MASATS Door Systems

Masats door gear Goals System Problems Maintenance

Goals The goals for this training are: To introduce the Masats door system Explain the functionality of the system Explain how to adjust the system

Goals System Problems Maintenance Components Pneumatic system Electrical system Safety devices Adjustments

Components THE DOOR GEAR ON EURO 4 MAGIQ IS LOCATED BEHIND THE DROP DOWN COVER IN THE N/S/F LOCKER AS SHOWN HERE

Components THE DOOR RAM CYLINDER ON THE MAGIQ IS LOCATED IN THE ENTRANCE STEPWELL.

Components THE DOOR GEAR ON EURO 4 FUTURA IS LOCATED BEHIND THE HEATER BOX COVER, IN THE O/S/F LOCKER AS SHOWN HERE Pneumatics CITEA SLE - XLE

Components THE DOOR RAM CYLINDER ON THE FUTURA IS LOCATED IN THE ENTRANCE STEPWELL

Components INTERIOR EMERGENCY DUMP BUTTON MAGIQ DOOR CONTROLS EXTERIOR EMERGENCY DUMP HANDLE AND OPEN/CLOSE BUTTON

Components FUTURA DOOR CONTROLS OPEN/CLOSE BUTTON EXTERIOR EMERGENCY DUMP BUTTON INTERIOR EMERGENCY DUMP BUTTON Pneumatics CITEA SLE - XLE

Pneumatic systems Outputs to door ram 2 1 9 dump handles Air supply in 1 Door control valve 2 Door pump 3 Reduction during opening and closing 4 Pressure switch for emergency operation indication 5 Emergency handle locking 6 Front door interior emergency valve 7 Exterior emergency valve 8 Rear door 9 Emergency operation (reset) valve 10 Disconnect driver's front door switch (>3 km/h) 11 Two-way valve 12 Two-way valve emergency circuit Air supply in 11 & 12 10 4 3 1

Pneumatic systems DOOR OPEN AN ELECTRICAL REQUEST IS DELIVERED VIA THE NODE TO VALVE 1. THE AIR SUPPLY WAITING AT THE VALVE IS DELIVERED THROUGH VALVE 9 TO THE TOP OF THE DOOR RAM CYLINDER. AIR IN THE BOTTOM OF THE CYLINDER IS EXHAUSTED FROM VALVE 1 VIA THE SPEED REGULATOR SCREW/MUFFLER.

door open situation 1 Door control valve 2 Door pump 3 Reduction during opening and closing 4 Pressure switch for emergency operation indication 5 Emergency handle locking 6 Front door interior emergency valve 7 Exterior emergency valve 8 Rear door 9 Emergency operation (reset) valve 10 Disconnect driver's front door switch (>3 km/h) 11 Two-way valve 12 Two-way valve emergency circuit

Pneumatic systems DOOR CLOSE AN ELECTRICAL REQUEST IS DELIVERED VIA THE NODE TO VALVE 1. THE AIR SUPPLY WAITING AT THE VALVE IS DELIVERED TO THE BOTTOM OF THE DOOR RAM CYLINDER. AIR IN THE TOP OF THE CYLINDER IS EXHAUSTED BACK THROUGH VALVE 9 TO VALVE 1, AND OUT OF THE SPEED REGULATOR SCREW/MUFFLER.

door closed situation 1 Door control valve 2 Door pump 3 Reduction during opening and closing 4 Pressure switch for emergency operation indication 5 Emergency handle locking 6 Front door interior emergency valve 7 Exterior emergency valve 8 Rear door 9 Emergency operation (reset) valve 10 Disconnect driver's front door switch (>3 km/h) 11 Two-way valve 12 Two-way valve emergency circuit

Pneumatic systems EMERGENCY DUMP IF THE DUMP HANDLES OR BUTTONS ARE ACTIVATED, THE WARNING BUZZER AND LIGHT WILL BECOME ACTIVE. THE AIR SUPPLY TO VALVE 5 IS ISOLATED, AND THE REMAINING AIR IN THE SYSTEM IS EXHAUSTED VIA VALVE 5 AND VALVE 1. THE DOOR CAN NOW BE OPENED MANUALY.

Emergency dump situation 1 Door control valve 2 Door pump 3 Reduction during opening and closing 4 Pressure switch for emergency operation indication 5 Emergency handle locking 6 Front door interior emergency valve 7 Exterior emergency valve 8 Rear door 9 Emergency operation (reset) valve 10 Disconnect driver's front door switch (>3 km/h) 11 Two-way valve 12 Two-way valve emergency circuit

Pneumatic systems EMERGENCY DUMP VEHICLE IN MOTION IF THE DUMP HANDLES OR BUTTONS ARE ACTIVATED WHILST THE VEHICLE IS IN MOTION, AN ELECTRICAL SIGNAL IS DELIVERED AT VALVE 10. THIS DELIVERES AN AIR SUPPLY VIA SHUTLE VALVE 11 THROUGH VALVE 1, TO THE BOTTOM OF THE DOOR RAM. ALSO AN AIR SUPPLY IS DELIVERED VIA SHUTLE VALVE 12 TO VALVE 9, TO PREVENT THE AIR FROM THE TOP OF THE DOOR RAM EXHAUSTING VIA VALVE 1. THIS KEEPS THE DOOR CLOSED UNTIL THE VEHICLE IS STATIONARY AND THE SPEED SIGNAL IS LOST. THE DOOR CAN NOW BE OPENED MANUALY.

Emergency dump situation Bus in motion 1 Door control valve 2 Door pump 3 Reduction during opening and closing 4 Pressure switch for emergency operation indication 5 Emergency handle locking 6 Front door interior emergency valve 7 Exterior emergency valve 8 Rear door 9 Emergency operation (reset) valve 10 Disconnect driver's front door switch (>3 km/h) 11 Two-way valve 12 Two-way valve emergency circuit

Pneumatic systems

Pneumatic systems

Pneumatic systems

Pneumatic systems

Electrical systems 5: DOOR CONTROL VALVE OPEN/CLOSE 6: DOOR CONTROL DASHBOARD SWITCH 7: 4 BAR PRESSURE SWITCH (INPUT) 8&9: ENTRANCE AND STEP LIGHTS (OUTPUT) 1: FRONT DOOR OPEN SIGNAL (OUTPUT) 2: FRONT DOOR CLOSE SIGNAL (OUTPUT) 3: EMERGENCY DUMP SPEED BLOCKING 4: DOOR OPEN INDICATION (OUTPUT)

Electrical systems 6:- SWITCH OFF WAKE UP (OUTPUT) 7:-WAKE UP SIGNAL (INPUT) 8:-WAKE UP SIGNAL TO CENTRE DOOR (INPUT 9:- DOOR HANDLE LOCKED SWITCH 10:- DOOR HANDLE OPEN/CLOSE BUTTON 1:- RECYCLE SWITCH (VERTICAL MOVEMENT) 2:- RECYCLE CUT OFF SWITCH (HORIZONTAL MOVEMENT) 3:- SENSITIVE EDGE 4:- DOOR HANDLE LOCKED SIGNAL (INPUT) 5:- DOOR OPEN/CLOSE SIGNAL (INPUT)

Electrical systems AS YOU CAN SEE THE CENTRE DOOR ELECTRICAL DRAWINGS ARE BASICALY THE SAME AS THE FRONT DOOR DRAWINGS. HOWEVER ITEM 3 HAS BEEN ADDED. THIS IS THE SLEEPING COMPARTMENT LOCKER PROTECTION SWITCH, WHICH WHEN ACTIVATED PREVENTS THE CENTRE DOOR BEING ACTIVATED WHILST THE LOCKER IS OPEN.

Safety devices RECYCLE CUT OFF SWITCH (HORIZONTAL MOVEMENT) 2 3 STEP LIGHT SWITCH 1 RECYCLE SWITCH (VERTICAL MOVEMENT)

Safety devices LOCKER PROTECTION SWITCH This switch protects the luggage flap behind the middle door and the middle door itself

Adjustments Components 1 Upper door catch 2 Upper door bracket 3 Upper door pump bracket 4 Door pump bar 5 Door pump 6 Lower door bracket 7 Door stop 8 Swivel bar 9 Command bar 10 Command bar bracket 11 Lower door catch 12 Locking bracket

When a door has been completely removed Adjustments When a door has been completely removed ` • The door pump (5) and the upper door pump bracket (3) should be positioned in a way that the bolts are in the middle of the slotted holes. • The width of the door can be adjusted by moving the door plate in the slotted holes of the door brackets (2) and (6). • The height of the door can be adjusted by moving the swivel bar (8) over the door pump bar (4).

Adjustments When a door has been completely removed • The door catches (1) and (11) have to be adjusted to lock the door properly when the door is closed. The door catches on the door are equipped with slotted holes and can be adjusted. • The door stop (7) prevents the door from damaging against the exterior of the coach. • The alignment of the door can be set by vary the command bar (9) in length. • For the proper function of the lights and the safety system the rings that control the horizontal movement end switches have to be adjusted properly. This is done by wrenching the rings over the door pump bar. • The vertical movement end switch has to be activated when the door lifts. This can be adjusted by moving the actuating cam in the slotted holes. • For the protection of the central door the lever of the driver's sleeping compartment flap switch can be adjusted. Pneumatics CITEA SLE - XLE

Adjustments CHECK AND ADJUST In general the adjustment of front door and central door are the same. For the central door, as an extra, you have to adjust the driver's sleeping compartment flap switch. When the complete door has been removed or is renewed there is an adjusting sequence that has to be followed. The electrical operation has to be disconnected by removing the connector of the door control valve. The pneumatic system has to be in operational order. Disconnect the command bar bracket from the door before starting the adjusting sequence.

Adjustments 1. Position the door pump and the upper door pump bracket so that the bolts are in the middle of the slotted holes. 2. Release the air out of the door pump by operating the emergency valve. Width of the door 1. Remove the covers of the door brackets. 2. Loosen the bolts of the door brackets. 3. Adjust the width of the door by moving the door in the slotted holes of the door brackets. 4. The width of the door is correct when the door is parallel with the door pillars and the gaps on both sides are equal. 5. The door strips may not touch the door pillars when the door is closing. 6. Tighten the bolts when the door is set correctly (Tightening torque 26 Nm). 7. If the angle of the door is not correct you can adjust this by changing the position of the door pump. Pneumatics CITEA SLE - XLE

Adjustments Height of the door 1. Make sure the swivel bar is in the lowest position. 2. In closed position the door has to rise 11 mm in order to fit proper in the coach. 3. To achieve the value of 11 mm you have to adjust the swivel bar over the door pump bar. 4. Loosen the clamping bolts of the swivel bar. 5. The height can be adjusted by moving the swivel bar (1) over the door pump bar (2). 6. Tighten the clamping bolts of the swivel bar (Tightening torque 26 Nm). Pneumatics CITEA SLE - XLE

Adjustments You have to mark the door pillar rubber at Lower door catches 1. Mark the door pillar rubber at the bottom of the lower door catch. You have to mark the door pillar rubber at the left and right side of the entrance. 2. Mark the door contact strip at the lower door catch according figure. You have to mark the contact strip at the left and right side of the door. Pneumatics CITEA SLE - XLE

Adjustments 3. Close the door by hand and measure the distance between the marks on door contact strip and door pillar rubber. 4. Adjust the lower door catches to achieve the value of 11mm. 5. Tighten the bolts of the lower door catches (Tightening torque 25 Nm). 6. Tighten the upper door catches in the lowest position. 7. Close the door by operating the door control valve. 8. Check whether the door rises to the correct height (the door has to fit proper in the entrance). 9. Check from the inside if the lower door catches from door and door pillar fit correct. You need to bend the door rubber a little aside and use a torch to see the position of the door catches from the inside. 10. Tighten the bolts when the door catches are set correctly (Tightening torque 25 Nm). Pneumatics CITEA SLE - XLE

Adjustments Upper door catches 1. Adjust the upper door catches in a way that, during closing of the door, the distance between door catches and the catches of the door pillar is 3 mm. 2. The door should now fit correctly in the entrance. 3. Tighten the bolts when the door catches are set correctly (Tightening torque 25 Nm). 4. Only for front door: 5. If the right upper door catch doesn’t fit correctly, you have to fill out the space under the upper door catch with shims. Door stop 1. Loosen the lock nut of the door stop. 2. Adjust the length of the door stop so that the door opens as far as possible without damaging the outside of the coach. 3. The door stop may not touch the door rubber. 4. Tighten the lock nut when the door stop is set correctly. Pneumatics CITEA SLE - XLE

Adjustments Alignment of the door 1. Install the command bar bracket (1) at the door. (Tightening torque 25 Nm). 2. Align the door by adjusting the length of the command bar. 3. The alignment of the door is set correct when the door fits tightly against the door rubber. 4. Tighten the lock nut when the door is set correctly. Horizontal movement end switches 1. Loosen the screws (1) of the two rings mounted on the door pump bar. In some cases there is only one ring for adjustment. 2. Adjust the upper ring so that when the door is almost closed the light will go out. 3. Adjust the lower ring in the same position as the upper ring. 4. When the rings are correctly set tighten the screws.

Adjustments Vertical movement end switch 1. Loosen the bolts (2) of actuating cam (3). 2. Adjust the actuating cam so the actuating cam presses gently against the vertical movement end switch without activating the switch. 3. When the actuating cam is set correctly tighten the bolts (2). Driver's sleeping compartment flap switch Magiq 1. Loosen the lock nut (1). 2. Install the arm on the switch in the position that it switches when the sleeping compartment flap is closed. 3. Tighten the lock nut (1).

Adjustments Driver's sleeping compartment flap switch Futura 1. Adjust the switch by turning in or out the switch. 2. Tighten the lock nut.

Masats door gear Goals System Problems Maintenance

Problems The main problems with this Masats door gear are related to the Emergency Dump; The reactivation of the door gear system not always reacts as it should. Either it’s to slow or it opens too fast. (Temperature dependant). This is caused by the reactivation valve in the pneumatic system. The reaction of this valve can be adjusted slightly, but this not always solves the problem. Do not use the emergency dump for normal opening of the doors. Always use the normal operating equipment.

Masats door gear Goals System Problems Maintenance

Maintenance To ensure a good operation of the door system the door system should be checked daily including the emergency valves and the door contact strips on the door panels. • The command bar under the door on the outside of the coach must be greased at least once every 6 month. • The door rubbers should be checked frequently and if necessary treated with talcum powder. Preferable during winter period. • Check and grease the locks frequently. • Check door reverse operation. • Check door contact strips operation (Magiq). • Check for correct functioning of the safety systems (e.g. the anti trap devices).

Maintenance THE DOOR GEAR SHOULD BE REGULARLY CHECKED FOR SECURITY, AND LUBRICATED TO PREVENT MALFUNCTION.

Questions?

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