2011-2016 Chrysler Minivan Service Manual (13315

Transcription

CHRYSLER / DODGE MINIVAN
SERVICE MANUAL
2011-2016 MODEL YEAR
Main:
Local:
Fax:
(800) 956-6668
(952) 890-7851
(952) 808-2775
TM
Your Life. Your Ride.
6591 W. Hwy 13
Savage, MN 55378
www.rollxvans.com
CHRYSLER / DODGE MINIVAN
2011-2016 MODEL YEAR
SERVICE MANUAL
#13315-006
October 2015
TABLE OF CONTENTS
Important Item Locations ...................................................................................................................... 1
Battery Information - General ............................................................................................................... 6
Battery Information - Draw Test Procedure .......................................................................................... 8
Rollx Vans Door (Motor Bar) - Troubleshooting .................................................................................... 9
Rollx Vans Door (Motor Bar) - Replacement Parts ............................................................................. 10
Passenger Sliding Door - Troubleshooting ..........................................................................................11
Door Modifications .............................................................................................................................. 12
Exhaust System.................................................................................................................................. 14
Exterior / Van Dimensions .................................................................................................................. 16
Fuel System........................................................................................................................................ 17
Front Suspension (Struts)................................................................................................................... 23
Rear Suspension ................................................................................................................................ 24
Engine Mounting (Cradle Drop) .......................................................................................................... 25
Torque Specifications (Suspension) ................................................................................................... 26
Interior..................................................................................................................................................27
Kneeler - Troubleshooting....................................................................................................................31
Kneeler - Replacement Parts...............................................................................................................32
Kneeler - Removal ..............................................................................................................................33
One Touch System - Troubleshooting..................................................................................................35
One Touch System - Overview.............................................................................................................36
One Touch System Interface -Basic Operation....................................................................................38
One Touch System Interface - Setup.................................................................................................. 39
One Touch System Interface - Debugger... ........................................................................................ 40
One Touch System - Error Codes....................................................................................................... 42
One Touch System - Relay Board Troubleshooting........................................................................... 45
In The Floor - Troubleshooting ........................................................................................................... 46
In The Floor - Replacement Parts ...................................................................................................... 47
TABLE OF CONTENTS
In The Floor - Ramp Motor Removal...................................................................................................48
Folding Ramp - Troubleshooting ........................................................................................................ 49
Folding Ramp - Replacement Parts ................................................................................................... 50
Folding Ramp - Motor Install / Removal and Adjustment ................................................................... 53
Rear Heat & Air................................................................................................................................... 55
Remote System - Troubleshooting ..................................................................................................... 57
Remote System - Location & Wiring .................................................................................................. 58
Seat Detector - Location & Description .............................................................................................. 60
Seat Wiring - Driver’s Side (2011-2016)..............................................................................................61
Seat Wiring - Passenger’s Side (2011-2012) ..................................................................................... 69
Seat Wiring - Passenger’s Side (2013-2016) ..................................................................................... 75
One Touch - Wiring (With Door Open Limit Switch) Built Before 8/26/2013............................................79
One Touch - Wiring (With Door Detector) Built After 8/26/2013..............................................................81
One Touch - Wiring (No Can Bus) Built After 3/17/2014.........................................................................83
One Touch - Wiring (With Wing Window Interface) Built After 3/24/2014...............................................85
One Touch - Wiring (Compustar 7200 w/ Flashing lights) Built After 4/30/2015.....................................87
Rollx Vans Power Door (Motor Bar) - Wiring ..................................................................................... 89
Security By Pass Wiring & Installation................................................................................................91
Security By Pass Unlock Sequence....................................................................................................92
Security By Pass Programming...........................................................................................................93
Maintenance Information .................................................................................................................... 95
Warranty ............................................................................................................................................. 96
IMPORTANT ITEM LOCATIONS
OEM Main Wire Harness
(Floor Along Driver’s
Side)
Rollx Vans Main Wire Harness
(Ceiling Along Passenger’s Side)
Rear Heat & A/C Front
Connections
OTC
Main Fuse
ITF Ramp Access
Panel
ITF Ramp Override
Switch
Neutral Safety
Signal Splice
Driver Seat
Detector
Power Seat
Connector(s)
OTC fuse panel
(Under Glove Box)
Rear Heat
and Air Unit
Wing Window Interface
(after 4/15/2014)
Security By-Pass
(If equipped)
OTC Remote
Receiver
Door Detector
Passenger
Seat
Detetector
(replaced door open limit)
(after 4/15/2014)
(after 8/26/2013)
Power Seat
Connector
Passenger Sliding Door
Open Limit Switch
Kneeler
(Before 8/26/2013)
OTC Remote
Programming
Switch
Rear Heat Connections
Rear A/C Connections
One Touch Controller
(OTC) Board
OTC RelayBoard
PAGE
1
Main Fuse
OTC Remote Receiver
(Engine Compartment)
(Passenger’s Side D-Pillar)
6way Seat Fuse
(40 Amp)
(If Equipped)
Rear Heat & A/C
Unit
Main OTC Fuse
(40 Amp)
OEM Wire Harness
Rollx Vans Main Wire Harness
Runs Along Driver’s
Side Floor
Runs Along Passenger’s
Side Ceiling
Passenger Sliding Door Open Limit Switch
OTC Fuse Panel
(Passenger’s Lower Slider Door Track)
(Under Glove Box - Must Pull Back Fabric)
Rollx Vans Remote
Power Tie Down
(If Equipped)
Used Before 8/26/2013
6way controller
(If Equipped)
Ignition Hot
Neutral Safety
Vans are equipped with a Ignition Hot and
Neutral Safety Panel to allow for quick
connection. See OTC Wiring for more
information.
PAGE
2
ITF Ramp Motor Access Plate
OTC Relay Board
(Located On The Floor Of The Driver’s Slider Door Area)
(Behind Rear Passenger Quarter Panel)
Manually engage or
disengage the motor with
the ratchet.
Access hole
Rear AC (Rear Connections)
Rear Heat (Rear Connections)
(Behind Rear Right Tire)
(Right Rear Tire)
Rear Heat & A/C (Front Connections)
Kneeler and One Touch Controller
(Under Passenger’s Side Front Seat Area)
(Passenger’s Side Rear Storage Area)
Universal Door Detector
Used After 8/26/2013
(behind panel)
Rear Heat
OTC Board
Rear A/C
Kneeler
PAGE
3
Neutral Safety Signal
ITF Ramp Override Switch
(Engine Compartment)
(Driver’s Side B-Pillar)
NOTE: Rollx Vans taps into the
“TRS T3 SIGNAL” at the
“TRANSMISSION SOLENOID
PRESSURE SWITCH” to pick up
the Neutral Safety signal.
*See OTC WIRING for diagram
Passenger’s Door Detector
Wing Window Interface (Built After 4/14/2014)
(Replaced The Door Open Limit Switch after 8/26/2013)
(Passenger’s Side D-Pillar)
Built before 4/15/2014 (location was passenger D-Pillar)
Built after 4/15/2014 (location is passenger side C-Pillar)
Driver’s Power Seat Connector
(Passenger’s Same)
OTC Remote Programming Switch
PAGE
4
Rollx Vans Ignition Hot & Neutral Safety Board Wiring
2008-2016 Chrysler Minivans (built after 5/28/2009)
BK (8 GA.)
-
40A
RD (8 GA.)
RD (8 GA.)
FUSE
+
RED (12V CONSTANT)
*
FUSE PANEL
(BEHIND GLOVE BOX)
1 AMP
REMOTE
1 AMP
Neutral Safety
DOOR DETECTOR
1 AMP
CONTROLLER PWR
N
R
D
P
2
PK / GN
(OEM IGNITION HOT)
Nuetral
Safety
Ignition
Hot
1
4 (OEM CAV 9)
8
13 GN/DB
17
21
3
7
12
16
20
23
PK / GN (12V IGNITION HOT)
*(To Inition Hot)
located under
steering column
TAPS INTO OEM IGNITION
HOT (PK/GN WIRE) THAT IS
LOCATED BEHIND THE CENTER
BEZEL GOING INTO THE RADIO
Power Folding Rear Sofa
If the van is equipped with a Power Folding Rear Sofa, Rollx Vans disables the FOLD/TAILGATE
SWITCH MUX which would allow the seat to be stowed into the floor. Rollx Vans cuts the LG/TN wire
at the switch.
Pin Wire Color Gauge
4
1
8
5 Cut
PAGE
5
1
2
3
4
5
6
7
8
LG/YL
LG/TN
LG/DB
LG/VT
22
22
22
22
Function
NO CONNECTION
SEAT SWITCH SELECTOR SIGNAL
SEAT FOLD SIGNAL
SEAT STOW SWITCH SIGNAL
FOLDING SEAT SWITCH RETURN
NO CONNECTION
NO CONNECTION
NO CONNECTION
BATTERY INFORMATION - GENERAL
The following procedure should be used to test the current draw from any battery
used in our vans.
1) Insure the battery is fully charged.
2) Remove the key from the ignition switch.
3) Close all the doors including the sliding doors and the rear tailgate.
4) Close all the windows including the rear vent windows.
5) Remove the negative (Black) cable from the battery and move it to a safe location
away from both the positive (Red) and negative terminals of the battery.
6) Acquire a Digital Multimeter with a 20 Amp current range function. NOTE: A
standard van can draw between 15 and 17 amps of current when it is first powered
up (When the battery is reconnected). You must use a multimeter with a 20 Amp
range. Using a Multimeter with a lower current range function will damage the
meter if it does not have an internal fuse. If it has an internal fuse, it will be blown.
NOTE: DO NOT RUN THE ROLLX VANS OTC OR TRY TO START THE VAN WHEN
YOU HAVE THE METER CONNECTED! YOU WILL DAMAGE THE METER!
7) Place the function switch of the Multimeter in the 20 Amp Current Measurement
position.
8) Connect the negative (black) probe (wire lead) to the black jack on the multimeter.
9) Most multimeters have more than one red jack for the positive (red) probe. They
usually have one jack for measuring AC & DC voltage and resistance, along with a
second Jack for measuring AC & DC Current. Some multimeters have more than
one red jack for measuring current (three red jacks total). As an example a meter
might have two red jacks, one rated for 200 Milliamps and a second for 20 Amps.
You should use the 20 Amp plug (or the one with the largest rating).
10) Acquire two test jumpers with alligator clips (Radio Shack # 278-002). Attach one
jumper to the positive (Red) probe and the other to the negative( Black) probe.
11) Turn the multimeter on.
12) Attach the other end of the jumper clipped on the positive (red) meter probe to the
disconnected battery cable.
NOTE: Polarity does not matter much when measuring current. A positive current
is the same as negative current. Disregard the polarity indicator on the multimeter
during these tests.
13) Attach the jumper on the negative (black) meter probe to the negative terminal of
the battery.
NOTE: YOU MAY GET A SPARK WHEN YOU ATTACH THE JUMPER. THIS IS
NORMAL. ALL THE CURRENT BEING USED BY THE VAN IS NOW RUNNING
THROUGH THE METER. AS MUCH AS 15-17 AMPS).
PAGE
6
BATTERY INFORMATION - GENERAL
14) The Multimeter should now show a reading. Keep your eye on the meter and
watch the draw. A typical van can have from 18 to 28 computer modules in it.
They are all woke up when power was applied to the van by attaching your meter
probes. As you watch the current reading you will note that it will start to fall. This
happens as the computers in the van decide they are not needed and put
themselves to sleep. Chrysler says it can take up to thirty minutes for everything
to go into sleep mode.
The current should drop in stages similar to the sequence below:
a. The reading will start as high as 15-17 amps for a short period of time.
b. It then fall to 6-8 amps for a short time.
c. Then 1 to 1.5 amps for a period of time.
d. It will then settle on around .800 amps (800 Milliamps) for a while.
e. Then it may drop to .100 to .200 amps (100 to 200 Milliamps) for period of
time.
f. Finally it will drop all the way into sleep mode, .040 to .100 amps (40 to 100
Milliamps) and will stay there until the van is woke up.
g. Note: The values you will see will vary from van to van, from van type to
type and by the number and type of accessories installed on the van. The
important thing is that it drops to a value less the 100 Milliamps (.100
Amps) for a standard van when it goes into sleep mode.
15) You can wake the van simply by opening the driver’s side door for a few seconds,
then closing it.
16) Watch the meter again to see the van go into sleep mode again. You should repeat
this test until you are satisfied the van’s “Sleep Mode” is functioning correctly.
PAGE
7
BATTERY INFORMATION - DRAW TEST PROCEDURE
This picture shows a complete setup for a Draw Test:
Note the black probe attached to the negative terminal and the red probe attached to the
negative battery cable.
This picture shows a typical multimeter. Note the current range switch settings and
current probe jack markings are all in yellow for uA (Microamps), mA (Milliamps and A
(Amps).
Also note that the meter has two Jacks for current measurement, “20A” and “uA/mA”. On
this meter, for our Draw Test, we would place the Function Switch in the “A” (for Amps)
position and plug the Red Probe into the “20A” Jack. The Black Probe always goes in the
Black Jack.
PAGE
8
ROLLX VANS DOOR (MOTOR BAR) TROUBLE SHOOTING
Symptom
Door does not operate.
Possible Cause
Front passenger door is locked.
Switch is stuck.
Blown fuse.
Manual release handle is not engaged.
Door will open, but ramp will not
deploy.
Door will open, but not close or
door will "jump" closed.
Door "ratchets" when operating
(make sure kneeler is off).
Door open limit switch needs adjustment.
Remedy
Unlock front passenger door.
Make sure all user switches are not stuck.
Replace 30 or 15 amp blade fuse located
underneath hood near battery.
Turn handle all the way counter-clockwise.
Adjust the door open limit swtich (#7 on next
page). The switch can be accessed by the
passenger side rear speaker area (remove the
speaker first).
Ramp up limit switch is not engaged.
Adjust the cam for up limit.
Gear on motor is stripped.
Gear on bar is stripped.
Replace motor.
Replace gear rack (bar).
PAGE
9
PAGE
10
2
3
4
5
1
1
1
1
Item Qty.
1
1
1
1
1
1
15
8
11
17
4
10
9
Description
Part #
DOOR BAR ASM (INCLUDES THE 3 FOLLOWING)
10026ASM
MTR BAR DOOR OPENER (RACK AND ASSEMBLY)
10026
WIRE HARNESS 5.5" FOR
310-1059
MTR 12V 10NM 10MM DOUBLE
210-1011
GEAR RACK (SPECIFY LONG OR SHORT)*
10026-4
LONG BAR
1126318
3/8 X 1 STRIP
ARM BAR (FOR MOTOR BAR)
10026-22
WIRE HARNESS 5.5" FOR
310-1059
10026-15ASM
MOTOR ONLY W/GEAR ASM (INCLUDES WIRE HARNESS AND SHIMS**)
* LONG USED BEFORE ~2001 IF NO REAR HEAT & AIR
** SHIMS ONLY NEEDED IF BEFORE ~2003 BUT ALWAYS SENT WITH MOTOR
1
2
3
Item Qty.
6
1
7
1
8
1
9
1
10
2
11 N/A
12 N/A
13
2
14
1
15
1
16
1
17
2
18
1
5
16
18
6
13
7
Description
BRKT MTR BAR LIMIT SWITCH
SWITCH DPDT (CHERRY)
HANDLE CHROME INSIDE
DOOR BRACKET A (DOOR BRACKET B - )
DOOR ARM PLATE
MANUAL RELEASE TENSION ADJUSTMENT
1/4-20 NYLOCK NUT
#6 NYLOCK NUT
1/4-20X3/4 HEX HEAD SCREW
5/8-20X1 HEX HEAD SCREW (ADJUSTMENT)
SHIM KIT FOR DOOR OPENERS (INCLUDES ALL 3 - VARYING SIZES)
#10-32X2 HEX HEAD (5/32) PARTIALLY THREADED SCREW
#10-32X2-1/2 HEX HEAD (5/32) PARTIALLY THREADED SCREW (NUT ON BACK)
12
14
12
COM
COM
Part #
MB1006
E19-50H
6022
MB1001 (MB1002)
MB1005
NA
SHOP SUPPLY
SHOP SUPPLY
SHOP SUPPLY
SHOP SUPPLY
10026-12
SHOP SUPPLY
SHOP SUPPLY
NC
NO
NC
NO
Rollx Vans Power Door Exploded View
ROLLX VANS DOOR (MOTOR BAR) REPLACEMENT PARTS
PASSENGER SLIDING DOOR TROUBLESHOOTING
Note: Using the “Debug Mode” on the OTC board is a good resource to assist you in trouble shooting.
Refer to the “One Touch System Interface Debugger” section and verify all the Inputs (limit switches)
are functioning normally.
Symptom
Possible Cause
Remedy
Van is NOT in park.
Place van into park..
Overhead on/off switch is turned to the OFF
position.
Turn switch to ON position.
OTC program failure.
OEM B-Pillar Swich Failure (switch needs to be
functioning for our sytem to work).
Ramp sliding door does NOT OPEN
with interior Rollx Vans user switch /
Rollx Vans remote.
with interior OEM push buttons after
pressing OTC reset button.
Ramp sliding door does NOT
attempt to CLOSE after ramp stows.
Ramp sliding door attempts to close
(door motor runs) after ramp stows,
but door does not move.
Ramp sliding door kicks back when
opening.
Ramp sliding door kicks back when
closing.
manually.
Ramp sliding door closes half way
and then moves back and forth.
Ramp sliding door will NOT CLOSE
manually.
Replace OEM B-Pillar switch.
Defective Rollx Vans Remote.
See Remote Troubleshooting section.
Broken wire in the door harness.
Test & repair open circuit or Replace harness.
Door lock actuator failure.
Replace door lock actuator.
Bad user switch.
Try another user switch/ replace defective switch.
Low voltage.
Bad OTC board.
Main OTC fuse (40 amp) is blown.
OEM overhead ON / OFF switch is OFF.
Defective door detector.
Check or replace the van's battery.
Replace OTC board.
Replace fuse under hood by battery.
Replace door track assembly and contact
customer service.
Replace the door detector
Ramp up limit switch is not being activated.
Adjust or Replace the ramp up limit.
Defective door open bracket.
Adjust or replace the bracket.
Defective OEM door track assembly.
Press OTC reset button, press interior OEM push
button to see if door will close automatically. If
door still does not respond, review OTC board
display.
Defective OEM door track assembly.
Obstruction.
Door out of adjustment.
Ramp needs adjustment (Foldout only).
OEM door module needs software update.
Check door track for any debris and remove.
Adjust or replace the door open bracket, latch or
cable.
Adjust door and strikers.
Adjust folding ramp to stow more.
Update software from Chrysler or Rollx Vans.
Excessive cabin pressure.
Shut off AC/Heater fan, and open a window.
Door not latching in full open position.
Ramp sliding door opens and van OEM Door Ajar Pin Switch (Rollx Vans Door Close
kneels, but when door is all the way signal) is never deactivated when door begins to
open.
open, van unkneels and cycle ends.
Ramp sliding door does not seal
when almost closed.
Press OTC reset button.
If the OTC thinks the door is open and closed it
will end the cycle. Examine switch / wiring.
Ramp needs adjustment (Foldout only).
Adjust folding ramp to stow more.
Defective OEM cinch motor.
Replace cinch motor.
Door is locked.
Unlock door.
Child safety lock is activated.
See OEM owner manual to deactivate child safety
lock.
Defective interior handle cable.
Adjust or replace cable.
Stuck door open limit switch.
Adjust swtich located in rear of lower door track.
Door handle is not releasing.
Pull handle to disengage latch and slide to close.
Obstruction.
Check door track for any debris and remove.
Door track assembly is seized.
Replace modified power sliding door track.
PAGE
11
DOOR MODIFICATIONS
Door extension kits
part numbers and
descriptions
INNER DOOR SKIN (Extension)
Driver Side - #B08180-D5
Passenger Side - #B08180-P5
-B08180-D5-KIT-ITF
DOOR SKIN SVC KIT, ITF,DR
-B08180-D5-KIT-FO
DOOR SKIN SVC KIT,FO,DR
-B08180-P5-KIT-ITF
#10277 - Rivets (9 per Door)
DOOR SKIN SVC KIT,ITF,PS
-B08180-P5-KIT-FO
DOOR SKIN SVC KIT,FO,PS
Outer Sliding Door
#10277 - Rivets (6 per Door)
Current
#B08180-DP6 - L BRKT DOOR SKIN DR/PASS 08
Before 10/20/2008
#10503 - 1”X 1” 14GA ROLLED ANGLE
OEM BOLT (3)
#6505 480AA
#B08033
‘08 LOWER DOOR ARM
BRACKET
CABLE POWER DOOR 2008
#AR-2008
OEM LOWER DOOR ROLLER ARM
Passenger Side - #5020 920AB
Driver Side - #5020 921AB
BOLT (3) - #0115007
WASHER (3) - #1133004
DOOR TRACK EXT BKT UPPR 08
#B08030ASM
Needs to be painted to match van
PAGE
12
DOOR MODIFICATIONS
DOOR OPEN SWITCH
ASSEMBLY - #05089-003
Built Before 8/26/2013
ZOO
1/4-20X1/2” Hex Bolt
#0115001
M+
FHSCS 1/4-20X1/2 ZB
#94222
DOOR TRACK EXT BKT LOWR 08
#B08032
(#B08032-1 Vans Started after 7/21/2010)
DOOR TRACK EXT BKT LOWR 08 ASM
#B08032ASM
(#B08032-1ASM Vans Started after 7/21/2010)
(Includes Switch, Wire Harness, and Bracket)
SNAKE CONNECT BLOCK SLIDE ARM
#B08050 (Not Shown)
Door track kits and descriptions include OEM track and door open switch bracket
B08059ASM-DR
-TRACK, DOOR ASM 2008-2009, DR
68067847AA
-TRACK DOOR DR OEM 10-16
B08059ASM-PS
-TRACK, DOOR ASM 2008-2009,PS
B08059ASM-PS-2010 -TRACK , DOOR ASM 2010-2016,PS
Passenger Sliding Door Middle Track
BUMPER, MIDDLE TRACK
#9306K14
PAGE
13
EXHAUST SYSTEM
OEM Catalytic Converter /
O2 Sensor
Rollx Vans Exhaust
3.3L & 3.8L #B08200-SS
4.0L #B08202
3.6L #B11200-SS
Rollx Vans Weld
OEM Hanger
Rollx Vans begins their exhaust from the OEM Catalytic Converter (Rollx Vans does not modify the OEM
Catalytic Converter or OEM 02 Sensor). Rollx Vans Exhaust is welded to the OEM Catalytic Converter
and runs down the passenger side of the van.
Rollx Vans reuses the OEM Hangers to support the exhaust. Rollx Vans Exhuast is 2-1/4 inch diameter
aluminized tubing and replaces the OEM 2-1/2 exhaust.
Rollx Vans Exhaust
#B08201-SS
Rollx Vans Weld
PAGE
14
EXHAUST SYSTEM
Rollx Vans Exhaust
#B08201-SS
Rollx Vans Weld
OEM Muffler and
Tailpipe
Rollx Vans Exhaust continues over the rear axle and is welded to the OEM Muffler and Tailpipe.
Rollx Vans eliminates the OEM Resonator.
PAGE
15
EXTERIOR / VAN DIMENSIONS
-P = Passenger Side
-D = Driver Side
(Chrysler Vans Only)
#B08180-P4
#B08180-D4
(Dodge Vans Only)
#B08180-P4D
#B08180-D4D
(Before 12/2/08)
#B08180-P3
#B08180-D3
(Before 12/2/08)
#B08180-P2
#B08180-D2
(After 12/2/08)
#B08180-P3.2
#B08180-D3.2
(After 12/2/08)
#B08180-P2.2
#B08180-D2.2
#B08180-P1
#B08180-D1
Side Step Ground Effects
Service Kit # R0051
P.N.
Description
B08180-P1S
B08180-D1S
B08099
Qty
GFX PS SIDE STEP
GFX DS SIDE STEP
GFX SIDE STEP
BRACKET
1
1
2
When replacing either of these ground effects on a 2008 Chrysler van built before 12/2/08. order
as follows:
Ÿ D3 or P3 = it is necessary to replace both the D2 and D3 with the new D2.2 and D3.2
(same for passenger side).
Ÿ D2 or P2 = we have about 20 in stock of each so just replace that required piece until
out of stock, then follow above rule.
2011-2013 Chrysler / Dodge Minivan Dimension Sheet
3
1
A
2
4
5
8
6
6
7
Rollx Vans Chrysler/Dodge
In The Floor Ramp
11 Inch Drop
1
Floor to Ceiling Height
58
2
Passenger Sliding Door Opening Height
54.5
3
Floor to Overhead Console
57
4
Passenger Sliding Door Opening Width
31.5
5
Cargo Area Length (Rear "z" to Firewall Along Floor)
84
6
Ground Clearance - Ground Effect
7
7
Ramp Length
50
8
Ramp Width (Inside Wall to Inside Wall)
30
Cargo Area Width When Closed (Door to Door / Door to Ramp)
66.5
Ground Clearance - Lowest Point (Exhaust)
5.5
Cargo Area Length (Rear Sofa to Clip-in Base)
54.5
* All measurements are subject to change depending on various van configurations and should be used as approximations.
Measurement
Description
PAGE
16
Rollx Vans Chrysler/Dodge
Folding Ramp
11 Inch Drop
58
54
57
31.5
84
7
55.5
29
61.5
5.5
54.5
FUEL SYSTEM
2011-2016 Chrysler Town & Country / Dodge Grand Caravan (3.6L)
Rollx Vans Fuel / Emission System Overview
Red Text = Rollx Vans Equipment
Italic Text = OEM Parts
*See page 18 for Rollx Vans part #’s
To Engine
OEM Fuel Quick
Disconnect (5/16”, 0°)
OEM EGR Valve
OEM Plastic Line
OEM Quick Disconnect (3/8”, 45°)
Rollx Vans Main Fuel Metal Line (5/16”)
Pre-modified
OEM Setup
Rollx Vans Charcoal
Canister Vent Metal Line (3/8”)
OEM Charcoal
Canister
OEM Charcoal
Canister Vent Line
OEM Filler Neck Top
(Gas Cap)
Rollx Vans Filler Neck Metal Tube
OEM Fuel Fill
Vent Line
Rollx Vans Fuel Fill
Vent Hose (5/16”)
OEM Fuel
Tank
Rollx Vans Main Fuel Hose (3/8”)
Rollx Vans Charcoal
Canister Vent Hose (5/8”)
Rollx Vans Heat Shield
PAGE
17
DESCRIPTION
PAGE
18
DESCRIPTION QTY
OEM Charcoal
Canister
OEM Fuel Pump /
OEM Fuel Filter
10929- Fuel Hose 5/8- 53”
R7
00834
705- Hose Clamp #10 2
1012
6815
Fuel Vapor
1
Vent Hose
6168AA
P.N.
Charcoal Canister Vent Hose
1
2
OET Oetiker 9/16 Clamp
(OET 15)
1315
4721 OEM Fuel Vapor
Tube
799AD
QTY
37”
DESCRIPTION
R9 5/16 High
Pressure H-354a
H-211
P.N.
Fuel Fill Vent Hose
1
QTY
OEM Fuel Fill
Vent Line (metal)
(Gas Cap)
126299 5/16 x .028 Fusion
P.N.
Main Fuel Line (Metal)
Red Text = Rollx Vans Equipment
Italic Text = OEM Parts
OEM Fuel
Tank
OEM Charcoal
Canister Vent Line
3/8 x .028 Fusion
101865
QTY
1
QTY
B05019
P.N.
4721
615AD
10100022
OET
Heat Shield
2005-2016
1
DESCRIPTION QTY
Heat Shield
OEM Fuel Supply
Tube
Oetiker 9/16 Clamp
(OET 17)
1
2
H-212 R9 3/8 High Pressure 40”
H-355a
DESCRIPTION
Main Fuel Supply
Filler Neck 2008
B08103ASM
P.N.
DESCRIPTION
P.N.
1
QTY
Filler Neck Assembly
DESCRIPTION
P.N.
Charcoal Cantister Vent Line
FUEL SYSTEM
FUEL SYSTEM
OEM Fuel Filler Neck (Gas Cap)
OEM Fuel Fill Neck
OEM Fuel Fill Vent Line
Rollx Vans Fill Neck Extension
#B08103
(Aluminized Steel Tubing)
Rollx Vans Fuel Fill Neck
Assembly
#B08103ASM
OEM Quick Disconnect
with Rollx Vans Clamp #OET 1315 (5/16”)
Rollx Vans Fuel Fill Vent Hose
#H-211
(5/16” Fuel Injection Hose,SAE 30R9, Goodyear)
Rollx Vans welds a Fill Neck Extension onto OEM Fuel Fill Neck to extend the OEM Fuel Fill Neck to
the OEM Fill Neck Hose that attaches to the tank. The completed assembly is #B08103ASM that
includes the OEM Fuel Fill Neck welded to the Rollx Vans Fill Neck Extension. The modified filler neck
Is smoke tested for possible pin hole leaks.
Rollx Vans attaches a Fuel Fill Vent Hose that begins at the gas tank to the OEM Fuel Fill Vent Line
with a 9/16” clamp. This hose and the filler neck tube are routed underneath the frame.
PAGE
19
FUEL SYSTEM
Rollx Vans Main Fuel Hose
Part #H-212
(3/8” Fuel Injection Hose,SAE 30R9,180 PSI,WP,
CARB #c-u-06-002, Gates Corp.)
OEM Quick Disconnect with
Rollx Vans Clamp Part #OET 1317 (3/8”)
Rollx Vans Charcoal Canister
Vent Hose
Part #10929-00834
(5/8” Fuel/Emissions Hose,
SAE 30R7, Goodyear)
with #10 Hose Clamp
Part #H-211
(5/16” Fuel Injection Hose,SAE 30R9, Goodyear)
OEM Quick Disconnect with
Rollx Vans Clamp Part #OET 1315 (5/16”)
Rollx Vans re-uses the OEM Gas Tank.
Rollx Vans replaces OEM Fuel Fill Vent Hose with Rollx Vans Fuel Fill Vent Hose that runs to OEM Fuel
Vent Line near Filler Neck top (Gas Cap).
Rollx Vans replaces OEM Charcoal Canister Vent Hose with Rollx Vans Charcoal Canister Vent Hose
that runs to OEM Charcoal Canister. Rollx Vans does not modify the OEM Charcoal Canister or its mounting.
Rollx Vans replaces OEM Main Fuel Hose with Rollx Vans Main Fuel Hose that runs to Rollx Vans Main
Fuel Metal Line where it is attached to the flared metal line with the OEM Quick Disconnect.
OEM Charcoal Canister
(OEM mounting)
with #10 Hose Clamp
Rollx Vans Charcoal
Canister Vent Hose
Part #10929-00834
(5/8” Fuel/Emissions Hose,
SAE 30R7, Goodyear)
OEM Clamp
OEM Fuel Fill Hose
at Tank
PAGE
20
Rollx Vans Fill Neck Extension
Part #B08103ASM
(Aluminized Steel Tubing)
FUEL SYSTEM
A) Rollx Vans routes the Rollx Vans Main Fuel Metal Line (5/16”) under the driver’s side of the van using P-Clamps to secure.
B) The Rollx Vans Main Fuel Metal Line (5/16”) is routed up the rear z, flared and attached to OEM Quick Disconnect.
C) The Rollx Vans Main Fuel Metal Line (5/16”) is routed up under the engine compartment, flared and attached to OEM Quick Disconnect.
B
C
OEM Fuel Quick
Disconnect (5/16”)
OEM Fuel Quick
Disconnect (5/16”, 0°)
Rollx Vans Main Fuel
Metal Line (5/16”)
Part #126299
(5/16”X028/X13' FUSION)
Part #126299
(5/16”X028/X13' FUSION)
Engine Compartment
A
Part #126299
(5/16”X028/X13' FUSION)
PAGE
21
FUEL SYSTEM
A) Rollx Vans runs the Rollx Vans Canister Vent Metal Line (3/8”) under the passenger side of the van using P-Clamps to secure.
B) The Rollx Vans Canister Vent Metal Line (3/8”) is routed up under the engine compartment, flared and attached to OEM Quick Disconnect.
C) The Rollx Vans Canister Vent Metal Line (3/8”) is routed up the rear z, flared and attached to OEM Quick Disconnect.
B
OEM EGR Valve
C
OEM Quick Disconnect (3/8”, 45°)
Rollx Vans Charcoal
Part #101865
(3/8”X028X13' FUSION WELD)
OEM Plastic Line
Engine Compartment
Rollx Vans Charcoal
Part #101865
(3/8X028X13' FUSION WELD)
OEM Quick Disconnect (3/8”, 90°))
A
Rollx Vans Charcoal
Part #101865
(3/8”X028X13' FUSION WELD)
PAGE
22
FRONT SUSPENSION
Front Strut Mounting Bolts #B08001ASM
BOLTS:
5/16” -18 x 1” (QTY 6)
#0115055
WASHERS:
1/4” ZINC FLAT(QTY 6)
#1133004
LOCK WASHERS:
5/16” (QTY 6)
#1133892
Strut Collar Assembly #B08001ASM
*Reuse OEM strut collar nuts
to fasten collar to strut.
Strut Assembly
Stabilizer Bar Link
Adjustable
Camber Bolt #41-214
OEM
Camber Bolt
PAGE
23
REAR SUSPENSION
Vans Built Prior to 1-2-2013
COIL SPACER ON BOTTOM
SERVICE KIT #R0046
Coil Spacer
Coil Spacer
Vans Built After 1-2-2013
SNUBBER EXTENSION ON TOP
Traction Bar Spacers B08065
Upper Shock Mounts
p.n. B08071ASM-HD (Driver)
p.n. B08072ASM-HD (Passenger)
Snubber Extension Assembly
p.n. B08055ASM
Shock Absorber
Brake line bracket B08068ASM-DR
Brake line bracket B08068ASM-PS
Trailing Arm
BOLTS: (QTY 4)
M10-1.50 x 100mm
#0153998
Kneel Axel Mount B08022
Traction Bar
PAGE
24
WASHERS: (QTY 4)
1/2” ZINC FLAT
#1133012
ENGINE MOUNTING (CRADLE DROP)
BOLTS:
BOLTS:
M10-1.50 x 70mm (QTY 3)
#0153994
M12-1.50 x 70mm (QTY 2)
#38503
WASHERS:
WASHERS:
#1133008
#1133012
1” Motor Mounts
N05010 (QTY 5)
Left Side Engine Mount
Right Side Engine Mount
2.5” Motor Mount
N05011 (QTY 5)
Front Engine Mount
Left Crossmember Bracket
(Right side same)
OEM Isolator bolt
#4721 746AB (QTY 1)
BOLTS:
M12-1.75 x 50mm (QTY 4)
#0154004
WASHERS:
#1133012
1” Motor Mount
N05010 (QTY 4)
BOLTS:
M14-2.0 x 190mm (QTY 4)
#0122055
WASHERS:
#1133012
Left Cradle Mount
(Right side same)
PAGE
25
TORQUE SPECIFICATIONS
Torque Specifications
Location
Front Suspension
Rear Suspension
Engine & Cradle
Mounting
Item
Wheel nuts
Camber Bolts
Stabilizer Bar Link Nuts
Strut Collar-to-Body
Strut Collar-to-Strut
Wheel nuts
Trailing Arm Bracket-to Body Bolts
Trailing Arm Pivot Thru-Bolts
Traction Bar To Axle Bolts
Shock Absorber Upper Mounting Bolts
Shock Absorber Lower Mounting Bolts
Front Engine Mount
Right Side Engine Mount
Left Side Engine Mount
Left & Right Cradle Mounts
Left & Right Cross Member Brackets (M14 Bolts)
Left & Right Cross Member Brackets (M12 Bolts)
PAGE
26
Torque
100 Ft. Lbs.
116 Ft. Lbs.
65 Ft. Lbs.
21 Ft. Lbs.
21 Ft. Lbs.
100 Ft. Lbs.
40 Ft. Lbs.
129 Ft. Lbs.
60 Ft. Lbs.
55 Ft. Lbs.
55 Ft. Lbs.
83 Ft. Lbs.
40 Ft. Lbs.
70 Ft. Lbs.
120 Ft. Lbs.
120 Ft. Lbs.
40 Ft. Lbs.
INTERIOR
ITF Ramp
L-TRACK 4 HOLE
#FE753NA008-02-1
L-TRACK 3 HOLE
#10016
COVER DOGBONE
#B2205-1
DRILL&TAP PPH 8 X 1
SCREWS #31833
FHSCS 1/4-20X1
BOLTS #10929-03773
DRILL&TAP PPH 8 X 1
SCREWS #11263372
L-TRACK 12 HOLE
#10015-1
END CAP FLANGE
#QC06058
FHSCS 5/16-18X3/4
BOLTS #94254
L TRACK 5 HOLE
#10006-1
L TRACK 6 HOLE
#10007-1
QTY
8
16
10
10
1
1
1
1
1
23
7
P.N.
B 2205-1
31833
Q C 06058
11263372
10016
F E 753N A 008-02-1
10006-1
10007-1
10015-1
10929-03772
10929-03773
Description
CO V E R DO G B O NE
8 X 1 S C R E W S (for dog b one c overs )
E N D C A P F LA N G E TR K O M N I
8x 3/4 S C R E W S (for end c aps )
L TR A C K 3 H O LE (dog hous e)
L TR A C K 4 H O LE (pas s front c ras h)
L TR A C K 5 H O LE (pas s c argo)
L TR A C K 6 H O LE (rear z )
L TR A C K 12 H O LE (b ehind front s eats )
5/16-18X 3/4 B O LTS (for 5/16 L-T rac k )
1/4-20X1 B O LTS (for 1/4" L-T rac k )
Fold OutRamp
FHSCS 1/4-20X1
BOLTS #10929-03773
L-TRACK 4 HOLE
#FE753NA008-02-1
L TRACK 6 HOLE
#10007-1
FHSCS 5/16-18X3/4
BOLTS #10929-03772
L-TRACK 3 HOLE
#10016
DRILL&TAP PPH 8 X 1
SCREWS #31833
QTY
8
16
14
14
1
5
1
6
27
P.N.
B2205-1
31833
QC06058
11263372
10016
FE753NA008-02-1
10007-1
10929-03772
10929-03773
8x3/4 Drill&Tap PPH
#11263372
END CAP FLANGE
#QC06058
DRILL&TAP PPH 8 X 1
SCREWS #11263372
Description
COVER DOGBONE
8 X 1 SCREWS (for dog bone covers)
END CAP FLANGE TRK OMNI
8x3/4 SCREWS (for end caps)
L TRACK 3 HOLE (dog house)
L TRACK 4 HOLE (pass front crash & floor)
L TRACK 6 HOLE (rear z)
5/16-18X 3/4 BOLTS (for 5/16 L-Track )
1/4-20X1 BOLTS (for 1/4" L-Track )
PAGE
27
shooting in savage
INTERIOR
UNIVERSAL BELTS EXT
#5086227AA (NOT SHOWN)
CLIP IN SEAT BASE COVERS
#B08070-1
CLIP IN FOOTREST11 IN.,DR
#4003-11INCH-D-FOOTREST
#4003-11INCH-P-FOOTREST
CLIP IN BASE,11
#4003-11-ASM-DR
#4003-11-ASM-PS
(INCLUDES FOOTREST & COVERS)
CLIP IN COVER FLAP
(NOT SHOWN - NO PART #)
#B08070-1
SEAT BELT MOUNT BRKT "Z"
PART #STBLT1
SEATBELT EXT L TRACK
#5086227AA-L
SEATBELT EXT 2008 12"FEM/MALE
(NOT SHOWN) - MAKES SHOULDER
HARNESS LONGER
#5086227AA-EXT
DOOR PANEL INTERIOR
DRIVER
#B15802
PASSENGER #B15803
B PILLAR INTERIOR
DRIVER
#B8800-1
PASSENGER #B8801-1
Wheel Well Cover
Driver
#B8808-1
Passenger #B8807-1
Weather Stripping
LP78348
Interior Wire Cover #B8806-1
(may need to be painted to match)
PAGE
28
INTERIOR
Passenger Slider Door
W/ Fold Out Ramp
ROLLER CUSHION KIT
#22875T11
BRACKET STABILIZER
#F08018
STABILIZER COVER
(NO PART #)
S p a r e Ti r e S t o r a g e
TIRE COVER 2008 ASM
#B08060ASM
Tire Jack & Handle
KNEEL ACCESS COVER
(NO PART NUMBER)
Compressor
(if equipped)
SURE LOCK
#FE522
PAGE
29
INTERIOR
Flip Up Foot Rest
Service Kit R0052
REAR SOFA COVER
(NO PART #)
FLIP OUT MOUNT (RIGHT)
#B08097
FLIP OUT MOUNT (LEFT)
#B08096
Includes Brackets & Arms
A
C
ARM
B
BRACKET
D
LIFT-O-MAT SHOCK
#110435
MOUNTING HARDWARE
ITEM
A
B
C
D
P.N.
DESCRIPTION
10929-02112 1/4 - 20 X ½ TORX BOLT
173780
5/16 - 18 X 1 ALLEN BOLT
1168077
1/4 E CLIP
1168081
½ E CLIP
PAGE
30
QTY
8
4
2
2
KNEELER TROUBLESHOOTING
Symptom
Van does NOT LOWER to ground
while door is opening after Rollx
Vans user button is pressed.
Possible Cause
Kneel on / off switch is turned OFF.
Kneel motor.
Kneel chain is broken.
After van is lowered to ground the
kneeler makes a loud ratcheting
sound.
Kneel down limit switch was not activated.
Kneel on / off switch is turned OFF.
Van will NOT RAISE when ramp is
stowed.
Kneel motor.
Kneel up limit switch is activated incorrectly.
Van raises and while door closing
the kneeler ratchets.
Kneel up limit switch is not activated.
PAGE
31
Remedy
Turn kneel switch to the ON position.
Review display board. Turn kneel switch to the
OFF position and press OTC reset button.
Temporarily operate sytem without kneel option
enabled.
Replace Chain.
Adjust kneel down limit switch. Replace if
broken.
Turn kneel switch to the ON position.
Review display board. Manually un-kneel van,
turn kneel switch to the OFF position and press
OTC reset button.
Adjust kneel up limit switch. Replace if broken.
Contact customer service.
Once door is closed and van is at normal
height, turn kneeling switch to the OFF position.
PAGE
32
1
1
1
1
1
15
16
Qty.
1
2
1
1.5
1
1
2
1
1
1
2
3
4
4
1
Item
1
2
3
3A
4
5
6
7
8
9
10
11
12
13
14
Description
ACTUATOR KNEELING ASM
50 CONN LINK
KNEEL CHAIN ASM 2008
CHAIN 50 ROLLER
KNEEL CHAIN SWIVEL
COTTER PIN
FLANGE BRG
SPRING TORSION ASM
SPROCKET FOR #50 CHAIN
KNEEL LIMIT SWITCH ASM
SWITCH TANG BZ-2RW80-A2
HCS 3/8-16 X 1YZ8 QPA
PPH MS 6-32 X 1 1/2Z
10-32 NYLOCK NMZ
ACTUATOR GUIDE ASM
Parts on Van
KNEEL AXLE MOUNT
RATCHET REVERSIBLE
SOCKET 3/8"
BOOT BLK "2005" KNEELACT
KNEEL ASSEMBLY BASE PLATE
1
B08022
800-0072*
4PW71*
152303*
K05100BKT-ASM
* Not Shown
Part #
K2XG20-12V-08RX-ASM
N0511-C
6261K534ASM-02 2008
6261K534
K05012
98338A220
10FDU06
LTR-075M-6-5ASM
6280K249
03220-003
6X284
0115105
1128838
1137015
K05006ASM
16
13
11
11
2
9
7
10
12
3
6
3A
15
8
6
5
2
4
Part# KNEEL SNG OT-02 - Desc. KNEEL ASM CHRY, SNG,
OTC, 2005-12v2 (COMPLETE ASM)
14
KNEELER REPLACEMENT PARTS
KNEELER REMOVAL
Rear Traction Bar
Step #1
A
A) Using a 7/16” socket and wrench disconnect the
kneel chain swivel bolt & nut from the kneel Axle
Mount.
.
Spare Tire Storage
Step #3
Step #2
A
B
A) Remove the kneeler cover located in the rear
cargo area.
A
Step #4
A
A) Disconnect the Kneeler Motor plug.
B) Cut the zip ties holding the wires in place.
C) Remove Kneeler
*Install new kneeler in reverse order
PAGE
A) Remove the 3 mounting bolts with a 9/16”
socket & wrench.
B) Remove the wires going to the limit switches
with a small phillips screw driver
33
This page was intentionally left blank
PAGE
34
ONE TOUCH SYSTEM TROUBLESHOOTING
Important: If OTC Board is removed, the OEM System will not operate normally unless the CAN
Bus Shunt is installed. The shunt is attached to the wire harness behind the OTC board. See OTC
Wiring Diagram for more information. ONLY APPLIES TO VANS BUILT PRIOR TO 3/17/2014.
Symptom
Remedy
Check that OTC ON/OFF switch is on. The power toggle switch is on
the actual OTC board itself.
No power to One Touch Controller (OTC).
Ensure the connections on the back of the OTC board are tight.
Check the OTC main fuse (40 amp) located near the vehicles main
battery.
Reset the OTC.The reset is located on the dash by the drivers left
knee and on the OTC board (red button).
Check battery voltage.
Battery is low. Turn off the OTC and charge battery. Note: The alarm
will sound when the battery voltage is below 11.4 VDC. This is to
OTC beeps 4 times when the user tries to
prevent the OTC system from draining the battery far enough as to
run a normal open/close cycle.
prevent the vehicle from starting. This level is adjustable in the
board's Setup menu.
The van's battery is dead.
The OTC display is garbled
Van has been sitting for an extended period of time. Charge the
battery.
Check the current draw by placing an ammeter in series with the
negative terminal on the battery with all doors closed and engine off.
The draw varies, but awake, the system should be less than .850
amps and when sleeping, less than .050 amps. Additional equiment
installed will also vary these numbers. See batery section for more
information.
Reset the OTC. The reset is located on the dash by the drivers left
knee and on the OTC board (red button).
PAGE
35
ONE TOUCH SYSTEM OVERVIEW
The Rollx Vans One Touch Controller, known as the OTC, is a Single Board Computer specifically
designed for the Rollx Vans system.
The OTC system was designed to be independent to the operation of the Chrysler computer system.
When power is removed from the OTC, it has no effect on the operation of the Chrysler system as long as
the OTC Shunt Plug is installed into the OTC Main Harness on all 2008 Chrysler Vans due to the CAN
BUS system (see OTC Wiring Diagram for more information).
The OTC is a low power system. When the OTC is in Sleep Mode with the Display disabled, it typically
draws less then 10ma of current from the battery. When awake in Idle Mode (not running a cycle) with the
Display enabled, it typically draws less than 200ma of current from the battery.
The current state of the OTC can be determined by viewing the Display. During open or close operation
the progress of the system can be tracked by watching the Display.
8
OTC V8.0
Sequence of Operation
Open Cycle
1) The OTC is activated by any Rollx Vans User Switch or Remote being pressed.
2) Door unlock command sent (1 sec.) To Front Passenger Door Control Module to unlock all doors.
3) Door open command sent to OEM B-Pillar Door Open/Close Button to open the passenger sliding door.
4) Door starts to open.
5) Kneeler motor is turned on and starts to lower van.
*If door fails to open within 2 seconds of User Switch being pressed, cycle stops (van unkneels and
cycle is ended)
6) Door reaches open position and activates Rollx Vans Door Open Limit Switch.
7) Passenger sliding door is disabled by OTC interrupting the CAN Bus signal with built in relay.
8) Ramp motor is turned on and starts to deploy.
9) Kneeler stops lowering when Kneel Down Limit Switch is activated.
10) Ramp stops deploying when Ramp Down Limit Switch is activated.
11) OTC enters Idle Mode.
12) OTC enters Sleep Mode.
Close Cycle
1) The OTC is activated by any Rollx Vans User Switch or Remote being pressed.
2) Ramp motor is turned on and starts to stow.
3) After a few seconds (ramp is off the ground and begun to slide into van) kneeler motor is turned on and
starts to raise the van.
4) Kneeler stops raising when Kneel Up Limit Switch is activated.
5) Ramp stops stowing when Ramp Up Limit Switch is activated.
6) Passenger sliding door is enabled by OTC reconnecting the CAN Bus signal with built in relay.
7) Door close command sent to OEM B-Pillar Door Open/Close Button to close the passenger sliding door.
8) OTC receives signal from OEM Door Ajar Pin Switch that door is closed.
9) OTC enters Idle Mode.
10) OTC enters Sleep Mode.
Note: There are “Watch Dogs” programmed in the OTC software that act as timers to end a function if the
function does not complete within a certain amount of expected and very reasonable time.
PAGE
36
ONE TOUCH SYSTEM - OVERVIEW
INPUTS
KNEEL DISABLE SWITCH (Violet wire) Allows the user to enable (the “I” position) or disable (the “O”
position) the kneeling system. There is no display for this input.
OTC CONTROLLER POWER (2 White/Red wires) Supplies power to the OTC Board
USER SWITCH INPUT (Blue wire) Active while any Rollx Vans user button or Rollx Vans remote is
pressed.
NEUTRAL INPUT (Green wire) Indicates the status of the gear shifter. When active, the van is either in
neutral or park. The OTC system will not run a operational cycle unless the van is in neutral or park.
DOOR OPEN LIMIT INPUT (Orange/Red wire) Active when the right side sliding door is fully open.
DOOR CLOSE LIMIT INPUT (Violet/Yellow wire) Active when the right side sliding door is fully shut.
RAMP UP LIMIT INPUT (Red/Green wire) Active when the ramp in the up position.
RAMP DOWN LIMIT INPUT (Red/White wire) Active when the ramp is in the down position.
KNEEL DOWN LIMIT INPUT (Yellow/Green wire) Active when the kneeler is in the down position.
KNEEL UP LIMIT INPUT (Yellow/White wire) Active when the kneeler is in the up position.
OUTPUTS
System Status: Indicates if the system is ready to except a command. It is off when the OTC is in sleep
mode. V8.0 Display will show Rollx Vans: Idle.
RAMP DOWN MOTOR OUTPUT (Red wire) Active when the OTC is driving the ramp down (V6.0 & V8.0
OTC boards have obstacle detection monitoring this output).
RAMP UP MOTOR OUTPUT (Red/Black wire) Active when the OTC is driving the ramp up (V6.0 & V8.0
OTC boards have obstacle detection monitoring this output).
KNEEL DOWN MOTOR OUTPUT (Yellow/Black wire) Active when the OTC is driving the kneeler up
KNEEL UP MOTOR OUTPUT (Yellow/Red wire) Active when the OTC is driving the kneeler up.
DOOR DISABLE OUTPUT (Orange/Blue) Used by the OTC to disable the Chrysler right side door
controller anytime it wants to open the ramp. This prevents the right side door controller from banging the
right side sliding door against the ramp.
DOOR CONTROL OUTPUT (Orange) OTC sends a command to the Chrysler system to open or close the
right side sliding door.
RAMP DISABLE OUTPUT (Red/Blue wire) Active anytime when the OTC is driving the ramp up or down. It
indicates the ramp manual mode is disabled.
DOOR UNLOCK OUTPUT (Green/White) OTC sends a command to the Chrysler system to unlock the
doors at the beginning of an open cycle.
PAGE
37
ESC
ESC
PAGE
38
DOWN
ENTER
Scrolls
Last Error
Kneel Down
ESC
UP
ENTER
START
Rollx Vans
Idle
Hardware Version
V-X.XX
ESC
DOWN
ENTER
ENTER
UP
Serial #
XXXXX
DOWN
UP
Manual
Kneeler
Kneel Up
DOWN
UP
Rollx Vans Service
800-956-6668
Software Version
Mod X
DOWN
ENTER
ESC
ESC
ENTER
Password
Required
DOWN
UP
ENTER
Data Logger
Setup
DOWN
UP
#02 0000:00:00
Status: Err# XX
ESC
UP
#03 0000:00:00
Status: Err# XX
(Move to next Log Entry)
DOWN
ENTER
#01 0000:00:00
Scrolls Error Info
To get into setup a password is required. Setup options
include Cycle Tester, Battery Alarm Level, Debugger,
Cycle Counter, Ramp Type, Kneeler Mode, and Obstacle
Detection Level. For more info on Debugger see next
page. Also see OTC 6.0 User Interface Flowchart for
more in depth information.
ESC
UP
#01 0000:00:00
Status: Err# XX
(Move to previous Log Entry)
#02 0000:00:00
Scrolls Error Info
#03 0000:00:00
Scrolls Error Info
One Touch Controller Basic Operation
1) How to manually kneel van
2) How to check software and hardware versions
3) How to review error codes in Data Logger
ONE TOUCH SYSTEM INTERFACE-BASIC OPERATION
ONE TOUCH SYSTEM INTERFACE - SETUP
Options within Setup
Setup
View Data Log
START
Password Good
View the past 30 errors recorded. Hit enter to view Error
Details.
UP
ENTER
ESC
DOWN
Setup
Data Logger Mode
Select “Log All Mode” or “Log Error Only Mode” to decide
which type of errors to record. Default is “Log Error Only
Mode”.
Setup
Engineering
Setup
Cycle Counters
Displays the number of Open and Close cycles.
Setup
Kneeler
Select if Kneel System installed or not. Default is “Yes”.
Setup
Battery Alarm
Select the Battery Alarm Trip Point between 10.9 vdc and
12.4 vdc. If OTC reads vdc below Trip Point, OTC will not
operate. Default is “11.5 vdc).
Setup
Cycle Tester
Select the number of cycles between 10 and 99 you want
the system to run automatically in order to test. Hit Esc to
stop.
Setup
Serial Number
Select between “Input Test Mode” and “Output Test Mode”
to test OTC System operation. THIS IS VERY USEFUL.
For more information see How To Use Debugger on next
page.
Setup
Debug
Displays current Clock Time.
Setup
Hobbs Meter
Setup
OB Detect Level
PAGE
Select the sensitivity of the ramp’s obstacle detection
between 0 and 9. “0” is the weakest and “9” is the
strongest (ramp is very hard to stop at “9”). Default is “5”.
39
ONE TOUCH SYSTEM INTERFACE - DEBUGGER
How to Use Debugger
(Output Test Mode)
START
Use extreme caution when using the Output Test Mode. The
Output Test Modes sends the signal directly to the OTC Relay
Board which results in power going to the called motor. No
safeties are in place (ie. The Ramp Down will operate the ramp
regardless if the door is open or closed.
Output Test Mode
UP
ENTER
ESC
Output Test Mode
Ramp Down
Relay should click and ramp should go out.
Output Test Mode
Door Unlock
All OEM Doors should unlock.
Output Test Mode
Door Close
Closes the passenger sliding door.
Output Test Mode
Door Open
Opens the passenger sliding door.
Output Test Mode
Kneel Down
Press and hold to operate the kneeler and lower the van.
Relay should click.
Output Test Mode
Kneel Up
Press and hold to operate the kneeler and raise the van.
Relay should click.
Output Test Mode
Ramp Enable
Relay should click.
Output Test Mode
Ramp Up
Relay should click and ramp should go in.
DOWN
PAGE
40
ONE TOUCH SYSTEM INTERFACE - DEBUGGER
How to Use Debugger
(Input Test Mode)
START
Input Test Mode
UP
ENTER
ESC
The Input Test mode is very useful for testing the various limit
switches the systems requires. To operate:
1) Select a Limit Switch (Input) you would like to test from the
list below.
2) Notice if the Switch is “On” or “Off” when it is suppose to be.
The audible beeps let you test the switch by hand without
looking at the OTC Board.
- On (activated) = Double Beeps
- Off (not activated) = Single Beeps
Input Test Mode
Ramp Up
ON when ramp is all the way in.
Input Test Mode
Neutral
ON when van is in Park or Neutral.
Input Test Mode
Door Close
ON when passenger sliding door is closed.
Input Test Mode
Door Open
ON when passenger sliding door is all the way open.
Input Test Mode
Kneel Sw
ON when Dash Kneel On/Off switch is on.
Input Test Mode
Kneel Down
ON when kneeler is all the way down (knelt).
Input Test Mode
Kneel Up
ON when kneeler is all the way up (normal).
Input Test Mode
Ramp Down
ON when ramp is all the way out.
DOWN
PAGE
41
ONE TOUCH SYSTEM - ERROR CODES
For information about OTC Interface and how to use the Debugger, please refer to 'One Touch System - v8.0
Advanced Interace' section. Remember, in Input Test Mode, double beeps indicate the switch is on or activated and
single beeps indicate that it is not. Also refer to the 'One Touch System - Relay Board Troubleshooting' for more
information about the Relay Board, its Overide Switches and LED Indicator Lights.
Code
Description - What Caused the Code
Everytime before the OTC cycles, it checks the Main
Battery's voltage. If reading is below the value set in the
OTC Setup, the OTC will continue to operate, but will
indicate a low battery warning. The default value is 11.5
volts.
Diagnostic Tests
More Information
Rollx Vans recommends starting your van every 4-5 days,
Perform a Draw Test
allow it to run 15-20 minutes to keep the battery at a
Follow instuctions in 'Battery Information - Draw Test Procedure' sufficient state of charge.
Section
A timer is included on the OTC that will shut it off after 5
minutes UNLESS in Setup Mode. Update OTC if needed.
Error 1 - Battery Low Error
Code
Error 11 - Door Control Error
Diagnostic Tests
Output Test
Place OTC in Debug - Output Test Mode to verify OTC operates
the door correctly by sending signal to OEM B-Pillar Switch
and/or OEM Front Passenger Door Unlock Switch.
1) Check Door Open.
2) Check Door Close.
3) Check Door Unlock.
4) Check Ramp Enable. This closes a relay on the OTC Relay
Board that enables the ramp to run (prevents the ramp from
running if the door is not open, door open enables ramp enable).
Door Control Output failure (The OTC did not successfully
control the door to open or close). The OTC did not
receive the signal that the door came off the OEM Door
Ajar Switch when opening or did not receive the signal that
the door came off the Rollx Vans Door Open Switch when
closing. Once the OTC sends the signal to open the door,
it waits about 2 seconds to see if the Door Ajar Switch is
not activated. If the Door Ajar Switch is still active, this
message will appear.
More Information
OEM B-Pillar Switch / Door On/Off
If off, the OEM Overhead Power Sliding Door On/Off
Switch will prevent the door from operating from the OEM
B-Pillar Switch. The OTC uses this switch to open or close
the door. When off, the OTC can not control the door.
Make sure the switch is on and try hitting the OEM B-Pillar
switch. If the door still does not work, likely an OEM issue.
If OEM function works, but OTC does not check wiring.
Door Unlock Switch
Door must be unlocked to open. First try OEM Unlock
Switch in Passenger Front Door. The OTC uses this switch
to unlock all the doors before an Door Open Command is
sent. If OEM Switch does not unlock doors, likely an OEM
issue. If OEM functions, but OTC does not check wiring.
Input Test
Place OTC in Debug - Input Test Mode to verify limits operate
correctly.
1) Check Door Open (Rollx Vans Door Open Switch), by
opening door all the way in Door Open.
2) Check Door Close (OEM Door Ajar Switch), by close door
all the way in Door Close. Rollx Vans taps into OEM Door Ajar Door Ajar Switch
Switch in Lower B-Pillar (See OTC Wiring for more
If the OEM Door Ajar Switch is not deactivated within 2
information).
seconds of the start of the cycle, Door Control Error will be
returned.
PAGE
42
Code
Error 18 - Ramp Obstacle
Detection Error
Diagnostic Tests
Check Error Log for multiple Obstactle Detection Errors. If
there are many, raise the level in Setup.
Input Test
correctly.
1) Check Ramp Up [Limit Switch] by operating the ramp with
Power Overide Switch (ITF Ramp) or manually raising (Folding
Ramp).
2) Check Ramp Down [Limit Switch] by operating the ramp
with Power Overide Switch (ITF Ramp) or manually raising
(Folding Ramp).
Code
Error 23 - Neutral Status Error
OTC detected that the ramp may have hit an obstruction
on the in or out cycle. The OTC detects an obstruction by
measuring the current generated from the ramp motor.
The obstruction could be something in the way or a Ramp
Limit is not recognized. If this current exceeds the set limit
in the OTC Setup (default is 5, scale is 1-10 with 1 being
the most sensative)
More Information
Setup - OB Detect Level (default is 5, scale is 1-10 with 1
being the most sensative)
If a Ramp Limit Switch fails, the Obstacle Detection should
activate and cause an error. If the Obstacle Detection
does not activate, the Ramp Watchdog Timer should. This
will also cause an error (Error 27) and end the cycle.
Everytime before the OTC cycles, it checks to make sure
the van is in Park. This is for safety and can not be
changed.
More Information
Diagnostic Tests
Input Test
Place OTC in Debug - Input Test Mode to verify OTC recognizes Refer to Important Item Information or OTC Wiring
if the van is in Park correctly
Diagram for more information about where Rollx Vans gets
1) Check Neutral by placing the van in and out of Park and
this signal.
listening for the double beeps from the debugger.
Code
Error 25 - Emergency Stop
Error
Diagnostic Tests
Operate User Button to verify working correctly.
Anytime a Rollx Vans User or Remote Button is pressed
during an open or close cycle, the system will stop
immediately. If a Hard Wired User Button is held down
long enough, the OTC will think it has been pressed twice
and thus, cause an error.
More Information
This is a safety feature and can not be changed.
Code
Error 27 - Ramp Watchdog
Error
Once the OTC sends the signal to start running the ramp
motor in or out, a timer starts. If enough time passes
before the proper limit switch is activated at the end of the
cycle, the OTC will return this error. This is a safety feature
to limit power to the motor in case of mulitple failures.
Diagnostic Tests
More Information
Operate the In-The-Floor ramp with Power Overide to help
Not available on Folding Ramps.
determine if motor and ramp are functioning correctly.
Several factors such as low battery, cold weather or debris
Output Test
can prevent the motor from operating correctly. If low
battery, very cold or a bad motor, the motor may run too
the ramp motor correctly.
slow causing this watchdog to activate. Debris can also
1) Check Ramp Open.
prevent the motor or ramp operating at correct speed, also
2) Check Ramp Close.
causing this error.
If a Ramp Limit Switch fails, the Obstacle Detection should
Input Test
activate and cause an error (Error 18). If the Obstacle
Detection does not activate, the Ramp Watchdog Timer
correctly.
should. This will also cause an error.
1) Check Ramp Up [Limit Switch] by operating the ramp with
Power Overide Switch (ITF Ramp) or manually raising (Folding
If OTC Debug Output Test does not activate the motor
Ramp).
being tested, try the overides located on the OTC Relay
2) Check Ramp Down [Limit Switch] by operating the ramp
Board. This will inidicate a communication problem
with Power Overide Switch (ITF Ramp) or manually raising
between the One Touch Controller and One Touch Relay
(Folding Ramp).
Board.
PAGE
43
Code
Once the OTC sends the signal to operate the OEM Door,
a timer starts. If enough time passes before the proper
limit switch is activated at the end of the cycle, the OTC will
return this error.
More Information
If OEM B-Pillar Switch is not working, try the OEM
Overhead Door Switch and make sure the OEM Overhead
Door On/Off Switch is on.
Error 28 - Door Watchdog Error
Diagnostic Tests
Operate the OEM Door with the OEM B-Pillar Switch to
determine of OEM Door is functioning properly.
Input Test
correctly.
all the way in Door Close. Rollx Vans taps into OEM Door Ajar
information).
If Door Limits function correctly and door cycles open and close
okay, the issue is with the door taking too long to open or close.
Check alignment or motor.
Output Test
the door correctly by sending signal to OEM B-Pillar Switch
If an Output is an issue, the Door Control Error (Error 11)
and/or OEM Front Passenger Door Unlock Switch.
will likely display.
1) Check Door Open.
2) Check Door Close.
Code
Once the OTC sends the signal to operate the Kneeler, a
timer starts. If enough time passes before the proper limit
switch is activated at the end of the cycle, the OTC will
return this error.
More Information
Error 29 - Kneeler Watchdog
Error
Diagnostic Tests
Operate the Kneeler with Power Overide to help determine
Reset - Esc - Kneel Up/Kneel Down
if motor is functioning correctly.
Input Test
correctly.
1) Check Kneel Up [Limit Switch], by raising Kneeler until
switch is activated or activate switch by hand.
2) Check Kneel Down [Limit Switch], by Lowering Kneeler until
switch is activated or activate switch by hand.
Testing with Power Overide is preferreed since it will incidicate
if Limit Switch is being properly activated by Actuator's Guide.
When Kneel Actuator reaches its run limit, it will begin to ratchet
making a terrible sound. This is simply the motor's clutch
mechanism, is not damaging but should try and be minimized.
If OTC Debug Output Test does not activate the motor
being tested, try the overides located on the OTC Relay
Output Test
Board. This will inidicate a communication problem
between the One Touch Controller and One Touch Relay
the Kneeler correctly.
Board.
1) Check Kneel Up.
2) Check Kneel Down.
Also a low battery, bad motor or cold weather causing the
motor to run very slowly can return this error.
Code
Error 33 - Door Ajar Error
Diagnostic Tests
Operate the OEM Door with the OEM B-Pillar Switch to
determine of OEM Door is functioning properly.
The OTC will not run a Cycle if the door is Ajar (Not fully
opened or closed). If Ramp deployed, open door fully. If ramp
stowed, fully close and latch door.
More Information
If OEM B-Pillar Switch is not working, try the OEM
Overhead Door Switch and make sure the OEM Overhead
Door On/Off Switch is on.
Input Test
correctly.
all the way in Door Close. Rollx Vans taps into OEM Door Ajar
information).
PAGE
44
ONE TOUCH SYSTEM - RELAY BOARD TROUBLESHOOTING
OUTPUTS
RELAY BD OTC VERSION 2
P.N. 08044-003
ORDER #OTCV8 RELAY BD
Run to the Kneeler and Ramp Motors
INPUTS
Run from the OTC Control Board
LED Indicator Lights
Manual push button test switches
*Pressing the switches should operate each
function as shown on the board as long as the board
is working properly. Remember, in order to run the ramp,
the Ramp Enable must also be pressed at the same time.
Pressing a switch is the same as sending a
ground to the terminal.
PAGE
45
IN THE FLOOR TROUBLESHOOTING
Symptom
Possible Cause
Door is not fully open.
Remedy
Check the upper or lower door tracks for
obstructions, ensure door opens freely and
latches.
Door open limit not detected -faulty door detecor Replace door detector or trouble shoot & repair
or wiring (For vans with Door detectors).
circuit. See OTC Wiring diagrams.
Ramp will NOT DEPLOY after door
opens automatically.
Door open limit not detected - faulty door open
limit switch or wiring. (For vans with door open
limit switches).
Ramp down limit switch may be activated or
wiring is bad.
Replace or adjust door open limit switch or
trouble shoot & repair circuit. See OTC wiring
diagrams.
Engage ramp motor. Refer to the "Important
Items location" section of this manual.
See limit switch adjustment and OTC wiring
diagram.
Bad ramp motor or chain is too tight.
Check wiring, loosen chain or replace motor.
Ramp motor not engaged.
Engage ramp motor. Refer to the "Important
itmes location" section of this manual.
Bad ramp motor or chain is too tight.
Check wiring, loosen chain or replace motor.
Ramp motor not engaged.
Ramp will NOT STOW
automatically.
diagram.
Start vehicle. Press OTC reset button and press
Low voltage from the battery.
Rollx Vans user button again.
Door open limit switch may be activated or wiring
Ramp will deploy before door is all
is shorted to ground.
repair wiriing.
the way open.
Replace door detector or trouble shoot & repair
Faulty door detector or wiring is bad.
wiring. See OTC Wiring diagrams.
Clear obstruction and press Rollx Vans user
Obstacle is detected.
Ramp will STOP mid-cycle.
button.
Chain is too tight.
Loosen chain by adjusting tensioner.
Ramp will start to deploy or stow
Ensure that there are no objects on top of cover
Pressure on cover plate or chaiin is too tight.
plate or loosen chain.
then stop functioning.
Ramp up limit switch may be activated.
PAGE
46
47
N05021G-F
N05021G-B
N08025-11
N08026-11
N05039
R0013
11107632
1137185
1126331
1137023
115109
1136206
N1-N1DXLA
N005001ASM
1173912
N05017ASM
N05016ASM
B08032ASM
05089-002
92510A351
2483K18
N05003ASM
CHRLCL035
24412
10929-02112
1133004
N05049
97517A130
N05048
32
34
40
21a
33 21
26
30
3
28
1
ITF RAMP ROLLER UPDATE
3/8 NYLON FLAT WASHER
3/8-16 YZ8 NE NYLOCK
5/16-18 x 1 SLDR 3/8
5/16-18 NTE JAM NYLOK
HCS 3/8-16X1.5YZ8 QPA
3/8 -16 HX JAM Z NUT
ROLLER, ITF RAMP PLATE
RAMP ITF ASM
5/16-18X2 S/S FHSCS
TRACK FLOOR PLATE FRONT ASM
TRACK FLOOR PLATE REAR ASM
TRACK TRACK EXT.BKT, LOWER 08,ASM
DOOR OPEN SWITCH ASSEMBLY
ALUMINUM UNTHREADED (ACTIVATOR)
PRECISION MINATURE IDLER
ROLLER PLATE 2008, CHYSLER
CONN LINK #35 CARBON
LOCKING HOLE & VENT
SS TORX BHCS 1/4-20
1/4 USS F/W Z
TEFLON BLOCK FOR ITF RAMP
RIVETS
SPACER ROLLER CUSHIONED
SEE PAGE 15
SEE PAGE 15
CARPET TRIM FRONT
CARPET TRIM BACK
FLOOR TRACK DRIVER
FLOOR TRACK PASSENGER
RAMP LIMIT SWITCH BRACKET (use with N08111ASM)
PAGE
17
18
19
20
21
21a
22
23
24
26
27
28
30
31
32
33
34
35
36
37
38
39
40
1
10
2
2
2
2
2
4
1
2
1
1
1
1
1
2
1
1
1
4
4
2
4
2
1
1
1
1
1
1
1
37
16
20
2
27
18
23
35
5
3
17
19
4
14
12
8
38
31
30
22
13 13a
16
6
7
36
15
9
39
10
24
Item Qty.
Description
Part #
1
1 ITF ACCESS PLATE
N05019
2
1 MOTOR GEAR BOX ITF 2008 ASM
N08111ASM
N08111-MTR/GEAR ASM
1 MOTOR WITH GEAR ONLY
2
1 MOTOR GEAR BOX, ITF 2014ASM
N14111ASM
START DATE 1/2/14
2
1 ITF MOTOR ONLY (START DATE 1/2/14)
218-2001
3
6 1/4-20 YZ NE NYLOCK
1137183
4
10 CHAIN ROLLER SS #35
35
5
1 TENSIONER/SPROCKET ASM ITF
10005
6
2 ROLLERS CUSHIONED
22875T11
7
8 SS TORX BHCS 1/4-20
10929-02112
8
1 FLAP ASM ITF RAMP
N05014ASM
3 PRECISION MINATURE IDLER*
2483K18
3 5/16" x 1/16" NYLN WSHR
76002
3 HCS 1/4-20X1 1/4 YZ8QP*
0115007
3 1/4-20 YZ NE NYLOCK*
1137183
9
7 SS TORX BHCS 1/4-20
10929-02112
10
2 HCS1/4-20X1YZ8 QPACK
0115005
12
2 HCS 1/4-20 X 3/4 YZ8 QPA
0115003
13
1 CHAIN ANCHOR
N05033
13
1 CHAIN ANCHOR (STARTE DATE 1/2/2014)
N14033
N14034
13a 2 MOTOR SPACERS (STARTE DATE 1/2/2014)
IN THE FLOOR (METAL SPRINGS ) REPLACEMENT PARTS
IN THE FLOOR RAMP MOTOR REMOVAL
ITF Ramp Motor Removal
Step #1
Step #2
ITF MOTOR
ITF ACCESS PLATE
Remove
Remove
ROLLER PLATE
A) Remove the 2 allen bolts that attach the
roller plate to the chain anchor using a 5/32”
allen bit.
** With the ramp in and passenger slider door
open.
A) Remove the 4 bolts securing the ITF motor
access plate using: T27 torx bit.
Step #3
Slide Ramp
Out
A
Master Link
B
Step #4
A
B
SPACERS
A) Lift up on the roller plate and slide the ramp
out slightly to gain access to the chain
anchor.
B) Remove spacers (set aside).
Step #5
A) Remove the master link closest to the gear,
then disconnect the anchor from the chain.
B) Pull the chain out of the motor
housing.
Step #6
B
A
A
A) Remove the 4 limit switch screws and
remove switches from motor housing.
B) Remove the (5) 1/4” mounting nuts for the
motor using a 7/16” socket w/ extension.
PAGE
A) Unplug the connector for the motor and
remove motor from van.
*Install new motor in reverse order.
48
FOLDING RAMP TROUBLESHOOTING
Symptom
Possible Cause
Ramp fuse or circuit breaker is blown.
Door is not fully open.
Remedy
Reset circuit breaker on top of ramp motor
housing or check ramp fuse and replace if
needed with a 30amp fuse.
Check the upper or lower door tracks for
obstructions, ensure door opens freely and
latches.
Ramp will NOT DEPLOY after door Door open limit not detected -faulty door detector Replace door detector or trouble shoot & repair
opens automatically.
or wiring (For vans with Door detectors).
Door open limit not detected - faulty door open
limit switch or wiring. (For vans with door open
limit switches).
Ramp down limit switch may be activated or
wiring is bad.
Bad ramp motor or wiring.
Ramp up limit switch maybe activated.
Ramp will NOT STOW
automatically.
Ramp fuse or circuit breaker is blown.
Bad ramp motor or wiring.
Low voltage from the battery.
Ramp will deploy into the door.
Door open limit switch is activated or wiring
shorted to ground.
Faulty door detector or wiring is bad.
Ramp will STOP mid-cycle.
Obstacle is detected.
Weak ramp motor.
PAGE
49
trouble shoot & repair circuit. See OTC wiring
diagrams.
diagram.
Check wiring or replace motor.
diagram.
Reset circuit breaker on top of ramp motor
housing or check ramp fuse and replace if
needed with a 30amp fuse.
Check wiring or replace motor.
Start vehicle. Press OTC reset button and press
Rollx Vans user button again.
repair wiriing.
Replace door detector or trouble shoot & repair
Clear obstruction and reset OTC system.
Replace ramp motor.
PAGE
50
Item
1
2
3
4
5
6
7
8
9
10
11
12
11
2
3
8
10
9
Description
MOTOR RAMP (Does not include connector (OTC only)
CAM FOR PICK UP ARM ALUM
#8-32X1/4 CUP POINT SET SCREW
ROLLER CROWNED YOKE
5/16-18 X 1-1/4 BHSCS
5/16-18 X 1-1/4 FHSC
BEARING/BUSHING
RAMP LIMIT SWITCH ASM
SWITCH MINI SNAP ACTING
SWITCH SPACER STD RAMP
S/S PPHMS 4-40X1 1/2
#4 sae 5/16od z f/w
12
Qty.
1
2
2
1
1
4
1
1
2
1
2
2
1
19
18
24
Part #
K01325A350
RLXRP00CAM-ALUM
N/A
CY36L
1124072
1124257
SF-2432-8
03220-004
7779K62
RLXRPOO-14
72498
1133066
6
Item
13
14
15
16
17
18
19
19A
19B
20
21
21A
22
22
23
24
Qty.
2
1
1
1
3
1
2
2
2
1
1
1
1
1
1
1
20
5
13
16
4
21
Description
4-40 S/S NYLOK NUT
RAMP CABLE W/BALL SHANK,
BHSCS 5/16-18 X 7/8
5/16-18HX JAM Z
5/16-18 FLAT NYLON WASHERS
CB 10AMP RESETTABLE
HCS 3/8-24 X 1 YZ8
3/8 HI-ALLOY L/W YZ
3/8 USS F/W Z
WOODRUFF KEY, 3/16X3/4 FLAT BOTTOM
PICK UP ARM (RAMP)
1/4-20X3/8 CUP POINT SET SCREW
5/16-18X1 3/4 FHSCS
5/16-18X1 3/4 FHSCS*
5/16-18HX JAM Z
MOTOR COVER FOLD OUT RAMP
7
21A
14
17
15
Part #
1170854
RLXR1100
24070
1137023
76062
CB-PM3-10
18834
1133893
1133008
N/A
RLXR2005 (INCLUDES SET SCREW)
N/A
1124259
1124259
1136204
RLXR2011
22
RLXR1000-04-OTC / RLXR1000-04-MB / RLXR1000-04-NARROW-MB
FOLDING RAMP REPLACEMENT PARTS
9
PAGE
51
Item Qty.
1
1
2
1
3
3
4
3
5
3
6
3
7
6
8
2
9
2
10
2
3
Description
RAMP STANDARD (RAMP NARROW)
RAMP CABLE W/BALL SHANK,
CLAMP INSULATED 3/8"
1/4-20 X 1/2 BHSCS
1/4-20 NTE JAM NYLOK
10-32 X 3/4 BHSCS
#10 SAE F/W Z
1/4 HI-ALLOY L/W YZ
3/8 USS F/W Z
3/8-16 YZ8 NE NYLOCK
4
2
RAMP SIDE OF HINGE
VAN SIDE OF HINGE
10
14
12
5
7
18
6
Part #
RLXR4000 (RLXR4000N)
RLXR1100
8863T13
1124049
1137020
1124042
1133074
1133891
1133008
1137185
19
8
Item Qty.
11
1
12
12
13
1
14
1
15
4
15
4
15
1
16
0.4
17
1
18
12
19
1
RLXR1000-05-OTC / RLXR1000-05-MB / RLXR1000-05-NARROW-MB
11
RAMP BASE
1/4-20x5/8 BOLT (#12)
15
Description
HCS 1/4-20X1/2 YZ8 QPA
1/4-20X5/8 SS BUTTON HEAD CAP SCREW
HINGE, RAMP FOLDING W BOLTS
CABLE GUIDE (ROUND DISC)
RIVETS*
#4 sae 5/16od z f/w
RUBBER BULB SEAL BACK FOAM*
ANTI-RATTLE RUBBER URETH FOR (Motor Bar Only)*
HINGE UPPER RAMP FO PAINTED
1/4-20 KEPS NUT
Ramp Base Weldment Assembly
13
1
HINGE (#13)
Part #
0115001
10929-02786
RLRX4006
RLXR1025
97517A130
1133066
NX504B1
27036
RLXR1007
1137410
RLXR4003
* Not Shown
16
17
KEPS NUT (#19)
RAMP
RAMP HINGE AREA CROSS SECTION
1/4-20 KEPS NUT (#18)
9
10
FOLDING RAMP REPLACEMENT PARTS
PAGE
52
FOLDING RAMP MOTOR INSTALL / REMOVAL AND ADJUSTMENT
Folding Ramp Motor Install (steps 1-19)
Ramp Removal Instructions (steps 1-4 + 15-19)
1. Remove carpeted motor panel. This is held on by two Phillip head screws.
2. Disconnect wires going to limit switches and motor.
3. Unbolt ramp. There are two bolts (3/8) that go into the side of the van above ramp
motor and two nuts (3/8) on the floor of the van-one nut is by the motor and one nut
is by b-pillar.
4. Remove ramp from van.
5. Extend ramp so it is laying flat.
6. Remove roller from pick up arm. Also, remove cable bolt.
7. Remove set screw from pick up arm. Then insert 5/16 bolt into pick up arm to pull pick
up arm off of motor shaft. If this does not work, cut motor shaft with a saw and
punch out scrap piece from pick up arm.
8. Remove limit switches off of ramp.
9. Take out the four Allen head bolts (3/16) holding ramp motor. Remove motor.
10. Insert new motor. Reinstall the four Allen head screws with lock tight.
11. Reinstall limit switches.
12. Remove cams off of old motor and install on the new ramp motor. You will need to
adjust these cams at step 16.
13. Reinstall pick up arm. Line up pick up arm and key way. Ensure Woodruff key is all
the way inserted into the pick up arm.
14. Reinstall set screw (3/16) with lock tight.
15. Reinstall ramp in the van. Secure ramp with original hardware.
16. Install wiring for limit switches and motor.
17. Adjust ramp cams. Refer to Ramp Adjustment Instructions.
18. Test ramp for proper limit switch adjustment.
19. Reinstall carpeted motor cover.
Folding Ramp Adjustment Process
1. Bring folding ramp into the stow position so it resting in the van where you want it.
2. Remove carpeted motor panel. This is held on by two Phillip head screws.
3. Locate Adjustment Cam Set Screws and loosen.
4. Rotate the Up Limit Cam until it activates the Up Limit Switch and tighten set screw.
5. Push ramp out slowly and rest on something that is 6 inches off the ground as shown
below.
6. Rotate Down Limit Cam until it activates the Down Limit Switch and tighten set screw.
7. Test ramp for proper limit switch adjustment and reinstall carpeted motor cover.
6 Inches
PAGE
53
FOLDING RAMP MOTOR INSTALL / REMOVAL AND ADJUSTMENT
Resettable Circuit Breaker
3/8 Nut
Pick Up Arm Roller
Phillips Head Screws
3/8 Bolt
Cable Bolt
Adjustment Cam Set Screw
Down
Adjustment Cams
Set Screw
Backstop
Adjustment
Bolt
Up
Adjustment Cams
Limit Switches
3/8 Nut
PAGE
54
REAR HEAT & AIR
If the heat lines need to ship with the Rollx
Vans hose & clamp extensions, you will
need to order the following:
705-1012 (QTY 12)
770-1162 (QTY 2)
770-1157 (QTY 10)
10220
(QTY 1)
H-153
(QTY 4)
1131823 (QTY 13)
1137183 (QTY 13)
FRONT
CONNECTIONS
Hose Clamps
705-1012 (6)
Heater Hose
H-153 (2)
WELDED ENDS
OEM CONNECTORS
REAR HEAT & A/C
MODEL YEAR 2012-2016
REAR HEAT
CONNECTIONS
Hose Clamps
705-1012 (6)
Heater Hose
H-153 (2)
ASSEMBLIES
#B2100-REAR HEAT LINE 5/8” (2 PER)
#B01200-RASM - REAR A/C LINE 5/16”
#B01201-RASM - REAR A/C LINE ½”
O-RINGS INCLUDED IN A/C ASSEMBLIES:
#68125530AA - AFTERMARKET O-RING 5/16”
#68030834AA - AFTERMARKET O-RING ½”
REAR BLOWER
OEM CONNECTORS
WELDED ENDS
REAR
A/C CONNECTIONS
55
PAGE
PAGE
56
REMOTE SYSTEM TROUBLESHOOTING
* If remote does not work first try to operate door and ramp from any interior Rollx Vans user button. If interior Rollx Vans
user button operates normally, see below for remote system troubleshooting
Symptom
Possible Cause
Remedy
Receiver out of range.
Try remote within 10 feet of van.
Door does not open when One
Overhead on/off switch is turned to the OFF
Touch remote is pressed.
position.
Remote batteries are dead.
Replace batteries.
Locate fuse under glove box and check /
Blown fuse.
replace fuse.
Neither One Touch remote works.
Receiver malfunction.
Replace receiver.
Lost Programming.
Reprogram (See OTC remote system).
PAGE
57
REMOTE SYSTEM LOCATION & WIRING (COMPUSTAR 6200)
Compustar 6200
OTC Remote Receiver
(Behind Rear Passenger Quarter
Panel Above Rear Heat Unit)
OTC Remote Transmitter
OTC Remote Receiver
(Rear View)
BLUE LED
Indicator Light
ANTENNA
To PROGRAMING
SWITCH
POWER
To USER SWITCH
CR2016 Batteries
(X 2)
1BAMR-ASM
ASM #03295-003
FUSE PANEL
(BEHIND GLOVE BOX)
1 AMP
REMOTE
Version 8
1 AMP
DOOR DETECTOR
1 AMP
CONTROLLER PWR
Nuetral
Safety
To Rollx Vans user
switches
Ignition
Hot
BK (8 GA.)
40A
FUSE
RD (8 GA.)
+
-
CM6200
Programming switch
BK
RD (14 GA.)
DB
ASM #03220-005
DB (20 GA.)
BK (20 GA.)
PROGRAMING SWITCH
ASM #03295-003
ANTENNA RUNS
UP PASSENGER
“D” PILLAR
Programming the Rollx Vans OTC Remote
*Shut off the OTC controller
*Activate the programming mode by pushing the button on the left side of the OTC
controller (PROGRAMMING SWITCH) 5 times within 7 seconds.
* Within 2 seconds after pushing the button 5 times, press the single remote button for .5
Seconds. Wait 30 seconds and press the remote to operate the system.
*Repeat the sequence if programming an additional remote.
PAGE
58
REMOTE SYSTEM LOCATION & WIRING (COMPUSTAR 7200)
Compustar 7200 with Flashing Lights
OTC Remote Receiver
(Behind Rear Passenger Quarter
Panel Above Rear Heat Unit)
OTC Remote Transmitter
OTC Remote Receiver
(Rear View)
BLUE LED
Indicator Light
Antenna
To User Switch
To PROGRAMING
SWITCH
POWER
Park Light Flashers
Ground
CR2016 Batteries
(X 2)
1BAMR-ASM
ASM #03295-003
FUSE PANEL
(BEHIND GLOVE BOX)
5 AMP
1 AMP
REMOTE
Version 8
Nuetral
Safety
To Rollx Vans user
switches
Ignition
Hot
BK (8 GA.)
40A
BK (20 GA.)
DB
BK
GN /WT (CAV 17)
BK(CAV 8)
GN(CAV 7)
WT/VT (20 GA.)
GNWT(CAV 2)
Tap into wire inside the van
RD(CAV 1)
CM
00
72
ASM #03295-003
Park Lamp Feed
(Right Rear Taillight)
ANTENNA RUNS
UP PASSENGER
“D” PILLAR
Programming the Rollx Vans OTC Remote
*Shut off the OTC controller.
*Activate the programming mode by pushing the button on the left side of the OTC
controller (PROGRAMMING SWITCH) 5 times within 7 seconds.
* Within 2 seconds after pushing the button 5 times, press the single remote button for .5
Seconds. Wait 30 seconds and press the remote to operate the system.
PAGE
+
59
-
Programming switch
ASM #03220-005
DB (20 GA.)
PROGRAMING SWITCH
RD (14 GA.)
FUSE
RD (8 GA.)
SEAT DETECTOR LOCATION & DESCRIPTION
Seat Detector Location
Seat Detector Description
The Rollx Vans Seat Detector essentially simulates the functionality of a driver or passenger front seat
in the event where the seats are disconnected from the van (FIG A & B).
The simulated functions are:
Seat Belt Buckle Switches
*Seat Position Sensors
*Seat Belt Retractors
*Seat Thorax
*Active HeadRests
*Occupant Detection
FIG A
FIG B
Passenger’s Seat Plug
Driver’s Seat Plug
PAGE
60
61
8
1
10
1
2.4 OHM
510 ohm
TO CIGARETE LIGHTER
Body Side Wire
Body Side
BK (20 GA.) - CAV 1
m
1K
RD (20 GA.)
GN (20 GA.)
2.4 OHM
510
oh
PAGE
Seat Detector Plugs
YL/GN (20 GA.) - CAV 17
25 A
(FUSED B+)
ROLLX VANS CIRCUIT BREAKER
WT (20 GA.)
OR/RD (12 GA.)
LG/GY (18 GA.) - CAV 21 (LEFT SEAT THORAX SQUIB 1 LINE1)
LG/DG (18 GA.) - CAV 19 (DR. SEAT BELT RETRACTOR TENSIONER LINE 1)
LB/VT (18 GA.) - CAV 20 (LEFT SEAT THORAX SQUIB 1 LINE 2)
LG/YL (18 GA.) - CAV 18 (DR. SEAT BELT RETRACTOR TENSIONER LINE 2)
LG/GY (20 GA.) - CAV 6 (SEAT BELT BUCKLE SWITCH)
BK/RD (20 GA.) - CAV 5 (HEAD REST OUT)
LB/VT (20 GA.) - CAV 3 (SEAT POSITION SENSOR VOLTAGE)
PK/WT (20 GA.) - CAV 4 (HEAD REST IN)
LB/WT (20 GA.) - CAV 2 (SEAT POSITION SENSOR DATA)
(GROUND)
(Seat sensor wire for seat detector)
21
TO PASSENGER SIDE
SEAT PLUG
BODY SIDE CONNECTOR #A16031-ND
Pins: A25032-ND QTY 1
A1650-ND QTY 4
20
19
3
8
15
22
1
14
2
9
4
TOP
Updated on 6/19/2015
2011-2016 Chrysler Minivan
C376/I405 Driver Side with MANUAL SEAT With Seat Detector
BODY SIDE
2011-2016
DRIVER ’S SIDE MANUAL
62
FRONT VIEW
1
om
Fr
OE
M
15
22
20
PINS: A1661-ND QTY 7
A1341-ND QTY 4
# A16037-ND
SEAT SIDE CONNECTOR
21
15
19
2
4
SEAT SENSOR JUMPER
TOP
9
1
BK (20 GA.) - CAV 17
3
8
14
BK/RD (20 GA.) - CAV 1 (GROUND)
C376/I405 Driver Seat with MANUAL SEAT - With Seat Detector
SEAT SIDE
4
10
18
24
1
5
11
19
PAGE
4
2011-2016
DRIVER ’S SIDE MANUAL
PAGE
63
8
1
10
1
Body Side Wire
510 ohm
2.4 OHM
m
Seat Detector Plugs
RD (20 GA.)
(GROUND)
25 A
OR/RD (12 GA.)
RELOCATED OEM CIRCUIT BREAKER
RD (12 GA.)
(FUSED B+)
BK (12 GA.) - CAV 1
YL/GN (20 GA.) - CAV 17
RD (12 GA.)
2.4 OHM
510
oh
Body Side
1K
TO PASSENGER SIDE
SEAT PLUG
RD (12 GA.) - CAV 22
OR/RD (12 GA.)
21
BODY SIDE CONNECTOR # A 16031-ND
A1650-ND QTY 4
20
19
3
8
15
22
1
14
2
9
4
TOP
C376/I405 Driver Side with POWER ONLY - With Seat Detector
BODY SIDE
2011-2016
DRIVER ’S SIDE POWER ONLY
64
FRONT VIEW
(GROUND)
SEAT SENSOR JUMPER
BK (20 GA.) - CAV 17
RD (12 GA.)
- CAV 22
(FUSED B+)
BK (12 GA.) - CAV 1
3
22
1
TOP
20
A1661-ND QTY 6
A1341-ND QTY 4
# A16037-ND
9
15
2
4
SEAT SIDE CONNECTOR
21
19
8
14
C376/I405 Driver Seat with POWER ONLY - With Seat Detector
SEAT SIDE
4
10
18
24
1
5
11
19
1
PAGE
4
2011-2016
DRIVER ’S SIDE POWER ONLY
PAGE
65
8
1
10
1
Body Side Wire
510 ohm
2.4 OHM
BK (12 GA.) - CAV 1
m
1K
RD (20 GA.)
RD (12 GA.)
2.4 OHM
510
oh
Body Side
Seat Detector Plugs
YL/GN (20 GA.) - CAV 17
25 A
OR/RD (12 GA.)
RD (12 GA.)
(FUSED B+)
GY/DB (20 GA.) - CAV 15 (HEATED STEERING WHEEL RETURN)
LG/VT (20 GA.) - CAV 14 (RIGHT FRONT SEAT HEATER CONTROL)
PK/YL (20 GA.) - CAV 13 (FUSED OUTPUT)
DB/LG (20 GA.) - CAV 12 (HEATED STEERING WHEEL FEED)
TN/WT (20 GA.) - CAV 11 (HEATED SEAT SENSOR RETURN)
WT/GY (20 GA.) - CAV 9 (CAN BUS +)
TN/DB (20 GA.) - CAV 10 (R.F. HEATED SEAT TEMP SENSE)
WT/OR (20 GA.) - CAV 8 (CAN BUS -)
LG/WT (20 GA.) - CAV 7 (HEATED SEAT MODULE SUPPLY)
(GROUND)
2
22
1
TO PASSENGER SIDE
SEAT PLUG
RD (12 GA.) - CAV 22
OR/RD (12 GA.)
21
19
14
3
8
BODY SIDE CONNECTOR # A 16031-ND
A1650-ND QTY 4
20
15
9
4
TOP
C376/I405 Driver Side with POWER & HEAT - With Seat Detector
BODY SIDE
2011-2016
DRIVER ’S SIDE POWER & HEAT
66
FRONT VIEW
(GROUND)
NOTE: OEM wires that are eliminated/ do not run through the harness:
OEM CAV 4 (LG/GY)
OEM CAV 13 (TN/OR)
OEM CAV 14 (OR/RD)
OEM CAV 18 (TN/YL)
OEM CAV 19 (LG/GY)
RD (12 GA.)
- CAV 22
(FUSED B+)
BK (20 GA.) - CAV 17 (SEAT SENSOR JUMPER)
GY/DB (20 GA.) - CAV 15 (HEATED STEERING WHEEL RETURN)
PK/YL (20 GA.) - CAV 13 (FUSED OUTPUT)
DB/LG (20 GA.) - CAV 12 (HEATED STEERING WHEEL FEED)
TN/DB (20 GA.) - CAV 10 (R.F. HEATED SEAT TEMP SENSE)
LG/WT (20 GA.) - CAV 7 (HEATED SEAT MODULE SUPPLY)
BK (12 GA.) - CAV 1
22
1
TOP
20
A1661-ND QTY 12
A1341-ND QTY8
# A16037-ND
9
15
2
4
SEAT SIDE CONNECTOR
21
19
8
14
3
C376/I405 Driver Seat with POWER AND HEAT - With Seat Detector
SEAT SIDE
4
10
18
24
1
5
11
19
1
PAGE
4
2011-2016
DRIVER ’S SIDE POWER & HEAT
Seat Detector Plugs
Cut off from (BLACK)
Memory plug
8
1
10
1
Cut off of YL plug coming
from under the seat
Cut off of WT plug coming
from under the seat
51
0
m
oh
1
K
51
0
oh
m
Cut/Twist & Heat shrink
Body Side Wire
HM
(SEAT BELT BUCKLE SWITCH)
(R.F. HEATED SEAT TEMP SENSE)
(FUSED OUTPUT)
(SEAT BELT RETRACTOR TENSIONER LINE 2)
(HEATED STEERING WHEEL RETURN)
(RT. FRONT SEAT HEATER CONTROL)
(ADJUSTABLE PEDALS MORTOR FORWARD)
sensor wire for seat detector)
RD (20 GA.)
RD (12 GA.)
(SENSOR GROUND)
VT/GY (20 GA.) - CAV 27
BK (12 GA.) - CAV3
BK (12 GA.) - CAV3
(GROUND)
(FUSED B+)
RD (12 GA.)
25 A
2
3
1
RD (12 GA.) - CAV 1
TO PASSENGER SIDE
SEAT PLUG
OR/RD (12 GA.)
BODY SIDE CONNECTOR # A1364-ND
A1341-ND QTY 4
23
29
34
28
33
37
1
5
10
16
TOP
9
15
22
4
BODY SIDE
OR/RD (14 GA.) - CAV 2
OR/RD (12 GA.)
(ADJUSTABLE PEDAL SENSOR )
VT/LB (20 GA.) - CAV 26
GN/LB (20 GA.) - CAV 23 (ADJUSTABLE PEDALS MORTOR REARWARD)
GN/WT (20 GA.) - CAV 22
YL/GN (20 GA.) - CAV 21 (Seat
LG/GY (18 GA.) - CAV 20 (THORAX SQUIB 1 LINE 1)
LG/DG (18 GA.) - CAV 18 (SEAT BELT RETRACTOR TENSIONER LINE 1)
LB/VT (18 GA.) - CAV 19 (THORAX SQUIB 1 LINE 2)
LG/YL (18 GA.) - CAV 17
GY/DB (20 GA.) - CAV 16
LG/VT (20 GA.) - CAV 15
PK/YL (20 GA.) - CAV 14
LB/VT (20 GA.) - CAV 12 (SEAT POS SENSOR VOLTAGE)
DB/LG (20 GA.) - CAV 13
(HEATED STEERING WHEEL)
LB/WT (20 GA.) - CAV 11 (SEAT POS SENSOR DATA)
(HEAD REST GROUND)
(HEAD REST DR. SOLENOID)
(HEATED SEAT SENSOR RETURN)
BK/RD (20 GA.) - CAV 10
PK/WT (20 GA.) - CAV 9
TN/WT (20 GA.) - CAV 8
OR/LG (20 GA.) - CAV 7 (ADJUSTABLE PEDAL SWITCH REARWARD)
LG/GY (20 GA.) - CAV 6
TN/DB (20 GA.) - CAV 5
(HEATED SEAT MODULE SUPPLY)
(ADJUSTABLE PEDAL SWITCH FORWARD)
OR/LB (20 GA.) - CAV 2
LG/WT (20 GA.) - CAV 1
C376/
I405 Drivers Side with POWER & HEAT & MEMORY With Seat Detector
HM
O
2.
4
67
O
PAGE
2.
4
2011-2016
DRIVER ’S SIDE MEMORY
68
13
11
9
7
5
3
1
4
PAGE
1
8
6
4
2
14
12
10
1
5
11
19
4
10
18
24
FRONT VIEW
(SEAT BELT BUCKLE SWITCH)
(R.F. HEATED SEAT TEMP SENSE)
LG/YL (18 GA.) - CAV 17
(ADJUSTABLE PEDALS MORTOR FORWARD)
(SEAT SENSOR JUMPER)
BK (12 GA.) - CAV3
BK (12 GA.) - CAV3
RD (12 GA.) - CAV 1
(GROUND)
1
9
15
22
28
33
37
4
SEAT SIDE CONNECTOR
3
2
#A16019-ND
PINS: A25032-ND 3 per van
1
A1661-ND QTY18
SEAT SIDE CONNECTOR
# A 1359-ND
23
29
34
5
10
16
TOP
SEAT SIDE
OR/RD (14 GA.) - CAV 2
(SENSOR GROUND)
VT/GY (20 GA.) - CAV 27
(FUSED B+)
(ADJUSTABLE PEDAL SENSOR )
VT/LB (20 GA.) - CAV 26
GN/LB (20 GA.) - CAV 23 (ADJUSTABLE PEDALS MORTOR REARWARD)
GN/WT (20 GA.) - CAV 22
BK (20 GA.) - CAV 21
LG/GY (18 GA.) - CAV 20 (THORAX SQUIB 1 LINE 1)
LG/DG (18 GA.) - CAV 18 (SEAT BELT RETRACTOR TENSIONER LINE 1)
LB/VT (18 GA.) - CAV 19 (THORAX SQUIB 1 LINE 2)
(HEATED STEERING WHEEL RETURN)
(RT. FRONT SEAT HEATER CONTROL)
(FUSED OUTPUT)
(SEAT POS SENSOR VOLTAGE)
(HEATED STEERING WHEEL)
GY/DB (20 GA.) - CAV 16
LG/VT (18 GA.) - CAV 15
PK/YL (16 GA.) - CAV 14
LB/VT (20 GA.) - CAV 12
DB/LG (20 GA.) - CAV 13
LB/WT (20 GA.) - CAV 11 (SEAT POS SENSOR DATA)
(HEAD REST GROUND)
(HEAD REST DR. SOLENOID)
BK/RD (20 GA.) - CAV 10
PK/WT (20 GA.) - CAV 9
TN/WT (20 GA.) - CAV 8
OR/LG (20 GA.) - CAV 7 (ADJUSTABLE PEDAL SWITCH REARWARD)
LG/GY (20 GA.) - CAV 6
TN/DB (20 GA.) - CAV 5
NOTE: OEM wires that are eliminated/ do not run through the harness:
OEM CAV 4 (LG/GY)
(HEATED SEAT MODULE SUPPLY)
LG/WT (20 GA.) - CAV 1
OEM CAV 13 (TN/OR)
OEM CAV 14 (OR/RD)
(ADJUSTABLE PEDAL SWITCH FORWARD)
OR/LB (20 GA.) - CAV 2
OEM CAV 18 (TN/YL)
OEM CAV 19 (LG/GY)
C376/
I405 Drivers Seat with POWER & HEAT-& MEMORY With Seat Detector
2011-2016
DRIVER ’S SIDE MEMORY
8
1
10
1
From Drivers
Side seat
OR/RD (12 GA.)
Body Side
Wires
YL/GN (20 GA.) - CAV 17
2.4 OHM
m
m
2.4 OHM
GY/LG (18 GA.) - CAV 21
LB/DG (18 GA.) - CAV 19
VT/LB (18 GA.) - CAV 20
LB/YL (18 GA.) - CAV 18
LB/LG (20 GA.) - CAV 9
(SEAT THORAX SQUIB 1 LINE 1)
(SEAT OCCUPANT DETECTION RETURN)
(SEAT OCCUPANT DETECTION SIGNAL)
LB/GY (20 GA.) - CAV 7
LB/DG (20 GA.) - CAV 8
(SEAT BELT BUCKLE SWICHT SENSE)
(SEAT BELT SWITCH SENSE)
(HEAD REST GROUND)
(PASS SEAT POS SENSOR DATA)
(HEAD REST PASS SOLENOID +)
VT/LB (20 GA.) - CAV 3
PK/DB (20 GA.) - CAV 4
LB/TN (20 GA.) - CAV 6
(PASS SEAT POS SENSOR VOTAGE)
BK (12 GA.) CAV 1
WT/LB (20 GA.) - CAV 2
BK/RD (20 GA.) - CAV 5
(GROUND)
21
A1650-ND QTY 4
20
19
3
8
15
22
1
14
2
9
4
TOP
C378 Passenger Side with MANUAL SEAT With Seat Detector
BODY SIDE (NO OCCUPANT DETECTION CIRCUIT)
1K
To Chassis
GND
Seat Detector Plugs
69
510
oh
PAGE
510
oh
2011-2012
PASSENGER ’S SIDE MANUAL
70
7
1
1
PAGE
4
14
8
BK (20 GA.) - CAV 17
LB/DG (18 GA.) - CAV 19
VT/LB (18 GA.) - CAV 20
GY/LG (18 GA.) - CAV 21
LB/YL (18 GA.) - CAV 18
(HEAD REST GROUND)
22
20
PINS: A1661- ND QTY 9
A1341- ND QTY 4
# A16037-ND
SEAT SIDE CONNECTOR
21
15
2
4
19
TOP
9
1
8
14
3
Updated on 6/3/2014
C378 Passenger Seat with MANUAL - With Seat Detector
SEAT SIDE
2011-2012
71
2.4 OHM
8
RD (20 GA.) - CAV 22
OR/RD (14 GA.) - CAV 22
GY/LG (18 GA.) - CAV 21
(FUSED B+)
2.4 OHM
1
LB/YL (18 GA.) - CAV 18
TN/DB (20 GA.) - CAV 12 (RIGHT FRONT HEATED SEAT TEMP SENSE)
LB/LG (20 GA.) - CAV 9 (SEAT OCCUPANT DETECTION RETURN)
LB/DG (20 GA.) - CAV 8 (SEAT OCCUPANT DETECTION SIGNAL)
(HEAD REST GROUND)
(GROUND)
LB/DG (18 GA.) - CAV 19 (SEAT BELT RETRACTOR TENSIONER LINE 1)
VT/LB (18 GA.) - CAV 20
1K
510 ohm
m
10
1
OR/RD (14 GA.)
From Drivers
Side seat
Body Side
Wires
BK (12 GA.) - CAV 1
YL/GN (20 GA.) - CAV 17
2
22
1
21
19
14
3
8
A1650-ND QTY 4
20
15
9
4
TOP
C378 Passenger Side with POWER & HEAT - With Seat Detector
BODY SIDE
(NO OCCUPANT DETECTION CIRCUIT)
Seat Detector Plugs
PAGE
510
oh
2011- (EARLY) 2012
PASSENGER ’S SIDE POWER & HEAT
72
14
8
(GROUND)
(HEAD REST GROUND)
LB/YL (18 GA.) - CAV 18
GY/LG (18 GA.) - CAV 21
(FUSED B+)
BK (20 GA.) - CAV 17
(RIGHT FRONT HEATED SEAT TEMP SENSE)
(RIGHT FRONT SEAT HEATER CONTROL)
OR/RD (14 GA.) - CAV 22
TN/DB (20 GA.) - CAV 12
LG/VT (20 GA.) - CAV 11
LB/DG (18 GA.) - CAV 19
VT/LB (18 GA.) - CAV 20
BK (12 GA.) - CAV 1
22
20
A1341- ND QTY 5
A25033-ND QTY 2
# A16037-ND
SEAT SIDE CONNECTOR
21
15
2
4
19
TOP
9
1
8
14
3
Updated on 6/3/2014
C378 Passenger Seat with POWER & HEAT - With Seat Detector
SEAT SIDE
7
1
1
PAGE
4
2011- (EARLY)2012
73
2.4 OHM
8
1K
RD (20 GA.) - CAV 22
OR/RD (14 GA.) - CAV 22
GY/LG (18 GA.) - CAV 21
(FUSED B+)
2.4 OHM
1
LB/YL (18 GA.) - CAV 18
LB/LG (20 GA.) - CAV 9 (SEAT OCCUPANT DETECTION RETURN)
(HEAD REST GROUND)
(GROUND)
VT/LB (18 GA.) - CAV 20
1K
510 ohm
m
10
1
OR/RD (14 GA.)
From Drivers
Side seat
Body Side
Wires
BK (12 GA.) - CAV 1
YL/GN (20 GA.) - CAV 17
2
22
1
21
19
14
3
8
A1650-ND QTY 4
20
15
9
4
TOP
C378 Passenger Side with POWER & HEAT - With Seat Detector
BODY SIDE (W/ OCCUPANT DETECTION CIRCUIT)
Seat Detector Plugs
PAGE
510
oh
2011- (LATE) 2012
74
14
8
(GROUND)
LG/VT (20 GA.) - CAV 11
LB/YL (18 GA.) - CAV 18
GY/LG (18 GA.) - CAV 21
(FUSED B+)
OR/RD (14 GA.) - CAV 22
BK (20 GA.) - CAV 17
TN/WT (20 GA.) - CAV 10
TN/DB (20 GA.) - CAV 12
(HEAD REST GROUND)
LB/DG (18 GA.) - CAV 19
VT/LB (18 GA.) - CAV 20
BK (12 GA.) - CAV 1
22
20
A1341- ND QTY 5
A25033-ND QTY2
# A16037-ND
SEAT SIDE CONNECTOR
21
15
2
4
19
TOP
9
1
8
14
3
Updated on 6/3/2014
C378 Passenger Seat with POWER & HEAT - With Seat Detector
SEAT SIDE (W/ OCCUPANT DETECTION CIRCUIT)
7
1
1
PAGE
4
2011-(LATE) 2012
2.4 OHM
(HEAD REST GROUND)
LB/YL (18 GA.) - CAV 18
LB/TN (20 GA.) - CAV 9 (SEAT OCCUPANT DETECTION RETURN)
(GROUND)
BK (12 GA.) - CAV 1
8
1K
RD (20 GA)
RD (20 GA.) - CAV 22
OR/RD (14 GA.) - CAV 22
GY/LG (18 GA.) - CAV 21
2
22
1
21
19
14
3
8
20
15
9
4
TOP
Stock # 47055 was the 1st van
with LB/TN in CAV 9
Vans built prior to 10/10/2012 have
the LB/TN in CAV6 NOT CAV 9
(FUSED B+)
2.4 OHM
1K
510 ohm
YL/GN (20 GA.) - CAV 17
1
75
VT/LB (18 GA.) - CAV 20
1
PAGE
10
OR/RD (14 GA.)
Seat Detector Plugs
From Drivers
Side seat
Body Side
Wires
To Chassis
GND
I406/C378 Passenger Side with MANUAL- With Seat Detector
2013-2016
14
7
8
1
PAGE
76
BK (20 GA.) - CAV 17
GY/LG (18 GA.) - CAV 21
20
PINS: A1661- ND
A1341- ND
# A16037-ND
QTY 6
QTY 4
SEAT SIDE CONNECTOR
21
22
2
4
15
TOP
19
1
9
3
8
14
with LB/TN in CAV 9
LB/DG (18 GA.) - CAV 19
VT/LB (18 GA.) - CAV 20
LB/YL (18 GA.) - CAV 18
(HEAD REST GROUND)
I406A/C378 Passenger Seat with MANUAL - With Seat Detector
SEAT SIDE
2013-2016
2.4 OHM
LB/YL (18 GA.) - CAV 18
8
1K
RD (20 GA)
RD (20 GA.) - CAV 22
OR/RD (14 GA.) - CAV 22
GY/LG(18 GA.) - CAV 21
2
22
1
21
19
14
3
8
20
15
9
4
TOP
with LB/TN in CAV 9
(FUSED B+)
2.4 OHM
LB/TN (20 GA.) - CAV 9 (SEAT OCCUPANT DETECTION RETURN)
1
1K
510 ohm
(HEAD REST GROUND)
(GROUND)
VT/LB (18 GA.) - CAV 20
1
77
10
OR/RD (14 GA.)
From Drivers
Side seat
Body Side
Wires
BK (12 GA.) - CAV 1
YL/GN (20 GA.) - CAV 17
I406/C378 Passenger Side with POWER & HEAT - With Seat Detector
PAGE
Seat Detector Plugs
2013-2016
14
7
PAGE
78
8
1
LG/VT (20 GA.) - CAV 11
GY/LG (18 GA.) - CAV 21
(FUSED B+)
LB/YL (18 GA.) - CAV 18
OR/RD (14 GA.) - CAV 22
20
A1341- ND QTY 4
A25033-ND QTY 2
# A16037-ND
SEAT SIDE CONNECTOR
21
22
2
4
15
TOP
19
1
9
3
8
14
with LB/TN in CAV 9
BK (20 GA.) - CAV 17
TN/WT (20 GA.) - CAV 10
TN/DB (20 GA.) - CAV 12
(HEAD REST GROUND)
(GROUND)
LB/DG (18 GA.) - CAV 19
VT/LB (18 GA.) - CAV 20
BK (12 GA.) - CAV 1
I406A/C378 Passenger Seat with POWER & HEAT - With Seat Detector
SEAT SIDE
2013-2016
OTC WIRING
(WITH THE DOOR OPEN LIMIT SWITCH)
ROLLX VANS ONE TOUCH CON
ITF Harness V6/ OTC Board V8 MO
KNEEL DISABLE (ON / OFF) SWITCH
(ASM #03220-001)
VT
N/C
VT (20 GA.)
1
N/C
DB / YL (20 GA.)
AUX I/O
4
TIPM
(Fuse box
under hood)
BK
DB / YL (20 GA.)
BK (20 G
BK (20 GA.)
CUT
WT/OR
BLACK
BLACK
BACK SIDE
SHUNT, 2005 HONDA
CAN BUS
#WM4814-ND-H ASM
1
1
WT/GY (CAV 12)
WT/GY
N/C
DOOR DISABLE
16
WT/OR
WT/GY
WT/OR (CAV 5)
(Chrysler Door Ajar Circuit)
N/C
BK (10 GA.)
N/C
(User switch)
(Neutral Safety)
(Door Open Limit)
(Door Closed Limit)
DB (20 GA.)
14
DG (20 GA.)
BACK SIDE
VT/YL (CAV 11)
WT / RD (20 GA.)
WT / RD (20 GA.)
BLACK
INPUTS
DMRR
Door Module Right Rear
Passenger’s side Door snake
(B-Pillar)
Twisted pairs run down B-Pillar
OR / RD (20 GA.)
VT / YL (20 GA.)
N/C
RD / DG (20 GA.)
RD / WT (20 GA.)
YL / DG (20 GA.)
1
RD
(20 GA.)
RD / BK (20 GA.)
YL / BK (20 GA.)
YL / RD (20 GA.)
BLACK
12
OUTPUTS
RD / W
YL / WT (20 GA.)
N/C
BACK SIDE
16
RES
N/C
RD
YL /
YL/RD
RD / DB (20 GA.)
1
(Unlock Output)
LG / WT (20 GA.)
BK
RAMP MOTOR
RD/DB
(Unlock Output)
OR (20 GA.)
N/C
(OEM CAV #1)
BK
BK
BLACK
6
5
1
(OEM CAV #4) PASSENGER DOOR MODULE
(Rollx Vans uses this to
unlock the door)
RD (12 GA.)
YL (12 GA.)
4
1
OEM B-PILLAR SWITCH
operate the door)
* = For pictures of location see
Important Information and Location
Section in Service Manual
BK GY
(-) (+)
KNEEL SYSTEM
Italic Font = OEM Wire
SCALE:
NONE
Rollx Vans, Inc.
DRAWING #:
12361
6591 West Highway 13
REVISION:
10
V-8.00 My11 Chrysler
UP LIMIT
YL / WT
DRAWN BY:
Jason Hodgkins
952.890.7851
Lynn Ringdahl
COPYRIGHT 2008
2
2
NC
NO
NC
1
1
NO
3
3
COM
Savage, MN 55378
CHECKED BY:
SWITCHES
* KNEEL LIMIT
(#6X284)
DOWN LIMIT
COM
BK
YL / DG
BK
RD (12 GA.)
REVISION HISTORY:
08330-001 INITIAL RELEASE. 11/25/2008
YL (12 GA.)
PAGE
79
OTC WIRING
(WITH THE DOOR OPEN LIMIT SWITCH)
NTROLLER WIRING DIAGRAM
OD E-F (W/ Limit Switch)
Compustar Remote
ROLLX VANS USER / RESET SWITCHES
(ASM #03220-005)
D-PILLAR
DASH
SET SWITCH (8/21/06)
12/27/12
BUILT BEFORE 8/26/2013
DASH
C-PILLAR
ITF RAMP OVERRIDE SWITCH
(DRIVER SIDE B PILLAR) #05175-001
BK
DB
BK
DB
BK
DB
OUT
BK
DB
DB (20 GA.)
DB (20 GA.)
IN
BK (20 GA.)
BK (20 GA.)
GA. X 3)
BK (20 GA.)
BK (20 GA. X 3)
14
OR (20 GA.)
C309
7
WT / RD (20 GA.) X 3
*
FUSE PANEL
(BEHIND GLOVE BOX)
1N4007
DIODES
1 AMP
REMOTE
1 AMP
DOOR DETECTOR
1 AMP
CONTROLLER PWR
BL (20 GA.)
RD (20 GA.)
8
1
Nuetral
Safety
WT / RD (20 GA.)
Ignition
Hot
WT / RD (20 GA.)
BK (8 GA.)
40A
FUSE
11DQ05-ND
DIODE
DG (20 GA.)
UP
LIMIT
/ BK
D
COM
BK
SWITCHES
* RAMP LIMIT
(#6X284)
RD (14 GA.)
COM
NO
BK (20 GA.)
3
RD (10 GA.)
RD
D / BK
3
2
GN/DB
(OEM CAV 9)
DB
1
4
8
13
17
21
3
7
NC
OR/RD (20 GA.)
BK (20 GA.)
NO
D
Neutral Safety
2
1
1
N
R
P
12
16
20
23
BK
#310-1059
Rollx Vans Remote Reciever
ASM #03220-005
RD (-)
YL (+)
*RELAY BOARD #OTCV8 RELAY BD
CM6200
ITF RAMP
# 08044-002
J1
J2
RD (10 GA.)
RAMP DN
KNL DN
OUTPUTS
INPUTS
OR (20 GA.)
RD (20 GA.)
BL (20 GA.)
PWR OVERRIDES
ANTENNA RUNS
UP PASSENGER
“D” PILLAR
BA
RAMP
ENABLE
ASM #03295-003
YL (12 GA.)
6
KNL UP
BK (12 GA.)
BK (10 GA.)
RAMP UP
2
NC
NO
1
3
COM
GND (To Body)
DOOR OPEN LIMIT SWITCH
(Passenger side lower door track)
BK (12 GA.)
RD (12 GA.)
PAGE
80
POWER OVERRIDE BUS
2
NC
DB (20 GA.)
WT (20 GA.)
-
+
*(To Inition Hot)
located under
steering column
RD / DG (20 GA.)
DOWN
LIMIT
RD (8 GA.)
OTC WIRING
(WITH THE DOOR DETECTOR)
ROLLX VANS ONE TOUCH C
LOCATION:
Passengers D-PILLAR
12
N/C
(Door Closed Status In)
BACK SIDE
*UNIVERSAL DOOR
DETECTOR
(13104-001ASM)
VT (20 GA.) (QUAD B + IN)
4
BL (20 GA.) (QUAD A + IN)
PK (20 GA.) (GND)
N/C
1
LOCATION:
OR/RD (20 GA.) (Door Open Status out) Passengers C-PILLAR
1
BL/YL (20 GA.) (Reset)
BK (20 GA.)
(GND)
(ASM #03220-001)
(V BAT)
VT
BK
TIPM
(Fuse box
under hood)
4
N/C
BK (20 GA.)
VT (20 GA.)
DB / YL (20 GA.)
N/C
1
CUT
Twisted pairs run down B-Pillar
16
Solder
(Chrysler Door Ajar Circ
LOCATION:
Passengers B-PILLAR Solder
WT/OR (20GA.)
BLACK
16
BLACK
LB/VT (20GA.)
LB/WT (20GA.)
N/C
BACK SIDE
DOOR DISABLE
SHUNT, 2005 HONDA
CAN BUS
#WM4814-ND-H ASM
WT/OR (CAV 5)
WT/GY (20GA.)
N/C
1
PSDMR
Power Sliding Door Module
N/C
BK (10 GA.)
DB (20 GA.)
1
BLACK
14
BACK SIDE
(User switch)
(Neutral Safety)
GN (20 GA.)
N/C
INPUTS
WT/GY (CAV 12)
WT / RD (20 GA.)
WT / RD (20 GA.)
OR / RD (20 GA.)
(Door Open Limit)
VT / YL (20 GA.)
(Door Closed Limit)
SWITCHE
* RAMP LIMIT
(#6X284)
RD / DG (20 GA.)
RD / WT (20 GA.)
N/C
2
NC
NO
YL / DG (20 GA.)
2
UP
LIMIT
DOWN
LIMIT
1
3
COM
YL / WT (20 GA.)
3
BK (20 GA.)
BACK SIDE
YL/RD
(Door Control)
RD/DB
6 PASSENGER DOOR MODULE
10
N/C
1
5
LG / WT (20 GA.)
(Unlock Output)
(VT/YL)
BK
BK
BLACK
unlock the door)
(OEM CAV #4)
LOCATION:
Passenger front door
BK
1
RAMP MOTOR
RD
RD / B
YL / BK
YL / BK (20 GA.)
YL / RD (20 GA.)
OR (20 GA.)
RD / DB (20 GA.)
BLACK
OUTPUTS
12
N/C
BK GY
(-) (+)
(CAV #1)
RD (12 GA.)
N/C
YL (12 GA.)
ECN # 13196
Rollx Vans, Inc.
Effective Stock # 47397
Effective Start Date: 8/26/2013
Savage, MN 55378
DRAWING #: 13266
952.890.7851
DRAWN BY:
COPYRIGHT 2008
Jason Hodgkins
1
4
KNEEL SYSTEM
OEM B-PILLAR SWITCH
operate the door)
YL / WT
UP LIMIT
SWITCHES
* KNEEL LIMIT
(#6X284)
DOWN LIMIT
2
2
NC
NO
BK
NC
1
1
NO
3
3
COM
COM
BK
YL / DG
RD (12 GA.)
REVISION HISTORY:
08330-001 INITIAL RELEASE. 11/25/2008
YL (12 GA.)
PAGE
81
NO
COM
RD
(20 GA.)
RD / BK (20 GA.)
1
NC
1
OTC WIRING
(WITH THE DOOR DETECTOR)
9/23/2013
CONTROLLER WIRING DIAGRAM
OD F (W/ Door Detector)
BUILT BETWEEN:
8/26/2013 - 3/17/2014
(ASM #03220-005)
DASH
RESET SWITCH (8/21/06)
4
DB
BK
D-PILLAR
DB
DASH
C-PILLAR
BK
BK
DB
BK
DB
1
DB (20 GA.)
BK (20 GA.)
ITF RAMP OVERRIDE
SWITCH
(DRIVER SIDE B
PILLAR) #05175-001
BK (20 GA.)
OUT
LOCATION:
Back side of the lower slider door track
BK (20 GA. X 3)
e Right
BK (20 GA. X 3)
DB / YL (20 GA.)
DMRR
* FUSE PANEL
(BEHIND GLOVE BOX)
1 AMP
REMOTE
1 AMP
IN
DOOR DETECTOR
1 AMP
CONTROLLER PWR
7
cuit)
14
(B-Pillar)
OR (20 GA.)
Nuetral
Safety
C309
VT/YL (CAV 11)
Ignition
Hot
1N4007
DIODES
8
1
LOCATION:
Passengers B-PILLAR
BL (20 GA.)
RD (20 GA.)
11DQ05-ND
DIODE
BK (8 GA.)
40A
FUSE
RD (14 GA.)
BK (20 GA.)
ITF RAMP
RD (-)
RD (10 GA.)
#310-1059
DB (20 GA.)
ES
RD (8 GA.)
-
+
*(To Inition Hot)
located under
steering column
N
R
D
P
2
Neutral Safety3
BK
K
YL (+)
GN/DB
(OEM CAV 9)
D
DB
BK
1
4
8
13
17
21
7
12
16
20
23
LOCATION:
On the transmission
# 08044-002
J1
J2
RD (10 GA.)
RAMP DN
RAMP UP
KNL DN
RAMP
ENABLE
OUTPUTS
INPUTS
OR (20 GA.)
RD (20 GA.)
BL (20 GA.)
PWR OVERRIDES
YL (12 GA.)
6
KNL UP
CM6200
ASM #03220-005
BK (10 GA.)
ASM #03295-003
GND (To Body)
LOCATION:
Passenger’s side D-Pillar
ANTENNA RUNS
UP PASSENGER
“D” PILLAR
BK (12 GA.)
RD (12 GA.)
PAGE
82
POWER OVERRIDE BUS
DG (20 GA.)
OTC WIRING
(WITH THE DOOR DETECTOR NO CAN BUS)
12
N/C
LOCATION:
Passengers D-PILLAR
BACK SIDE
*UNIVERSAL DOOR
DETECTOR
(13104-001ASM)
VT (20 GA.) (QUAD B + IN)
4
BL (20 GA.) (QUAD A + IN)
PK (20 GA.) (GND)
N/C
1
LOCATION:
OR/RD (20 GA.) (Door Open Status out) Passengers C-PILLAR
1
BL/YL (20 GA.) (Reset)
BK (20 GA.)
(GND)
(ASM #03220-001)
(V BAT)
VT
BK
TIPM
(Fuse box
under hood)
4
N/C
VT (20 GA.)
PSDMR
Power Sliding Door Module
BK (20 GA.)
DB / YL (20 GA.)
N/C
1
(Chrysler Door Ajar Circ
WT / RD (20 GA.)
WT / RD (20 GA.)
BK (10 GA.)
DB (20 GA.)
BLACK
INPUTS
BACK SIDE
14
N/C
(User switch)
DG (20 GA.)
(Neutral Safety)
OR / RD (20 GA.)
(Door Open Limit)
VT / YL (20 GA.)
(Door Closed Limit)
SWITCHE
* RAMP LIMIT
(#6X284)
RD / DG (20 GA.)
RD / WT (20 GA.)
NC
YL / DG (20 GA.)
COM
2
NO
2
UP
LIMIT
DOWN
LIMIT
1
3
YL / WT (20 GA.)
3
BACK SIDE
YL/RD
(Door Control)
RD/DB
10
N/C
LG / WT (20 GA.)
(Unlock Output)
(OEM CAV #1)
BK
BK
unlock the door)
(OEM CAV #4)
LOCATION:
BK
BLACK
1
5
1
RAMP MOTOR
RD
RD / B
YL / BK
YL / BK (20 GA.)
YL / RD (20 GA.)
OR (20 GA.)
RD / DB (20 GA.)
BLACK
OUTPUTS
12
N/C
BK GY
(-) (+)
RD (12 GA.)
YL (12 GA.)
1
4
KNEEL SYSTEM
OEM B-PILLAR SWITCH
operate the door)
UP LIMIT
Rollx Vans, Inc.
ECN # 14078
Effective Stock # 47655
Savage, MN 55378
DRAWING #: 14072
952.890.7851
DRAWN BY:
COPYRIGHT 2008
Jason Hodgkins
YL / WT
SWITCHES
* KNEEL LIMIT
(#6X284)
DOWN LIMIT
2
2
NC
NO
NC
1
1
NO
3
3
COM
COM
BK
YL / DG
BK
RD (12 GA.)
REVISION HISTORY:
08330-001 INITIAL RELEASE. 11/25/2008
YL (12 GA.)
PAGE
NO
COM
BK (20 GA.)
RD
(20 GA.)
RD / BK (20 GA.)
1
NC
1
83
OTC WIRING
(WITH THE DOOR DETECTOR NO CAN BUS)
3/13/2014
OD F (Dropped the CAN BUS)
(ASM #03220-005)
DASH
RESET SWITCH (8/21/06)
4
DB
BK
D-PILLAR
DB
BUILT BETWEEN:
3/17/2014 - 3/24/2014
DASH
C-PILLAR
BK
BK
DB
BK
DB
1
DB (20 GA.)
BK (20 GA.)
ITF RAMP OVERRIDE
SWITCH
(DRIVER SIDE B
PILLAR) #05175-001
BK (20 GA.)
OUT
LOCATION:
BK (20 GA. X 3)
e Right
BK (20 GA. X 3)
DB / YL (20 GA.)
DMRR
* FUSE PANEL
(BEHIND GLOVE BOX)
1 AMP
REMOTE
1 AMP
IN
DOOR DETECTOR
1 AMP
CONTROLLER PWR
7
cuit)
14
(B-Pillar)
OR (20 GA.)
Nuetral
Safety
C309
VT/YL (CAV 11)
Ignition
Hot
1N4007
DIODES
8
1
LOCATION:
Passengers B-PILLAR
BL (20 GA.)
RD (20 GA.)
11DQ05-ND
DIODE
BK (8 GA.)
40A
FUSE
RD (14 GA.)
BK (20 GA.)
ITF RAMP
RD (-)
RD (10 GA.)
#310-1059
DB (20 GA.)
ES
RD (8 GA.)
-
+
*(To Inition Hot)
located under
steering column
N
R
D
P
2
Neutral Safety3
BK
K
YL (+)
GN/DB
(OEM CAV 9)
D
DB
BK
1
4
8
13
17
21
7
12
16
20
23
LOCATION:
On the transmission
# 08044-002
J1
J2
RD (10 GA.)
RAMP DN
RAMP UP
KNL DN
RAMP
ENABLE
OUTPUTS
INPUTS
OR (20 GA.)
RD (20 GA.)
BL (20 GA.)
PWR OVERRIDES
YL (12 GA.)
6
KNL UP
CM6200
ASM #03220-005
BK (10 GA.)
ASM #03295-003
GND (To Body)
LOCATION:
ANTENNA RUNS
UP PASSENGER
“D” PILLAR
BK (12 GA.)
RD (12 GA.)
PAGE
84
POWER OVERRIDE BUS
DG (20 GA.)
OTC WIRING
(WITH WING WINDOW INTERFACE)
PSDMR
Power Sliding Door Module Right
LOCATION:
VT
N/C
BK (20 GA.)
VT/BL (20 GA.)
VT/YL (20 GA.)
N/C
VT (20 GA.)
N/C
BL/YL (20 GA.)
1
1
LOCATION:
Behind OTC Board
VT (20GA.)
R
OR/
12
BACK SIDE
N/C
N/C
WT / RD (20 GA.)
(V BAT)
WT / RD (20 GA.)
WT / RD (20 GA.)
(V BAT)
(V BAT)
BLACK
BACK SIDE
14
INPUTS
DMRR
Door Module Righ
Passenger’s side Door
(B-Pillar)
1
VT/YL (CAV 11)
8
C309
(User switch)
(Neutral Safety)
DG (20 GA.)
OR / RD (20 GA.)
(Door Open Limit)
VT / YL (20 GA.)
(Door Closed Limit)
(Ramp Up Limit)
(Ramp Down Limit)
RD / DG (20 GA.)
RD / WT (20 GA.)
N/C
1
2
NC
NO
2
COM
1
5
(Unlock Output)
(VT/YL)
BK (20GA.)
BK (20GA.)
unlock the door)
(OEM CAV #4)
LOCATION:
BK (20GA.)
BLACK
BK GY
(-) (+)
(CAV #1)
RD (12 GA.)
N/C
YL (12 GA.)
1
4
KNEEL SYSTEM
OEM B-PILLAR SWITCH
operate the door)
ECN # 14112
Rollx Vans, Inc.
Effective Stock #: 01060
Savage, MN 55378
DRAWING #: 14083
952.890.7851
DRAWN BY:
COPYRIGHT 2008
Jason Hodgkins
YL / WT
UP LIMIT
SWITCHES
* KNEEL LIMIT
(#6X284)
DOWN LIMIT
2
2
NC
NO
BK
NC
1
1
NO
3
3
COM
COM
BK
YL / DG
RD (12 GA.)
REVISION HISTORY:
08330-001 INITIAL RELEASE. 11/25/2008
YL (12 GA.)
PAGE
85
NO
COM
10
1
3
(Ramp Enable)
N/C
LG / WT (20 GA.)
NC
1
BK (20 GA.)
(Ramp Down)
(Ramp Up)
(Kneel Down)
(Kneel Up)
(Door Control)
YL / BK (20 GA.)
YL / RD (20 GA.)
OR (20 GA.)
RD / DB (20 GA.)
BLACK
UP
LIMIT
DOWN
LIMIT
1
3
YL / WT (20 GA.)
N/C
BACK SIDE
SWITCHES
* RAMP LIMIT
(#6X284)
YL / DG (20 GA.)
RD
(20 GA.)
RD / BK (20 GA.)
OUTPUTS
BK (20GA.)
BK (10 GA.)
DB (20 GA.)
OBSTACLE DET.
DB
(Chrysler Door Ajar Circuit)
(Door Open Status out)
(Reset)
BL/YL (20 GA.)
(GND)
PK (20 GA.)
(GND)
BK (20 GA.)
1
12
BL/YL (20GA.)
BK (20GA.)
.)
GA
(20
VT (20 GA.)
(QUAD B + IN)
YL
/
T
V
BL (20 GA.)
(QUAD A + IN)
.)
0 GA
D (2
BK
DB
BK
PK (20GA.)
N/C
4
*UNIVERSAL DOOR
DETECTOR
(13104-001ASM)
4
Door Detector Extension
LOCATION: 66”
Passengers C-PILLAR
VT (20GA.)
BL (20GA.)
4
N/C
BACK SIDE
WING WINDOW FLAPPER
BLACK
N/C
D
1
1
16
R
(ASM #03220-001)
DASH
RESET SWITCH
OTC WIRING
(WITH WING WINDOW INTERFACE)
3/24/2014
OD H (W/ Wing Window Interface)
Right Rear Wing
Window Motor
(ASM #03220-005)
LOCATION:
Right Rear D-Pillar
3
D-PILLAR
BK
DB
BK
DB
BK
VT/BL
VT/YL
snake
BL
OR / BL
Rear Window Signal
BL /YL
OR / YL
Rear Window Return
BL
#05175-001 OUT
LOCATION:
Driver’s Side B-Pillar
RD (20 GA.)
BL /YL
*
RD (20GA.)
FUSE PANEL
(BEHIND GLOVE BOX)
BK (20 GA.)
1 AMP
REMOTE
1 AMP
IN
DOOR DETECTOR
1 AMP
BK (20GA.)
BK (20GA.)
BL (20 GA. X 3)
)
To Driver’s side
Window Switch
OR / YL
BK (20GA.)
BK (20GA.)
CUT
OR / BL
#14044-001ASM
DB (20 GA.)
ht Rear
Rear Window Return OR / YL
BK
WT/RD (20GA.X2)
BK (20 GA. X 3)
OR (20 GA.)
Nuetral
Safety
Ignition
Hot
7
1N4007
DIODES
DG (20 GA.)
14
BK (10 GA.)
BL (20 GA.)
RD (20 GA.)
BK (8 GA.)
DG (20 GA.)
40A
11DQ05-ND
DIODE
J2
BK (10 GA.)
BK (12 GA.)
YL/BK
KNL UP
BK (12 GA.)
RD/DB
P
I
M
RA
located under
steering column
N
R
D
P
)
(+
Neutral Safety3
GN/DB
(OEM CAV 9)
OTC BOARD
DB
DB (20 GA.)
YL
(Ramp -)
RD
(-)
YL (12 GA.) (Ramp +)
(Ramp Down)
RD (20 GA.)
(Ramp Up)
6
OR (20 GA.)
BL (20 GA.)
(Ramp Enable)
59
10
10
#3
(Kneeler +)
(Kneeler -)
PWR OVERRIDES
(Ramp +)
OUTPUTS
INPUTS
(User switch)
RD (12 GA.)
RAMP
ENABLE
TF
*(To Inition Hot)
2
RD (12 GA.)
(Remote Gnd.)
KNL DN
GND (To Body)
YL/RD
-
+
PK/GN (20 GA.)
RD
Programming
Switch
BK
7
12
16
20
23
GN/WT
RD
GN
BK
ASM #03295-003
LOCATION:
BK (12 GA.)
ANTENNA RUNS
UP PASSENGER
“D” PILLAR
RD (12 GA.)
PAGE
86
1
4
8
13
17
21
LOCATION:
On the transmission
CM6200
RAMP UP
ASM #03220-005
RAMP DN
RD/BK
(Remote Pwr.)
RD
RD (10 GA.)
BK (20 GA.)
J1
RD (8 GA.)
FUSE
RD (14 GA.)
# 08044-002
POWER OVERRIDE BUS
B
Rear Window Signal OR / BL
1
C-PILLAR
DASH
Built Between:
3/24/2014 - 4/30/2015
OTC WIRING
(COMPUSTAR 7200 W/ FLASHING LIGHTS)
PSDMR
Power Sliding Door Module Right
(ASM #03220-001)
DASH
RESET SWITCH
LOCATION:
1
VT
4
N/C
N/C
N/C
BK (20 GA.)
VT/BL (20 GA.)
VT/YL (20 GA.)
N/C
VT (20 GA.)
N/C
BL/YL (20 GA.)
1
4
1
LOCATION:
Behind OTC Board
12
*UNIVERSAL DOOR
DETECTOR
(13104-001ASM)
4
Door Detector Extension
LOCATION: 66”
Passengers C-PILLAR
BACK SIDE
N/C
VT (20GA.)
G
(20
VT
(20
GA.)
L
(QUAD B + IN)
Y
VT/
BL (20 GA.)
(QUAD A + IN)
(Door
Open
Status out)
)
.
A
20 G
(Reset)
BL/YL (20 GA.)
RD (
OR/
(GND)
PK (20 GA.)
(GND)
BK (20 GA.)
N/C
(V BAT)
WT / RD (20 GA.)
WT / RD (20 GA.)
(V BAT)
(V BAT)
1
BLACK
INPUTS
BACK SIDE
14
1
DMRR
Door Module R
Passenger’s side D
(B-Pillar)
1
VT/YL (CAV 11)
8
C30
DG (20 GA.)
(Neutral Safety)
OR / RD (20 GA.)
(Door Open Limit)
VT / YL (20 GA.)
(Door Closed Limit)
(Ramp Up Limit)
(Ramp Down Limit)
RD / DG (20 GA.)
RD / WT (20 GA.)
N/C
2
NC
NO
2
COM
1
5
(Unlock Output)
(VT/YL)
BK (20GA.)
BK (20GA.)
unlock the door)
(OEM CAV #4)
LOCATION:
BK (20GA.)
BK GY
(-) (+)
(CAV #1)
RD (12 GA.)
N/C
YL (12 GA.)
1
4
KNEEL SYSTEM
OEM B-PILLAR SWITCH
operate the door)
UP LIMIT
Rollx Vans, Inc.
ECN # 14112
Effective Stock #: 01060
Savage, MN 55378
DRAWING #: 14083
952.890.7851
DRAWN BY:
COPYRIGHT 2008
Jason Hodgkins
YL / WT
SWITCHES
* KNEEL LIMIT
(#6X284)
DOWN LIMIT
2
2
NC
NO
BK
NC
1
1
NO
3
3
COM
COM
BK
YL / DG
RD (12 GA.)
REVISION HISTORY:
08330-001 INITIAL RELEASE. 11/25/2008
YL (12 GA.)
PAGE
87
NO
COM
10
BLACK
3
(Ramp Enable)
N/C
LG / WT (20 GA.)
NC
1
BK (20 GA.)
(Ramp Down)
(Ramp Up)
(Kneel Down)
(Kneel Up)
(Door Control)
YL / BK (20 GA.)
YL / RD (20 GA.)
OR (20 GA.)
RD / DB (20 GA.)
BLACK
UP
LIMIT
DOWN
LIMIT
1
3
YL / WT (20 GA.)
N/C
BACK SIDE
SWITCHES
* RAMP LIMIT
(#6X284)
YL / DG (20 GA.)
1
OBSTACLE DET.
(Chrysler Door Ajar Circuit
(User switch)
RD
(20 GA.)
RD / BK (20 GA.)
OUTPUTS
BK (20G
BK (10 GA.)
DB (20 GA.)
12
BL/YL (20GA.)
BK (20GA.)
A.)
WT / RD (20 GA.)
BK
DB
BK
PK (20GA.)
N/C
VT (20GA.)
BL (20GA.)
16
BACK SIDE
WING WINDOW FLAPPER
1
BLACK
OTC WIRING
(COMPUSTAR 7200 W/ FLASHING LIGHTS)
NTROLLER WIRING DIAGRAM BUILT AFTER 4/30/2015 5/4/2015
OD J-L (MODEL YEAR 2008-2016) COMPUSTAR 7200
With Flashing Lights
Right Rear Wing
Window Motor
(ASM #03220-005)
LOCATION:
Right Rear D-Pillar
3
D-PILLAR
BK
DB
BK
DB
BK
VT/BL
VT/YL
R
Right Rear
Door snake
BL
OR / BL
Rear Window Signal
BL /YL
OR / YL
Rear Window Return
BL
#05175-001 OUT
LOCATION:
Driver’s Side B-Pillar
RD (20 GA.)
BL /YL
*
FUSE PANEL
(BEHIND GLOVE BOX)
RD (20GA.)
BK (20GA.)
BK (20GA.)
BL (20 GA. X 3)
GA.)
To Driver’s side
Window Switch
OR / YL
BK (20GA.)
BK (20GA.)
CUT
OR / BL
#14044-001ASM
DB (20 GA.)
t)
Rear Window Return OR / YL
BK
BK (20 GA.)
5 AMP
1 AMP
REMOTE
IN
WT/RD (20GA.X2)
BK (20 GA. X 3)
OR (20 GA.)
Nuetral
Safety
Ignition
Hot
7
1N4007
DIODES
14
DG (20 GA.)
09
BK (10 GA.)
BL (20 GA.)
RD (20 GA.)
BK (8 GA.)
DG (20 GA.)
40A
11DQ05-ND
DIODE
J2
RAMP DN
RD/BK
RAMP UP
BK (10 GA.)
BK (12 GA.)
KNL DN
YL/BK
KNL UP
RD (12 GA.)
RD (12 GA.)
RAMP
ENABLE
P
IT
F
M
RA
BK (12 GA.)
(
DB
BK
-
+
PK/GN (20 GA.)
*(To Inition Hot)
located under
steering column
N
R
D
P
Neutral Safety3
GN/DB
(OEM CAV 9)
Programming
Switch
7
12
16
20
23
2
1
4
8
13
17
21
LOCATION:
On the transmission
GN/WT (17)
DB (20 GA.)
YL
+)
(Ramp -)
RD
(-)
YL (12 GA.) (Ramp +)
(Ramp Down)
RD (20 GA.)
(Ramp Up)
6
OR (20 GA.)
BL (20 GA.)
(Ramp Enable)
59
10
10
#3
(Kneeler +)
(Kneeler -)
PWR OVERRIDES
(Ramp +)
OUTPUTS
INPUTS
(User switch)
BK (12 GA.)
RD/DB
GND (To Body)
YL/RD
ASM #03220-005
RD
RD (10 GA.)
(Remote Gnd.) BK (16 GA.)
J1
RD (8 GA.)
FUSE
# 08044-002
(Remote Pwr.) RD (16 GA.)
BK(CAV 8)
GN(CAV 7)
Park Lamp Feed
(Right Rear Taillight)
RD (12 GA.)
PAGE
88
WT/VT (20 GA.)
GNWT(CAV 2)
Tap into wire inside the van
RD(CAV 1)
CM
00
72
LOCATION:
ANTENNA RUNS
UP PASSENGER
“D” PILLAR
POWER OVERRIDE BUS
DB
Rear Window Signal OR / BL
1
C-PILLAR
DASH
ROLLX VANS POWER DOOR (MOTOR BAR) WIRING
Rollx Vans Power Door (Moto
Touchtronic Power Touch 1550-R
NC
NO
COM
VT (14)
Cut
RAMP UP
LIMIT SWITCH
#03220-004
1
4
8
3
7
ON
RD (10)
FUSE
30 A
-
RD (10 GA.)
+
BR (14 GA.)
YL (14 GA.)
DG (14 GA.)
OFF
FUSE
15 A
WT (14)
TN (16 GA.)
KNEEL
GN/DB
26 24 25
(OEM CAV 9)
COM
RAMP
POWER SWITCH
DASH KNEEL
DOWN L.E.D.
RD (14)
17
21
23
NC NO
CLOSE
GN/DB
3.6L
TRS T3 SIGNAL
DOOR
(OEM CAV 8)
RMP
DWN
DASH USER
SWITCH
#8981K520
26 24 25
Soldier all
remote
connections
COM
DB (14 GA.)
YL (20)
BR (14 GA.)
RD (14 GA.)
1
6
NC NO
KNEEL ON/OFF
SWITCH
#8981K519
GY (16 GA.)
GREY WRAP
Fuse Holder
#03220-019(X2)
KIT R0004
BR (16 GA.)
GY (14 GA.)
BK (14)
WT (14)
30
86
87A
30
86
87A
87
FIREWALL
C PI
USER
OPEN
5
10
FUSE
10 A
FUSE
1A
TRS T3 SIGNAL
BR
DG
2
3.3L
OPEN
PNK #10 (12V IN)
GRN #9
BLU #8
BLK #3 (GND)
RED #4 (12V LOGIC)
PNK #5 (12V IN)
YEL #6 (OUT 1, 5A)
ORG #7(OUT 2, 5A)
WHT/RED #1
BK (16 GA.)
BK (14)
P
RAMP
VT (16 GA.)
D
RD (16 GA.)
OEM VT/DG (14)
FOR DOOR AJAR
CHASSIS
GROUND
N
R
GRY/RED #2
TOUCHTRONICS
MODULE (#P1510-R)
NEUTRAL
SAFETY
10 AMP CIRCUIT BREA
OR
15 AMP GLASS FUS
DOOR
3
CLOSE
2
1
DOOR LOCK LIMIT SWITCH #6X284 IN
PASSENGER DOOR
(WHEN CLOSED, SENDS POWER TO
HARDWIRED SWITCHES)
WT (14 GA.)
ROLLX VANS
REMOTE
(BEHIND
GLOVE BOX)
85
87
85
RD (14 GA.)
BK (14 GA.)
DOOR OPEN
DOOR CLO
LOCAT
PAGE
89
ROLLX VANS POWER DOOR (MOTOR BAR) WIRING
8/19/2015
or Bar) Wiring Diagram v2
R Remote System (Jan. 2011)
AKER
SE
DG (16 GA.)
YL (16 GA.)
TO OEM
DOOR AJAR
NC
VT (14)
NO
MOTOR BAR
ILLAR
SWITCH
#310-1059
YL
DB
KNEELER
12
11
13
DG
DG
RD
WT
COM
BK
(-)
BR
BK (14 GA.)
GY
(+)
*
TO DASH
L.E.D.
KNEEL UP LIMIT
SWITCH
#03220-014
YL (14 GA.)
PK (14 GA.)
COM
COM
YL (16 GA.)
87A
30
86
87A
87
85
RAMP DOWN
30
86
87A
87
85
RAMP UP
30
WT (16 GA.)
86
87A
87
85
KNEEL DOWN
87
DG (14 GA.)
86
BR
JONES BLOCK
#3-142
BR (14 GA.)
30
YL
KNEEL DN
LIMIT SWITCH
#03220-013
OR (16 GA.)
YL (14 GA.)
DG
PAGE
90
85
KNEEL UP
RELAYS (#5-1393302-8)
TED IN OEM SPARE TIRE KIT COMPARTMENT
YL (14 GA.)
TN (16 GA.)
NC NO COM
GY (16 GA.)
NC
NO
NC
NO
OSE
COM
NC
NO
Toggle Switch
#4X203
RD (16 GA.)
DOOR OPEN
LIMIT SWITCH
(CHERRY)
#E19-50H
YL
13 11 12
BR(16 GA.)
PAGE
91
4
3
Fig 1
2
1
Step 5
*
1 AMP
REMOTE
FUSE PANEL
(BEHIND GLOVE BOX)
Ignition
Hot
Nuetral
Safety
SECURITY BY-PASS
5 AMP
Step 4
BR/YL (CAN L)
BR/RD (CAN H)
(PK)
Step 3
4
1
(BK) (RD)
(BK) (RD)
6
1
10
5
(To OTC Board)
Step 2
(GN/WT)
(Unlock Output)
(BL/BK)
(OEM CAV #4)
LOCATION:
the van to “unlock all doors w/
one press”.
Note: Some vans don’t have the plug behind the glove box (See Fig 1) in these cases locate the same
WT/BN & WT/BL Twisted Wires under the steering console.
Security By-pass module mounted here
WT/BR (CAN C-)
Step 1
DATA LINK #ADS-AL CA-ASM
#14084-001ASM
Security Bypass Chrysler
Security By-Pass Module
CHRYSLER TOWN & COUNTRY LTD
CHRYSLER TOWN & COUNTRY TOURING-L
CHRYSLER TOWN & COUNTRY TOURING-K
DODGE GRAND CARAVAN R/T
DODGE GRAND CARAVAN SXT
WT/LB (CAN C+)
1. Tap the CAN H/CAN L from
the module into the CAN C+/CAN Ccircuits on the plug behind the glove
box (on the right wall). See Fig 1
2. Tap the GN/WT (door unlock output)
wire into the GN/WT wire going in
through the passengers front door.
3. Attach the PK wire from the module
to the ignition hot on the fuse panel.
4. Plug in the RD wire from the module
to fuse panel power with a 1amp fuse.
5. Plug in the BK wire to the ground
point on the fuse panel.
STEP:
INSTALLATION
INSTRUCTIONS
Chrysler/Dodge Security By-Pass Installation Instructions
Use on models:
Note: May need to set the settings on
SECURITY BY-PASS WIRING & INSTALLATION
SECURITY BY-PASS UNLOCK SEQUENCE
Setting up Unlock Sequence
All doors must unlock on first press of key fob
To enable this function do one of the following:
For vehicles with the EVIC: Fig A
1. Use the EVIC control pad (see Fig B) Up/Down buttons & highlight “SYSTEM SETUP”, then Select.
2. Next use the Up/Down buttons to highlight “Remote Unlock Sequence”, then Select.
3. Now highlight the “Unlock All Doors on 1st Press” section, then Select
Fig B EVIC Control Pad
(Located on left side of steering wheel)
Fig A
Electronic Vehicle Information Center
UP
SELECT
DOWN
For vehicles without the EVIC:
1. Perform this operation while standing outside the vehicle using the OEM key fob.
2. Push & hold the LOCK button on the key fob for at least 4 seconds, but no longer than 10 seconds.
Then, push & hold the UNLOCK button while still holding the LOCK button.
3. Release both buttons at the same time.
4. Lock the doors and then Unlock (making sure all doors unlock on 1st press).
Testing The OTC System
1. Close All doors and lift gate.
2. Stand outside vehicle and lock doors with the OEM Remote.
3. Watch the “Security Alarm” red indicator light on the dash.
4. Wait 20 seconds until the red light on the dash flashes slowly.
5. Once the system is armed use the OTC remote to operate the system.
6. All doors should unlock and open cycle will begin.
PAGE
92
SECURITY BY-PASS PROGRAMMING
Chrysler/Dodge Security By-pass
Reset & Programming Sequence
FACTORY RESET PROCEDURE
DISCONNECT all connectors from the 4
When LED flashes red,
module EXCEPT the black 4-PIN
RELEASE programming button.
1
connector.
x
LED will turn solid red, for 2
seconds .
5
3
Now DISCONNECT the black 4-pin
connector.
PRESS & HOLD the programming
button while reconnecting the 4-pin
connector until the led flashes red.
RESET COMPLETED.
RECONNECT all connectors
6
2
INSTALLATION MODE SELECTION
1
PRESS & RELEASE the
programming button 1 time.
PRESS & HOLD the
programming button until LED
turns solid GREEN.
2
LED flashes twice.
MODULE PROGRAMMING PROCEDURE
6
Turn key to OFF position.
Close driver door.
UNLOCK
1
2
Insert key into ignition.
7
Remove key.
UNLOCK
Re-open driver door to wake
up data bus.
OFF
8
UNLOCK
UNLOCK
UNLOCK
3
Press UNLOCK on the OEM
remote.
UNLOCK
Turn key to ON position.
ON
4
5
9
LED will turn solid RED.
Programming complete.
Within 5 seconds, LED
will flash GREEN rapidly.
PAGE
Wait, LED will turn solid
GREEN for 2 seconds,
Then shut off.
93
PAGE
94
MAINTENANCE INFORMATION
Doors
Door track - Periodically make sure lower door track is free of debris and vacuum track out.
Make certain to clear out any water and ice that may be present. In the front of each door track
there are plugs that can be removed to allow an air hose to be inserted to help remove debri.
Rollx Vans power door (If equipped) - Every 6 months lube the gear rack (bar) with a high
quality white lithium grease. Make sure to clean off any old grease first.
Kneel System
Kneel chain - Every 6 months spray the chain inside the rubber boot with a high quality oil to
lubricate and protect. DO NOT USE WD40.
Ramps
Folding ramp - Every 6 months spray the ramp’s lower and upper hinge with high quality silicon lubricant.
In The Floor ramp - Every 6 months spray the ramp access cover’s flap hinge with a high
quality silicon lubricant. Also spray the two silver strips on the underside of the ramp to reduce
friction.
PAGE
95
WARRANTY
New Rollx Vans Van Warranty Coverage Information
Rollx Vans provids a limited warranty on its minivan against defects in material or workmanship
for a period of 3 years or 36,000 miles, whichever comes first. For warranty specifics please
refer to an Owner’s Manual or contact Rollx Vans Customer Service.
For all warranty or reimbursement needs, you must have prior authorization by the Rollx Vans
Service Department.
1.
Call 1-800-956-6668, and a Rollx Vans Customer Service Representative will assist you
in any concerns or issues you have with your van.
2.
The service representative will evaluate what repair is needed, and either set up
an appointment with an “At Home” Service Technician or direct you to a nearby service
facility. An authorization number must be issued.
Rollx Vans will work with many repair facilities. Rollx Vans reserves the right to approve a repair shop or recommend an alternative.
Rollx Vans may request that defective/damaged parts be returned to our Customer Service Department for inspection. If parts are found to be damaged because of abuse or neglect, reimbursement for the new replacement parts may be denied. Rollx Vans reserves the right to use
rebuilt components.
Rollx Vans will ship all warranted replacement parts by nationwide carrier. In most cases, shipment will be by ground transport and absorbed by Rollx Vans. Any other mode of transportation
will be at the expense of the customer.
Our Mission
To improve the quality of life of people with disabilities of all income levels by delivering the best
modified vehicle.
We intend to keep that customer for life by following up with a level of service that exceeds all of their
expectations.
Our Values
Quality • Compassion • Honesty • Integrity • Fairness
PAGE
96

2011-2016 Chrysler Minivan Service Manual (13315

Transcription

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