SECTION rear door and mechanism

Transcription

1 / 1 SECTION lock solenoid Lock cylinder small cylinder gros cylindre supply Solenoid limit switches connecting rod lock lever rotating cam DOOR OPENING INDICATOR LIGHT (Green indicator light) optional Figure 1 - Rear Door Motor (Typical) DESCRIPTION and operation See Figures 1 and 2. See Figure 3 for the door control lever positions. The rear door consists of two glazed panels. The panels are actuated by a door motor, located in the baselight directly above the rear door. The motor is a geared differential pneumatic device with two horizontally opposed cylinders of different diameters. Connected to the panels by a series of shafts and rods, the door motor transmits movement to the panels allowing the opening and the closing of the door. The opening and closing times of the panels vary according to the programming of the vehicle. The main door control valve, located on the pneumatic control panel on the driver s left-hand side, enables pressurization of the door system. Placing the main door control valve in the neutral position cuts off the air supply from the door s pneumatic circuit so that the door panels can be opened manually. NOTE: The door control system is only supplied with air once the pressure reaches 65 psi (448 kpa) or 80 psi (552 kpa), depending on the calibration value of the sequence valve. See the vehicle s pneumatic diagram for more information.

2 2 / Door panel3 2. Door panel sensitive edge 4. Door shaft 5. Upper pivot support Bolt torque: 17 ±2 LB-ft (23 ±3 N M) 6. Roller support Bolt torque: 17 ±2 LB-ft (23 ±3 N M) 7. upper pivot ball joint upper pivot ball joint adjustment screw Locknut torque: 45 ±5 LB-ft (61 ±7 N M) 9. upper Door shaft arm 10. roller Guide 11. roller Locknut torque: 17 ±2 LB-ft (23 ±3 N M) 12. upper ball joint mounting bolt 13. Parallelism adjustment screw 14. door shaft lever 15. cage bearing 16. motor baseplate Mounting bolts torque: 18 ±1 LB-ft (24 ±1.5 N M) 17. Door motor 18. Limit switch (LS1 and LS2) 19. rotating cam connecting rod locknut torque: 17 ±2 LB-ft (23 ±3 N M) 21. lower pivot support Bolt torque: 17 ±2 LB-ft (23 ±3 N M) 22. lower pivot locknut torque: 45 ±5 LB-ft (61 ±7 N M) 23. lower Door shaft arm 24. touch bar (optional) Figure 2 - Rear Door Details and Torques (Typical)

3 Front door open rear door unlocked (-2) Front door open rear door unlocked (+2) / 3 A. normal mode: The driver uses the door control lever to open the rear door. The rear door switch is placed in the normal position and the door control lever is placed in one of the rear door unlocked positions. (-1) (+1) Front door open 17 Front door closed rear door unlocked (0) Front door closed rear door locked rear door locked The rear door circuit is fed by the micro contact of the door control. A green light located above the rear door (optional) and an LED on the control panel light up, indicating that the opening of the door is permitted. The kneeling system deactivates itself. If the vehicle is equipped with a rear ramp, the ramp system also deactivates. To open the door, the passengers can then activate one of the optional rear door actuators. For more information on the rear door actuators, see the annexes at the end of this section. During normal operation, when the main control valve is activated and the rear door is closed, the rear door supply solenoid valve, normally open, allows the passage of air to the door motor. The door opening cycle will only start once the operator has performed the function of opening the rear door. An electro-pneumatic system, with a five-position door control lever, is used by the operator to deactivate the locking solenoid on the rear door motor. OPENING CYCLE Figure 3 - Door Control Lever In order for the operator to start the opening cycle of the rear door, the master control switch must be in the normal or lights position; the speed of the vehicle must be lower than 3 km/h (2 mph); the vehicle must not be in the kneeling position and the ramp must be completely stowed. To unlock and open the rear door, two methods of operation are possible: NOTE: When no optional rear door actuator is installed, the operator opens the door by means of the door control lever. In this case, no green lamp signals the door opening authorization. B. manual mode: The driver uses the rear door switch to open the door. The rear door switch is placed in the doors open position. The rear door circuit is fed by the switch. A green light, located above the rear door (optional), and an LED on the control panel light up, indicating that the opening of the door is permitted. The kneeling system deactivates itself. If the vehicle is equipped with a rear ramp, the ramp system also deactivates. The door then opens without the necessity of activating one of the optional door actuators. Following the opening of the door in one of the above modes, a signal is generated and is sent to the supply valve solenoid, which closes and cuts off the supply of air to the large door cylinder. Pressurization of the large cylinder is interrupted and air is released by the door control valve s exhaust port. Air pressure is now applied exclusively to the small cylinder piston, which pushes the rack inside the door motor toward the large cylinder. The movement of the rack starts a rotating movement of the pinion, which turns the sector shaft in a counter-clockwise direction. The rotating movement of the sector shaft is transmitted to a rotating cam, and then to the linkage that opens the panels. During the opening of the door, the panels are guided toward the door posts. The door is equipped with a damping cushion for the end of its sequence, which cushions the entire opening cycle of the door.

4 4 / On vehicles equipped with a damping cushion installed on the door shaft, a lever fixed to the door shaft activates a damping valve that directs compressed air toward a restrictor, which cushions the door at the end of its cycle. On vehicles equipped with a damping cushion integrated into the door motor, a spring compresses at the end of the cycle, whenever the diaphragm in the motor closes the exhaust port, and forces air to the controlled damping port to cushion the panels. In the open position, each panel is perpendicular and as close as possible to the side of the vehicle. A brake interlock mechanism applies the brakes every time the rear door is opened or every time the sensitive edges detect an obstruction. The interlock functions automatically, thus the operator has no direct control over this feature. For more information regarding the brake interlock, see section : braking system. Depending on the programming of the vehicle, an accelerator interlock system may deactivate the accelerator command whenever the rear door is open. Such a system prevents the motor from turning faster than at idle. For more information on the accelerator interlock system, see section : motor and accessories. CLOSING CYCLE In order for a closing cycle to start and finish properly, the door must be clear of any passengers and obstructions. A. When the initial door opening function has been performed in normal mode, the closing cycle commences when no door actuator (optional) is activated. This means that the contact bars are released and no obstruction is detected by the presence sensor or the motion detectors. B. When the door opening function has been performed in manual mode, the closing cycle commences when the driver places the rear door switch in the normal position. In both cases, the closing cycle only completes if the sensitive edges do not detect any obstruction between the central door joints. The contact joint of each sensitive edge includes a rubber section, sealed at the upper and lower ends with an end cap that forms an hermetic cavity. A flexible tube, fixed to the end caps of each door, allows the transmission of air displaced from the sealed edge cavity to the sensitive edge switches (OPS). Mounted on the door motor support, these detectors function independently or jointly to activate the door control supply, which in turn, activates the rear door solenoid valve supply. See Figures 4 and 5. As soon as an obstruction is detected, the door closing cycle is interrupted and the panels reopen completely. Following the end of the closing movement of the panels, the sensitive edges remain active for a period of 3 to 4 seconds. Following a complete closing cycle, the kneeling system is reactivated. Also, if the vehicle is equipped with a rear ramp, the ramp system is reactivated. As well, the door opening authorization light (optional) and the LED on the control panel extinguish. Obstruction pressure switches (OPS) Sensitive edge line Sensitive edge line Integrated pressure cavity Figure 4 - Installation of Sensitive Edges Figure 5 - Obstruction Pressure Switch (OPS)

5 / 5 As soon as the brake pedal is pressed or the accelerator pedal is released and pressed again, the brake interlock and the accelerator interlock (optional) are deactivated, provided that the door control lever is placed in one of the rear door locked positions. A rear door locking system engages as soon as the bus starts to move and reaches a speed in excess of 3 km/h (2 mph). The rear door lock consists of a locking solenoid valve, used to engage the door lock cam lever in a slot when the vehicle is in motion. The exposed part of the plunger is attached to the door lock lever. When the solenoid valve is activated, the plunger is pulled into position, engaging the cam lever in the slot of the door lock cam, thus preventing the door from opening. Rear door verification The rear door verification table has been created to simplify the verification, the diagnostics and the adjustment of the door system. This table is divided into two parts: verification section. This section indicates each sequential step to follow to conduct a complete verification of the rear door system. It includes a description of each verification, the reasons for them and a list of the potential problems that could be encountered at the time of verification. repair section. This section covers the diagnoses of the problems encountered in the previous section and how to correct them. It proposes, for each case, one or more additional verifications with related comments that help to better understand the situation. Solutions to these problems are also proposed in this section. Instructions To conduct a complete verification of the rear door system: a. Follow the sequence verification proposed in the verification section, taking each objective into consideration. b. If no problem is encountered during verification, proceed to the next sequence number: If a problem is observed, identify it in the potential problems column in the verification section. c. Then, refer to the secondary verification associated with this problem on the repair section. Whenever a section proposes more than one secondary verification, proceed in the sequence indicated. d. According to the results based on the secondary verification, refer to the adjustment column for the appropriate corrective action to be taken. The procedures proposed in this column correspond to those under heading adjusting the front door in this section. To diagnose a problem specifically encountered in service: a. Identify the problem encountered in service in the potential problems column in the verification section. b. Then refer to the secondary verification associated with this problem in the repair section. When a section proposes more than one secondary verification, proceed as follows: c. According to the results based on the secondary verification, refer to the adjustment column for the appropriate corrective action to be taken. The procedures proposed in this column correspond to those under heading adjusting the front door in this section.

6 6 / REAR Door Verification Table Verification section Repair section Seq. Initial Verification Objective Potential Problem Secondary Verification Observation Adjustment 1 Perform a complete door cycle, with and without air pressure in the system. Verify the smooth movement of the door, while ensuring that there is no rubbing, or jamming, nor any suspicious noises and faulty components. The movement of the door is not smooth. a. Ensure that the door rubber seals overlap without binding. b. Verify whether there is any play with the motor installation while shaking the two panels simultaneously. c. Verify the symmetry of the door. Door rubber seals bind. Adjust the connecting rods according to the procedure for adjusting the connecting rods. If the problem persists, conduct the following secondary verification. The rotary cam and/or the motor move. The height of the panels is not equal, i.e. there is more than 1 /8 in. (3 mm) difference between the top of the window of panel 3 and the top of the window of panel 4. The screws of the upper bearing cage are loose. The rollers are not pressed completely on the surface of the guide. Tighten the motor mounting screws, or replace the motor. Correct according to the procedure for adjusting the height of the panels (and the subsequent procedures). Tighten the screws to a torque value of 7 lb-ft (10 N m). Verify whether the side of the roller support is perpendicular to the top of the door panel. For a precise verification, use a door guide template (optional). See the annex optional verification tools of this section. Correct if necessary d. With the panels open, measure the distance between the panels. Take a measurement on the inside of the panel and one on the outside; always use the same point of reference (under the door window, for example). e. With the panels open and closed, verify whether the stop rubber seals under the panels or the cover of the brushes rub on the lower door shaft arms. The sensitive edges are not parallel. The difference between the two measurements is more than 1 /4 in. (6 mm). Rubbing or obstruction of one or both panels. Correct according to the procedure for adjusting the parallel alignment of closed panels (and the subsequent procedures). Correct the parallel alignment of the door according to the procedure for adjusting the parallel alignment of open panels and adjusting end of sequence stops. Adjust according to the procedure for adjusting the bottom of the door.

7 / 7 Verification section Repair section Seq. Initial Verification Objective Potential Problem Secondary Verification Observation Adjustment 2 Drive at a speed of more than 3 km/h (2 mph), and place the rear door switch in the automatic position. Then, slow down to a speed less than 3 km/h. Once the sequence is finished, return the switch to its normal position. Verify that the lock is released in time to allow the door to open freely when the vehicle is at a speed less than 3 km/h. The door does not open. a. Verify the lock release. The lock must be between 2 and 3 mm (1/16 in) and 1/8 in) of the top of the cam. b. Verify the state of the muffler. Adjust the lock according to the procedure for regulating the speed of lock release. The muffler is blocked. Replace the muffler. 3 When the vehicle is immobile, put the rear door switch in the automatic position and replace it in the normal position. Verify that door performs a complete door cycle. The door does not open. The door opens partially and closes again. a. Verify the power from the supply solenoid valve. b. Verify the state of the input signal for the LS2 switch circuit. See the vehicle s wiring diagram. The solenoid valve is supplied. There is no supply to the solenoid valve. Change the solenoid valve. Repair the supply circuit for the solenoid valve. See the vehicle s electric diagram. The signal is activated. Adjust the LS2 switch according to the procedure for adjusting limit switches. The signal is not activated. Repair the LS2 switch circuit. The door opens and remains open. c. Verify the state of the input signal for the LS2 switch circuit. See the vehicle s wiring diagram. The signal is activated. Adjust the LS2 switch according to the procedure for adjusting the limit switches. The signal is not activated. Repair the LS2 switch circuit. d. Verify the state of the input signal for the LS1 switch circuit. See the vehicle s wiring diagram. The signal is not activated. Repair the LS1 switch circuit. e. Disconnect the solenoid valve. f. If equipped with a photoelectric presence detector, verify the strength of the input signal to the detector. See the coach wiring diagram. g. If equipped with touch bars, verify the strength of the input signal to the touch bars circuit. See the coach wiring diagram. The door remains open. Change the solenoid valve. The signal is activated. Replace the detector. The signal is activated. Repair the touch bars circuit.

8 8 / Verification section Repair section Seq. Initial Verification Objective Potential Problem Secondary Verification Observation Adjustment 4 Wait for the complete closing of the door and reactivate the door immediately using one of the sensitive edges. From the beginning of the closing cycle, activate and hold each sensitive edge alternately. Ensure that the holding time of each edge is a minimum of 6 seconds. Following this delay, release the edge. The door must close again. The door immediately closes again. The door closes again before 6 seconds. a. Verify the state of the input signal for the sensitive edges circuit. See the coach wiring diagram. b. Verify the state of the air pipeline. The signal is deactivated. Repair the sensitive edges electric circuit. If the circuit is correct, conduct the following secondary verification. Leaks or pinches in the air pipeline. No leak or pinch in the air pipeline. Repair the faulty pipeline and/or to change the faulty sensitive edge. Change the faulty sensitive edge switch (red switch). 5 If equipped with a photoelectric presence sensor, just prior to the complete closing of the door, position yourself under the sensor in order to keep the door open. 6 If equipped with ultrasonic motion detectors, just prior to the complete closing of the door, activate one of the sensors. Allow the door to close again by itself and repeat with the other two sensors. 7 If equipped with touch bars, place them outside the sensor s field of detection, in order to start a door closing cycle and from the beginning of the closing cycle, activate one of the touch bars. Repeat with the other bar. 8 Exit the vehicle. During a door-closing cycle, insert your wrist between the rubber of the sensitive edges, in the center of the door. Verify that the detector stays active until the end of the closing cycle,i.e., until the LS1 switch is deactivated. Verify that the motion detectors and the Class module are working properly. Verify that the touch bars stays active until the end of the closing cycle, i.e., until the LS1 switch deactivates itself. Verify the condition of the rubber of the sensitive edges and ensure that they are not too sensitive. The door does not open. One of the detectors does not respond to an activation request. One of the components of the Class module (RAM, CPU, the tension of the internal supply) is faulty. The door does not open or the touch bars do not keep the door open. a. Verify the state of the input signal of the photoelectric presence detector. See the coach wiring diagram. a. Verify the state of the LEDs. LPS (left detector), MSU (central detector) and RPS (right detector). b. Verify the state of the SYSTEM LED on the Class module. a. Verify the state of the input signal of the touch bar s circuit. See the coach wiring diagram. The signal is deactivated. Verify and repair the detector s electric circuit. If the circuit is correct, replace the detector. The signal is activated, but the door does not open. One of the LEDs lights up red. The detecting SYSTEM blinks the red light quickly to orange). Open the door with the sensitive edges and reactivate the sensor. Verify if the detector captures the presence of an obstruction. If yes, withdraw the obstruction. If not, change the sensor. Verify tension to the module input. If the tension is inadequate, test for the reason and correct. If tension is adequate, change the module. The signal is deactivated. Verify and repair the contact bars electric circuit. If the circuit is correct, replace the bars. a. Replace the rubbers. 9 Following the end of the closing cycle, shake panel # 3 slightly to recreate the vibrations of normal operation. Verify the minimum sensitivity of the switches and the sensitive edges. The door must remain closed. The door opens. a. Verify the state of the input signal of the sensitive edges circuit. See the coach wiring diagram. The signal is activated. Disconnect the terminal of one of the switches and repeat the vibrations. Repeat with the other switch. Change the faulty switch.

9 / 9 Verification section Repair section Seq. Initial Verification Objective Potential Problem Secondary Verification Observation Adjustment 10 Place the door control lever in one of the rear door unlocked positions. Ensure that the circuit is functioning properly and verify for adjustment of the door controller switch. The green light above the door (optional) and the door unlocked LED on the control panel must light up and the interlock must engage. The green light (optional) does not light up. The LED on the Instrument panel does not light up. The interlock is malfunctioning. a. If equipped with a photoelectric presence sensor or an ultra-sonic motion detector, verify the state of the input signal of entry of the sensor or the detector. See the coach wiring diagram. The signal is not activated. Verify and repair the electric circuit of the input module for the presence sensor. See the coach wiring diagram. The signal is activated. Verify and replace the bulbs. b. Verify and repair the electric circuit of the LED lamp Instrument panel module. If the circuit is correct, replace the module. c. Verify the state of the input signal of the door controller switch. See the vehicle s wiring diagram. The signal is not activated for the three lever positions. Verify and repair the door controller circuit. The signal is activated. Proceed to secondary verifications 3b and 3c. The brakes are not applied. d. Verify the state of the output signal from the brake interlock valve. See the vehicle s wiring diagram. The signal is not activated. Verify and repair the electronic circuit for the brake interlock valve. See section : braking System. The signal is activated. Verify and repair the electronic circuit for the brake interlock valve. See section : braking System. The accelerator does not cut out (only if the programming of the vehicle includes this function). e. Verify the state of the output signal from the accelerator interlock valve. See the vehicle s wiring diagram. The signal is not activated. Verify and repair the electronic circuit for the accelerator interlock valve. The signal is activated. Verify and repair the electronic circuit for the accelerator interlock valve. 11 If equipped with a photoelectric presence sensor, return toward the rear door and to stand in the center of the door. From ground level, raise a hand until there is detection. Measure the distance between the underside of the touch bars (optional) or the grab handles and the point of detection. Verify that the height of detection is located between 10 and 20 cm (4 and 8 in.) under the touch bars or the grab handles. The detection height is not within the prescribed range. a. Verify the cleanliness of the sensor. The sensor is dirty. Clean the sensor. The sensor is clean. Change the sensor.

10 10 / Verification section Repair section Seq. Initial Verification Objective Potential Problem Secondary Verification Observation Adjustment 12 If equipped with a photoelectric sensor and touch bars, push the hand on the sensitive edges and displace it toward the inside. Measure the distance between the sensitive edges and the point of detection. Verify that the depth of field of the sensor is between 10 and 15 cm (4 and 6 in.) to avoid the detection of the touch bars. The detection distance is not within the prescribed range. a. Verify the sensor support. The support is badly positioned. Adjust the support. 13 Verify the operational speed of the door. Use a stopwatch or a Door-o-Meter (optional). For the procedure on using the Door-o-Meter, see the annex optional verification tools, at the end of this section. Verify that the opening and closing speeds are within prescribed tolerances. The time varies according to the programming of the vehicle. The opening and closing speeds are not within prescribed limits. a. Improper closing speed. Adjust the speed of closing according to the procedure for adjusting the speed of panel closing. b. Improper opening speed. Adjust the speed of opening and the damping effect according to the procedure for adjusting the speed of panel opening and the procedure for adjusting the damping. c. Speed of closing and/or opening does not adjust itself according to the procedure adjusting the door panel speed. Change the motor.

11 / 11 Rear DOOR ADJUSTMENTS ADJUSTING THE CONNECTING ROD While tightening or loosening a connecting rod, always use two wrenches, one to hold the rod, and the other for the locknut, thereby avoiding the forcing of the rod and ball joint. 1. Cut off the air supply to the door system. 2. On each rod, unscrew the locknut on each ball joint. 3. Disconnect the two connecting rods at the door shaft lever side. See Figure Completely tighten each ball joint by holding the ball joint in position and turning the rod. 5. While still holding the ball joint in position and turning the rod, loosen the knuckle approximately 3 /4 in. (2 cm). Keep a constant tension on each, but do not turn the motor cam of the door. + CAUTION: Do not apply too much tension, nor permit too much play on the rods. The rods could be damaged during operation of the door mechanism. 6. Center the limit switches on their mounting plate. Adjust the switches in such a way that there is a 1 /8 in. (3 mm) play between the switch rollers and the motor s rotary cam. See Figure Reconnect the rod for panel 4 to the door shaft lever. 8. Push the panel against the outside rubber seal until no visible light is evident (less than 20 % luminosity). 9. Turn the rotary cam until a click is heard from the LS1 limit switch. 10. Open the door manually and verify that the LS2 limit switch is working; a click will be heard. 11. Repeat steps 7 to 10 on panel Return air pressure to the doors and close the panels. 13. Tighten the connecting rods one complete turn. 14. Verify manually the pressure of each panel by pushing them from outside the vehicle. Both panels should move freely, while displaying a certain amount of resistance, and should react in an identical manner for the same amount of applied pressure. Adjust the rods again, if necessary, continuing to ensure that equal tension is applied to each. 15. Remove air pressure from the door system. 16. Before performing a final tightening of the locknuts, ensure that all the connecting rods are oriented the same way. 17. Completely tighten the locknuts for each ball joint. 18. Tighten the parallel alignment adjusting screw on the upper door shaft arm; the screw must rest against the arm. See Figure Use a medium grade thread locker (blue) on the parallel alignment adjusting screw, if necessary. 20. Manually recheck the operation of the door. loosen the locknut of each rod ball joint Disconnect the rods from the door shafts Figure 6 - Disconnecting the Connecting Rods Figure 7 - Adjusting the Limit Switches 1 /8 in (3 mm)

12 12 / ADJUSTING THE HEIGHT OF THE PANELS 1. Cut off the air supply to the door system. 3. Disconnect the two connecting rods at the door shaft lever side. 3. Use lower door shaft arm to raise the door shaft. 4. Slide a piece of wood under the shaft to maintain it in an elevated position. 5. Remove the door shaft lever. 6. Adjust the height by adding or removing 1 /32 in. (1 mm) thick shims under the door shaft lever. 7. Reinstall, while aligning the two reference points of the door shaft lever. Tighten the bolts to the torque values indicated. See Figure Adjust the upper brush according to the heading adjusting the upper brush in this section. 9. Adjust the lower brushes according to the heading adjusting the bottom of the door in this section. 10. Manually recheck the operation of the door. Figure 8 - Parallel Alignment Adjustment Screw ADJUSTING THE UPPER BRUSH 1. Adjust the upper door brush while loosening the retaining screws from inside the vehicle. 2. Move the brush down so that there is a gap between the top of the door panels and the brush. 3. Check from outside the vehicle, with closed door panels, that the brush lightly touches the outside of the door. If it does not touch, reposition the brush. retaining Bolt 37 ±2 lb-ft (50 ±3 N m) Align the reference points The upper door brush must be installed correctly. Its positioning is determined by the curve in the brush. The brush must curve toward the inside, toward the door. See Figure 10. Figure 9 - Door shaft lever 4. Tighten the brush retaining screws. proper Installation of the upper brush Figure 10 - Upper Brush Installation

13 / 13 ADJUSTING THE BOTTOM OF THE DOOR See Figure Close the panels. 2. Loosen the screws of the bottom door cover and position the cover so that it does not touch the lower door arm and that it is positioned equally above the door lower pivot support. Tighten the screws at each end of the cover. 3. Loosen the screws holding the brush. 4. Adjust the height of the brush so that it touches the floor when the door is closed. 5. Tighten the screws for the brush and the cover. 6. Open the door and verify that there is no contact between the floor and the lower brush. The rubber stops at the bottom of the door must be 3 /16 in. (5 mm) from the highest point of the floor covering. Cut the rubber stops, if necessary. ADJUSTING THE PARALLEL ALIGNMENT OF CLOSED PANELS 1. Cut off the air supply to the door system. 2. Loosen the connecting rod of each panel simultaneously, in order to lengthen them and to allow the motor cam to rest against its internal stop. The panels may be slightly open at this stage. 3. Starting with panel 4, tighten the connecting rod, in order to push the rear of the panel against the outside seal. Push on the exterior rubber seal just until no light shows through (less than 20 % luminosity). 4. Tighten the connecting rod one complete turn. 5. Repeat steps 3 and 4 on panel When the two panels are pressed against the seal, tighten the connecting rods simultaneously, in order to apply pressure that will push the panels against the seals and will align them parallel to each other. 7. Stop tightening the rods when the motor s rotary cam starts to turn, indicating that the maximum pressure has been reached, or when the door panels are parallel to each other. 8. Return air pressure to the doors and close the panels. 9. Manually verify the pressure of each panel by pushing on each one from outside the vehicle. Both panels should move freely, while displaying a certain amount of resistance, and should react in an identical manner for the same amount of applied pressure. Adjust the rods again, if necessary. 10. Cut off the air supply to the door system. 11. Tighten the parallel alignment adjustment screw on the arm of the upper door shaft; the screw must rest against the arm. See Figure Apply a medium grade thread locker (blue) to the parallel alignment adjustment screw, if necessary. 13. Verify that the roller supports are correct in relation to the door. Correct if necessary. 14. Check that the top of each roller support forms a 90º angle with a vertical line formed by the door jamb. See Figure 12. If the roller supports are not adjusted correctly, correct according to the heading adjusting roller supports in this section. If the roller supports are correctly adjusted, proceed to the heading adjusting the vertical alignment of the center seal also in this section. Door bottom COVER lower BRUSH RUBBER stop) roller support vertical line of the door jamb Figure 11 - Door Bottom Figure 12 - Roller Support Verification

14 14 / ADJUSTING ROLLER SUPPORTS 1. Loosen the roller support bolts. Push on the support so that the roller leans on the outside face of the roller guide when the door is open and on the inside face when the door is closed. Tighten the bolts. 2. If the center of the door points toward the exterior, add a shim under the upper pivot support, in order to push the rear of the panels to their maximum and bring the center toward the interior. 3. Verify which type of exterior seal is used on the panels. See Figure 13. a. If they are equipped with type 1 seals, go directly to step 5. b. If they are equipped with type 2 seals, go to step For those panels with type 2 seals only: a. If the center of the panels points toward the inside of the vehicle, adjust the support screw on the arm of the upper door shaft. Start with panel 3. b. Tighten the support screw against the arm of the door shaft to open the panel toward the outside of the vehicle; this creates pressure in the linkage. The pressure of the door against the exterior seal will then be loosened. c. Re-establish the pressure of the door panel against the rubber seal using the connecting rods, so that the door is straight and pressed firmly against the seal. There must be pressure on the linkage to avoid movement of the panels. d. Repeat the procedure on panel 4, in order to close the gap between the two rubber seal joints. 5. If a proper parallel alignment has still not been achieved, add shims under the roller support. 6. Return air pressure to the door system. 7. Adjustment of the roller supports may alter the parallel alignment of the panels in the closed position. Check again that the closed panels are parallel with each other. Reapply the procedure adjusting the parallel alignment of closed panels, if necessary. 8. Proceed to adjusting the vertical alignment of the center seal. ADJUSTING THE VERTICAL ALIGNMENT OF THE CENTER SEAL 1. While standing inside the vehicle, measure the distance between the rubber door seals, at the top and at the bottom of the open doors. A difference of 1 /16 in. (2 mm) and less between the two measurements is acceptable. 2. Loosen the ball joint locknut on each upper door shaft arm. See Figure Remove the ball joint mounting bolt. 4. Screw in the ball joint to open the top of the joint made by the rubber door seal and loosen the ball joint to close the top of the seal. To ensure a symmetrical movement of the panels, adjust the gap while unscrewing or while screwing in each ball joint the same number of turns. 5. Once the adjustment is complete, replace the ball joint mounting bolt and tighten. Apply medium grade thread locker (blue), if necessary. 6. Open the panels so that they are at a 90º angle with each other. Adjust the angle of the ball joint; it must be parallel with the top of the bolt. 7. Retighten each ball joint locknut. 8. Return air to the door system, and recheck the adjustment. 9. Once the adjustment is satisfactory, proceed to adjusting the air gap between the rubber seals. Adjusting THE AIR GAP BETWEEN THE sensitive edges 1. Look between the two rubber seals toward the rear of the vehicle, to verify whether they contact each other and ensure that there is no light visible between the two seals. 2. Adjust the roller of panel 4 in the guide s hollow that will allow the panel to move toward the outside and will help the gap to close again by itself. 3. If the adjustment is not sufficient, adjust the roller on panel 3 while pushing it toward the door shaft ball joint. This allows the panel to return toward the inside and close the gap. mounting bolt Type 1 Type 2 locknut ball joint Figure 13 - Types of Exterior Rubber Seals Figure 14 - Upper Door Shaft Arm Ball Joint

15 / The adjustment of the air gap between the rubber seals changes the parallel alignment of the panels in their open position. Verify the parallel alignment and adjust according to the heading parallel alignment of open panels and adjusting end of sequence stops in this section. PARALLEL ALIGNMENT OF OPEN PANELS AND Adjusting END OF SEQUENCE STOPS See Figure Loosen the bolts on the roller support for both panels and allow the door mechanism to take up any slack. This will allow the door panels to come to rest and to align themselves correctly. 2. Check that the roller for each panel is straight. Correct as necessary. 3. If there is still an improper parallel alignment of the door panels, adjust the end of sequence door stops in such a way that the rollers at the top of each panel, slide in the guide and lightly come into contact with the limit stop during the door open sequence: a. Open the panels. b. Loosen the locknut of the limit stop, then unscrew the limit stop by the number of turns necessary to obtain a good adjustment. c. Tighten the locknut of the limit stop once the adjustment has been made. REGULATING THE LOCK RELEASE SPEED 1. Adjust the distance between the lock and the underside of the rotary cam, while adjusting the lock cylinder bracket, attached to the door motor, or by adjusting the length of the lock cylinder connecting rod. 2. Verify and adjust the lock release speed: a. Raise the vehicle using a jack. CAUTION: VEHICLE HOISTING. Follow your internal safety procedure, and use appropriate safety equipment for your protection. See section 18: Hoisting and Towing in this manual regarding lifting and towing procedures before raising or lowering the vehicle. b. Deactivate the ABS/ATC by activating the rear door switch for a period of 3 seconds. c. Accelerate the vehicle. When the vehicle indicates a speed in excess of 3 km/h (2 mph), put the rear door switch to the automatic opening position and slow down the vehicle. Verify that the lock releases in time to allow the door to open freely when the vehicle is at a speed less than 3 km/h (2 mph). d. To adjust, tighten the screw located at the end of the lock cylinder to its maximum. e. Loosen the screw by three turns. f. If the lock does not open within the prescribed timeframe, turn the screw an additional half-turn, until the required adjustment is achieved. Adjusting THE limit switches See Figure Activate the LS2 limit switch manually for a period of 3 to 5 seconds. The door should close by itself. 2. Adjust the position of the limit switches by loosening the two retaining screws of the switch mounting plate. 3. Slide the plate on the guides in such a way as to still activate the LS1 switch when the door is closed and the LS2 switch when the door is open. 4. Tighten the retaining screws. Figure 15 - End of Sequence Stops Figure 16 - Limit Switches LS1 and LS2

16 16 / ADJUSTING THE DOOR PANEL SPEED 1. Activate the door and verify the time that it takes for the panel to open and close using a stopwatch or a Door-o-Meter (optional). 5. Tighten the locknut while ensuring that the adjustment screw maintains its setting. Ensure that the locknut is well tightened. 6. Recheck the time taken for panel closing and, if necessary, readjust. For the procedure on the use of the Door-o-Meter (optional), see the annex optional verification tools at the end of this section. 2. Before commencing the adjustment for the closing and the opening, loosen the damping adjustment screws. See Figures 17 or 18, according to the option. adjustment screw Whenever the opening and closing speeds of the panels require adjustment, always start by adjusting the closing speed. Figure 17 - Damping Cushion on the Door Shaft + CAUTION: When making adjustments, never force the adjusting screws in a clockwise direction. The excessive tightening pressure (metal on metal) will damage the motor cylinder cap. SPEED OF PANEL CLOSING 3. If the measured closing speed is not within prescribed tolerances, adjust the panel closing speed by turning the closing speed adjustment screw. See Figure 19. a. Loosen the locknut for the closing speed adjustment screw. b. Screw in the adjustment screw to slow down the closing of the panels and unscrew the screw to increase the panel closing speed. 4. Measure the speed of panel closing using a stopwatch or the Door-o-Meter (optional). If the measured time is again not within accepted tolerances, repeat the adjustment. damping adjustment screw Figure 18 - Damping Cushion Integrated into Motor A B For the procedure on the use of the Door-o-Meter (optional), see the annex optional verification tools at the end of this section. C A. OPENING SPEED ADJUSTMENT SCREW B. CLOSING SPEED ADJUSTMENT SCREW C. DAMPING ADJUSTMENT SCREW (OPTIONAL) Figure 19 - Speed Adjustment and Damping Screw

17 / 17 SPEED OF PANEL OPENING When calculating the opening time of the door, allow 3 seconds to pass after the closing of the door between each test. This permits the application of maximum pressure to the door and has an affect on the damping at the end of the door cycle. 7. Close the door panels. 8. Measure the speed of panel opening using a stopwatch or the Door-o-Meter (optional). For the procedure on the use of the Door-o-Meter (optional), see the annex optional verification tools at the end of this section. 9. If the measured opening speed is not within prescribed tolerances, adjust the speed of opening of the panels by turning the opening speed adjustment screw. See Figure 19. a. Loosen the locknut for the adjustment screw. b. Screw in the adjustment screw to slow down the opening of the panels and unscrew the screw to increase the panel opening speed. 10. Measure the speed of panel opening using a stopwatch or the Door-o-Meter (optional). If the measured time is again not within accepted tolerances, repeat the adjustment. 11. Tighten the locknut while ensuring that the adjustment screw maintains its setting. Ensure that the locknut is well tightened. 12. Recheck the time taken for panel closing and, if necessary, readjust. 13. If the opening speed adjustment has been completed, conduct the adjusting the damping. ADJUSTING THE DAMPING A. SEQUENCE-END DAMPING cushion INSTALLED ON THE DOOR SHAFT See Figure If the damping adjustment screw has been previously loosened, proceed to step 2. If not, open and close the door several times, in order to determine the operation and effects of the damping sequence. The door should open without any knocking or banging. Location of the start of damping 2. Turn the damping adjustment screw in a clockwise direction in order to shut off the air supply to the valve. 3. Open the door. 4. The door must stop its cycle between half and two thirds of its cycle. This position indicates the start of the damping sequence. See Figure 20. If the door stops at this position, go directly to step 17 in order to complete the damping adjustment. If not, proceed to the following steps. 5. Cut off the air supply to the door system. Adjusting the cam See Figure Close the door manually. 7. Loosen the cam mounting screw. 8. Align the side of the cam parallel to the bracket. 9. Tighten the mounting screw. side of cam and bracket to be aligned cam Mounting Screw Figure 20 - Desired Stop Position Figure 21 - Cam Alignment

18 18 / Adjusting the position of the valve See Figure Loosen the two mounting screws of the valve bracket. 11. Place the valve wheel at the place where the flat side of the cam starts. The wheel must rest lightly on the cam. 12. If the wheel is not located at the center of the top of the cam, add a shim of the required thickness under the valve bracket. See Figure Tighten the mounting screws of the valve bracket. Adjusting the position for the start of damping 14. Apply air pressure to the door system. 15. Restart the procedure from step 3, in order to verify the position where damping starts. Once the correct position has been attained, proceed to step 17. Adjusting the final damping 16. Loosen the valve adjusting screw by five turns. 17. Perform several operating sequences of the door and adjust the position of the valve adjustment screw. Wait approximately 3 seconds between each cycle. 18. Once the damping effect has reached the desired level, tighten the locknut on the valve adjusting screw. flat side of cam bracket mounting screw B. SEQUENCE-END DAMPING cushion INTEGRATED INTO THE DOOR MOTOR See Figure If the damping adjustment screw has been previously loosened, proceed to step 2. If not, open and close the door several times, in order to determine the operation and effects of the damping sequence. The door should open without any knocking or banging. 2. To adjust the restriction of the damping effect, screw in completely the damping adjustment screw and unscrew it by three turns. 3. Open the door and observe the manner in which the control functions. 4. Turn the adjustment screw in a clockwise direction one quarter turn at a time. Continue adjusting until the door no longer knocks and the speed of the door is within the prescribed tolerances. 5. Ensure that the door is operating properly and measure the closing speed using a stopwatch or the optional Door-o-Meter. Figure 22 - Adjusting the Position of the Cam center of the height of the cam Figure 23 - Verification of the Position of the wheel

19 / 19 Replacement and testing MAIN DOOR CONTROL VALVE The main door control valve is located on the pneumatic control panel on the driver's left-hand side. For information on the main door control valve, see section : front door and mechanism in this manual. DOOR Controller The door controller, located in the driver control panel, is a five-position electropneumatic device that is actuated by the door control lever. For information on the main door control valve, see section : front door and mechanism in this manual. DOOR MOTOR See Figure 24. Removal 1. Release the pressure from the door system. 2. Open the door motor compartment, located directly over the front door. 3. Disconnect the connecting rods from the door motor rotating cam rods. 4. Disconnect the wiring and air hoses from the door motor components. 5. Remove the bolts and washers attaching the motor baseplate to the vehicle. Remove the baseplate from the door motor compartment. NOTE: For information on door motor disassembly and reassembly, see the manufacturer s documentation. Installation 1. Lift the motor baseplate into the door motor compartment. 2. Attach the motor baseplate to the vehicle using bolts and flat washers. Apply thread locker to hold the bolts into place. Tighten the bolts. See Figure 2 for torque value. 3. Connect the connecting rods to the door motor rotating cam rods. 4. Connect the wiring and air hoses to the motor baseplate. Lock solenoid operation test The lock solenoid functions at a voltage of 24-volts DC with a pulse current of 18 A and a holding current intensity of 0.4 A. To test the lock solenoid: 1. Connect a test voltmeter between the solenoid control terminals and connect a variable voltage source to the terminals (such as a battery and a variable resistor wired in series). Slowly increase the voltage on the solenoid and note the voltage required to move the solenoid plunger. 2. If the voltage required to move the plunger is higher than that indicated above, replace the solenoid. 3. Connect an ammeter wired in series to the solenoid winding. Increase the voltage to the recommended value and note the intensity of the current. If the solenoid plunger does not move, replace the solenoid. DOOR SHAFTS REMOVAL 1. Release the pressure from the door system. 2. Disconnect the upper and lower door shaft arms. 3. Disconnect the connecting rod from the door shaft lever. 4. Remove the retaining bolt attaching the door shaft lever to the door shaft. Remove the lever. 5. Remove the cage bearing by removing the three screws under the support plate. 6. Remove the door shaft from its housing. On certain vehicles, the lower door shaft pivot may be unscrewed from underneath the bus, and then removed.

20 / THREAD PROTECTOR 2 SMALL CYLINDER CAP 3. GASKET 4. SMALL CYLINDER 5. assembly bolt 6. STARWASHER 7. WASHER 8. circlip 9. U-TYPE GASKET 10. SMALL PISTON 11. O-RING 12. MOUNTING BOLT lb IN ( n m) 13. LOCKWASHER 14. PINION 15. slotted spring pin 16. RACK 17. O-RING 18. LARGE piston 19. U-TYPE GASKET 20. circlip 21. WASHER 22. STARWASHER 23. assembly bolt 24. PINION BOX 25. SECTOR SHAFT 26. LARGE SPRING 27. assembly bolt 28. RETAINING RING 29. WASHER 30. RETAINER 31. NUT 32. SMALL SPRING 33. LARGE CYLINDER 34. SEAT 35. SOCKET SCREW 36. NUT 37. WASHER 38 O-RING 39. UNIION 40. SUPPLY SOLENOID VALVE 41. BALL 42. LARGE CYLINDER CAP 44. MOUNTING BOLT lb IN ( n m) 45. NEEDLE 46. O-RING 47. WASHER 48. NUT Figure 24 - Door Motor - Exploded View

21 / 21 INSTALLATION 1. Release the pressure from the door system. 2. If necessary, remove the retaining bolt on the door shaft lever. See Figure 9. Disassemble the door shaft and remove the cage bearing from the door shaft assembly. 3. To adjust the parallel alignment of the panels, screw or unscrew the upper pivot ball joint of each panel until eight threads are visible between the locknut and the ball joint. 4. Apply removable thread locker to the threads in the cage bearing. See Figure Apply removable thread locker to the threads of the lower door shaft pivot. Install the lower pivot. Make sure the threads and the pivot base are clean. 6. Install the door shaft by inserting the upper section of the shaft in the hole in the support plate and by positioning the bottom of the door shaft on the lower door shaft pivot. 7. Insert the cage bearing and its lug on the upper section of the door shaft, and insert the three screws under the support plate. See Figure 26. Tighten the three screws to the torque indicated in Figure Insert the door shaft lever, taking care to align the reference points on the door lever and the door shaft. See Figure Install the retaining bolt on the door shaft lever, making sure it remains accessible when the door is open. It must point in the same direction as the upper door shaft bracket. Tighten the retaining bolt to the recommended torque. See Figure Make sure the door shaft is level. If required, add shims under the door shaft lever. Never install more than six shims under the door shaft lever. The shafts should turn freely upon application of a force no greater than 3 lb (13 N) measured at the end of the arm with the door motor linkage disconnected. 11. Connect the connecting rod ball joint to the door shaft lever. Make sure the ball joint shows the same amount of threads as the ball joint on the other panel. 12. Connect the upper door shaft arm ball joint to the upper pivot of the panel. Make sure the ball joint shows the same amount of threads as the ball joint on the other panel. 13. Ensure that the door shafts move freely without any interference. 14. Restore pressure to the door system. Tighten to a torque of 7 lb-ft (10 N m) Apply a drop of thread locker Figure 25 - Application of Thread Locker on Cage Bearing Figure 26 - Installation of Cage Bearing Retaining bolt 37 ±2 lb-ft (50 ±3 N m) Upper door shaft arm Figure 27 - Installation of Door Shaft Lever

22 22 / DOOR GLASS See Figure It is recommended that the door panel be removed and the glass be replaced on a workbench, but these instructions can also be carried out without removing the door panel from the bus. 3 5 Removal 1. Remove the rubber seal from both sides of the door panel by removing the screws that hold it. 2. Remove the upright by withdrawing the bolts. 3. Loosen the bolts on the upright. 4. Remove the rubber weatherstripping and the glass by slipping it into the upper and middle crossbeams for the top pane, or the middle and lower crossbeam for the bottom pane. 5. Remove the rubber weatherstripping from the glass. 6. Remove any bits of glass or dust from the inner groove of the rubber weatherstripping, if necessary Installation 7 1. Attach the rubber weatherstripping to the new glass and make sure it fits properly. 2. Lubricate (e.g. with soap and water) the outside of the rubber weatherstripping and slip it gently into the upper and middle crossbeam for the top pane, or middle and lower crossbeam for the bottom pane. Make sure that the weatherstripping is inserted tightly into the inner groove. 3. Install the door panel upright and make sure the rubber weatherstripping fits solidly into the upright. 4. Tighten the bolts slowly until a torque of 8 lb-ft (11 N m) is attained. 5. Use a piece of wood or nylon (approximately in) to push the rubber weatherstripping properly into place (even with the upright). 6. Install the rubber strip in the upright and the rubber strip in the upright. 7. Reinstall the screws and tighten properly Rubber seal 2. weatherstrip 3. SCREw 4. DOOR JAMB 5. bolt torque value: 8 lb-ft (11 N m) 6. window 7. lower door rail 8. bolt 9. STOP 10. COver 11. brush 8 9 Figure 28 - Door Glass Assembly (Typical)

23 / 23 Door panels See Figure 2. Removal NOTE: Before removing the front door, inspect the brushes and rubber seals. Replace them if damaged. NOTE: If both door panels must be removed, start with panel Cut off the air supply to the door system. 2. Open the door panels manually. 3. Disconnect the air hoses and sensitive edge wires. 4. Remove the door bottom cover, the brush guard and the lower brush. 5. Support the door panel and remove the mounting bolt from the upper pivot ball joint. 6. Lean the top of the panel backward and remove the roller from the roller guide. 7. Lift up the panel just so that the pivot joint disengages from the panel s lower ball joint. 8. Repeat on the other panel if necessary. PREPARATION BEFORE INSTALLATION (NEW PANELS) 1. Before installing the doors, check if the sensitive edges work properly by pressing the edges and by checking if air evacuates. 2. If the panel is equipped with a touch bar, make sure it functions properly. 3. Verify the torque of the roller support bolts and the upper pivot support. See Figure 2 for the recommended torque values. 4. Remove the door bottom cover, the brush guard and the lower brushes for each panel. 5. For the brush guard, cut the rubber on the door bottom (optional) in order to have 1/8 in. (3 mm) of material under the metal support and to ensure that there is a sufficient clearance with the floor covering. See Figure Cut the surplus material from the bottom of the door rubber. Align with the bottom mounting of the panel. See Figure 30. Installation NOTE: Before installing the door panels, ensure that the door shaft pivots freely without any restrictions. Adjust if necessary. NOTE: If both panels must be installed, install panel 3 first. 1. Cut off the air supply to the door system. 2. Preadjust each upper door shaft arm by unscrewing the locknut and turning the ball joint until there are eight threads between the ball joint and the locknut. See Figure 14. measure 1/8 in (3 mm )and cut off the excess material Figure 29 - Preparation of Rubber Stops Figure 30 - Preparation of Rubber Seals

24 24 / Remove the door bottom cover, the brush guard and the lower brush. 4. Insert the roller in the roller guide. Be careful with the electrical wires and the sensitive edge hoses. 5. Lift up the door and insert the lower pivot in the ball joint of the lower door shaft arm. 6. Remove the mounting bolt from the upper pivot. 7. Align the ball joint with the upper pivot support and insert the mounting bolt in the ball joint. Adjust the ball joint so it does not interfere with the mounting bolt during the opening of the door. The ball joint must be parallel the head of the bolt when the panels are open at a 45 angle. Sensitive edge system Replacing the obstruction pressure switches (OPS) 1. Open the baselight over the rear door to access the door motor base plate. 2. Remove the two electrical connections from the switch. 3. Carefully disconnect the conduit from the pressure-sensitive edge of the switch. 4. Remove the screws that hold the switch in place. Remove the switch. 5. Install the switch by following the steps in reverse order. Do not fully tighten the mounting bolt at this point. Tighten only sufficiently to allow the door to move without any interference. 8. Tighten the ball joint locknut. 9. If necessary, repeat the previous steps of this procedure to install panel Connect the sensitive edges to the obstructions pressure switches (OPS). 11. Install the lower brush, the brush guard and the door bottom cover on each panel. 12. Ensure that the door panels move freely without any interference. Check the operation of the door according to the front door verification table at the end of this section and perform the recommended adjustments. 13. On each panel, remove the mounting bolt from the ball joint and apply medium strength thread locker (blue). Tighten the bolt completely. REPLACING THE sensitive edge WEATHERSTRIPping 1. Disconnect the sensitive edge air hose of the OPS switch on the base plate of the rear door motor. 2. Remove the two retaining screws in the upper and lower portions of the weatherstrip, and slowly slide the strip out of the lip of the attaching part, making sure not to damage the sensitive edge hose. 3. Disconnect the sensitive edge hose from the plastic connection. 4. Reconnect the sensitive edge hose of the new weatherstrip to the plastic connector, while placing the material of the new strip in the lip of the holding mechanism. 5. Install the fillister head screws. 6. Reconnect the sensitive edge hose to the OPS switch. MAINTENANCE For the installation of optional equipment (touch bars, sensors, etc.), see the annexes at the end of this section. To maintain reliable operation of the door motor, the hardware, the door controller and the limit switches, see the manufacturer s inspection and maintenance chart supplied by Nova Bus. In addition to the manufacturer s recommendations, Nova Bus recommends a rigorous inspection of all moving parts of the door motor 30 days after the initial installation. All connections must be verified and tightened, if necessary. All locknuts on adjustment screws must also be verified. Tighten accordingly.

25 / 25 SECTION A touch bars General description See Figure A1. There are two touch bars; one installed on each door panel. In order for the passenger to disembark from the vehicle, the passenger will engage the door open sequence by slightly pushing the touch bars. The doors will only open after the operator has set the door control lever to the appropriate door open position and the green light indicates to the passenger that the doors may be opened. TOUCH BARS installation Each touch bar is installed vertically on each door panel using four mounting bolts. Figure A1 - Rear Door Touch Bar (Optional)

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27 / 27 SECTION B photoelectric motion sensor GENERAL DESCRIPTION See Figures B1 and B2. The motion sensor is installed at the base of the rear door motor compartment. The lenses of this device are located behind the green passenger light. The sensor emits infrared light rays that detect all motion by means of optic triangulation. The device is activated when the door switch is set to either one of the two positions used for opening the rear door. The green passenger light above the doors indicates to passengers that they can exit the vehicle. Signs placed on both sides of the doors indicate to passengers that they should touch the door panel to open the doors. Any hand motion within this area redirects the infrared ray toward the photoelectric sensor. A signal is then produced and directed to open the doors. The sensor does not falsely detect objects situated outside of its field of detection. Operating temperatures range from -13 F to 133 F (-25 C to 55 C) at a maximum ambient humidity of 85% RH. CAUTION: The DC output circuit contains a short-circuit protection circuit. When controlling loads with a large surge current, such as capacitive loads, ensure that surge currents do not exceed maximum current output capacities. If the short-circuit protection current is activated, it can be reset by turning the current off and back on again, using the ON/OFF operation. INSTALLATION 1. The photoelectric sensor is mounted to a support cradle that is mounted to the base plate located below the door motor. See Figure C1. 2. Carefully check the wiring before turning on the power; inadequate wiring can damage the internal circuitry. Ensure that all the wire connections are tight and secure. 3. Align the lens of the photoelectric sensor rear door centerline. The sensor s depth perception field should be adjusted between 2 to 4 in. (5 and 10 cm) from the interior face of the door panels. Maintenance The high degree of tolerance that the lenses have to dust and dirt permits extended periods of use between maintenance procedures. The sensor is enclosed in a waterproof plastic box. photoelectric sensor support cradle base plate Sensor and green light location Figure B1 - Photoelectric Sensor Installation Figure B2 - Photoelectric Sensor Location

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29 / 29 SECTION C ultrasonic motion detectors DESCRIPTION See Figure C1. There are three motion detectors; one installed near the green light on the base plate, and one on each rear door panel. The detectors use ultrasonic technology to detect motion acoustically. Detector activation occurs when the rear door switch is set to the normal rear door open position. The green light informs passengers to exit the vehicle. Signs placed on both door panels direct passengers to touch the panel to open the doors. Any hand motion within this area is detected and produces a signal directing the doors to open. The detectors only detect objects within the field of detection. Installation One detector is attached to a support that is bolted to the underside of the rear door baseplate behind the green exit light. The other two detectors are mounted directly to the inside of each rear door panels, near the top of each door. lateral detectors The detectors are attached to a bracket by a screw. The mounting brackets are attached to the door by rivnuts installed in the door panels. 1. Attach the assembled detector and bracket to each door using two screws, washers, and lock washers. 2. Apply two tight layers of heat shrink tubing to cover the detectors. 3. Route the cable through the hole into the roller bracket and up to the controller area. Loosely tie the cable to the sensitive edge tubing - do not pinch the plastic tubing. center detector The center detector is mounted to a bracket installed using rivnuts into the underside of the door operator base plate. 1. Attach the detector to the bracket using a screw, washer, and lock washer. 2. Center the detector in the opening with the attaching screw to the curbside of the vehicle. 3. Use two screws, lock washers, and flat washers to attach the assembled detector/bracket to the base plate. The detector must clear the base plate surface; use spacing washers if necessary. 4. Route the cable up to the controller mounting area. Apply two layers of heat shrink tubing and route the cable up to the controller. Maintenance The lenses do not need frequent cleaning, and the detectors can be used for extended periods with minimal maintenance. See the manufacturer s manual for additional information. Figure C1 - Motion Sensors

30 30 / CLASS controller DESCRIPTION See Figure C2. The CLASS controller is mounted to the vehicle structure to the right of the right-hand door panel. The CLASS controller contains the system s signal-processing and control electronics. See the Vapor Bus International class user manual and class diagnostic software user manual for detailed information on the CLASS system and diagnostic software. Installation The CLASS controller is attached to the structure by a mounting plate and four nuts and washers. After the installation of a new module, start the autocalibration (self-profiling mode) of the system. Figure C2 - CLASS Controller AUTO-CALIBRATION MODE 1. Start the Class diagnostic software. 2. Click on the icon for the auto-calibration mode (SP mode) to open the corresponding window. See Figure C3. 3. In the options tab, set the recommended parameters as follows: - Self Profile Mode - Finalize - Set No Floor - OFF - Targets at 6% For more information on the options and the parameters of the auto-calibration mode for the CLASS system, see the user s manual in the manufacturer s diagnostic manual. 4. Change the vref spm (tension reference) to Press on the button start self profiling mode. This will trigger a sequence of four opening and closing cycles of the door. 6. The calibration parameters, recorded by the system at the time of cycling, appear in the parameters window. In this window, click on the button save to eeprom. The new parameters will then be sent to the EEPROM, where they will be saved default. Figure C3 - Self Profiling Mode Window

31 / 31 SECTION D optional verification tools DOOR GUIDE TEMPLATE Description The door guide template is a tool that allows you to verify that the top of the panel is perpendicular to the door roller shaft. See Figure D1. This check is performed at the time of the general verification of the door using the rear door verification table. Fabrication To fabricate a door guide template, fashion a piece of 12 GA stainless steel according to the dimensions indicated in Figure D1. USE Press side a of the template on the panel, along the roller support, and side b on the underside of the roller. Make sure that side a and side b of the template are fully pressed against their respective surfaces. If they are completely pressed, the roller support is perpendicular to the top of the panel. See Figure D1. door Guide template dimensions in inches tolerances ± 1 /16 in. round the corners r 1 /8 in. round all sharp edges side B side A Figure D1 - Fabrication and Use of the Door Guide Template

32 32 / Door-o-meter Installation 1. Before installing the Door-o-Meter, pressurize the pneumatic system and close the door. The primary circuit must have a minimum pressure of 120 psi (827 kpa). 2. Viewed from inside the vehicle, the device is installed close to the right-hand door shaft of the front door panel. It is held in place by a permanent magnet and a flexible, U-shaped clamp. See Figure D2 for the proper installation of the Door-o-Meter. 3. The door s motion detector operates by way of a potentiometer driven by a flexible rubber wheel. Before attaching the device and beginning the timing of the door opening, adjust the position of the rubber wheel so that the white dot on the shaft is facing the front of the device. See Figure D3. 4. In order to ensure good adhesion between the rubber wheel and the ball-joint (see Figure D4), completely screw in the magnet behind the housing. Figure D2 - Rubber Wheel and Ball Joint gap of 1 / 8 in. (3 mm) The magnet is attached to a sliding door. If it is necessary to open the device s housing, it is important to replace the door correctly, in such a way that the magnet is in its proper place. 5. Any slippage between the rubber wheel and the ball joint will create an erroneous reading for the timing of the door movement. To avoid any slippage, ensure that the rubber wheel, as well as the ball joint are clean. It is advisable to clean both before starting the test procedures with some rubbing alcohol. 6. Install the magnet so that it is mounted on a metallic object on the door of the vehicle. 7. Attach the flexible clamp to the ring of the metallic mounting while revolving the Door-o-Meter toward the mounting. REMOVAL 1. Rotate the Door-o-Meter toward the front so as to free the flexible clamp. 2. Pull lightly on the housing in order to separate the magnet from the metallic mounting. Figure D3 - Orientation of the Door-o-Meter rubber wheel ball joint flexible u-clamp Figure D4 - Rubber Wheel and Ball Joint

33 / 33 OPERATION TIMER MODE This mode allows for the verification of the opening and closing times of the panels. 1. To start the device, place the right-hand momentary switch to the on (marche) position. The state of the battery and the program version number are displayed for 2 seconds. For reliable readings, use the device only with properly charged batteries. 2. Once the device is on, the display appears on the screen. See Figure D5. The Door-o-Meter is now in timer mode. 3. To test the opening time, place the left-hand momentary switch in the capteur ir position and activate a dooropening cycle. When the door is completely open, the display indicates on the first line, in the following order, the air reaction time and the time associated with the movement of the door-opening until damping. See Figure D6. A maximum delay of 10 seconds is allocated to detecting the start of the air reaction time, and a maximum delay of 5 seconds is allocated to the movement of the door opening. The delay of 10 seconds allows the operator to adjust the command for the front door opening. If one of the delays is exceeded, the screen on the device displays an error and returns to its default setting. If there is slippage between the rubber wheel and the ball joint, corresponding to 45 % or more, relative to the initial position, the word slippage (glissement) appears momentarily on the second line of the display A maximum delay of 10 seconds is allocated to detecting the start of the air reaction time, and a maximum delay of 5 seconds is allocated to the movement of the door opening. The delay of 10 seconds allows the operator to adjust the command for the front door opening. If one of the delays is exceeded, the screen on the device displays an error and returns to its default setting. 4. To test the closing of the door, place the left-hand switch in the capteur ir position and activate a door-closing cycle. When the door is completely closed, the second line on the display indicates the following, the air reaction time and the time associated with the movement of the door closing until it reaches its initial position. See Figure A6. 5. To conduct a new test, ensure that the door is in the closed position and repeat the previous steps. In the TIMER mode, the device automatically stops after 10 minutes of inactivity. If the device starts a test where the flexible rubber wheel is not properly oriented, it is possible that the movement of the shaft is not sufficient to trigger a measurement of the timing of a door opening cycle. Stop the device, reorient the wheel and restart the test. line 1 : OP (opening) line 2 : CL (closing) Figure D5 - Default Display Figure D6 - Opening and Closing Values Displayed