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Summary of Contents for ADOR CAYMAN 202
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Page 1: Always Read And Follow These Warnings
02.12.2025 RACK AND PINION DRIVE INSTALLATION MANUAL CAYMAN 202 automatic doors VOLKSWAGEN CRAFTER 2, MAN TGE Version 18.00... -
Page 2: Table Of Contents
The plans are subject to change. Only use the latest version. 10.1 Rack-and-pinion drive..........................29 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 ........................... 32... -
Page 3: Safety Instructions
1.1 Intended use > Secure the workplace against unauthorised access. The Cayman 202 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 202 rack-and-pinion drive for sliding doors Cutter 1 piece > Drive Wire for pulling through 3 metres > Controller... -
Page 5: Product Description
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 VW Crafter from 2018 and MAN TGE 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 pin Centre adjustment of sliding door 6.1 Instructions before starting installation Before installing the drive, the position of the sliding door must be checked. This setting affects the operation of the drive. 1. Wash out the guides of the door slide with petrol and wipe them with a dry cloth. -
Page 8: Wiring Harness And Connection Diagram
6.2 Wiring harness and connection diagram 1. Cayman 202 drive 2. Cayman 202 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. -
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 the fixed contacts group to the control button... -
Page 10: Controller Installation And Minus Terminal Connection
6.4 Controller installation and minus terminal connection Main wiring Nut M6 harness 6,5 мм In the car C-pillar place and screw up a 030.00.007.0005 Toothed washer controller with two self-tapping screws 4,2х12 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: Means 'Additional Information' 6.6 Actuator And Actuator Wiring Harness Installation
6.6 Actuator 030.05.001.0002 and actuator harness installation 030.00.007.0021 Direct connection of activator (blue- blue) Handle Cable Carriage Lock drive Activator Direct connection 030.05.001.0002 of activator (green - green) Blue wire of the activator harness Activator harness 030.00.007.0021 The movable contacts group can also be in the contact switch area of the of the vehicle. - Page 13 Installation of the actuator 030.05.001.0002 Remove the door lock by loosening 3 screws (Fig. 5). Remove the door lock from the cavity of the sliding door. Drill a Ø4 mm hole in the latch lever (Fig. 6). Lock mounting Insert the drive rod into the drilled hole (Fig. 7). screws Reinstall the door lock and screw it tight.
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Page 14: 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. 9. 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 15: Rack Mounting
6.8 Rack mounting The length of the rack depends on the installation variant. Only saw off the rack on the left! Fasten the rack with 1x to 3x spacer H4 depending on the installation situation. Do not process! Do not process! Spacer H4 Rack Sliding door... - Page 16 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 Fig. 14. Use the drill holes in the rack to align the drill holes holes on the sliding door with a marker.
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Page 17: Brackez Mounting
6.9 Bracket mounting Remove the door seal in the mounting area of the bracket Fig. 12. Door seal Position the bracket on the C-pillar as follows horizontally so that level Mark drilling points Bracket 030.10.002.0001 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 bracket is 8 mm ±... -
Page 18: Preliminary Preparation
6.10 Preliminary preparation Attach the balljoint Attach the balljoint with the bracket (SW14), Fig. 16. to bearing Close the door manually. Check to be sure that racks of the bearing item and the balljoint do not make the door closing difficult, Fig. 17. No obstraction of the sliding door Install the door drive on the rack, Fig. -
Page 19: The First Cycle
The first cycle 7.1 The first cycle of rack-and-pinion drive Clean the rack housing from cuttings, Fig. 20, 21. 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 20: 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. 22. SW 14 Adjust the length of the ball joint (Fig. 23) in such a way that the sliding door lies cleanly against the seal. -
Page 21: 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. 26 and 27. Insert the cover strip into the rack groove Rack groove Fig. -
Page 22: 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 23: 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 24: Optional Accessories
Optional accessories 8.1 Remote control 8.2 Touch button 8.3 Uninterruptible power supply (UPS) (only Croco 107) You can use the remote control to operate the sliding door at any time. This touch button reacts to a light Regardless of the vehicle's supply voltage, the sliding door can be touch. -
Page 25: Handle Covers
8.4 Handle cover outside 030.05.000.0005 and inside 030.05.000.0006 Outside handle cover 030.05.000.0005 Put the outside handle cover to the handle itself, mark on and make two holes with diameter Ø3,5 mm. Screw up the cover on the handle with two Self-tapping Self-tapping Outside handle cover... -
Page 26: Safety Edge On Door Edge
8.5 Safety edge 030.18.000.0020 on door edge Fig. 31 Fig. 32 Fig. 33 Fig. 34 To fit the safety edge, degrease both sides of the outer closing edge of the sliding door using Apply primer (adhesion promoter) to the inside of the safety edge. Slide the safety edge over the closing edge without removing the protective film. - Page 27 Cable to drive Fig. 38 Cayman 202: Connect the corresponding receiver to the control unit Fig. 35 Fig. 37 as shown in Fig. 38. 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 28: Notes
Notes 9.1 Emergency door opening from the outside 1. Remove the cover, if present, (Fig. 39). 2) Pull the door 2. Pull and hold the door handle (Fig. 40). handle and hold it 3. Pull the left-hand part of the door towards you (Fig. 40). 3) Pull the back side of the door 4. -
Page 29: Manual Mode Reset
Manual mode reset 10.1 Rack-and-pinion drive 1. Remove the stop angle (Fig. 42). 2. Pull off the drive plug (Fig. 42). Remove the stop angle 3. Unscrew the balljoint (Fig. 43). 4. Remove the drive off the rack (Fig. 43). The sliding door now operates manually. -
Page 30: Extensions
Extensions 11.1 Switching the remote control receiver on/off with the vehicle's central locking system (30.99.000.0001) Connection to the cables to the vehicle contact switch > Operation via handle on the outside and inside Sliding door unlocked/locked > Signal scanning of the vehicle's central locking system Vehicle wiring harness to the contact switch The ‘Remote control with 1 key’... -
Page 31: Coupling The Electric Step With The Ador Drive
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 30.99.000.0013 30.99.000.0011 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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