Plug Sliding Door System

Maintenance Manual

MM Version
Release date
2.2
2021-05-10
Document ID PS1600001
Project name Plug Sliding Door System 1
Project ID PS1

File name PlugSlidingDoor_MM_PS1600001.PDF

Template version 20210311R1.8
 Plug Sliding Door System Revision history
Maintenance Manual

Revision history
Revision Date By Description
Prepared: Torque setting catch block adjusted from 26±2Nm to 20±2Nm pos 12.
2.2 2021-05-10
M.Stoelinga Adjusted revision history details.
Prepared:
2.1 2021-03-26 Torque setting can be checked by checking the torque marking.
M.Stoelinga
Adjusted torque setting order.
Prepared:
2.0 2021-03-19 Adjusted torque setting value of the shaft coupler from 13±1Nm to
M.Stoelinga
22±2Nm pos 3.
Added repair option to sensitive edge chapter.
Prepared: Adjusted references.
1.3 2020-05-25
M.Stoelinga Added torque settings chapter.
Minor text changes.
Prepared: Minor text improvements.
1.2 2019-12-06
M.Stoelinga Updated references.
Prepared: Adjusted the air leakage test to an acceptable air leakage of 0.2 and 2
1.1 2019-07-24
M.Stoelinga bar
Updated Acronyms and Abbreviations.
Added Air leakage test.
Prepared:
1.0 2019-07-19 Added microswitches chapter.
M.Stoelinga
Lay-out changes.
Removed applying grease onto the electric actuator.
Prepared:
0.1 2019-04-15 Initial version.
M.Sandtmann

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 Plug Sliding Door System Preface
Maintenance Manual

Preface
The Quality System of Ventura Systems is accredited to EN ISO 9001:2015.

All rights reserved. Disclosure to third parties of this document or any part thereof, or the use of any information contained
therein for purposes other than provided for by this document, is not permitted, except with prior and express written
permission from Ventura Systems.

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 Plug Sliding Door System Table of contents
Maintenance Manual

Table of Contents
1 Introduction ........................................................................................................................................................................................... 6
1.1 Purpose........................................................................................................................................................................................... 6
1.2 Scope .............................................................................................................................................................................................. 6
1.3 Definitions ...................................................................................................................................................................................... 6
1.4 Acronyms and Abbreviations ......................................................................................................................................................... 6
1.5 References ...................................................................................................................................................................................... 7
1.5.1 External documents ................................................................................................................................................................ 7
1.5.2 Ventura Systems documents .................................................................................................................................................. 7
1.6 Overview......................................................................................................................................................................................... 7
2 Door installation safety ......................................................................................................................................................................... 8
2.1 General ........................................................................................................................................................................................... 8
2.2 Disclaimer ....................................................................................................................................................................................... 8
2.3 Safety alert symbols ....................................................................................................................................................................... 9
2.4 Safety instructions ........................................................................................................................................................................ 10
3 Maintenance........................................................................................................................................................................................ 11
3.1 Safety parts ................................................................................................................................................................................... 11
3.1.1 Lever block ............................................................................................................................................................................ 11
3.1.2 Emergency release ................................................................................................................................................................ 12
3.1.3 Sensitive edge........................................................................................................................................................................ 13
3.1.4 Obstruction detection unit.................................................................................................................................................... 14
3.2 Wear parts .................................................................................................................................................................................... 15
3.2.1 Overcenter soft stopper ........................................................................................................................................................ 15
3.2.2 Cushioning rubber bearing house ......................................................................................................................................... 16
3.2.3 Guide rollers .......................................................................................................................................................................... 16
3.2.4 Catch block ............................................................................................................................................................................ 17
3.2.5 Bottom stopper ..................................................................................................................................................................... 18
3.3 Parts inspections .......................................................................................................................................................................... 19
3.3.1 Door shafts ............................................................................................................................................................................ 19
3.3.2 Electric Actuator .................................................................................................................................................................... 20
3.3.3 Filter regulator ...................................................................................................................................................................... 21
3.3.4 Tension steel cables .............................................................................................................................................................. 22
3.3.5 Clamping force test ............................................................................................................................................................... 23
3.3.6 Grease bearing house ........................................................................................................................................................... 24
3.3.7 Grease spiral cable guiding shaft .......................................................................................................................................... 25
3.3.8 Air leakage test ...................................................................................................................................................................... 25
4 Torque Settings.................................................................................................................................................................................... 28
5 Operational checks .............................................................................................................................................................................. 30
5.1 Operation and controls ................................................................................................................................................................ 30
5.2 Safety checks ................................................................................................................................................................................ 30
6 Contact ................................................................................................................................................................................................ 31

List of Figures
Figure 1: Lever block .............................................................................................................................................................................. 11
Figure 2: Dismount the door leaf ........................................................................................................................................................... 13
Figure 3: Disconnect the sensitive edge connectors ............................................................................................................................. 13
Figure 4: connect multimeter to the obstruction detection unit .......................................................................................................... 14
Figure 5: Overcenter electric with unlock cylinder ................................................................................................................................ 15
Figure 6: Overcenter pneumatic with unlock cylinder .......................................................................................................................... 15
Figure 7: Pneumatic without overcenter function................................................................................................................................. 15
Figure 8: Left cushioning rubber ............................................................................................................................................................ 16
Figure 9: Right cushioning rubber .......................................................................................................................................................... 16
Figure 10: Bottom guide roller ............................................................................................................................................................... 16
Figure 11: Distance between bottom lever and guiding rail ................................................................................................................. 16
Figure 12: Location of the catch blocks and catch wedges. .................................................................................................................. 17
Figure 13: Catch block and wedge right ................................................................................................................................................. 17
Figure 14: Bottom stopper ..................................................................................................................................................................... 18
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 Plug Sliding Door System Table of contents
Maintenance Manual

Figure 15: Top bearing door shaft .......................................................................................................................................................... 19

Figure 16: Bottom bearing door shaft.................................................................................................................................................... 19
Figure 17: Electric Actuator .................................................................................................................................................................... 20
Figure 18: Filter regulator ...................................................................................................................................................................... 21
Figure 19: Regulator ............................................................................................................................................................................... 21
Figure 20: Tension meter ....................................................................................................................................................................... 22
Figure 21: Obstruction test setup .......................................................................................................................................................... 23
Figure 22: Front and back bearing housings .......................................................................................................................................... 24
Figure 23: Left spiral cable ..................................................................................................................................................................... 25
Figure 24: Right spiral cable ................................................................................................................................................................... 25
Figure 25: Legend for air leakage images .............................................................................................................................................. 26
Figure 26: Testing complete door system .............................................................................................................................................. 26
Figure 27: Testing door open position ................................................................................................................................................... 26
Figure 28: Testing door open position ................................................................................................................................................... 27
Figure 29: mark the fasteners with a torque marker............................................................................................................................. 28
Figure 30: torque setting overview. ....................................................................................................................................................... 28
Figure 31: World map Ventura locations ............................................................................................................................................... 31

List of Tables
Table 1: Definitions................................................................................................................................................................................... 6
Table 2: Acronyms and abbreviations ...................................................................................................................................................... 6
Table 3: External documents .................................................................................................................................................................... 7
Table 4: Ventura Systems documents ...................................................................................................................................................... 7
Table 5: Maintenance frequencies......................................................................................................................................................... 11
Table 6: Air leakage values ..................................................................................................................................................................... 25
Table 7: General contact information .................................................................................................................................................... 31
Table 8: Parts contact information......................................................................................................................................................... 31

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 Plug Sliding Door System Introduction
Maintenance Manual Purpose

1 Introduction
1.1 Purpose
This maintenance manual describes maintenance and small adjustment procedures for the Ventura plug slide door system.
Together with the Installation manuals and system drawings makes a complete set of maintenance documentation. It is important
to follow all instructions. All instructions must be conducted without air/electric power unless mentioned otherwise. The
instructions should be executed for the left and right door leaf when the system contains two door leaves. A well-adjusted door
system is less vulnerable to failure. The right maintenance is crucial for the durability of the door system.

1.2 Scope
The purpose of this document is to guide trained service mechanics trough the maintenance steps of the plug slide door system.
When repairs have to be made, the mechanic needs to use the repair manual, or the proper service instruction.

1.3 Definitions
Definition Description
Wear is progressive damage to a part caused by relative motion with respect to another
Wear part
substance or part.
Safety part A safety part is a part, which is important to the overall safety of a system.
Table 1: Definitions

1.4 Acronyms and Abbreviations

Abbreviation Description
DCU Door Control Unit
HQ Headquarters
IATF International Automotive Task Force
IM Installation Manual
ISO International Standardization Organization
REG Regulation
PS Plug Slide
PSI Pound-force per Square Inch
Table 2: Acronyms and abbreviations

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 Plug Sliding Door System Introduction
Maintenance Manual References

1.5 References
1.5.1 External documents
Reference Description Date
Standard bus procurement guidelines : A standardized request for proposal
APTA:2013 2013-05-01
contract form for the transit industry
IATF 16949:2016 Automotive quality management system standard 2016-10-01
ISO 9001:2015 ISO Standard for Quality Management Systems – Requirements. 2015-10-01
Uniform provisions concerning the approval of category M2 or M3 vehicles with
REG 107 Rev 08 regard to their general construction (Incorporating all valid text up to: 2019-10-15
Supplement 1 to 08 series of amendments)
TS 155 Rev 2 Bus door safety systems 2017-11-23
Table 3: External documents

1.5.2 Ventura Systems documents

Reference Type Description Revision Date
PS1600002 IM Plug Sliding Door System : Installation Manual 3.2 2021-05-10
PS1600003 CM PS1 Electric Ventura DCU : Commissioning Manual 1.0 2019-05-24
QM000001 DG Documentation Guideline 4.0 2021-01-04
Table 4: Ventura Systems documents

1.6 Overview
Section 1 gives an introduction, definitions and overview of this document.
Section 2 contains the general door system safety instructions, safety symbols and disclaimer.
Section 3 contains the maintenance instructions.
Section 4 contains checks before commissioning the system.

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 Plug Sliding Door System Door installation safety
Maintenance Manual General

2 Door installation safety

2.1 General
Safety of the operator and bystanders is one of the main concerns in designing and developing a new piece of equipment.
Ventura's door systems have the proper safety features for common use of the system. An accident can often be avoided by
recognizing potentially hazardous situations before an accident occurs. As you install, operate, or maintain the door system, you
must be alert to potential hazards. Make sure you have the necessary training, skills and tools to perform any assembly, or
maintenance procedures. Improper operation and maintenance of this door system may result in a dangerous situation that may
cause injury or death.

Ventura Systems cannot anticipate every possible circumstance that may involve a potential hazard. The warnings in this
document and on the product are not all-inclusive. If a method of installation or operation is used, which is not specifically
recommended by Ventura Systems, you must satisfy yourself that it is safe for you and for others. You should also ensure that the
door system will not be damaged or be made unsafe by the installation and/or operational methods you choose. The information,
specifications and illustrations in this document are based on the information that was available at the time this document was
written and can change at any time without notice.

2.2 Disclaimer
The information contained in this maintenance document is based upon reliable technical data at the time the document was
published. These instructions are intended for use by persons having the technical knowledge to maintain this door system. The
instructions are to be used at the maintenance mechanic’s own discretion and risk. Ventura Systems assumes no responsibility for
results obtained or damage incurred from the use of this material either in whole or in part by the installer. This document
provides basic instructions for the maintenance of the door system in a step-by-step sequence that will work in most types of
maintenances. While effort has been made to ensure the information in this document is correct and complete, we would
appreciate it if you would contact us in case of errors.

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 Plug Sliding Door System Door installation safety
Maintenance Manual Safety alert symbols

2.3 Safety alert symbols

This document contains safety messages which alert you to potential personal injury hazards. Obey all safety messages in this
document to avoid possible injury or death. The following key words and layouts calls for your attention: DANGER, WARNING,
CAUTION and NOTICE. Below are examples of these safety messages. The NOTE message is used for additional information but
these are not threatening for the mechanic, bystanders, nor the door system.

DANGER! NOTICE

Indicates an imminently hazardous situation which, if Indicates that equipment or property damage can
not avoided, will result in death or serious injury. This result if instructions are not followed.
signal word is limited to the most extreme situations.

NOTE
WARNING!
Additional information important but not
Indicates a potentially hazardous situation which, if threatening for people or to the system.
not avoided, could result in death or serious injury.

CAUTION!

Indicates a potentially hazardous situation which if

not avoided, may result in minor or moderate injury.

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 Plug Sliding Door System Door installation safety
Maintenance Manual Safety instructions

2.4 Safety instructions

WARNING! NOTICE
This door system is designed for a specific Do not modify the door system or safety devices.
application; Unauthorized modifications may impair its function
DO NOT modify or use this unit for any application and safety.
other than for which it was designed.
If equipment has been altered in any way from the
original design, Ventura Systems does not accept
Door systems operated improperly or by untrained any liability for injury or warranty.
personnel is dangerous. Lack of operation knowledge
may cause high risk. If replacement of parts is necessary, genuine factory
replacement parts must be used to restore the door
system to its original specifications.
Do not install this door system if it is damaged. If you
are in doubt if the door system has a defect,
*always disconnect the air and/or electric power
immediately stop the installation and contact
while replacing parts. Safety features may not be
Ventura Systems.
active while replacing parts.

Do not connect the door system to air or electric Ventura Systems will not accept responsibility for
supply during the maintenance process. If the damages as a result of the use of unapproved parts.
manual states otherwise, follow the manual.
While working on the Ventura door systems wear
appropriate personal protective equipment.
This list may include but is not limited to:
Do not attempt to install the door system under • Protective shoes with slip resistant soles
influence of drugs or alcohol. • Protective goggles, glasses or face shield
• A hard hat

Follow the regional and country laws and safety

precautions.

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 Plug Sliding Door System Maintenance
Maintenance Manual Safety parts

3 Maintenance
Maintenance of a door system should only be performed when the bus is positioned on a flat surface to prevent
distortion/twisting of the bus body, which can lead to inaccurate measurements of the portal.

Whenever the amount of cycles is past, we advise to execute the applicable maintenance. At the table below, we address the
chapter names.
Minimal
Cycles assumption Applicable for
maintenance
Safety parts
75.000 Every 3 months
Operational checks
150.000 Every 6 months Wear parts
300.000 Every 12 months Parts inspections
Table 5: Maintenance frequencies

Execute at least the minimal maintenance intervals.

3.1 Safety parts

The checks in this chapter are very important. If these parts are not installed correctly, it can have great consequences for the
safety of the system. When the system has two door leaves, the checks must be executed for both sides.
Ventura Systems recommend to execute all safety checks regularly and at least according to the maintenance intervals mentioned
in the table "Maintenance frequencies".
3.1.1 Lever block

Figure 1: Lever block

WARNING!

When the lever block is not in place, the door leaf could get off the guiding roller when twisted, leading to situations with a
high risk of injury to persons. It is very important the lever block is in place.

1. Check if the lever block is present at the bottom of the lever.

2. Check if the lever block is in the right position. It has to be inside the rail of the door leaf.
3. Check if the bolt is on torque.

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 Plug Sliding Door System Maintenance
Maintenance Manual Safety parts

3.1.2 Emergency release

The emergency release is not always supplied by Ventura. In case the emergency release is supplied by Ventura, execute the
following check.
Apply power and/or pressure to the system and put the door(s) in closed position.

CAUTION!

Be aware the system could move when applying power and/or pressure to the system.

1. When the system is active, activate the emergency release.

The following events should occur.
2. The power/pressure is released from the system.
3. The door(s) can be opened manually.
• Reset the emergency release.
• Open and close the door(s) using the power source.

WARNING!

Remove the power and/or pressure from the system after executing this step and before you continue.

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 Plug Sliding Door System Maintenance
Maintenance Manual Safety parts

3.1.3 Sensitive edge

• Press against the right mid seal at a height of 1 meter or less. The doors go to open position.
• Press against the left mid seal at a height of 1 meter or less. The doors go to open position.
When the door leaves do not open when pressing the mid seals as described, perform the following checks or execute the repair
instruction.

Disconnect the sensitive edge.

• Remove the bolts which connect the door leaf to the door arm.
• Disconnect the connector from the spiral cable The full door leaf could be removed to continue
or a second engineer needs to hold the door, while executing the checks.
• Connect a multimeter to the connector of the sensitive edge.

Figure 2: Dismount the door leaf Figure 3: Disconnect the sensitive edge connectors

1. Be sure there is no force pressing the mid seal which can activate the sensitive edge. Resistance is 1200 or 8200 Ω
depending on the resistor of the sensitive edge.
2. Apply force onto the mid seal of the door leaf. Resistance is approximately 0. ~0 Ω
In case all checks are approved, reinstall the door leaf.
Reinstall the door leaves following the instructions in the installation manual. Also execute the callibration of the doors.
NOTE

The sensitive edge is malfunctioning when the resistance is infinite. ∞ Ω.

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 Plug Sliding Door System Maintenance
Maintenance Manual Safety parts

3.1.4 Obstruction detection unit

Only applicable for pneumatic systems.

Apply power and/or pressure to the system and put the door(s) in closed position.

CAUTION!

Be aware the system could move when applying power and/or pressure to the system.

Figure 4: connect multimeter to the obstruction detection unit

1. If a signal is measured, the obstruction detection unit works properly.

WARNING!

Remove the power and/or pressure from the system after executing this step and before you continue.

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 Plug Sliding Door System Maintenance
Maintenance Manual Wear parts

3.2 Wear parts

These parts wear out and must be replaced when damaged, worn, after the prescribed cycles or after the prescribed time the
parts are in usage. When a part has an amount of maximum cycles, it will be mentioned.
3.2.1 Overcenter soft stopper
Apply power and/or pressure to the system and put the doors in closed position.

CAUTION!

Be aware the system could move when applying power and/or pressure to the system.

Figure 5: Overcenter electric with unlock Figure 6: Overcenter pneumatic with Figure 7: Pneumatic without overcenter
cylinder unlock cylinder function

• Check if the lever touches the soft stopper (1) in closed position, with power/pressure.
• Check if the rubber bush of the soft stopper (1) is not worn. Inner dimension following system drawing.

WARNING!

Remove the power and/or pressure from the system after executing this step and before you continue.

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 Plug Sliding Door System Maintenance
Maintenance Manual Wear parts

3.2.2 Cushioning rubber bearing house

Figure 8: Left cushioning rubber Figure 9: Right cushioning rubber

• Check if the cushioning rubber (1) is present at both sides of the mechanism.
• Check if there is no visible damage on the cushioning rubber.
3.2.3 Guide rollers

Figure 10: Bottom guide roller Figure 11: Distance between bottom lever and guiding rail

• Check if the guide rollers (1) on the lever(s) are not worn or damaged in any way. Check for damage visually and feel if
there are no worn places on the guide rollers.
The guide rollers are located at the bottom lever. See left image above.
• Measure if the clearance between the bottom lever and the guiding rail is the same as described in the installation
manual over the full length of the door movement.
If the clearance is not the same, adjust the height of the door shaft following the installation manual.

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 Plug Sliding Door System Maintenance
Maintenance Manual Wear parts

3.2.4 Catch block

Apply power and/or pressure to the system and put the door(s) in closed position.

CAUTION!

Be aware the system could move when applying power and/or pressure to the system.

Figure 12: Location of the catch blocks and catch wedges. Figure 13: Catch block and wedge right

• Check if the catch wedge (2) is caught by the catch block (1) when the door is closed.
• Check if the catch block (1) or catch wedge (2) is not worn or damaged.

WARNING!

Remove the power and/or pressure from the system after executing this step and before you continue.

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 Plug Sliding Door System Maintenance
Maintenance Manual Wear parts

3.2.5 Bottom stopper

Figure 14: Bottom stopper

• Check if the bottom stopper (1) is present.

• Check if the bottom stopper (1) is not worn or damaged.

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 Plug Sliding Door System Maintenance
Maintenance Manual Parts inspections

3.3 Parts inspections

These parts can get affected by usage and must be re-adjusted or cleaned when needed. Check the distance settings of the door
system in open and closed position following the installation manual. Check the torque settings of the door system following the
installation manual.
3.3.1 Door shafts
• Check if the door shaft is free from vertical play (up and downward movement).
If the door shaft is free from vertical play, continue without executing this step. If there is play, execute the following checks.

Figure 15: Top bearing door shaft Figure 16: Bottom bearing door shaft

• Check the settings following the installation manual.

• Check if the bearing bush (1) and pivot point at the bottom of the door shaft are not worn or damaged.
• Check if the bearing bush (1) and pivot point at the top of the door shaft is not worn or damaged.

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 Plug Sliding Door System Maintenance
Maintenance Manual Parts inspections

3.3.2 Electric Actuator

Figure 17: Electric Actuator

• Check if the surface between the cover strip (3) and the aluminum profile of the actuator is clean from dirt and other
impurities. (When cleaning do not use any aggressive cleaning materials and / or fluffy cloths.)

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 Plug Sliding Door System Maintenance
Maintenance Manual Parts inspections

3.3.3 Filter regulator

Check if the system is equipped with a regulator or a filter regulator. If there is no regulator or a filter regulator, skip this step.
1. Check if the pressure of the pneumatic system is 8* bar.
*in case of an electric system with a non-Ventura DCU,
check if the pressure of the pneumatic system is 6 bar.
2. The filter regulator is semi-automatic, meaning the filter will drain itself when the pneumatic pressure drops below 0.3
bar (4.3 PSI) and the drain is open.
3. Replace the filter when it is not clear white.

Figure 18: Filter regulator Figure 19: Regulator

Open drain by turning clockwise

Close drain by turning counter clockwise

NOTICE

Depending on the filter regulators location, it is advised to keep the drain closed so it will not spill dirt over vital parts of the
bus.

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 Plug Sliding Door System Maintenance
Maintenance Manual Parts inspections

3.3.4 Tension steel cables

Figure 20: Tension meter

1. Put the doors in open position.

2. Apply the tension meter as described by the manufacturer.
• Check if the tension in the cable is 260-310 Newton.

NOTE

When using a sonic tension meter, the tension has to be 33-39 hertz.

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 Plug Sliding Door System Maintenance
Maintenance Manual Parts inspections

3.3.5 Clamping force test

Be assured all safety features of the system are active. Execute the obstruction test following the applicable regulations for your
company. (Regulations Ventura meets are REG107, TS155)

Figure 21: Obstruction test setup

1. Setup the measurement system following the user manual included with the measurement tool.
2. Apply power and/or pressure to the system.

CAUTION!

Be aware the system could move when applying power and/or pressure to the system.

3. Put the doors in open position.

4. Execute the test according to the applicable regulations.
When the test is not successful;
• Check the safety parts of system.
• Check adjustments following the installation manual.

WARNING!

Remove the power and/or pressure from the system after executing this step and before you continue.

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 Plug Sliding Door System Maintenance
Maintenance Manual Parts inspections

3.3.6 Grease bearing house

Figure 22: Front and back bearing housings

NOTICE

If a refill of grease is needed, do not use more than 20gr. When the bearing house has too much grease, the friction will hinder
a smooth opening and closing movement of the door system.

• Check the greasing of the bearing houses on the front (1) and back (2). Both housings are greased before delivery.
• If necessary, grease front and back housing using the lubrication nipples (3). Both bearing houses have to be refilled every
year (Normal use, 20gr grease)
• If grease is needed, grease the bearing house with 10 gr. grease, move the door leaf a few times.
Grease again with 10gr. grease.

NOTE

Use "Arcanol MULTITOP" or a grease with similar specifications

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 Plug Sliding Door System Maintenance
Maintenance Manual Parts inspections

3.3.7 Grease spiral cable guiding shaft

Figure 23: Left spiral cable Figure 24: Right spiral cable

Before continuing, place the doors in open position.

• Check if shaft (1) on left and right side is clean of dirt.
• Check if there is a layer of grease on top of the left and right shaft (1) which helps the spiral cable (2) run smoothly over
the shaft. Apply grease when needed.

NOTE

Use "Kroon Multi Purpose Lithep EP2" or a grease with similar specifications

3.3.8 Air leakage test

All stated air leakage test values are applicable solely on one door system. Only check the leakage on door systems when the door
is not functioning correctly or air leakage is hearable.
Check for damaged air pipes or connectors. Try to find where the leakage is coming from. Is there any air leak noise? Can you feel
air coming from the connectors or pipes?

To reduce air leakage, maintain the filter regulator at least every 2 months. Manually drain the bowl according to the maintenance
manual. Change the filter element inside the bowl, at least every year.

Starting pressure of the test is 8 Bars, test time is one minute.

The leakage value is a constant indicator in testing supplied pneumatic parts.
Cylinder type Air leakage value (Bar)
Common cylinder 0.1
Rodless cylinder 1.0
Table 6: Air leakage values

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 Plug Sliding Door System Maintenance
Maintenance Manual Parts inspections

The following explanation uses icons how to connect the

Manometer. The icons used are displayed in the legend.

Figure 25: Legend for air leakage images

Testing the complete door system

Figure 26: Testing complete door system

1. Connect the testing device between the filter regulator and the rest of the door system as shown in the image above.
2. Start the engine of the bus, air pressure should be 8 Bar.
3. Let go of the air pressure at the filter regulator.
4. Set the test device on "open".
5. Turn up the air pressure at the filter regulator till 8 Bar.
6. Turn on the manometer at the testing device by pressing the left button and check the pressure.
7. Set the test device on "testing".
8. Measure the pressure drop for 1 minute in open position, the value from 8 Bar should not drop more than 1 Bar. Repeat
this for the closed position.
9. Set the test device on "open".
10. Let go of the air pressure at the filter regulator.
11. Remove the testing device and fit the air tubes in their original state.
12. Turn up the air pressure at the filter regulator till 8 Bar.
13. If the value drops more than 1 Bar in one minute, contact Ventura Support.

Testing door open

Figure 27: Testing door open position

1. Connect the testing device between the closed position of the cylinder and the rest of the door system as shown in the
image above.
2. Start the engine of the bus, air pressure should be 8 Bar.
3. Close the door.

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 Plug Sliding Door System Maintenance
Maintenance Manual Parts inspections
4. Set the test device on "open".
5. Open the door.
6. Turn on the manometer at the testing device by pressing the left button a check the pressure.
7. Set the testing device on "testing"
8. Measure the pressure drop for one minute in open position. The value of 8 Bar should not drop more than 1 Bar.
9. Set the testing device on "open".
10. Close the door.
11. Remove the testing device and fit the air tubes in their original state.

Testing door closed

Figure 28: Testing door open position

1. Connect the testing device between the open position of the cylinder and the rest of the door system as shown in the
image above.
2. Start the engine of the bus, air pressure should be 8 Bar.
3. Open the door.
4. Set the test device on "open".
5. Close the door.
6. Turn on the manometer at the testing device by pressing the left button a check the pressure.
7. Set the testing device on "testing"
8. Measure the pressure drop for one minute in open position. The value of 8 Bar should not drop more than 1 Bar.
9. Set the testing device on "open".
10. Open the door.
11. Remove the testing device and fit the air tubes in their original state.

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 Plug Sliding Door System Torque Settings
Maintenance Manual

4 Torque Settings
All generic plug slide settings that require torque tightening are in this chapter. Check all mentioned fasteners on the correct
torque settings. In case of a double leaf system, check both sides. The torque settings of marked fasteners may be verified by
checking if the marking is intact.
The fasteners which connect Ventura parts onto the vehicle are, in most cases, non-Ventura parts. Therefor the torque of these
fasteners is not defined by Ventura.

After setting a part to torque specification, mark the connection

with a torque marker.

Figure 29: mark the fasteners with a torque marker.

The position in the system overview have details in the following part of this manual. In the second part the torque settings are
described.

Figure 30: torque setting overview.

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 Plug Sliding Door System Torque Settings
Maintenance Manual

Position 1 Position 2 Position 3

121±9 Nm, 2 per side 22±2 Nm, 2 per side 22±2 Nm, 2 per side
Position 4 Position 5 Position 6

22±2 Nm, 3pc 9±1 Nm, 2pc 45±4 Nm, 4 per side
Position 7 Position 8 Position 9

59±5 Nm, 4 per side 22±2 Nm, 1 per side 26±2 Nm, 2 per side
Position 10 Position 11 Position 12

9±1 Nm, 1 per side 45±4 Nm, 1 per side 20±2 Nm, 2 per side

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 Plug Sliding Door System Operational checks
Maintenance Manual Operation and controls

5 Operational checks
Execute these checks before applying power.

WARNING!

Applying power to an unchecked system may result in a potentially hazardous situation which, if not avoided, could result in
death or serious injury.

No. Check Verified by Approved

Be assured all fasteners are on torque as described in the installation manual of this
1.
system.
2. Check if no cables/tubes are loose on the system.
3. Check if all parts are in place.
4. Manually check if the door leaf/leaves open and close without obstructions.
5. All safety parts are connected.

After these checks, the power may be applied.

5.1 Operation and controls

These checks are all with power and/or pressure.
No. Check Verified by Approved
In case of Pneumatic parts: There is no leakage in the pneumatic system. Also, no leakage
1.
while opening and closing the doors.
2. In case of electric parts: Check if the electric parts and wires has no short circuits or damages.
3. Check if all settings match the installation manual.

5.2 Safety checks

These checks are all with power and/or pressure.
No. Check Verified by Approved
1. All emergency buttons are functioning.
2. Check pneumatic obstruction detections. (if applicable)
Apply an obstruction while closing. Doors open again. Test left and right separately.
3.
*CAUTION!
Apply an obstruction while opening. Doors go to half open position. Test left and
4.
right separately. (if applicable) *CAUTION!
5. Check if the mechanism goes overcenter in closed position. (if applicable)

CAUTION!

Do not use body parts to apply an obstruction.

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 Plug Sliding Door System Contact
Maintenance Manual

6 Contact

Figure 31: World map Ventura locations

Ventura Systems Ventura Systems Ventura Systems Inc

Ventura Systems HQ
Asia Pacific Australia North America
Unit 10 on the 13/F
De Marne 216 PO Box 284 160 Gibson Ct
Fotan Industrial Centre
8701MH Bolsward Sanctuary Cove QLD 4212 NC 28034
26-28 Au Pui Wan Street
The Netherlands Australia Dallas
Hong Kong
+31 (0) 51 557 7750 +852 2712 6001 +1 704-691-0311

+31 (0) 51 557 3410 +852 2512 2325 +1 704-691-0313

support@venturasystems.com info@venturasystems.hk info@venturasystems.com.au info@venturasystems.com
www.venturasystems.com
Table 7: General contact information

Ventura Systems Ventura Systems Inc

Ventura Systems HQ Ventura Systems Australia
Asia Pacific North America
parts@venturasystems.com info@venturasystems.hk info@venturasystems.com.au info@venturasystems.com
+31 (0) 515 577485

Table 8: Parts contact information

Contact your local Agent for parts.

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