTS DIAGRAMS AND tue 4
5. exclusion may not apply Important The warranty registration card must be completed and returned to Ricon within 20 days after instal lation of this Ricon product for the warranty to be valid The warranty is not transferable The warranty gives specific legal rights and there may be other rights that vary from state to state SHIPMENT INFORMATION Ricon does not sell directly to the user because of the specialized nature of this product The product is distributed through a worldwide network of authorized Ricon dealers who perform the actual installation Be sure installation kit contains all items listed on kit packing list Please report any missing items immediately to Ricon Product Support The warranty and owner registration cards must be completed and returned to Ricon within 20 days for the warranty to be valid The Sales Service Personnel must review the Warranty and this Operator Manual with user to be certain that they understand safe product operation Instruct the user to follow operating instructions without exception C GENERAL SAFETY PRECAUTIONS The following general safety precautions must be followed during installation operation service and maintenance Under circumstances should installation maintenance repair or adjustments be attempted without the immediate presence of a person capable of rendering aid An injury matter how slight must be attended Administer first aid or seek medical atten
6. 1 NUT HEX 5 16 18 NYLON INSERT 2 28314 12 SPRING COMPRESSION 0 297 OD X 0 75 1 254524 13 WASHER DELRIN CLUTCH 1 R25 0106 14 SPROCKET CLUTCH 1 R25 0105 15 ASSEMBLY MECH CLUTCH PIN AND PLATE 1 R25 0115 16 CLIP RETAINER SPRING 1 R25 0107 17 ROLLPIN 1 8 X 1 SST 2 28354 18 ASSEMBLY WELD LEVER CLUTCH 1 R25 0123 19 SLEEVE CLUTCH 1 R25 0103 20 BRACKET SUPPORT CLUTCH 1 R25 0101 21 SPRING FLAP LATCH PIN 1 25442 22 DECAL PATENT DOOR OPERATORS 1 32 10 174 3200002 This page intentionally left blank 3200002
7. GRAM MOTOR 000000000 O FIGURE 3 3 RDO2500 ELECTRICAL WIRING DIAGRAM TRIPPED WHE DOOR OPENE This page intentionally left blank SPARE PARTS his chapter contains parts diagrams and lists for the RICON RDO2500 Series Power Sliding Door Operator The diagrams are exploded views of lift components with individual components referenced by numbers Each accompanying parts list contains the part reference number description quantity used and the Ricon stock number For parts identification locate the part on the appropriate drawing and note the reference number The parts list that accompanies each drawing will list the stock number of the desired part PRODUCT MODEL AND KIT NUMBERS 3200002 4 1 32PD250 G FIGURE 4 1 POWER DOOR OPERATOR RDO2500 SERIES 3200002 FIGURE 4 1 POWER DOOR OPERATOR RDO2500 SERIES SERIAL No s 250001 and HIGHER REF DESCRIPTION QTY PART NO 1 MS 10 24 X 3 8 PHIL PAN 4 28109 2 COVER DOOR OPENER 1 R25 0003 3 SOC BUTTON HD 5 16 18X2 3 28146 4 ROLLER SLIDER 38 ID X 72 L 2 01511 5 BOLT SHOULDER 3 8X3 4 2 28377 6 BRACKET MAIN MOTOR MOUNTING 1 R25 0001 7 CLAMP NYLON 5 16 BLACK 1 28 02 351 8 MOTOR ASSY 1 V2 ES 040 9 RELAY MODIFIED 2 R25 0005 10 BLOCK SUPPORT MOTOR BRACKET 1 R25 0007 1
8. Installation Instructions c Install the forward door using the three 8 Phillips head sheetmetal screws provided 4 CHAIN HOOK INSTALLATION Refer to the Installation Instructions provided in the Power Door Operator Kit for information pertaining to your particular vehicle make or model 3200002 2 1 5 CHAIN ASSEMBLY Route chain inside the vehicle passing it through the Delrin bushing previously installed in the interior door panel see Installation Instructions Refer to Figure 2 1 Route chain around three rollers and spur gear Close sliding door completely and route chain around roller on the forward door bracket and door operator rollers Be certain not to twist chain between the forward door bracket and door operator rollers Refer to Figure 2 2 Once the chain has been routed around the forward door bracket roller pull chain toward the sliding door and install washer over the chain While maintaining a taut pull on the chain insert the forward hook end of the spring through the chain link behind the washer Attach the rear hook end of spring through eyelet on the forward door bracket B ELECTRICAL INSTALLATION Refer to the Installation Instructions provided in the power door operator kit for information pertaining to your particular vehicle make model C INSTALL COVER 1 Insert release from inside to outside and insert clip to secure it see Installation Instructions 2 Place cover ov
9. OMPONENT TERMS 1 Gearmotor Opens and closes the vehicle door Main plate Mounts the door operator assembly securely to the vehicle door Exit rollers Routes chain to and from gearmotor of the gear sprocket and easier manual operation of the vehicle door Cover Houses the door operator assemoy _ END OF TABLE ll INSTALLATION he chapter provides instructions for installing the RICON RDO2500 Series Power Sliding Door Operator into most full size vans Custom installations are possible in other types of vehicles Please contact Ricon Product Support for assistance if a question arises that is not covered here it is impractical to provide specific informa tion in this manual for every possible application N CAUTION This Ricon product requires a precise installation The product must be installed by a trained authorized Ricon service technician The following instructions explain the four basic steps for installing the power door operator A Mechanical B Electrical C Install cover D Installation verification A MECHANICAL INSTALLATION 1 VAN PREPARATION a Safely park van on a flat level surface and turn off engine b The power door operator must be attached directly to the metal of the vehicle Remove existing door panels interfering carpet plywood molding wall paneling etc Clear area of all loose material N WARNING WEAR PROTECTIVE CLOTHING AND EYE
10. PROTECTION ALL TIMES BATTERIES CONTAIN ACID THAT CAN BURN IF ACID COMES INTO CONTACT WITH SKIN IM MEDIATELY FLUSH AFFECTED AREA WITH WATER AND WASH WITH SOAP NOT SMOKE OR USE OPEN FLAME IN THE VICINITY OF BATTERY ALWAYS WORK IN A PROPERLY VENTILATED AREA DO NOT LAY ANYTHING METALLIC TOP OF BATTERY Atvehicle engine compartment disconnect the positive cable from the battery d With the door closed check the clearance between the side of the van door and the van body Verify that the clearances at the right and left side of the door are the same width Door should operate freely and easily before installing door operator e Drill mounting holes as specified in the Installation Instructions provided with the Power Door Operator kit 2 DOOR OPERATOR INSTALLATION Refer to the Installation Instructions provided in the Power Door Operator kit for information pertaining to your particular vehicle make and model 3 FORWARD DOOR BRACKET INSTALLATION a Position the forward door bracket as shown in the Installation Instructions and using the bracket as a template mark the mounting hole locations NOTE Be certain that the roller on the forward door bracket assembly is properly aligned vertically with the exit roller of the Power Door Operator If not aligned properly the chain will create excessive noise b Center punch the mounting hole locations then drill the mounting holes see
11. ches only OPEN MOTION CLOSE MOTION POSSIBLE CAUSE REMEDY Battery terminals dirty Ground connection Battery defective Battery discharged Circuit breaker defective Switch defective Loose connection Toggle switch defective Wiring connection Limit switch at right door defective Motor defective Poor ground connection Toggle switch defective Wiring connection Limit switch at left door defective Left motor defective Ground connection Clean tighten Clean repair Check battery capacity charge battery power wire or replace END OF TABLE 1 ELECTRICAL WIRING DIAGRAM DIAGRAM LEGEND a Color Codes Bak b Connectors Green w black W O Orange w black Y BK EN D OF TABLE Violet w black White w orange Yellow w black Refer to Figure 3 1 The standard electrical connectors used by Ricon are Molex 062 Series These con nectors have terminal numbers stamped onto the rear Use these numbers and colors to identify all wires RECEP TACLE R Volts Circuit current Left rating is also given signal to lift Attempt checks door system Deploy Attempt first Non sequenced DO followed by OUT d l SPDT LIMIT SWITCH GROUND WIRE CROSSINGS NOT CONNECTED CONNECTED FIGURE 3 2 DIAGRAM SYMBOLS 2 WIRING DIA
12. er power door operator and secure using supplied screws D VERIFY INSTALLATION Be certain there is interference with operation of the door operator by interior exterior components Verify proper manual operation of door operator Ensure that the serial number decal is properly located and affixed to the power door operator E CUSTOMER ORIENTATION IMPORTANT Customer Orientation 3200002 t DOOR BRACKET FIGURE 2 2 WASHER INSTALLATION ON CHAIN ASSEMLBY Ricon Sales Service Personnel must review the Warranty and Operator Manual with the customer to be certain they understand safe operation of the equipment Instruct the customer to follow the operating instructions without exception lil MAINTENANCE egular maintenance of the RDO2500 Series Power Sliding Door Operator will provide optimum per R formance During the Ricon warranty period maintenance inspections must be performed by an authorized Ricon service technician at least once every six months or sooner depending on usage After the warranty period maintenance inspections are recommended at the same intervals N CAUTION This Ricon product is highly specialized Maintenance must be performed by an authorized Ricon service technician using Ricon replacement parts Modifying or failing to properly maintain this product will void the warranty and may result in unsafe operating conditions To maintain the warranty this p
13. nical condition of vehicle road hazards over loading failure to follow operating instructions or acts of Nature i e weather lightning flood Note Ricon recommends this product be inspected by an authorized Ricon service technician at least once every six months or sooner if necessary Any required maintenance should be performed at that time N WARNING THIS PRODUCT HAS BEEN DESIGNED AND MANUFACTURED TO EXACT SPECIFICATIONS MODIFICATION OF THIS PRODUCT IN ANY RESPECT CAN BE DANGEROUS This Warranty is Void if The product has been installed or maintained by someone other than an authorized Ricon service techni cian The product has been modified or altered in any respect from its original design without written authoriza tion by Ricon Ricon disclaims liability for any personal injury or property damage that results from operation of a Ricon prod uct that has been modified from the original Ricon design No person or company is authorized to change the design of this Ricon product without written authorization by Ricon Ricon s obligation under this warranty is exclusively limited to the repair or exchange of parts that fail within the applicable warranty period Ricon assumes no responsibility for expenses or damages including incidental or consequential damages Some states do not allow the exclusion or limitation of incidental or consequential damages so the above limi tation or
14. roduct must be inspected at least every six months or sooner depending on usage A MAINTENANCE SCHEDULE TABLE 3 1 PERIODIC MAINTENANCE Check and clean chain and rollers Check manual operation of power door operator per instructions in the Op Verify proper operation erator Manual Chapter 11 REMOVE DOOR PANELS Check spur gear and bushings for signs of wear Replace if needed Check wiring and limit switches for proper connection and or interface points Adjust as required END OF TABLE TROUBLESHOOTING GUIDE The troubleshooting guide is designed to provide a logical starting point to locate general problems that could occur with the door operator However not all possible problems or combinations of problems are listed The guide does not incorporate routine safety precautions or preliminary procedures and assumes that the vehicle battery is fully charged and the battery terminals are clean and tight N WARNING THE TROUBLESHOOTING GUIDE DOES NOT INCORPORATE ROUTINE SAFETY PRE CAUTIONS OR PRELIMINARY PROCEDURES DURING THE RICON WARRANTY PERIOD AN AUTHORIZED RICON SERVICE TECHNICIAN MUST PERFORM TROUBLESHOOTING AFTER THE WARRANTY PERIOD IT IS RECOMMENDED THAT TROUBLESHOOTING CONTINUE TO BE PERFORMED BY AN AUTHORIZED RICON SERVICE TECHNICIAN TABLE 3 2 TROUBLESHOOTING GUIDE SYMPTOM NO OPERATION No power to door operators Power to swit
15. tion immediately Protective eyeshields and appropriate clothing should be worn at all times Avoid injury exercise caution when using door operator and be certain that hands feet legs and clothing are out of the path of the moving door and lift Batteries contain acid can burn If acid comes contact with skin immediately flush affected area with water and wash with soap Always work properly ventilated area Do not smoke or use an open flame near battery Do not lay anything metallic on top of battery Check under vehicle before drilling to avoid damaging the frame subframe members wiring hydraulic lines fuel lines fuel tank etc Read and thoroughly understand the operating instructions before attempting to use door operator Inspect the product for any unsafe condition before using If unusual noise or movement is present not use product until the problem is corrected Keep others clear during operation The product requires regular periodic maintenance A thorough inspection is recommended at least once every six months The product should be maintained at the highest level of performance D COMPONENT TERMINOLOGY The references used throughout this manual are illustrated in Figure 1 1 and defined in Table 1 1 Refer to Service Manual Chapter IV Spare Parts for more details FIGURE 1 1 RDO2500 POWER DOOR OPERATOR COMPONENTS TABLE 1 1 RDO2500 SERIES C
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