TECHNICIAN CERTIFICATION VER10917

Transcription

1 TECHNICIAN CERTIFICATION VER10917

2 Table of Contents Brief Overview of the ATC Conversion and Operation 3 Receiving the Vehicle 4 ATC Warranty 5 ATC Warranty Procedure 6 Vehicle Operation 7 Suggested Tools 8 Primary Components 9 Primary Components 2 10 Primary Components 3 11 Troubleshooting - General 12 Troubleshooting - Door 13 Troubleshooting - Lift 14 Airbag Warning Diagnosis 15 Airbag Warning Diagnosis (continued) 16 Airbag Components & Door Magnet (Driver Side Conversion) 17 DTC Codes 18 Hydraulics 19 Hydraulic Components 20 Hydraulic Cylinder Adjustments 21 Hydraulic Swing Cylinder Components 22 Manual Hydraulic System Operation 23 Limit Switch Function & Adjustment 24 Latch System 25 Door Seal Leak 26 Dealer Certification Test 27 2

3 Brief Overview of the ATC Conversion and Operation The door opening is controlled independently from the lift operation. This is to allow someone to open and close the door without having to deploy the lift. It also enables a user to avoid having to open the door completely in the case where they may encounter an obstruction. However, to insure the door is opened far enough to prevent the lift from hitting it on deployment, there is a tilt switch mounted on the door that insures it is opened far enough to prevent damage. To prevent injury and damage to the door, it will not open if the seat belt is plugged into its receptacle. A seat belt extension plugged in will also prevent the door from opening. Once the door has moved far enough to satisfy the tilt switch, the user can hit the lift out button. The lift will then move outwards until it hits the out limit switch. At this point the controller will automatically turn off the horizontal switch and start lowering the lift. The lift will continue to lower until either the user stops it, or it runs out of stroke. There is no down limit switch to allow the unit to reach the ground on various terrain. When the unit runs out of stroke the pump will go into bypass mode, which is a valve that limits the amount of up pressure the pump will generate. There is also a hold valve in the unit that will prevent cylinder movement whenever the control button is released. With the door open and the system deployed, the user will hit the in button for the lift. The controller will turn on the pump and open the vertical up valve making the lift rise. This will continue until the unit hits the up limit switch at which point the controller will stop the vertical cylinder and start the horizontal cylinder moving inward. The lift will continue to move inward until the user releases the button or the lift reaches the inner limit switch. Once the inner limit switch is activated, the controller will allow the door to close. The door will continue to close as long as the key-fob button is held and the door has not activated the door closed limit switch. Once this switch is activated the controller will turn the pump off. 3

4 Receiving the Vehicle DEALER CHECK IN: The procedure for receiving the vehicle is fairly straightforward and involves 4 documents. First, the Check in Sheet. The purpose of this sheet is to make sure there is no damage to the vehicle during shipping, and also to make sure the vehicle is prepared correctly for delivery to the customer and that the customer has been properly trained to understand and operate the vehicle. WARRANTY REGISTRATION: This document is required to validate the warranty. It also registers important customer data and helps to insure they have been properly instructed in the use of their vehicle. All ATC documents can be found at atconversions.com/dealer-documents Dealer Check In & Warranty Registration must be filled out completely and submitted back to ATC within 72 hours of customer delivery. Submit to service@atconversions.com 4

5 ATC Warranty WARRANTY/SERVICE GUIDELINES: This explains how our procedure works. Our goal is to help the customer get repairs as quickly as possible. Failure to follow the procedure can result in delays in getting parts, repairs, and payment. Warranty payment can also be invalidated by failure to follow the correct procedure. ATC WARRANTY: It is important for the costumer to understand what the warranty covers and how long. All ATC documents can be found at atconversions.com/dealer-documents The Warranty/Service Guidelines form must be filled out completely and submitted back to ATC within 72 hours of customer delivery. Submit to 5

6 ATC Warranty Procedure WARRANTY PROCEDURE AND RATE CHART: Dealers are allowed one hour to diagnose and/or make simple repairs. This hour does not require pre-approval. Beyond that, pre-approval is required. The purpose of this is to help determine the most efficient procedure to effect repairs of the vehicle. The rate chart explains the maximum accepted times for many common repairs. All ATC documents can be found at atconversions.com/dealer-documents The Warranty Prior Authorization form must be submitted BEFORE any work can be performed. Submit to 6

7 Vehicle Operation LIFT SPECIFICATIONS DOT Private Use lift Operator must back into lift Lift rating: 750 Pounds Minimum unobstructed platform operating volume: 57,000 cubic inches. OPERATING THE LIFT To ensure that the lift is operated in a safe manner, the following precautions should be understood and followed. VEHICLE SETUP To increase safety, your vehicle and wheelchair should be configured for safe driving by a professional. This includes required controls and wheelchair configuration on the lifting platform. Seat belt modification or extension may be required depending on the size of the wheelchair and individual application which should also be configured by a professional. NOTE: An aftermarket seatbelt and/or extension must not be used unless it latches into the OEM receptacle. When this OEM receptacle is latched, it is a safety feature which will not allow the door to open. If the door opens with the seatbelt positioned in any other way, it could possibly cause injury to the occupant or damage to the vehicle. KEY FOB BUTTONS ALWAYS START VEHICLE PRIOR TO OPENING OR CLOSING DOOR AND RAMP. ACCIDENTALLY DEPRESSING THE OPEN SWITCH COULD CAUSE DAMAGE. KEY FOB BUTTON DESCRIPTION 1. Press and hold OPEN for the gullwing door to Open. 2. Press and hold CLOSE for the gullwing door to Close. 3. Press and hold for the lift to go Up and In. 4. Press and hold for the lift to go Out and Down. An aftermarket Alarm/Remote Start system may have been installed to interface with the TouchTronics control modules if the truck was not originally equipped with a remote start system. The aftermarket FOBs may be used but are not needed

8 Suggested Tools The following lists are tools, supplies and equipment that may be needed to repair or adjust an ATC converted vehicle. BASIC TOOLS screwdrivers hex keys open end wrenches, line wrenches ratchet driver in 1/4 and 3/8, maybe 1/2 cutting pliers extensions sockets torque wrench work light, fluorescent or LED pliers channel locks crescent wrench breaker bar or impact gun SAFETY GEAR eye protection fire extinguisher oil spill collector gloves rags ELECTRICAL TOOLS circuit tester digital multimeter wire snips crimping tool wire strippers Solder gun and solder SUPPLIES ATF (Automatic Transmission Fluid) rubber cement bed liner touch up spray undercoating touch up spray silicone sealant penetrating oil automotive bulb seal black seam seal electrical tape 8

9 Primary Components The following pages contain images that show the locations of the primary components that make up the ATC system. A should familiarize themselves with these components, their function, and the typical location of them. Due to the variety of vehicles that ATC converts, there will be some minor differences in where some of these components are located, but they are usually in the same general area. CONVERSION DOOR LIFT ARM LIFT CYLINDER LIFT POST HYDRAULIC MANIFOLD TRANSFER CASE COVER SWING CYLINDER FLOOR PAN DRY SIDE FLOOR PAN LIFT POST DRY SLIDE LIFT PAN SEAT PAN 9

10 Primary Components 2 The following pages contain images that show the locations of the primary components that make up the ATC system. A should familiarize themselves with these components, their function, and the typical location of them. Due to the variety of vehicles that ATC converts, there will be some minor differences in where some of these components are located, but they are usually in the same general area. DOOR CLOSE LIMIT SWITCH LATCH MECHANISM PAN OUT LIMIT SWITCH DOOR TILT SWITCH PAN PIVOT ARM DOOR LIFT TURNBUCKLE DOOR CYLINDER ADJUSTMENT LIFT ROLLERS 10

11 Primary Components 3 The following pages contain images that show the locations of the primary components that make up the ATC system. A should familiarize themselves with these components, their function, and the typical location of them. Due to the variety of vehicles that ATC converts, there will be some minor differences in where some of these components are located, but they are usually in the same general area. MAIN BREAK & TERMINAL BLOCK LIFT PAN IN LIMIT SWITCH MANUAL OVERIDE VALVES SWING CYLINDER ADJUSTMENT LIFT PAN UP LIMIT SWITCH MANUAL PUMP 11

12 Troubleshooting - General VEHICLE DOESN T GO INTO GEAR. In order to put the vehicle in gear, the brake must be pressed and the ignition key on. If the door is closed and the hydraulic pump will still run when the door closed button is pressed, the door in limit switch needs adjusted or replaced. BATTERY CHARGE IS GETTING LOW. If the lift is operated multiple times without the vehicle running it will drain the battery. We always recommend having the vehicle running when using the lift. OPERATION IS JERKY/INTERMEDIATE. This is often caused by a weak battery in the key fob, or not being close enough to the vehicle. Other items that can cause this is interference is from other electronics such as other remotes, alarm systems, garage door openers, airports, etc. Air in the hydraulic system is the most common problem and can also cause unpredictable motion. An easy way to make sure is to bleed the system. Hydraulic System Air Bleeding Procedure 1. Make sure the lift is up and in the truck. 2. Make sure the door is closed. 3. Ensure all 6 of the manual valve controls are open. ATC recommends Lock Tite hydraulic sealant. Do not use teflon tape. 4. Once all are open, hold the open button for 20 to 30 seconds. The lift should not move, but this process will work a majority of the air out of the system and is a good start if air is suspected. 5. Once you are finished, check the fluid level in the reservoir and make sure it s still adequately filled. Sometimes air will get trapped in other places that the above process is unable to get out. In these cases each fitting will have to be slightly cracked to let a few drops of fluid out. If the fluid bubbles out, it s a sign of trapped air. When it comes out solid fluid, tighten the fitting and move on to the next troubleshooting item if needed. 12

13 Troubleshooting - Door DOOR DOESN T CLOSE ALL THE WAY. The door closed limit switch may need adjustment: If the door stops and the hydraulic pump also stops, yet the door is not closed all the way, this is an indication that the door closed limit switch needs adjusted inward. If the door stops moving inward and the pump is still running, this is an indication that something has physically stopped the door from moving further inward. Often this is caused by the lift not being all the way in, usually caused by a defective or out of adjustment in limit switch. When the lift is moved up and in, the pump should automatically shut off once the lift pan is in. If it does not, then a limit switch is the likely problem the controller will not allow the door to close until it is told by the lift in limit switch that the lift pan is in its proper place. Also Look for items that may be blocking the door or the linkage. An incorrect adjustment on the door closing cylinder swivel can also cause the cylinder to bottom out before the limit switch makes contact. DOOR DOESN T STAY TIGHT. This can be caused by the door magnet on the forward portion of the door not functioning correctly. Also, air in the hydraulic system can allow the cylinder to creep back. Bleeding the air out of the system can remedy this. (See hydraulic system bleeding guide). This can also be caused by a piston seal leak inside the cylinder that would allow pressure to bleed off and the door to creep open. A faulty hold valve in the manifold can also cause this. DOOR MOVES WHEN DRIVING. This could be caused by the same factors as above, as well as the front door magnet may be out of adjustment or not function. If the front of the door can easily be moved with the vehicle running, and in drive, then the magnet is likely not holding the door. To test it, apply the brake and place the vehicle in gear with the door open. Touch the magnet with a piece of steel and see if it is energized. If so, then the magnet will need adjusted to make full contact with the striker plate. DOOR WILL NOT OPEN. If the door will not open, make sure the seat belt isn t plugged in there is a safety switch to prevent door from opening if the seat belt is hooked to prevent personal injury as well as damage to the door system. Also make sure the vehicle is in park and the brake pedal is not depressed. To determine if the issue is electrical or hydraulic, check the latch release signal on the door controller. If it is lit up, and the hydraulic pump is running, but the door doesn t open, the issue is with the hydraulic system. 13

14 Troubleshooting - Lift GENERAL Make sure that the manual valve operation knobs are all in. Any of these being pulled out can cause erratic and unpredictable hydraulic issues. Most often the cause of hydraulics systems not performing correctly is having air in the hydraulic system. LIFT DOESN T GO IN. Usually caused by the up limit switch needing adjustment or replaced. If the pump is turning on but the lift is not moving in, the likely problem is the valve in the manifold. If there is 12 volts on the manifold solenoid, with the pump running and the lift isn t moving in, the valve cartridge likely needs replaced. LIFT DOESN T GO OUT. This is most commonly caused by the tilt switch, which is mounted to the linkage connecting to the door. This switch ensures that the door is open far enough before allowing the lift to come out so the lift doesn t damage the door. To determine if the tilt switch is faulty, open the door and see if the door open switch on the lift controller is lit. If it does not, look for damage to the wiring going to it, or it could be a faulty switch. LIFT DOESN T GO UP. If the lift won t go up, often the cause is a weak battery. We recommend always having the vehicle running when using our system. A belt buckle plugged can also cause the lift to not operate. LIFT DOESN T GO DOWN. This is normally caused by the out limit switch needing adjustment or replacement. If the pump is running and the lift still won t go down the solenoid valve on the manifold would be suspect. If it has 12vdc going to it and still not operating, the valve probably needs replaced. LOW POWER ON LIFT. This is often caused by low pressure in the hydraulic system, which can be corrected by adjusting the pressure setting on the pump. It can also be caused by air in the system (see hydraulic system bleeding guide). Other causes can be debris in the guide mechanisms causing binding, needing additional lubrication on the plastic bearing strips and low fluid. * Instructional/adjustment videos about our conversion can be found at 14

15 Airbag Warning Diagnosis HIGH RESISTANCE CHECK SOLDER CONNECTIONS These wires are located under the console, over to the floor kick panel, up to the head liner and inside the door panel where connected to the seat belt roller. The connections should be hand soldered with heat shrink to eliminate excessive resistance. 15

16 Airbag Warning Diagnosis (continued) Seat Belt Retractor Failure MALFUNCTIONING SEAT BELT RETRACTOR Should the seat belt retractor be subjected to excessive moisture, the Service Air Bag warning will illuminate. Retractor Wiring Retractor Location Retractor Moisture Protection 16

17 Airbag Components & Door Magnet (Driver Side Conversion) RETRACTOR WIRE COLORS Red 18 ga. and Grey 18 ga. DOOR MAGNET WIRE COLORS Orange Green 18 ga. to Black ground. Red and Black to Red Power. PRETENSIONER Yellow w/ Orange 18 ga. & Orange w/ Yellow 18 ga. Dielectric Grease must be used on connector 17

18 DTC Codes The following are pertinent DTC codes encountered with our system and their description. Knowing the locations and type of problem can help track down where a wiring issue may be. RELATED SDM TROUBLE CODES DTC B008F Rollover Protection Disable Switch Circuit DTC B0098 Passenger Air Bag Disable Switch Circuit DTC B0014 Right Air Bag Deployment Loop DTC B0021 Left Air Bag Deployment Loop DTC B0085 Left front side impact sensor DTC B0086 Right front side impact sensor DTC B0087 Left rear side impact sensor DTC B0088 Right rear side impact sensor DTC B0083 Left front Impact Sensor DTC B0084 Right front Impact Sensor DTC B0081 Passenger Presence Module DTC B0079 Driver seat position sensor DTC B0080 Passenger seat position sensor DTC B0015 Driver seat belt retractor pretensioner deployment loop DTC B0022 Passenger Seat belt retractor pretensioner deployment loop DTC B001A Driver anchor pretensioner Deployment loop DTC B001B Passenger anchor pretensioner Deployment loop DTC B Deployment commanded DTC B Deployment commanded too many times DTC B0071 Passenger seat belt tension sensor circuit DTC B0019 (stage 1) Passenger instrument panel air bag deployment loop DTC B0020 (stage 2) Passenger instrument panel air bag deployment loop DTC B0016 Left roof rail air bag deployment loop DTC B0023 Right roof rail air bag deployment loop DTC EXTENSIONS: Open/High Resistance: 0D, 04, 05, 71 Short to Voltage: 01 Short to Ground: 02, 03, 0E Open/high resistance or short to ground: 06 Signal bad: 39, 08, 0F Passenger presence sensor malfunction: 00 Passenger presence sensor above threshold: 11 Passenger presence sensor incorrect component installed: 3A Passenger presence sensor calibration not learned: 4B Passenger presence sensor plausibility failure: 5A Passenger presence sensor invalid serial data received: 71 18

19 Hydraulics POWER UNIT: The power unit consists of the pump, motor, and reservoir. The motor turns the pump, the pump creates both pressure and flow, and the reservoir holds the excess fluid required for the system. As a cylinder moves, there is a difference of volume from one side to the other due to the volume occupied by the cylinder rod. As it moves, the reservoir either supplies the extra fluid needed, or stores the excess fluid depending on the direction of the cylinder movement. The fluid used in our system is common Automatic transmission fluid (ATF). MANIFOLD: The inlet and outlet of the power unit goes directly to the manifold. The manifold is primarily a controller that channels the fluid to where it s supposed to go. It does this using valve cartridges that are all standard and replaceable. In the ATC trucks, there are 3 circuits. One is for the horizontal control, one for the vertical, and one for the door. The valves are controlled by the solenoids which allow the signals from the controller to turn the desired circuit on and off. In the case of controller issues, these can also be manipulated manually by opening the appropriate red knob. CYLINDERS: These convert the hydraulic pressure and flow into movement. ATC cylinders are all custom made and are dual acting, requiring pressure to move either way. VELOCITY FUSES: These are safety devices that our mounted on the rod side inlets to the vertical and door cylinder. Their job is to monitor the flow and shut it off in the case of excess flow (like if a hose gets cut). If a hose or hydraulic failure causes a free flow, these valves will hold the cylinder in place to prevent injury. They will continue to hold until the problem is corrected. Once the problem has been fixed, the cylinder needs to be moved a little in the opposite direction to reset it, and it will be back to functioning normally. STARTER SOLENOID: This is usually found mounted directly to the motor, or can be mounted remotely. Its basically a relay to take a low current signal and switch on the higher current that the motor requires. CAUTION: Before removing any fittings, hoses, etc. on a hydraulic system, make sure that the position of the item controlled by the circuit being worked on is in a safe position. When a hydraulic system is open, there is nothing to hold the item in place. For example, opening a connection on the door circuit may cause the door to slam down due to gravity. If you are working on the lift circuits, have the lift out and down. On the door circuit, have the door down or well supported. Before opening the lines to a circuit, the lift should be up and in truck. You can then open the manual valves for that circuit to help bleed off any residual pressure. Be prepared for some pressure to remain creating possible spraying of fluid. Have plenty of rags around and protect anything that can get damaged. 19

20 Hydraulic Components HYDRAULIC PUMP HYDRAULIC MANIFOLD PUMP SOLENOID PUMP GROUND PRESSURE ADJUSTMENT VALVE SOLENOID (x6) ATF FILL CAP VALVE MANUAL OVERRIDE (x6) MANUAL HAND PUMP 20

21 Hydraulic Cylinder Adjustments DOOR LIFT CYLINDER SWING CYLINDER TURNBUCKLE JOINT LENGTH ADJUSTMENT TURNBUCKLE JOINT LENGTH ADJUSTMENT The opposite mounting end of each cylinder is static and cannot be adjusted. The Pan Lift Cylinder cannot be adjusted 21

22 Hydraulic Swing Cylinder Components SWING CYLINDER The swing cylinder has internal cushions that dampen the start and stop motion when actuated ORIFICE TYPES SWING CYLINDER ATF FLUID INLET A Velocity Fuse is located on the base end line of both the vertical and horizontal cylinder. It s purpose it to stop the motion of the cylinder in case a hose ruptures. To reset the velocity fuse after it has been triggered, run the cylinder in the opposite direction. SPEED REDUCTION ORIFICE 22

23 Manual Hydraulic System Operation The hydraulic hand pump can be used to operate any of the hydraulic circuits in case of emergency or loss of battery power. Manual operation should not be used for daily operation of the hydraulic system. In a situation where manual operation of the hydraulic system is necessary, first ensure electrical power to the system has been shut off, and all electrical controls are off. PIN A1 A2 A3 B1 B2 B3 Pull Red Pin to Acuate* Door Open Tray / Chair Up Horizontal Tray Out Door Close Tray / Chair Down Horizontal Tray In * Make sure to move Pin counterclockwise back to the original position before operation. A detailed video for Manual Pump Operation can be found on our website at atconversions.com/servicedesk TO OPERATE PUMP: 1. Ensure there is adequate automatic transmission fluid in the reservoir tank, located under the hood.. 2. Ensure there are no objects or persons in the way of operating the ramp. 3. Insert handle for hand pump into pump handle receptacle. 4. Operate pump and ensure the pump is building pressure (resistance to pumping) before operating any of the manual valves. It may take additional strokes of the hand pump to fully prime the system if it has not been used recently. 5. Select which hydraulic cylinder or operation you wish to move and select appropriate valve to operate (A or B). Do not operate more than one valve at a time. 6. Pull the appropriate red Pin while simultaneously operating the hand pump to move the cylinders while verifying safe motion of the ramp. The red Pin may be pulled out and turned clockwise to lock position so it does not have to be held while pumping. A1 A2 A3 B1 B2 B3 Hydraulic Manifold Hand Pump Location 23

24 Limit Switch Function & Adjustment The limit switches give the controller feedback as to where the system components are in their articulation. The controller uses this information to determine what cylinder to operate. These switches work by completing the circuits path to ground. Limit switch contact should be adjusted by turning the target bolts. Ensure there is no interference with motion of the tray and target, and that the limit switch is touching the target to ensure proper ground signal to the controller. Switches are adjusted by threads for and distance to contact or target Door Closed Limit Switch: Turns the Hydraulic pump off when closed. 2. Pan Out Limit Switch: controls how far the pan gets deployed and allows the pan lowering sequence to begin. 3. Pan In Limit Switch: controls how far the pan gets stowed inside. 4. Pan Up Limit Switch: controls how high the pan is lifted. 5. Tilt Limit Switch: allows the pan to deploy when the door is fully open. 24

25 Latch System DOOR LATCH ADJUSTMENT PROCEDURE: Arm striker position: This is mounted to the arm that opens and closes the door. This striker bracket is slotted so it can be adjusted along the arm. It should be set as low as it can go but not bottoming out on the latch cam surface when it closes the door. If this is too low the extreme forces present will bend some of the latch components. If the arm striker does not move inward far enough to move the latch plate correctly the door cylinder may need to be adjusted. 2. Latch striker position: This is mounted to the door and allows the latch cam to pull the door in and secure it. It is also slotted to allow adjustment. It should be set such that the slot in the cam plate engages it fully, but the striker does not bottom out in the slot on the cam plate. If it is allowed to bottom out it will bend many of the components. 3. Once the Latch adjustments are complete, the door closed position needs to be set. This is accomplished by moving the entire latch assembly in or out as required to position the door correctly. 4. After completing the adjustments, double check to make sure that nothing is bottoming out on the latch creating any binding. If all is properly adjusted, make sure all fasteners are tightened. 25

26 Door Seal Leak Water intrusion into the door is normal for all vehicles. ATC utilizes the existing door seal and joins both ends with an additional piece of seal. These are glued with rubber cement. Water enters the door from the window seals and collects inside the door. Weep holes are added in the bottom of the door, along with the OEM holes to allow most water to escape. Residual moisture is retained inside the door because of it s OEM design. When the door is opened Gull Wing style, this residual moisture will run out from behind the door panel. WEATHER SEAL JOIN AREA OEM WEEP HOLES ATC WEEP HOLES 26

27 Dealer Certification Test If you have reviewed the material contained in this document and are ready to take the ATC Dealer Certification Test, go to the following web address. The test will be instantly graded and the results will be sent to ATC s Dealer Division. We look forward to working with you and your team. 27