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Summary of Contents for ADOR CAYMAN 102
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Page 1: Always Read And Follow These Warnings
02.14.2025 RACK AND PINION DRIVE INSTALLATION MANUAL CAYMAN 102 automatic doors MERCEDES SPRINTER BR907, 906 from 2006 VOLKSWAGEN CRAFTER 2006-2018 Version 22.00... -
Page 2: Table Of Contents
The plans are subject to change. Only use the latest version. 10.1 Rack-and-pinion drive..........................30 Extensions........................... 11.1 Switching the remote control receiver on/off with the vehicle's central locking system......11.2 Coupling the electric step with the Ador drive..................11.3 Connection diagram of the extensions..................... Information ........................... 33... -
Page 3: Safety Instructions
1.1 Intended use > Secure the workplace against unauthorised access. The Cayman 102 rack-and-pinion drive is designed for the automatic opening and closing of > Only use the cables specified in the cable plan. sliding doors. The door operator is only suitable for use in panel vans. -
Page 4: List Of Tools And Aids
15 pieces Open the packaging units and check for completeness. Drills 2,5; 3,2; 5; 6,5 1 piece each Drill 1 piece Cayman 102 rack-and-pinion drive for sliding doors Cutter 1 piece > Drive Wire for pulling through 3 metres > Controller... -
Page 5: Other Symbols And Visualisation Aids Important Information And Technical Instructions Are Specially Emphasised To Clarify
5 Product description Controller Door drive Main wiring harness Control button Cradle Balljoint Rack 5.1 Product description This rack-and-pinion drive is designed to open and close sliding door in Mercedes Sprinter (906, 907) and VW Crafter to 2018 minibus. The layout of the units is shown on the base of the universal minibus prototype. -
Page 6: Operating Elements
Durability and failure-free operation of ADDITIONAL CONTROL MAIN CONTROL BUTTON Ador's drive depend directly on the quality BUTTON of installation. Installation in specialised workshops is recommended. Experienced non-specialists should prepare themselves well and seek help if necessary. 5.3 Operating elements Ador's drive is an electromechanical device powered from electric battery of a minibus. -
Page 7: Means 'Important Information'. 6 Installation
Installation LATCH TENON MIDDLE ADJUSTMENT OF A SLIDING DOOR 6.1 Instructions before starting installation Before installing the drive, adjust the minibus’s door because its adjustment influences the drive operation. 1. Wash out the door carriage guides with petrol and wipe them with dry rags. 2. -
Page 8: Wiring Harness And Connection Diagram
1. Cayman 102 drive 2. Cayman 102 controller 3. Drive wiring harness coupling 4. LED Torch 5. Controller wiring harness plug 6. Main wiring harness coupling 7. Terminals of the ground wires “-” to the minibus’s body 8. Main wiring harness 9. -
Page 9: Main Wiring Harness Layout
6.3 Main wiring harness layout 030.00.007.0005 All wires must be protected and firmly attached to avoid any breakage, abrasion or chafing. Terminal of +12V/30A wire to Starting point of installing Main harness terminals to Main harness socket positive terminal of accumulator the main harness to the control button Branch №... -
Page 10: Controller Installation And Minus Terminal Connection
6.4 Controller installation and minus Self-tapping Main wiring harness terminal connection screws ST 4,2х12 030.00.007.0005 In the car C-pillar place and screw up a Controller 102 Toothed washer controller with two self-tapping screws 4,2х12 036.00.000.0001 from the hardware bag as shown in fig. 1 Ground wire “-”... -
Page 11: Positive Wire Connection To Power Supply
6.5 Positive wire connection to power supply Connect the wire terminal +12V of the main wiring harness to a free positive accumulator terminal, which is under a driver’s feet. Fix the wire terminal +12V of the main wiring harness with the standard accumulator nut. Before connecting, please, take the fuse 30A out of the fuse terminal block. -
Page 12: Actuator And Actuator Wiring Harness Installation
6.6 Actuator 030.05.001.0003 and actuator wiring harness installation 033.00.007.0003 Blue wire of the actuator wiring harness Upper locking Direct connection mechanism Movable contacts (blue- blue, green – green ) 030.05.006.0001 Green wire of the Cable actuator wiring harness Actuator wiring harness Carriage 033.00.007.0003 Actuator... - Page 13 Removing the upper locking mechanism Remove the upper locking mechanism by loosening 2 screws (Fig. 6). Upper Locking Clamp the end of the cable. mechanism Secure the cable with a rope or wire against falling Fig. 7). Takedown screws Fig. 6 Cable Rope or wire Fig.
- Page 14 Dissemple the lock door. To do so undo three screws from its fixation (fig. 8). The lock cannot be detached until upper locking Cable mechanism is attached and cable connected. Remove the lock from the door housing. Disconnect the labeled cable (fig. 9). Screw for the Set the rod instead of it, and fix the cable on the lock lock fixing...
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Page 15: Layout Of Sliding Door Limit Switch And Control Button Installation
6.7 Layout of sliding door limit switch 030.00.006.0001 and control button installation Movable contacts group Mark the drill holes as shown in Fig. 12. Drill two holes with Ø14 mm and two holes with Ø2.5 mm. Attach the blue cable to the upper flag The control button can be positioned anywhere. -
Page 16: Rack Mounting
6.8 Rack mounting It is recommended to lay two linings H4 between the rack and the sliding door panel (fig. 15). The lining H4 comes as a set of three. Rack 030.00.009.0002 Do not process! Spacer H4 030.00.005.0001 Do not process! Spacer H4 Rack Sliding door... - Page 17 This page shows the recommended installation location for the rack on the sliding door. Remove the door panelling when the sliding door is unhinged or closed sliding door. The recommended position for the rack is shown in shown in Fig. 16. Align the holes in the rack with the holes on the sliding door with a marker.
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Page 18: Bracket Mounting
6.9 Bracket mounting Marker up hole centres Remove the door seal in the mounting area of the bracket, Fig. 17. Position the bracket on the C-pillar as follows horizontally so that level A of the rack is 9 mm ± 1 mm higher than level B of the bracket and dimension C between the rack and the Door seal... -
Page 19: Preliminary Preparation
6.10 Preliminary preparation Attach the balljoint with the bracket (SW14), Fig. 21. Close the door manually. Check to be sure that racks of the bearing item and Screw balljoint the balljoint do not make the door closing difficult, to bracket Fig. -
Page 20: The First Cycle
The first cycle 7.1 The first cycle of rack-and-pinion drive Clean the rack housing from cuttings, Fig. 25, 26. Connect the drive to the controller. Insert the switch fuse 30A into the fuse block. Thereby, the controller will produce a long audio signal! Press the control button. -
Page 21: Drive Adjustment
7.2 Drive adjustment Adjustment via the balljoint Sliding door moves inward Position of the balljoint with the sliding door correctly closed sliding door as shown in Fig. 27. SW 14 Adjust the length of the ball joint (Fig. 28) in such a way that the sliding door lies cleanly against the seal. -
Page 22: Monting Of Door Drive Cover And Decorative Cover Strip
7.3 Monting of decorative cover strip Cut the cover strip to fit the rack. Carefully insert the cover strip intp the rack goove as shown in Fig. 30 and 31. Insert the cover strip into the rack groove Rack groove Fig. -
Page 23: Functions Of The Rack-And-Pinion Drive And Setting The Controller
7.4 Functions of the rack-and-pinion drive and setting the controller OPENING / CLOSING THE SLIDING DOOR Press the control button briefly, ~ 0.5 sec. The sliding door starts moving immediately after the control button is released. STOPPING THE OPENING MOVEMENT To stop the sliding door during the opening movement, briefly press the control button. -
Page 24: Warning Sticker
Self-adhesive warning sticker is located outside 7.5 Warning sticker on the panel of the sliding door. It should be noticeable. -
Page 25: Liability Act, The Informationformation Containformationed Information This Brochure
Optional accessories 8.1 Remote control 8.2 Touch button You can use the remote control to operate the sliding door at any time. This touch button reacts to a light touch. Attach the receiver sufficiently close to the controller. Connect the two couplings of the wiring harness to the In standby mode, it lights up GREEN. -
Page 26: Handle Covers
8.3 Handle cover outside and inside Outside handle cover Put the outside handle cover to the handle itself, 030.05.004.0001 mark on and make two holes with diameter Ø3.5 mm. Outside handle cover Screw up the cover on the handle with two self-tapping 030.05.004.0001 Self-tapping Self-tapping... -
Page 27: Safety Edge On Door Edge
8.4 Safety edge 030.18.000.0020 on door edge Fig. 37 Fig. 38 Fig. 39 Fig. 40 Apply primer (adhesion promoter) to the inside of the safety edge. To fit the safety edge, degrease both sides of the outer closing edge of the sliding door using Slide the safety edge over the closing edge without removing the protective film. - Page 28 Cable to drive Fig. 44 Cayman 102: Connect the corresponding receiver to the control unit Fig. 43 Fig. 41 as shown in Fig. 44. Drill a hole (hole at least Ø8 mm for the rubber grommet) in the front face of the sliding door, to feed through the cables of the safety edge and insert a rubber grommet (Fig.
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Page 29: Notes
Notes 9.1 Emergency door opening from the outside Self-tapping screw 4,2х16 1. Remove the cover, if present, (Fig. 45). 2. Pull and hold the door handle (Fig. 46). 2) Pull and hold on the door handle 3. Pull the left-hand part of the door towards you (Fig. 46). 3) Pull the rear part of the door towards yourself 4. -
Page 30: Manual Mode Reset
Manual mode reset 10.1 Rack-and-pinion drive Uncover the inside handle Open the door manually, having unscrewed handle covers. (fig. 48). Remove the clamper (fig. 49). Uncover the drive (fig. 49). Disconnect the drive plug (fig. 49). Uncover the outside handle Fig. -
Page 31: Extensions
11.3 Connection diagram of the extensions 11.2 Coupling the electric step with the Ador drive (30.99.000.0011 und 30.99.000.0013) 11.2 11.1 30.99.000.0011 30.99.000.0013 30.99.000.0011 +12V 30.99.000.0004 Switches * Cable colours are symbolic The relays are used to switch the step depending on the movement of the sliding door. -
Page 32: Information
+49 731 250 68 210 info@ador-eu.de https://ador-eu.de/ The reprinting or other reproduction of documentation and accompanying documents of the products, even in part, is only in extracts, is only permitted with the express authorisation of the responsible ADOR country representative. Subject to technical changes.
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