Auto Cool
Contents
1. Figure1 Figure To install the cable Verify that the Internal emergency handle is on closed position Insert the cable into the hole see figure 2 fasten nuts M6 Page 29 FIAT Ducato PEUGEOT Boxer CITROEN Jumper Relay JJ PowerDoorAndStep com 888 928 8000 Power Door amp Step 015 0002 DL AN 7 LA A Y vA KA NN CNA x NJ Xa Xa Xa NA N N N D A N NA ray Vy Ny M NEN KAN N y N vA g D EA Si ASI e lt Insert the emergency handle 1 Move the handle to right for electrical operating 5 Clamping lug Washer 4 Bolt M4x8 OO Washer 4 8 i LL LL EEE Spring Nylock Nut M5 Page 30 A N y DL FIAT Ducato PEUGEOT Boxer CITROEN Jumper Relay 015 0002 DL ajpuey A9U96J9U13 E Power Door amp Step PowerDoorAndStep com 888 928 8000 VE EL E 9yoe1q ajpuey 49U96J9U 1 Internal emergency door kit PN 160 15 000 Insert the emergency handle 7 Move the handle to left for manual operating Page 31 FIAT Ducato dg k PEUGEOT Boxer Step CITROEN Jumper Relay PowerDoorAndStep com 01 5 0002 DL 888 928 8000 Recommended Torques newton meter TORQUE2. LocknutM4 2 Page 7 Roller Chain Installation FIAT Ducato RA PEUGEOT Boxer Step CITROEN Jumper Relay Ed a A 015 0002 DL Chain sealing rubber 113 15 001 Page 8 Roller Chain Installation FIAT Ducato DOGE PEUGEOT Boxer Step CITROEN Jumper Relay 898 928 8000 015 0002 DL Drill O12 Page 9 Door Limit Switch Installation FIAT Ducato Sg ki PEUGEOT Boxer Step CITROEN Jumper Relay 015 0002 DL PowerDoorAndStep com 888 928 8000 Page 10 Electrical Connections FIAT Ducato Der PEUGEOT Boxer Step CITROEN Jumper Relay o 015 0002 DL VSS Connection up to 2012 ACC Solder and isolate Original Black Blue wire On the BSI from the 52V Black connector 17 way Redundant vehicle speed signal LN connector 17 way White Gray wire to VSS Detector Page 11 Wiring VSS connection FIAT Ducato Sg k PEUGEOT Boxer Step Bo CITROEN Jumper Relay PowerDoorAndStep com CER lt es 0 1 5 0 0 0 2 DL 888 928 8000 VSS Connection From 2013 Page 12 Electrical Connections FIAT Ducato ag ki PEUGEOT Boxer Step CITROEN Jumper Relay PowerDoorAndStep com 01 5 0002 DL 888 928 8000 Version length L2 Side cover 45 Cut Model L 2 Page 13 Gear motor Covers Installation Model L 2 FIAT Ducato ag h PEUGEOT Boxer Step gi CITROEN Jumper Relay
3. PowerDoorAndStep com 01 5 0002 DL 888 928 8000 Parts list of ASD system Designation Part No Quantity Pneumatic safety switch 122 10 047 1 Pneumatic safety switch ASSY 160 10 042 Philips Screw 6x3 8 646 08 01 7 2 Pneumatic Safety Strip 112 06 109 2m Rubber Tube 113 06 06 7 1 Operating switch 124 00 018 1 Signal lamp 124 10 069 1 Decal 125 00 018 1 Fuse 30A 125 10 084 1 Hex flange nut M8 601 08 008 1 1 1 2 4 1 6 1 Gear Motor Cover 153 00 0021 Side Cover L3 153 02 0021 Flat socket head screw M6x20 613 06 020 1 Screw 8x3 4 646 08 024 Drain pan 153 04 0021 Rubber grommet 112 04 000 Side Cover L2 153 15 021 Page 16 Part List Power Door amp Step PowerDoorAndStep com 888 928 8000 FIAT Ducato PEUGEOT Boxer CITROEN Jumper Relay 015 0002 DL Electric Harness Fiat Ducato 116 15 002 DL ITEM NO PART NUMBER DESCRIPTION QTY 1 128 17 116 Bracket 1 2 124 10 504 VSS detector 1 3 124 38332 Control unit AK 105L V1 913 1 4 124 02 006 LD 007 1 Remote control kit 1 5 124 02 906 Remote Control Set 1 6 124 13 902 Latching relay 12v ASSY 1 7 124 00 032 Buzzer 12v 1 8 124 10 052 Socket terminal relay 1 9 R2A4 124 Relay 1 Page 17 Wiring FIAT Ducato Sg PEUGEOT Boxer Step CITROEN Jumper Relay PowerDoorAndStep com 01 5 0002 DL 888 928 8000 a N ASD Fiat Ducato Original Door
4. TORQUE Nm Nm Page 32 FIAT Ducato Ki PEUGEOT Boxer Step CITROEN Jumper Relay PowerDoorAndStep com 01 5 0002 DL 888 928 8000 Automatic Sliding Door user s Manual The Automatic Sliding Door system ASD manufactured by Auto Cool Ltd conforms with the requirements of the European regulations The ASD is approved by the German TUV in Munich it complies with the EEC DIRECTIVE 72 245EC and obtained the certificate of compliance No 2004 104 EC Operation Instructions The door is operated by a switch located on the dashboard To open press the switch shortly door opens to the end of its range To close press the switch shortly door closes and locks To change its direction while in motion press the switch shortly the door will change direction To control the opening range continuous pressure on the control switch will set the door in motion upon its release the door will stop Visual status indications when the vehicle s main ignition switch is on the indication control light is visible Dim light the door is closed Bright light the door is open Audio status indicators independently of the vehicle s main switch the vehicle s buzzer is always functioning whenever the door is in closing motion Safety measures The system includes safety features to protect the passengers Closing when encountering an obstruction the controller automatically reverses
5. e Check safety switch e Reset the system by extracting the fuse and returning it to its place e Check control unit AK105 3 Door does not close completely e Check voltage of battery if low start the engine 4 Door does not open although the electrical motor is engaged e Check position of the locker unit which annuls the OEM locking system of the door 5 Door does not automatically reverse when encountering an obstruction during the closing mode Check safety pneumatic switch Check pressure tube amp switch e Check control unit 6 Noise from the door s chain during opening and or closing modes e Check installation and alignment of all wheel supports front and rear as well as the gear motor support e Very loose chain may also jump over and cause damage to the sprocket s main motor e Check chain tension and if needed shorten it by removing one or two links 7 Remote control unit does not function e Check connection of power terminals e Check battery of the key unit transmitter It issue still persist replace remote control receiver with two transmitters 8 If equipped with VSS the door operates although the vehicle is in motion over 5Km h e Check connections to the VSS unit e Check VSS unit 9 Buzzer does not operate during the closing mode e Check buzzer or replace it Please note The system performs automatic reset after the ASD has been disconnected from the power either when replacin
6. 015 0002 DL Version length L3 PowerDoorAndStep com 888 928 8000 Sikaflex 43 Drain pan Covers Kit PN 151 00 0021 Page 14 Gear motor Covers Installation FIAT Ducato Sag ki PEUGEOT Boxer Step CITROEN Jumper Relay PowerDoorAndStep com 01 5 0002 DL 888 928 8000 Parts list of ASD system Designation Part No Unit Qty Gear Motor Support 111 00 0021 Idler Wheel 107 11 004 1 Hex Bolt M6x25 DIN 933 8 8 632 06 025 Gear Motor ASSY 111 00 013 601 06 006 Hex Bolt M6x16 DIN 933 8 8 632 06 016 Front Idler 111 02 017 SE Front Idler Support 128 08 018 Thick Washer 6 DIN 7349 600 32 061 Washer 6 DIN 735 600 12 080 Hex Bolt M6x30 DIN 933 8 8 632 06 030 Hex Nut M6 DIN 934 CI6 601 02 006 Hex Lock Nut M6 DIN 985 CI8 602 02 006 Rear Idler 111 02 003 Socket button bolt M6x16 ISO 7380 10 9 614 06 016 Hex Lock Nut M4 DIN 985 CI8 602 02 004 Hex Bolt M4x16 DIN 933 8 8 632 04 016 Rear Idler Cover 153 01 0021 1 1 6 2 3 2 1 2 2 4 1 Chain Holder 128 00 0021 1 Roller Chain 178 00 002 1 183 links L 2936mm 1 Connecting link 900 01 072 2 Slide Strip 134 01 002 1 2 1 Flat socket head screw M4x20 DIN 799 613 04 020 Cable strap 125 10 015 600 04 061 2 28 Limit Door Switch 124 00 039 4 29 Self drill screw 8x1 2 647 08 003 1 Page 15 Part List FIAT Ducato Sag ki PEUGEOT Boxer Step CITROEN Jumper Relay
7. latches mechanism amp operation with handles 160 15 201 ITEM NO PART NUMBER DESCRIPTION QTY 1 111 15 201 Fiat Ducato locker bracket ASSY 1 2 125 10 014 Cable strap 100mm 2 3 125 10 016 Cable sirap 150mm 3 4 601 06 006 Hex flange nut M6 DIN 6923 2 5 125 10 005 Plastic clamp UC 2 3 8 1 6 646 08 020 Phillips screw 6x3 8 1 7 613 06 016 Socket flat head screw M6X16 2 of Fiat Ducato locker ASSY 111 15 201 ITEM NO PART NUMBER DESCRIPTION QTY 1 128 15 201 Actuator bracket 1 2 110 01 006 10 Lock actuator ASSY 1 3 110 11 006 Actuator ASSY 1 5 128 36 309 V363 V408 Lock Actuator arm 1 6 Philips cross Screw 4 2 4 7 632 04 016 Hex bolt M4x16 DIN933 1 8 128 15 203 Cables adapter 1 9 602 02 004 Lock nut M4 DIN985 Page 18 Lock Actuator ASSY installation FIAT Ducato Sag PEUGEOT Boxer Step CITROEN Jumper Relay PowerDoorAndStep com 01 5 0002 DL 888 928 8000 m NC SA e lovver release cable Cancel the lower latch Page 19 Cable Diagram FIAT Ducato ig PEUGEOT Boxer Step CITROEN Jumper Relay PowerDoorAndStep com 01 5 0002 DL 888 928 8000 Page 20 Lock Actuator ASSY installation FIAT Ducato DOEK PEUGEOT Boxer Step CITROEN Jumper Relay Sa 015 0002 DL Hex flange nut M6 gt i Socket flat head screw M6X16 AN sY AS NA Page 21 Lock Actuator ASSY ins
8. Power FIAT Ducato L2 L3 L4 PEUGEOT Boxer Door amp CITROEN Jumper Relay Step PowerDoorAndStep com 888 928 8000 ASD LHD Automatic Sliding Door PN 015 0002 DL Recommendation Please print this instruction manual in color 01 04 15 FIAT Ducato Der PEUGEOT Boxer Step CITROEN Jumper Relay 988 908 8000 ah 015 0002 DL Pneumatic safety strip Operating switch Signal light Gear motor Buzzer Control unit Remote control receiver Main Fuse Wiring harness Lock Actuator ASSY Page 1 ASD System Overview FIAT Ducato Sg N PEUGEOT Boxer Step CITROEN Jumper Relay PowerDoorAndStep com 01 5 0002 DL 888 928 8000 Supplied Template Cut according to dimensions Drill 7 x2 Cut according to Template Page 2 Cutting and Preparation FIAT Ducato PEUGEOT Boxer CITROEN Jumper Relay 015 0002 DL Power Door amp Step PowerDoorAndStep com 888 928 8000 p Y Drill 94 according to detail 24 DA Step 1 Align chain slide strip 24 to the right and bottom of the track Step 2 Mark amp drill thru the right strip hole 4 mm Step 3 Attach the right strip using screw M4x20 amp nut M4 Tightly pressed chain slide strip to the surface of track Mark amp drill thru the left strip hole 4 mm Step 5 Attach the left strip using screw M4x20 amp nut M4 Attach the left strip using screw M4
9. g the fuse or by disconnecting the Battery The system resets itself within two minutes Please be patient Page 34
10. tallation FIAT Ducato Kun h PEUGEOT Boxer Step CITROEN Jumper Relay 988 908 8000 015 0002 DL AQ Lock Actuator ASSY Safety strip Pneumatic Switch ASSY PN 160 10 042 Transmitter Left Sliding Door edge Safety Switch Clean surface carefully with alcohol to insure good contact of the pneumatic safety strip lt a Pneumatic Safety Strip PN 112 06 109 Rubber tube gt Drill hole for rubber tube Page 22 Pneumatic Safety Strip amp Pneumatic Switch Installation FIAT Ducato dg k PEUGEOT Boxer Step CITROEN Jumper Relay PowerDoorAndStep com 01 5 0002 DL 888 928 8000 Pressure Safety Switch Hex key N 4mm PN 160 10 042 Pneumatic Switch PN 122 10 047 Sensitivity adjustment N Pp Increase Sens Decrease Sens PN 160 10 042 Page 23 FIAT Ducato gf PEUGEOT Boxer Step CITROEN Jumper Relay PowerDoorAndStep com 888 928 8000 015 0002 DL Disconnect C Pillar Sliding door Beige yellow Violet black Pneumatic safety strip Cut ff Page 24 Wiring Power Door amp Step PowerDoorAndStep com 888 928 8000 OE pink wire plug sliding door FIAT Ducato PEUGEOT Boxer CITROEN Jumper Relay 015 0002 DL Operating by OE handle latch OE red black wire plug sliding door Sliding door locker c cb 5 Internal micro s
11. the door direction to open all the way In addition a pneumatic switch is attached to the front side of door pillar which upon sensing pressure performs the same function and retracts immediately Opening when encountering an obstruction th e controller stops the door ASD system is connected to the OE VSS device The door operates only at speed of less than 5 km h Emergency facility The system has inside and outside optional emergency releasing handle Operating one of them will result in disconnecting the ASD mechanism device and the door will function manually immediately Please note The system performs automatic reset after the ASD has been disconnected from the power either when replacing the fuse or by disconnecting the Battery The system resets itself within two minutes Please be patient Page 33 FIAT Ducato gf k PEUGEOT Boxer Step CITROEN Jumper Relay PowerDoorAndStep com 01 5 0002 DL 888 928 8000 ASD Basic Troubleshooting 1 Door does not function e Check main fuse Check connections of power terminals to the control unit motor and operating switch e Check Control units AK 105L e Check motor 2 Door does not operate upon commencing the closing mode or when reaching the fully closed positions it reverses Check the safety pneumatic pressure tube disconnect the plugs of pressure switch and close the door e If the issue is not solved try to regulate the sensitivity of the pressure switch
12. witch Operating switch Plug p _ _ L Plu White Blue Black i sa wa us i i a v o Pulse Detecto cl 5 Q 9 m 0 Elie White F Plug E Connect to VSS Ri as Te cs cs TTT E Pulse E Green 9 4 gt 85 8 N a amp 0 2 86 30 Black Red Oi Qi O O latch Relay 12 V Battery 12V Red 1 5mm Red Remote Control receiver Red 1 5mm Remote Control receiver Page 25 Wiring Diagram Power Door amp Step PowerDoorAndstep com 888 928 8000 Automatic Sliding Door External emergency door opening kit PN 111 03 013 Page 26 FIAT Ducato dg N PEUGEOT Boxer Step CITROEN Jumper Relay PowerDoorAndStep com 01 5 0002 DL 888 928 8000 Recommended Emergency door opening system location min 1000mm FIAT Ducato PEUGEOT Boxer CITROEN Jumper Relay 015 0002 DL Power Door amp Step PowerDoorAndStep com 888 928 8000 Nut 6 ST a External emergency door opening KIT PN 111 03 013 w Internal emergency handle Spring 140 03 013 Emergency Door Handle 111 03 0131 A VASI Socket head M5x12 Emergency Handle Cover 151 03 131 Page 28 FIAT Ducato PEUGEOT Boxer CITROEN Jumper Relay 015 0002 DL Power Door amp Step PowerDoorAndStep com 888 928 8000
13. x20 amp nut M4 Make sure the screw is entirely inside 25 Oe Socket flat head screw M4x20 2 gt Lock nut M4 a2 Page 3 Chain Slide Strip Installation Section A A FIAT Ducato Sg ki PEUGEOT Boxer Step gi CITROEN Jumper Relay 015 0002 DL PowerDoorAndStep com 888 928 8000 Original nuts x3 GPP Hex head screw M6x16 1 7 6 Flange nut M6 1 2 O Washer6 A Page 4 Gear motor installation FIAT Ducato PEUGEOT Boxer CITROEN Jumper Relay Power JJ PowerDoorAndStep com 888 928 8000 Door amp Step 015 0002 DL View A gt Lock nut M6 Wheel Hex bolt M6x30 CI Nut ve 14 Hex bolt M6x16 Lock nut M6 Hex head bolt M6x25 2 Ce 6 Flange nut M6 Thick washer 6 H 2 5mm 12 Washer 6 13 P Hex head bolt M6x30 1 P Nut M6 15 gt Lock nut M6 Page 5 Gear motor Installation FIAT Ducato poor JN PEUGEOT Boxer Step gi CITROEN Jumper Relay 8889288000 lt lt 015 0002 DL 20m Drill 7mm x2 Cut according to Template N2 a i kabak kak tg 9 Drill O7mm x2 o sl Qu A 17 P Socket button head screw M6x16 2 7 6 Flange nut M6 2 Page 6 Rear Idler Installation FIAT Ducato PEUGEOT Boxer CITROEN Jumper Relay 015 0002 DL PowerDoorAndStep com 888 928 8000 Power Door amp Step RR Drill 016mm SP Hex head screw M4x16 2
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