ELECTRIC SLIDING DOOR INSTALLATION INSTRUCTIONS

Size: px

Start display at page:

Download "ELECTRIC SLIDING DOOR INSTALLATION INSTRUCTIONS"

Hester Strickland
6 years ago
Views:

1 MERCEDES SPRINTER VOLKSWAGEN CRAFTER EURO 4,5,6 from 2006 (Using original vehicle remote s key and door operating by pulling original door handle) ELECTRIC SLIDING DO INSTALLATION INSTRUCTIONS DUE TO UNANNOUNCED CHANGES IN THE VEHICLES, BEFE DERING, CHECK IF THE INSTALLATION DRAWINGS AND MATERIAL SUPPLY FITS YOUR SPECIFIC VEHICLE. ALEX IGINAL RESERVES THE RIGHT TO MAKE CHANGES IN ITS PRODUCTS WITHOUT ADVANCE NOTICE

2 ELECTRIC SLIDING DO MERCEDES SPRINTER, VOLKSWAGEN CRAFTER REQUIRED TOOLS PAGE 1 IGINAL BLACK MARKER Ø3mm (1/8") Ø6mm (1/4") Ø8mm (5/16") Ø10mm (3/8") Ø12mm (1/2") Ø14mm (9/16") Ø27mm (1.1/16") 5.5mm 8mm 10mm 15mm 4mm 5mm 6mm 1/4" Ø10mm (3/8") 8mm 10mm 3/8" CR MV M10 15mm ESD

3 ELECTRIC SLIDING DO 1 1 PAGE 2 * MAIN DRIVE ASSY. TEMPLATE P.N ! DRILL ONLY ONE WALL POSITION TEMPLATE (2 PIN) DRILL 9 HOLES Ø3mm 2 BLACK MARKER 3 ESD

4 ELECTRIC SLIDING DO 4 PAGE 3 ENLARGE HOLE TO Ø27mm 5 5mm 6 ENLARGE 2 HOLE TO Ø6mm CUT AWAY AS SHOWN & FILE OPENING AFTER CUTTING THE OPENING FILE AND COVER WITH PAINT TO PREVENT CROSION ENLARGE 4 HOLE TO Ø8mm ESD

5 ELECTRIC SLIDING DO PAGE 4 7 CUT AND DISCARD 10mm AFTER CUTTING THE OPENING COVER WITH PAINT TO PREVENT CROSION 8 FRONT WHEEL P.N BOLTS M6x15 +SELFLOCKING NUTS 2 SCREWS 5x19 SELFDRIVING ESD

6 ELECTRIC SLIDING DO 9 PAGE 5 MUST BE UP * TEMPLATE F LOCK P.N SCREWS 5x19 (SELF DRILLING) * DRILL 4 HOLES Ø6mm AND REMOVE TEMPLATE ENLANGE 4 HOLES 10 Ø14mm BLACK MARKER AFTER CUTTING THE OPENING AND COVER WITH PAINT TO PREVENT CROSION CUT ESD

7 ELECTRIC SLIDING DO PAGE 6 14 BLACK MARKER MARK AND REMOVE 15 IGINAL BOLTS BLACK MARKER INSTALL PLATE ACCDING TO THE MARK. MARK THE LOWER SIDE AND REMOVE TEMPLATE 16 BEND AS SHOWN DISCARD ESD

8 ELECTRIC SLIDING DO 17 PAGE 7 18 GRIND AWAY AS MARKED AND COVER WITH PAINT TO PREVENT CROSION MOT P.N LOCK ASSY. P.N INSTALL ACCDING TO THE MARK ON (FIG.15) 2 SUNKHEAD BOLTS M8x30 SOCKETHEAD BOLT M6x65 ESD

9 ELECTRIC SLIDING DO 21 PAGE 8 IGI NAL ELECTRONIC CONTROL BOX RELOCATE UNDER CO-DRIVER SEAT IGINAL PLUG SIGNAL TO OPEN IGINAL LOCK SEE ( PAGE 23 PLUG No 3 ) GREEN WIRE ROUTE WIRES THROUGH IGINAL CHAIN TO ACTUAT MICROSWITCH AND ACTUAT ASSEMBLY REMOVE 22! BEFE REMOVING THE LOWER DO ARM, MAKE SURE TO PROTECT THE DO FROM DAMAGING THE VEHICLE SIDE AND SUPPT THE DO. DISMANTLE THE ARM. SEE (FIG. 23 AND 24)! DO SUPPT ESD

10 ELECTRIC SLIDING DO PAGE 9 23 BLACK MARKER! 1. MARK LOWER ARM. 2. PROTECT THE DO FROM DAMAGING THE VEHICLE SIDE. (FIG. 22) 3. SUPPT THE DO IN DER TO PREVENT THE DO FROM FALLING. (FIG. 22) 4. DISCONNECT THE LOWER DO ARM.(2 BOLTS) 5. DISCONNECT THE LOWER CABLE. 6. CUT THE IGINAL LOWER CABLE (AS SHOWN ON FIG. 25). 7. REINSTALL ALL PARTS BACK ACCDING TO THE MARK. * THE IGINAL CABLE SHOULD BE CONNECTED TO THE LEVER ON THE ACTUAT ASSY. ( SEE FIG. 27) 24 REINSTALL ALL PARTS BACK REMOVE 25 CUT AWAY AS SHOWN RE-ROUTE IGINAL CABLE SEE (FIG. 27) ESD

11 ELECTRIC SLIDING DO 26 PAGE 10 REMOVE COVER PANEL. REINSTALL AFTER INSTALLING THE ACTUAT ASSEMBLY ESD

12 ELECTRIC SLIDING DO PAGE DISCONNECT IGINAL CABLE FROM INSIDE DO HANDLE. 2. RE-ROUTE IGINAL CABLE TO LOWER ACTUAT ASSY CONNECT NEW CABLE (P.N ) TO INSIDE DO HANDLE AND UPPER ACTUAT ASSY. 3 NEW CABLE P.N MOT P.N IGINAL CABLE ACTUAT ASSY. P.N RE-ROUTE IGINAL CABLE FASTEN UNIT AS SHOWN USING 5 SCREWS 5x19 (SELFDRILLING) RE-ROUTE IGINAL CABLE FROM LOWER DO ARM. WIRE HARNESS TO ELECTRONIC CONTROL BOX 2 4! MICROSWITCH SHOULD NOT BE PRESSED WHEN DO HANDLES ARE NOT BEING PULLED ADJUSTING BOLTS CABLE LEVER F MICROSWITCH! CABLE ADJUSTMENT 2, 3, 4 RELEASE 2 BOLTS AND ADJUST THE CABLE ACCDING THE DRAWINGS ESD

13 ELECTRIC SLIDING DO 28 PAGE 12 A 29 STOPPER A OPTION A IGINAL DO SLIDING MECHANISM * DO CONVEY TEMPLATE P.N DRILL Ø3mm AND ENLARGE Ø6mm 29A STOPPER B OPTION B IGINAL DO SLIDING MECHANISM * DO CONVEY TEMPLATE P.N DRILL Ø3mm AND ENLARGE Ø6mm ESD

14 ELECTRIC SLIDING DO PAGE PINS F BELT CLIP P.N CONVEY BRACKET P.N BELT CLAMP A P.N BOLTS M6x15 +LOCKWASHERS 31 INSTALL 2 BOLTS M6x20 +SELFLOCKING NUT M6 32! ONLY F LONG & EXTRA LONG BODY REMOVE STOPPER * REAR WHEEL TEMPLATE P.N (170") 6961 (274") LONG 7361 (290") E.LONG ESD

15 ELECTRIC SLIDING DO 33! PAGE 13A ONLY F LONG & EXTRA LONG BODY DRILL 8 HOLES Ø3mm 4325 (170") 6961 (274") LONG 7361 (290") E.LONG 34 ENLARGE 2 HOLES TO Ø27mm AND CUT ACCDING THE MARK * MARK AND REMOVE TEMPLATE ENLARGE 2 HOLES TO Ø6mm 35 35A SILICON PLEASE APPLY SILICON LAYER F INSULATION REAR WHEEL P.N O RIGI 2 BOLTS M6x15 +SELFLOCKING NUTS REAR WHEEL COVER P.N SCREWS ESD

16 ELECTRIC SLIDING DO 35B IGINAL COVER! PAGE 14 ONLY F SHT BODY REMOVE DISCARD 3665 (144") 5910 (232") 35C REINSTALL CUT AWAY AS SHOWN CUT AWAY AS SHOWN 35D * REAR WHEEL TEMPLATE P.N STOPPER ESD

17 ELECTRIC SLIDING DO 35E PAGE 14A ONLY F SHT BODY 3665 (144") 5910 (232") DRILL 8 HOLES Ø3mm 35F ENLARGE 2 HOLES TO Ø27mm AND CUT ACCDING THE MARK * MARK AND REMOVE TEMPLATE ENLARGE 2 HOLES TO Ø6mm 35G 35H REUSE IGINAL PLASTIC (FIG. 35C) REAR WHEEL P.N BOLTS M6x15 +SELFLOCKING NUTS SILICON PLEASE APPLY SILICON LAYER F INSULATION ESD

18 ELECTRIC SLIDING DO 36 PAGE 15 DISASSEUBLE MOT BEFE MOUNTING 3 SELFLOCKING NUTS M SUNKHEAD BOLTS M8x20 RELEASE IGINAL NUT. AFTER INSTALLING THE MAIN DRIVE ASSY. TIGHTEN IGINAL NUT TO REAR WHEEL MAIN DRIVE ASSY. P.N ESD

19 ELECTRIC SLIDING DO 39 PAGE 16! BEFE INSTALLING GEAR MOT, GLUE MOT PROTECT WITH SILICONE P.N SHAFT 3 SELFLOCKING NUTS M6 GEAR MOT WITH HALL SENS NO.D63 P.N SCREWS 5x19 (SELF DRILLING) FRONT WHEEL PLASTIC COVER P.N MAIN DRIVER PLASTIC COVER (P.N ) 4 SCREWS 5x19 (SELF DRILLING) ESD

20 ELECTRIC SLIDING DO 41 PAGE 17 INSTALL 2 BOLTS M6x15 +SELFLOCKING NUT M6 BELT 335cm P.N REAR BELT CLAMP P.N BOLTS M5x15 +STARWASHER BELT LENGTH ADJUSMENT! CLOSE THE DO. 7 TEETH 2. RELEASE BELT FROM REAR BELT CLAMP. 3. STRETCH THE BELT AND CUT ACCDING THE DRAWING, LEAVING 8 TEETH. 41A FRONT BELT ROUTING ESD

21 ELECTRIC SLIDING DO 42 PAGE 18 HIGH ROOF ONLY! UPPER ELECTRIC MOT DO SWITCH V.S.S (VEHICLE SPEED SENS) SEE (FIG. 45) ACTUAT BATTERY MAIN DRIVE ASSY. MOT SIGNAL TO OPEN IGINAL LOCK SEE (FIG. 21) ELECTRONIC CONTROL BOX No.298S SEE (FIG. 21) P.N S IGINAL FUSE BOX 43 AFTER IGNITION IGINAL YELLOW / BLACK WIRE IN GREY PLUG C1 PIN No 3 IN FUSE BOX. ESD

1 2 3 ELECTRIC SLIDING DO 44 PAGE 19 SWITCH BRACKET P.N. 2032-305 DO SWITCH DISCARD INSERT AND BEND LEVERS AS SHOWN DO SWITCH P.

22 1 2 3 ELECTRIC SLIDING DO 44 PAGE 19 SWITCH BRACKET P.N DO SWITCH DISCARD INSERT AND BEND LEVERS AS SHOWN DO SWITCH P.N V.S.S (VEHICLE SPEED SENS) SPEED OPTION PIN No 9 IGINAL BLACK PLUG IN THE INSTRUMENT PANEL 4 ESD

23 ELECTRIC SLIDING DO 46 LOCATE SPACER AND MARK AROUND BLACK MARKER! PAGE 20 F HIGH ROOF ONLY SHOULDER SPACER P.N DISCARD AND REMOVE ESD

24 ELECTRIC SLIDING DO PAGE F HIGH ROOF ONLY * LOCATE ON 2 IGINAL HOLES * SCREW 5x19 (SELF DRILLING) TEMPLATE P.N GUIDE F DRILL P.N * 50 GUIDE F HOLE 6 * GUIDE F HOLE 3 DRILL Ø3mm THROUGH THE GUIDE DRILL Ø6mm THROUGH THE GUIDE 51 * GUIDE F HOLE 10 DRILL Ø10mm DRILL THROUGH Ø10mm THE GUIDE ESD

ELECTRIC SLIDING DO PAGE 22 52! F HIGH ROOF ONLY GRIND 53 INSTALL FLATWASHER 0.5mm UNDER THE LOCK FLAP MOT WITH GEAR P.N. 5110-650 INSTALL ACCDING TO THE MARK IN (FIG.

25 ELECTRIC SLIDING DO PAGE 22 52! F HIGH ROOF ONLY GRIND 53 INSTALL FLATWASHER 0.5mm UNDER THE LOCK FLAP MOT WITH GEAR P.N INSTALL ACCDING TO THE MARK IN (FIG. 46) AFTER GRINDING AS MARKED COVER WITH PAINT TO PREVENT CROSION SCREW 5x19 UPPER LOCK ASSY. P.N SUNKHEAD BOLT M8(SPECIAL) BOLT 6x15 +SELFLOCKING NUT 54 SHOULDER SPACER GEAR FLATWASHER BOLT M5x25 SPECIAL BOLT LOCK 55 LOCK ASSY. SMALL PLASTIC COVER 2 SCREWS 5x19 (SELF DRILLING) P.N ESD

26 ELECTRIC SLIDING DO NEW PAGE 23 IGI NA L POTENTIOMETER + ELECTRONIC CONTROL BOX S DO STROKE HALF FULL REMOTE CONTROL PROGRAMING J2 J1 ( ) * A (+) B ( ) YELLOW BLACK VIOLET WHITE BROWN RED BLUE RED YELLOW GREEN BLACK BROWN ( ) * * * * SEE NEXT PAGE ELECTRIC STEP CONNECTION (-) SIGNAL WHEEL CHAIR LIFT EXTRACT OUTPUT (+) SIGNAL C WHEEL CHAIR LIFT OPERATION INTPUT (-) SIGNAL D PREVENTING DO FROM CLOSING (-) SIGNAL GREEN (+) (+) ( ) (+) RED CONNECT V.S.S IGINAL WIRE IGINAL BLACK PLUG IN THE INSTRUMENT PANEL PIN No 9 SEE PAGE 19 (FIG. 45) BLACK BLACK RED RED M UPEER ELCTRIC MOT YELLOW BLACK YELLOW BLACK M PUSH/PULL ASSY. MOT BLACK RED BLACK RED M RED CONNECT MAIN DRIVE ASSY. MOT WITH ENCODER RED SEE PAGE 8 (FIG. 21) (+) LOCK SIGNAL IGINAL PLUG, GREEN WIRE PIN No 3 MIDI FUSE 40A RED BATTERY RED CONNECT RED WHITE (+) RED YELLOW VIOLET BLACK (+) R - 30 K Ω R K Ω ( ) DO SWITCH (+) AFTER IGNITION BLACK GREEN YELLOW RED IGINAL WIRE YELLOW / BLACK IN GREY PLUG C1 PIN No 3 IN FUSE BOX. BLACK YELLOW SEE PAGE 18 (FIG. 43) BLUE NC NO BLACK BLACK YELLOW C SEE PAGE 11 (FIG. 27) M! MICROSWITCH SHOULD NOT BE PRESSED WHEN DO HANDLES ARE NOT BEING PULLED ACTUAT MOT ESD

27 ELECTRONIC CONTROL BOX ELECTRICAL CONNECTIONS (OPTION) A. Electric step connection output (-) signal Output (-) signal for operating an ALEX IGINAL electric step, pin 7 at the white 10 pin connector (plug 1) to be connected to step Electronic Control Box part No B. Wheel chair lift extract output (+) signal When the door is in full opening position, output (+) signal to wheel chair lift operation, is on pin 9 at the white 10 pin connector plug. C. Wheel chair lift insert door operation input(+) signal First input (+) signal pin 3 at pluge 3 will open the door. Second input (+) will close the door when wheel chair lift is on close position. D. Preventing door from closing (-) signal As long as there is input (-) on pin 2 at the white 4 pin connector (plug 3)door will not close. BEEPING SOUNDS Learning Mode: Fragmented beeping will be heard when door is at its first learning cycle. Opening Mode: Fragmented beeping will be heard when door is opening. Closing Mode: Fragmented beeping will be heard when door is closing. Obstacle Detection On Closing Mode: Continuous beeping will be heard. If the sliding door is obstructed during the closing procedure, it opens fully again(for 2 attempts). On third attempt the electric sliding door moves with increased force. ESD

28 ELECTRONIC CONTROL BOX Basic Programming Close / Open Cycle-Once installation completed, Make sure ignition is OFF and the door is OPEN, insert all plugs into the Electronic Control Box while leaving the Black plug No 4 for last. Once Black plug is connected, door will perform a slow movement close and open cycle and should not be interfered with. BLACK PLUG 4 PLUG 3 PLUG 2 PLUG 1 Programming Door Position at half way, This is handy when door needs to open half way only, when a seat is located near it, for example. As default, the module is supplied with the jumper inserted into FULL position. For positioning the door in the HALF way mode, move Jumper into socket HALF position. JUMPER HALF ESD 1024 FULL

29 ELECTRONIC CONTROL BOX Reprogramming sliding door Electronic Control Box: (In case or belt replacement) 1. Turn off ignition key. 2. Disconnect the black connector. 3. Reconnect the black connector. 4. Turn on ignition key. 5. Press and hold driver switch for 10 seconds Within time window of 30 seconds. 6. The door will operate by itself when the door stops in open position, it is ready for use. PCB leds color and number for all functions. LED1 (White) Remote Control-1 LED3 (White) Motor A Opening LED4 (Red) Motor A Closing LED5 (White) Motor B Opening LED6 (Red) Motor B Closing LED7 (White) Actuator Opening LED8 (Red) LED9 (Red) Actuator Closing LED11 (Yellow) Ignition LED12 (Blue) LED13 (Blue) Door Opened Led Driver Command Remote Control-2 Potentiometer adjustment for intensity level of stopping door while closing To reduce sensitivity of Electric Door turn the Potentiometer clockwise (-). To Increase sensitivity turn the Potentiometer counter clockwise (+). * Adjustment will take affect after turning ignition key off and on. SENSITIVITY POTENTIOMETER LED 12 LED 11 LED 9 DO POSITION PROGRAMING REMOTE CONTROL PROGRAMING LED 1 LED 13 LED 7 LED 8 LED 5 LED 6 LED 3 LED 4 ESD

30 ELECTRONIC CONTROL BOX Mercedes Sprinter Remote Control operation instruction: Pressing Twice on Pressing Once on Pressing Once on button will open the Sliding door. again while the door is on the move will stop the Sliding door. button will close the Sliding door. Volkswagen Crafter Remote Control operation instruction: Pressing Twice on Pressing Once on Pressing Once on button will open the Sliding door. again while the door is on the move will stop the Sliding door. button will close the Sliding door. ESD

31 TROUBLESHOOTING OPENING MODE 1. Door opens half way Verify jumper on electronic control box is in "full" position If not, insert it. Check for an obstacle or person blocking the door, check for dirt in the belt track. Reprogram door electronic control box. 2. Door starts to open and stops Check drive belt length and adjust it according to installation manual. Check the cable connecting actuator to original door lock. Micro switch installed in the door should not be pressed when the door handle isn't pulled. Check door is released from lock. If not, check contacts, release the lock. Check for an obstacle or person blocking the door, check for dirt in the belt track. Reprogram door electronic control box. 3. Door is not moving at constant speed Verify that the encoder cable (located on the electric motor side) is properly connected and not damaged. Repair if required. Close the door and check if problem is solved. If not, reprogram door electronic control box. Check drive belt leangth and adjust it according to installation manual. 4. Door stays locked Check the actuator assembly and motor. Check and adjust the actuator assembly cables for opening. Check contacts on door and on B pillar. Verify that children's lock is unlocked. If not set children s switch lock to unlock position. 5. While opening the door long beep sound. Close the door and re open it. If the problem continues: Verify that the encoder cable is properly connected on both sides and not damaged. Reprogram door electronic control box. ESDT

32 TROUBLESHOOTING CLOSING MODE 1. Long beep sound While closing the door. Open the door and re close it. If the problem continues: Verify that the encoder cable is properly connected on both sides and not damaged. Reprogram door electronic control box 2. In closing - the door opens by its self with a long beeping Check if there is an obstacle or person blocking the door, check for dirt in the belt track Check drive belt length and adjust it according to installation manual. *** If problem continues, adjust the potentiometer as per installation manual (turn the potentiometer clock-wise). 3. Door will close but not lock Check the main and upper latch operation and adjust if needed. Check contacts on door and on B pillar (clean). Check the cable connecting actuator to original door lock. 4. Door is not moving at constant speed Verify that the encoder cable is properly connected on both sides and not damaged. Repair as required. Close and open the door and check if problem is solved. If not, reprogram door electronic control box Check drive belt leangth and adjust it according to installation manual. *** If problem continues, adjust the potentiometer as per installation manual (turn the potentiometer clock-wise). ESDT

33 TROUBLESHOOTING REMOTE CONTROL AND BUTTONS 1. Remote control doesn't operate! Remote control operates only when ignition key is off. Check remote control's batteries. Replace if needed. Verify that the remote is programmed To the electric control box and reprogram if needed. Check if central locking signal wire is connected to electronic control box pin 4 plug 3. For vehicles with original remote control (as Sprinter / Crafter / Transit / Ducato, etc) 2. Door handle operation! Door handle operates only when ignition key is on. Micro switch installed in door should not be pressed when the door handle isn t pulled. Check micro switch remote control's batteries, replace if needed Reprogram door handle remote control to electronic control box. 3. Dash button doesn't operate! Driver button operates only when ignition key is on. Check connections after ignition. Check if the Blue LED in the driver button is on when the door is closed and flashing when the door is open. While pressing dash button Check output single on the button white wire to electronic control box. 4. Door does not work at all from dash switch and the remote control Check fuse of the door system. Check the battery voltage on the electronic control box main supply plug. OTHERS Check the belt for damage. Check the belt s length. If needed, readjust the belt for 6-7 teeth (as per installation manual). ESDT

TA V TA V

TA V TA V TA-3030 12V TA-3031 24V High Cooling Capacity Low Power Consumption Small Dimensions Low Weight Parallel Flow Condenser Aluminum Body ABS Acrylic Cover TA-3030 12V p.n. 4500-030 TA-3031 24V p.n. 4500-031