Chrysler | Town & Country 2011 | Service manual | Chrysler Town & Country 2011 Service manual

Chrysler / Dodge Minivan
Service Manual
2011-2014 Model Year
Main: Local: Fax: (800) 956-6668
(952) 890-7851
(952) 808-2775
Your Life. Your Ride.
6591 W. Hwy 13
Savage, MN 55378
www.rollxvans.com
TM
Chrysler / Dodge Minivan
2011-2014 Model Year
Service Manual
#13315-004
June 2014
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
OEM Power 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....................................................................................................................29
Kneeler - Replacement Parts...............................................................................................................30
One Touch System - Troubleshooting..................................................................................................31
One Touch System - Overview.............................................................................................................32
One Touch System - v8.0 Basic Interface............................................................................................34
One Touch System - v8.0 Advanced Interface - Setup ....................................................................... 35
One Touch System - v8.0 Advanced Interface - Debugger ................................................................ 36
One Touch System - v8.0 Error Codes ............................................................................................... 38
One Touch System - Relay Board Troubleshooting........................................................................... 41
In The Floor - Troubleshooting ........................................................................................................... 43
In The Floor - Replacement Parts ...................................................................................................... 44
Folding Ramp - Troubleshooting ........................................................................................................ 45
TaBle of conTenTS
Folding Ramp - Replacement Parts ................................................................................................... 46
Folding Ramp - Motor Install / Removal and Adjustment ................................................................... 49
Rear Heat & Air................................................................................................................................... 51
Remote System - Troubleshooting ..................................................................................................... 52
Remote System - Location & Wiring .................................................................................................. 53
Seat Detector - Location & Description .............................................................................................. 54
Seat Wiring - Driver’s Side (2011-2014)..............................................................................................55
Seat Wiring - Passenger’s Side (2011-2012) ..................................................................................... 63
Seat Wiring - Passenger’s Side (2013-2014) ..................................................................................... 69
One Touch - Wiring (With Door Open Limit Switch)............................................................................73
One Touch - Wiring (With Door Detector)............................................................................................75
One Touch - Wiring (No Can Bus).......................................................................................................77
One Touch - Wiring (With Wing Window Interface).............................................................................79
Rollx Vans Power Door (Motor Bar) - Wiring ..................................................................................... 81
Maintenance Information .................................................................................................................... 83
Warranty ............................................................................................................................................. 84
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
Rear Heat
and Air Unit
Driver Seat
Detector
Power Seat
Connector(s)
OTC fuse panel
(Under Glove Box)
Wing Window Interface
(after 4/15/2014)
OTC Remote
Receiver
Passenger
Seat
Detetector
Door Detector
(after 4/15/2014)
(after 8/26/2013)
Power Seat
Connector
Passenger Sliding
Door Open Switch
Kneeler
OTC Remote
Programming
Switch
(Before 8/26/2013)
One Touch Controller
(OTC) Board
Rear Heat Connections
Rear A/C Connections
OTC RelayBoard
Page
1
iMPorTanT iTeM locaTionS
Main Fuse
(Engine Compartment)
6way Seat Fuse
(40 Amp)
(If Equipped)
OTC Remote Receiver
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 Switch
OTC Fuse Panel
(Under Glove Box - Must Pull Back Fabric)
Power Tie Down
(If Equipped)
Used Before 8/26/2013
Rollx Vans Remote
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
iMPorTanT iTeM locaTionS
OTC Relay Board
(Behind Rear Passenger Quarter Panel)
ITF Ramp Access Plate
Rear AC (Rear Connections)
(Behind Rear Right Tire)
Rear Heat (Rear Connections)
(Right Rear Tire)
Rear Heat & A/C (Front Connections)
(Under Passenger’s Side Front Seat Area)
Kneeler and One Touch Controller
Rear Heat
OTC Board
Rear A/C
Kneeler
Page 3
Universal Door Detector
Used After 8/26/2013
(behind panel)
iMPorTanT iTeM locaTionS
ITF Ramp Override Switch
Neutral Safety Signal
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 (Built After 4/15/2014)
(On Passenger’s C-Pillar)
Wing Window Interface (Built After 4/14/2014)
(Behind Rear Heat & Air Unit)
OTC Remote Programming Switch
Driver’s Power Seat Connector
(Passenger’s Same)
Page 4
iMPorTanT iTeM locaTionS
Rollx Vans Ignition Hot & Neutral Safety Board Wiring
2008-2013 Chrysler Minivans (built after 5/28/2009)
BK (8 GA.)
-
+
40A
RD (8 GA.)
FUSE
RD (8 GA.)
RED (12V CONSTANT)
*
FUSE PANEL
(BEHIND GLOVE BOX)
1 AMP
REMOTE
Neutral Safety
1 AMP
DOOR DETECTOR
1 AMP
R
N
P
CONTROLLER PWR
D
2
PK / YL
(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
4
1
8
5 Cut
Page 5
1
2
3
4
5
6
7
8
LG/YL
LG/TN
LG/DB
LG/VT
Gauge
22
22
22
22
Function
NO CONNECTION
SEAT SWITCH SELECTOR SIG
SEAT FOLD SIGNAL
SEAT STOW SWITCH SIGNAL
FOLDING SEAT SWITCH RET
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).
3/26/2013
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).
2011 Trouble Shooting.xls
Page 9
Page 1
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
oeM PoWer door TrouBleShooTing
Note: In order to disable the OEM door from closing when the ramp is out, Rollx Vans interupts
Chryler’s CAN BUS circuit to prevent the door from getting any signal to close. The Scan tool will read
a “No Communication with the Right Rear Door Module” everytime the system deploys
the ramp. This is a normal trouble code and is to be excpected.
Symptom
Passenger sliding door does NOT
OPEN with interior Rollx Vans user
button.
Ramp sliding door does NOT
OPEN 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.
Possible Cause
Remedy
Van is NOT in park.
Overhead on/off switch is turned to the OFF
position.
OTC program failure.
Place van into park.
Turn switch to ON position.
OTC reads low voltage.
Start van's engine and press OTC reset button.
If door still does not open review OTC board
display and contact customer service.
Bad OTC board.
Press the OTC reset button and while in Idle
Mode press a user button and watch the LED.
Notice if OTC appears to be working properly.
Review error codes stored and call customer
service.
Main OTC fuse (40 amp) is blown.
Replace fuse under hood by battery.
OEM overhead ON / OFF switch is OFF.
Turn switch to ON position. This switch enables /
disables the OEM buttons located on the B
pillars that Rollx Vans uses to trigger the sliding
door to open or close.
Defective OEM door opener.
Operate door manually and contact customer
service.
Ramp up limit switch is not being activated
properly.
Close door manually, press OTC reset button,
and press Rollx Vans user button to operate
system again. If door still does not attempt to
close after ramp is stowed, review OTC board
display and contact customer service.
Defective door open bracket.
Adjust the bracket and contact customer service.
Defective OEM door opener.
Ramp sliding door kicks back when
opening or closing.
Obstruction.
Ramp needs adjustment (Foldout only).
OEM door sensitivity set low.
Ramp sliding door opens and van
kneels, but when door is all the way
open, van unkneels and cycle
ends.
OEM Door Ajar Pin Switch (Rollx Vans Door
Close signal) is never deactivated when door
begins to open.
Ramp sliding door does not seal
when almost closed.
Ramp sliding door does NOT
OPEN manually.
Ramp sliding door does NOT
OPEN manually from interior
handle, but does from exterior
handle.
Ramp sliding door closes half way
and then moves back and forth.
Ramp sliding door will NOT CLOSE
manually.
5/8/2013
Press OTC reset button.
Ramp needs adjustment (Foldout only).
Defective OEM cinch motor.
Door is locked.
Child safety lock is activated.
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 and contact customer
service.
Check door track for any debris and remove.
Adjust folding ramp to stow more.
Contact local Chrysler Dealership.
If the OTC thinks the door is open and closed it
will end the cycle. Examine switch / wiring.
Adjust folding ramp to stow more.
Operate door manually and contact customer
service.
Unlock door. When pulling door handle, pull
handle out and then slide door to open.
See OEM owner manual to deactivate child
safety lock.
Stuck door open limit swith, or CAN BUSS door Adjust swtich located in rear of lower door track,
opener Module.
or unplug module & wait 2 seconds.
Door handle is not releasing.
Obstruction.
2011 Trouble Shooting.xls
Page 11
Pull handle to disengage latch and slide to
close.
Check door track for any debris and remove.
Page 1
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
Door skin svs kit itf pass
-B08180-P5-KIT-FO
Door skin svs kit fo pass
#10277 - Rivets (9 per Door)
Outer Sliding Door
Current
#B08180-DP6 - L BRKT DOOR SKIN DR/PASS 08
Before 10/20/2008
#10503 - 1”X 1” 14GA ROLLED ANGLE
#B08033
‘08 LOWER DOOR ARM
(Spaceship bracket)
#10277 - Rivets (6 per Door)
OEM BOLT (3)
#6505 480AA
CABLE POWER DOOR 2008
#AR-2008
OEM LOWER DOOR ROLLER ARM
Passenger Side - #5020 920AB
Driver Side - #5020 921AB
DOOR TRACK EXT BKT UPPR 08
#B08030ASM
Needs to be painted to match van
Page 12
BOLT (3) - #0115007
WASHER (3) - #1133004
door ModificaTionS
DOOR OPEN SWITCH
ASSEMBLY - #05089-003
Built Before 8/26/2013
1/4-20X1/2” Hex Bolt
#0115001
M+
ZOO
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
- Door track asm 08-09 dr
B08059asm-dr-2010 - Door track asm 10-13 dr
B08059asm-ps
- Door track asm 08-09 ps
B08059asm-ps-2010 - Door track asm 10-13 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
#B08180-P = Passenger Side
#B08180-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
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
2011-2014 Chrysler Town & Country / Dodge Grand Caravan (3.6L)
Rollx Vans Fuel / Emission System Overview
(V5)
*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
OEM Filler Neck Top
(Gas Cap)
Rollx Vans Charcoal
Canister Vent Metal Line (3/8”)
OEM Charcoal
Canister Vent Line
Rollx Vans Filler Neck Metal Tube
OEM Fuel Fill
Vent Line
Rollx Vans Fuel Fill
Vent Hose (5/16”)
OEM Fuel
Tank
OEM Charcoal
Canister
Rollx Vans Charcoal
Canister Vent Hose (5/8”)
OEM Fuel Pump /
OEM Fuel Filter
Page 17
Rollx Vans Main Fuel Hose (3/8”)
Page 18
0°
OET 15
Rollx Vans Charcoal
Canister Vent Hose (5/8”)
Part #10929-00834
(FUEL LINE 5/8”-R7)
53 inches
OEM Quick Disconnect (5/8”)
OEM Charcoal
Canister
Rollx Vans Fuel Fill
Vent Hose (5/16”)
Part #H-211
(5/16” HIGH PRESSURE
HOSE-R9) 37 inches
OEM Quick
Disconnect (5/16”)
OEM Fuel Fill
Vent Metal Line
OEM Filler Neck Top
(Gas Cap)
Rollx Vans Main Fuel
Metal Line (5/16”)
Part #126299
(5/16”X028/X13' FUSION)
45°
OET 17
90°
OET 15
OEM Fuel
Tank
90°
Clamp #10
OEM Fuel Pump /
OEM Fuel Filter
45°
Clamp #10
90°
90°
OET 17
OEM Charcoal
Canister Vent Line
OEM Quick Disconnect (3/8”, 90°))
OEM Quick Disconnect (3/8”)
Rollx Vans Main Fuel Hose (3/8”)
Part #H-212
3/8” HIGH PRESSURE HOSE-R9)
40 inches
OEM Quick Disconnect (5/8”)
Rollx Vans Filler Neck
Part #B08103ASM
(FILLER NECK 2008 ASM)
Rollx Vans Charcoal
Canister Vent Metal Line (3/8”)
Part #101865
(3/8”X028X13' FUSION WELD)
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)
OEM Quick Disconnect
with #10 Hose Clamp
Rollx Vans Fuel Fill Vent Hose
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)
Rollx Vans Fuel Fill Vent Hose
OEM Quick Disconnect
with #10 Hose Clamp
Rollx Vans Charcoal
Canister Vent Hose
Part #10929-00834
(5/8” Fuel/Emissions Hose,
SAE 30R7, Goodyear)
OEM Fuel Fill Hose
at Tank
OEM Clamp
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
OEM Fuel Quick
Disconnect (5/16”)
C
OEM Fuel Quick
Disconnect (5/16”, 0°)
Rollx Vans Main Fuel
Metal Line (5/16”)
Part #126299
(5/16”X028/X13' FUSION)
Rollx Vans Main Fuel
Metal Line (5/16”)
Part #126299
(5/16”X028/X13' FUSION)
Engine Compartment
A
Rollx Vans Main Fuel
Metal Line (5/16”)
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.
OEM EGR Valve
OEM Quick Disconnect (3/8”, 45°)
B
C
Rollx Vans Charcoal
Canister Vent Metal Line (3/8”)
Part #101865
(3/8”X028X13' FUSION WELD)
OEM Plastic Line
Engine Compartment
Rollx Vans Charcoal
Canister Vent Metal Line (3/8”)
Part #101865
(3/8X028X13' FUSION WELD)
OEM Quick Disconnect (3/8”, 90°))
A
Rollx Vans Charcoal
Canister Vent Metal Line (3/8”)
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
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:
3/8” ZINC FLAT(QTY 3)
#1133008
1/2” ZINC FLAT(QTY 2)
#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)
#0122055
WASHERS:
3/8” ZINC FLAT(QTY 4)
#1133012
BOLTS:
M14-2.0 x 190mm (QTY 4)
#0122055
WASHERS:
3/8” ZINC FLAT(QTY 4)
#1133012
Left Cradle Mount
(Right side same)
Page 25
1” Motor Mount
N05010 (QTY 4)
TorQue SPecificaTionS
Location
Front Suspension
Rear Suspension
Engine & Cradle
Mounting
Torque Specifications
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
CLIP IN SEAT BASE COVERS
#B08070-1
FOLDOUT RAMP ROLLER ASM
(NOT SHOWN, FOLDOUT RAMP ONLY)
BRACKET STABILIZER, 2008 - #F08018
ROLLERS CUSHIONED - #22875T11
L-TRACK 12 HOLE #10015-1
L TRACK 5 HOLE - #10006
L TRACK 3 HOLE (FRONT) #10016
L-TRACK 4-(FRONT) #Fe200763
DOG BONE COVERS
#B2205-1
DOOR PANEL INTERIOR
DRIVER #B8802-1
PASSENGER #B8803-1
B PILLAR INTERIOR
DRIVER #B8800-1
PASSENGER #B8801-1
Wheel Well Cover
Driver
#B8808-1
Passenger #B8807-1
Interior Wire Cover #B8806-1
(may need to be painted to match)
L-TRACK 6 HOLE #10007-1
END CAP FOR SERIES L
#8663 END CAP
Page 27
inTerior
SEATBELT PASS, FEMALE, MED. SLATE
PART #1GX881D5AA
SEATBELT PASS. FEMALE, DK. SLATE
PART #1GX881S3AA
CLIP IN FOOTREST11 IN.,DR
#4003-11INCH-D-FOOTREST
#4003-11INCH-P-FOOTREST
CLIP IN COVER FLAP
(NOT SHOWN FLAP TO ACCESS SEAT
CONNECTORS)
#B08070
CLIP IN BASE,11
#4003-11-ASM-DR
#4003-11-ASM-PS
(INCLUDES FOOTREST)
SEAT BELT MOUNT BRKT "Z"
PART #STBLT1
KNEEL ACCESS COVER
(NO PART NUMBER)
TIRE COVER 2008 ASM
#B08060ASM
SEATBELT EXT L TRACK
#5086227AA-L
SEATBELT EXT 2008 12"FEM/MALE
(NOT SHOWN) - MAKES SHOULDER
HARNESS LONGER)
#5086227AA-EXT
Page 28
Kneeler TrouBleShooTing
Symptom
Possible Cause
Kneel on / off switch is turned OFF.
Remedy
Turn kneel switch to the ON position.
Van does NOT LOWER to ground while door is opening after Rollx Vans user button
is pressed.
Kneel motor or Broken Chain
Review display board. Turn kneel switch to the OFF position
and press OTC reset button. Operate without kneel option
enables. Contact customer service.
After van is lowered to ground the kneeler makes a loud ratcheting sound.
Kneel down limit switch was not activated.
Adjust kneel down limit switch. Replace if broken. Contact
customer service.
Kneel on / off switch is turned OFF.
Turn kneel switch to the ON position.
Kneel motor .
Review display board. Manually un-kneel van, turn kneel switch
to the OFF position and press OTC reset button. Contact
customer service.
Kneel up limit switch is activated incorrectly.
Adjust kneel up limit switch. Replace if broken. Contact
customer service.
Kneel up limit switch is not activated.
Once door is closed and van is at normal height, turn kneeling
switch to the OFF position.
Van will NOT RAISE when ramp is stowed.
Van raises and while door closing the kneeler ratchets.
Page 29
Qty.
1
2
1
1.5
1
1
2
1
1
1
2
3
4
4
1
1
1
1
1
Item
1
2
3
3A
4
5
6
7
8
9
10
11
12
13
14
15
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
1
Page 30
B08022
800-0072*
4PW71*
152303*
* 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
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
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.
Symptom
Remedy
Check that OTC ON/OFF switch is on. The power toggle switch
is on the actual board.
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.
Check the OTC Board fuse (1 amp) located in the Rollx Fuse
Panel behind the glove box.
Reset the OTC. The reset is located on the dash by the drivers
left knee or on the OTC Board.
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
OTC beeps 4 times when the user tries to
is to prevent the OTC system from draining the battery far
run a normal open/close cycle.
enough as to 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
equipment installed will also vary these numbers. See Battery
section for more information.
Reset the OTC. The reset is located on the dash by the drivers
left knee or on the OTC Board.
Page 31
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 32
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 33
ESC
ESC
Page 34
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 - v8.0 BaSic inTerface
one Touch SYSTeM - v8.0 advanced 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
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”.
Page 35
one Touch SYSTeM - v8.0 advanced 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 36
one Touch SYSTeM - v8.0 advanced 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 37
one Touch SYSTeM - v8.0 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).
Description - What Caused the Code
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 38
one Touch SYSTeM - v8.0 error codeS
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
Place OTC in Debug - Input Test Mode to verify limits operate
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
Description - What Caused the Code
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.
Description - What Caused the Code
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.
Description - What Caused the Code
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
Description - What Caused the 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
Place OTC in Debug - Output Test Mode to verify OTC operates
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
Place OTC in Debug - Input Test Mode to verify limits operate
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 39
one Touch SYSTeM - v8.0 error codeS
Code
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
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
Switch in Lower B-Pillar (See OTC Wiring for more
information).
Description - What Caused the 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.
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
Place OTC in Debug - Output Test Mode to verify OTC operates
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
Error 29 - Kneeler Watchdog
Error
Description - What Caused the 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
Diagnostic Tests
Operate the Kneeler with Power Overide to help determine
Reset - Esc - Kneel Up/Kneel Down
if motor is functioning correctly.
Input Test
Place OTC in Debug - Input Test Mode to verify limits operate
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
Place OTC in Debug - Output Test Mode to verify OTC operates
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.
Description - What Caused the Code
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
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
Switch in Lower B-Pillar (See OTC Wiring for more
information).
Page 40
one Touch SYSTeM - relaY Board TrouBleShooTing
RELAY BD OTC VERSION 2
P.N. 08044-003
ORDER #OTCV8 RELAY BD
OUTPUTS
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 41
This page was intentionally left blank
Page 42
in The floor TrouBleShooTing
Symptom
Possible Cause
Remedy
Door open limit switch is not being activated.
When a Open Cycle starts, the OTC will send a
command to the Chrysler System to unlock the
doors. It then sends a second command to the
Chrysler System to open the Right Side Sliding
Door. The OTC Computer then waits two
seconds and checks the Door Closed Limit
Switch. If it finds it still indicates the door is
closed, it assumes that a person (or and
obstacle) stopped the door opening sequence. It
then ends the open cycle and goes back into Idle
Mode. After ten to fifteen seconds it goes back
into Sleep Mode. This is the sequence of events
you will see if the Door Closed Limit Switch
malfunctions (sticks closed).
Ramp motor not engaged.
Engage ramp motor. Refer to the "Manual
Operation" section of this manual.
Ramp down limit switch needs adjustment to
deactivate.
Press Rollx Vans user button again to unkneel
van and close door. Review display on OTC
board and contact customer service.
Ramp will NOT DEPLOY after door
opens automatically.
Ramp motor.
OTC program failure.
Ramp will NOT STOW
automatically.
Ramp motor not engaged.
Ramp motor.
Low voltage from the battery.
Ramp will deploy before door is all
the way open.
Door open limit switch is shorted to ground or
malfuctioning.
Ramp will STOP AND REVERSE
mid-cycle.
Obstacle is detected.
Ramp will start to deploy or stow
then stop functioning.
Pressure on cover plate.
5/9/2013
Page 43
2011 Trouble Shooting.xls
Review display on OTC board and contact
customer service.
Press OTC reset button.
Engage ramp motor. Refer to the "Manual
Operation" section of this manual.
Review display on OTC board and contact
customer service.
Start vehicle. Press OTC reset button and press
Rollx Vans user button again.
Examine door open limit switch, connections,
and wiring.
Clear obstruction and press Rollx Vans user
button.
Review display on OTC board and contact
customer service.
Ensure that there are no objects on top of cover
plate.
Page 1
Page 44
17
18
19
20
21
21a
22
23
24
26
27
28
30
31
32
33
34
35
36
37
38
39
16
8
4
1
2
1
1
1
1
1
2
1
1
1
4
4
2
4
2
1
1
1
1
1
1
2
37
20
21a
N05021G-F
N05021G-B
N08025-11
N08026-11
32
34
1107632
N1-N1DXLA
N005001ASM
1173912
N05017ASM
N05016ASM
B08032ASM
05089-002
92510A351
2483K18
N05003ASM
CHRLCL035
24412
10929-02112
1133004
N05049
97517A130
N05048
33 21
26
30
3
28
1
3/8 NYLON FLAT WASHER
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 TORXBHCS 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
27
18
23
35
5
3
17
19
4
14
12
8
38
31
30
22
16
6
7
13
36
15
9
39
Item Qty.
1
1
2
1
1
3
6
4
10
5
1
6
2
7
8
8
1
3
3
3
3
9
7
10
2
12
2
13
1
14
4
15
2
10
24
Description
ITF ACCESS PLATE
MOTOR GEAR BOX ITF 2008 ASM
MOTOR WITH GEAR ONLY
1/4-20 YZ NE NYLOCK
CHAIN ROLLER SS #35
TENSIONER/SPROCKET ASM ITF
ROLLERS CUSHIONED
SS TORX BHCS 1/4-20
FLAP ASM ITF RAMP
PRECISION MINATURE IDLER*
5/16" x 1/16" NYLN WSHR
HCS 1/4-20X1 1/4 YZ8QP*
1/4-20 YZ NE NYLOCK*
SS TORX BHCS 1/4-20
HCS1/4-20X1YZ8 QPACK
HCS 1/4-20 X 3/4 YZ8 QPA
CHAIN ANCHOR
FPH MS 10-32X3/8 Z K
RAMP SPRING
1137183
35
10005
22875T11
10929-02112
N05014ASM
2483K18
76002
0115007
1137183
10929-02112
0115005
0115003
N05033
29504
N05044
N08111-MTR/GEAR ASM
Part #
N05019
N08111ASM
in floor (MeTal SPringS ) rePlaceMenT ParTS
folding raMP TrouBleShooTing
Symptom
Ramp will NOT DEPLOY after door
opens automatically.
Ramp will NOT STOW
automatically.
Possible Cause
Remedy
Ramp fuse or circuit breaker is blown.
Press Rollx Vans user button again to unkneel
van and close door. Reset circuit breaker or
check ramp fuse and replace if needed with 15
amp glass fuse located in glove box.
Door open limit switch is not being activated.
When a Open Cycle starts, the OTC will send a
command to the Chrysler System to unlock the
doors. It then sends a second command to the
Chrysler System to open the Right Side Sliding
Door. The OTC Computer then waits two
seconds and checks the Door Closed Limit
Switch. If it finds it still indicates the door is
closed, it assumes that a person (or and
obstacle) stopped the door opening sequence. It
then ends the open cycle and goes back into Idle
Mode. After ten to fifteen seconds it goes back
into Sleep Mode. This is the sequence of events
you will see if the Door Closed Limit Switch
malfunctions (sticks closed). This switch is
located in the Right Side Sliding Door Latch
Assembly.
Ramp down limit switch needs adjustment to
deactivate.
Press Rollx Vans user button again to unkneel
van and close door. Review display on OTC
board and contact customer service.
Ramp motor.
Press Rollx Vans user button again to unkneel
van and close door. Review display on OTC
board and contact customer service.
OTC program failure.
Press OTC reset button.
Ramp fuse or circuit breaker is blown.
Press Rollx Vans user button again to unkneel
van and close door. Reset circuit breaker or
check ramp fuse and replace if needed with 15
amp glass fuse located in glove box.
Ramp motor.
Ramp will deploy before door is all
the way open.
Door open limit switch is shorted to ground or
malfuctioning.
Ramp will STOP AND REVERSE
mid-cycle.
Obstacle is detected.
5/9/2013
2011 Trouble Shooting.xls
Page 45
Review display on OTC board and contact
customer service.
Examine door open limit switch, connections,
and wiring.
Clear obstruction and press Rollx Vans user
button.
Review display on OTC board and contact
customer service.
Page 1
Page 46
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
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
Qty.
2
1
1
1
3
1
2
2
2
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
COVER RAMP NEW GENERATION
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
10068
* For motor bar ramps only
22
RLXR1000-04-OTC / RLXR1000-04-MB / RLXR1000-04-NARROW-MB
folding raMP rePlaceMenT ParTS
9
Page 47
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
This page was intentionally left blank
Page 48
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 49
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
Page 50
3/8 Nut
rear heaT & air
FRONT
CONNECTIONS
Hose Clamps
705-1012 (6)
WELDED ENDS
OEM CONNECTORS
REAR HEAT & A/C
MODEL YEAR 2012-2014
REAR HEAT
CONNECTIONS
ASSEMBLIES
Hose Clamps
705-1012 (6)
#B2100-REAR HEAT LINE 5/8” (2 PER)
#B01200-RASM - REAR A/C LINE 5/16”
#B01201-RASM - REAR A/C LINE ½”
#68125530AA - AFTERMARKET O-RING 5/16”
#68030834AA - AFTERMARKET O-RING ½”
O-RINGS INCLUDED IN A/C ASSEMBLIES
REAR BLOWER
OEM CONNECTORS
WELDED ENDS
REAR
A/C CONNECTIONS
Page 51
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
Door does not open when One Touch remote is pressed.
Neither One Touch remote works.
Possible Cause
Receiver out of range.
Overhead on/off switch is turned to the OFF position.
Blown fuse.
Remedy
Try remote within 10 feet of van.
Turn switch to ON position.
Remove case by loosening screw on back and prying open.
Replace battery with battery type A23. Use second remote or
Rollx Vans user button.
Locate fuse box under glove box and check / replace fuse.
Receiver malfunction.
Review display on OTC board and contact customer service.
Lost Programming
Reprogram
(See OTC Remote System)
Transmitter battery is dead.
Page 52
reMoTe SYSTeM locaTion & Wiring
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
*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 53
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 54
Page 55
SEAT
DETECTOR
V 4.40
POWER
SEAT SENSOR
YL/GN
RD
BK
GROUND
SEAT BELT
LG/GY
SEAT POS SENSOR
LB/WT
SEAT POS SENSOR +
LB/VT
HEADREST +
PK/WT
HEADREST GND
BK/RD
SEAT BELT RETRACTOR Ln2 LG/YL
SEAT BELT RETRACTOR Ln1 LG/DG
SEAT THORAX SQUIB 1 Ln 2 LB/VT
SEAT THORAX SQUIB 1 Ln 1 LG/GY
#11134-001ASM-DR
TO CIGARETE LIGHTER
Body Side Wire
Body Side
2.4 OHM
2.4 OHM
1K
510 ohm
510 ohm
RD (20 GA.)
GN (20 GA.)
BK (20 GA.) - CAV 1
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
Pins: A1648-ND QTY 6
A1650-ND QTY 4
20
19
3
8
15
22
1
14
2
9
4
TOP
Updated on 6/3/2014
2011-2014 Chrysler Minivan
C376/I405 Driver Side with MANUAL SEAT With Seat Detector
BODY SIDE
2011-2014
driver ’S Side Manual
1
BK/RD
LG/YL
LG/DG
LB/VT
LG/GY
YL/GN
RD
BK
LG/GY
LB/WT
LB/VT
F
m
ro
M
OE
15
19
BK (20 GA.) - CAV 17
SEAT SENSOR JUMPER
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)
3
TOP
9
20
15
2
4
PINS: A1661-ND QTY 7
A1341-ND QTY 4
# A16037-ND
22
1
SEAT SIDE CONNECTOR
21
8
14
LG/YL (18 GA.) - CAV 18 (DR. SEAT BELT RETRACTOR TENSIONER LINE 2)
BK/RD (20 GA.) - CAV 5 (HEAD REST OUT)
LG/GY (20 GA.) - CAV 6 (SEAT BELT BUCKLE SWITCH)
PK/WT (20 GA.) - CAV 4 (HEAD REST IN)
LB/VT (20 GA.) - CAV 3 (SEAT POSITION SENSOR VOLTAGE)
LB/WT (20 GA.) - CAV 2 (SEAT POSITION SENSOR DATA)
BK/RD (20 GA.) - CAV 1 (GROUND)
Updated on 6/3/2014
2011-2014 Chrysler Minivan
C376/I405 Driver Seat with MANUAL SEAT - With Seat Detector
SEAT SIDE
4
10
18
24
4
Page 56
1
5
11
19
2011-2014
driver ’S Side Manual
Page 57
SEAT
DETECTOR
V 4.40
POWER
SEAT SENSOR
YL/GN
RD
BK
GROUND
SEAT BELT
LG/GY
SEAT POS SENSOR
LB/WT
SEAT POS SENSOR +
LB/VT
HEADREST +
PK/WT
HEADREST GND
BK/RD
SEAT BELT RETRACTOR Ln2 LG/YL
SEAT BELT RETRACTOR Ln1 LG/DG
SEAT THORAX SQUIB 1 Ln 2 LB/VT
SEAT THORAX SQUIB 1 Ln 1 LG/GY
#11134-001ASM-DR
Body Side Wire
Body Side
2.4 OHM
2.4 OHM
1K
510 ohm
510 ohm
RD (12 GA.)
RD (20 GA.)
(GROUND)
(Seat sensor wire for seat detector)
25 A
OR/RD (12 GA.)
RELOCATED OEM CIRCUIT BREAKER
RD (12 GA.)
(FUSED B+)
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)
BK (12 GA.) - CAV 1
YL/GN (20 GA.) - CAV 17
TO PASSENGER SIDE
SEAT PLUG
RD (12 GA.) - CAV 22
OR/RD (12 GA.)
21
BODY SIDE CONNECTOR # A 16031-ND
Pins: A25032-ND QTY 2
Pins: A1648-ND QTY 6
A1650-ND QTY 4
20
19
3
8
15
22
1
14
2
9
4
TOP
Updated on 6/3/2014
2011-2014 Chrysler Minivan
C376/I405 Driver Side with POWER ONLY - With Seat Detector
BODY SIDE
2011-2014
driver ’S Side PoWer onlY
BK/RD
LG/YL
LG/DG
LB/VT
LG/GY
YL/GN
RD
BK
LG/GY
LB/WT
LB/VT
(GROUND)
19
BK (20 GA.) - CAV 17
SEAT SENSOR JUMPER
RD (12 GA.)
- CAV 22
(FUSED B+)
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)
3
TOP
9
20
15
2
4
PINS: A25033-ND QTY 2
A1661-ND QTY 6
A1341-ND QTY 4
# A16037-ND
22
1
SEAT SIDE CONNECTOR
21
8
14
LG/YL (18 GA.) - CAV 18 (DR. SEAT BELT RETRACTOR TENSIONER LINE 2)
BK/RD (20 GA.) - CAV 5 (HEAD REST OUT)
LG/GY (20 GA.) - CAV 6 (SEAT BELT BUCKLE SWITCH)
PK/WT (20 GA.) - CAV 4 (HEAD REST IN)
LB/VT (20 GA.) - CAV 3 (SEAT POSITION SENSOR VOLTAGE)
LB/WT (20 GA.) - CAV 2 (SEAT POSITION SENSOR DATA)
BK (12 GA.) - CAV 1
Updated on 6/3/2014
2011-2014 Chrysler Minivan
C376/I405 Driver Seat with POWER ONLY - With Seat Detector
SEAT SIDE
4
10
18
24
1
5
11
19
1
Page 58
4
2011-2014
driver ’S Side PoWer onlY
Page 59
SEAT
DETECTOR
V 4.40
POWER
SEAT SENSOR
YL/GN
RD
BK
GROUND
SEAT BELT
LG/GY
SEAT POS SENSOR
LB/WT
SEAT POS SENSOR +
LB/VT
HEADREST +
PK/WT
HEADREST GND
BK/RD
SEAT BELT RETRACTOR Ln2 LG/YL
SEAT BELT RETRACTOR Ln1 LG/DG
SEAT THORAX SQUIB 1 Ln 2 LB/VT
SEAT THORAX SQUIB 1 Ln 1 LG/GY
#11134-001ASM-DR
Body Side Wire
Body Side
2.4 OHM
2.4 OHM
1K
510 ohm
510 ohm
RD (20 GA.)
RD (12 GA.)
BK (12 GA.) - CAV 1
YL/GN (20 GA.) - CAV 17
25 A
OR/RD (12 GA.)
RELOCATED OEM CIRCUIT BREAKER
RD (12 GA.)
(FUSED B+)
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)
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)
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)
TO PASSENGER SIDE
SEAT PLUG
RD (12 GA.) - CAV 22
OR/RD (12 GA.)
21
BODY SIDE CONNECTOR # A 16031-ND
Pins: A25032-ND QTY 2
Pins: A1648-ND QTY 15
A1650-ND QTY 4
20
19
3
8
15
22
1
14
2
9
4
TOP
Updated on 6/3/2014
2011-2014 Chrysler Minivan
C376/I405 Driver Side with POWER & HEAT - With Seat Detector
BODY SIDE
2011-2014
driver ’S Side PoWer & heaT
1
BK/RD
LG/YL
LG/DG
LB/VT
LG/GY
YL/GN
RD
BK
LG/GY
LB/WT
LB/VT
(GROUND)
RD (12 GA.)
- CAV 22
(FUSED B+)
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)
BK (20 GA.) - CAV 17 (SEAT SENSOR JUMPER)
LG/YL (18 GA.) - CAV 18 (DR. SEAT BELT RETRACTOR TENSIONER LINE 2)
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)
BK/RD (20 GA.) - CAV 5 (HEAD REST OUT)
LG/GY (20 GA.) - CAV 6 (SEAT BELT BUCKLE SWITCH)
PK/WT (20 GA.) - CAV 4 (HEAD REST IN)
LB/VT (20 GA.) - CAV 3 (SEAT POSITION SENSOR VOLTAGE)
LB/WT (20 GA.) - CAV 2 (SEAT POSITION SENSOR DATA)
BK (12 GA.) - CAV 1
TOP
9
20
15
2
4
PINS: A25033-ND QTY 2
A1661-ND QTY 12
A1341-ND QTY8
# A16037-ND
22
1
SEAT SIDE CONNECTOR
21
19
8
14
3
Updated on 6/3/2014
2011-2014 Chrysler Minivan
C376/I405 Driver Seat with POWER AND HEAT - With Seat Detector
SEAT SIDE
4
10
18
24
4
Page 60
1
5
11
19
2011-2014
driver ’S Side PoWer & heaT
Cut off from (BLACK)
Memory plug
SEAT
DETECTOR
V 4.40
YL/GN
SEAT SENSOR
YL/GN
POWER
RD
RD
GROUND
BK
BK
SEAT BELT
LG/GY
SEAT POS SENSOR LB/WT
SEAT POS SENSOR +LB/VT
PK/WT
HEADREST +
BK/RD
HEADREST GND BK/RD
PK/WT
SEAT BELT RETRACTOR Ln2 LG/YL
SEAT BELT RETRACTOR Ln1 LG/DG
SEAT THORAX SQUIB 1 Ln 2 LB/VT
SEAT THORAX SQUIB 1 Ln 1 LG/GY
#11134-001ASM-DR
m
0
2.4 OHM
2.4 OHM
1K
510 ohm
51
Page 61
oh
Cut off of YL plug coming
from under the seat
Cut off of WT plug coming
from under the seat
Cut/Twist & Heat shrink
Body Side Wire
WT/GY (20 GA.) - CAV 4 (CAN BUS +)
(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)
sensor wire for seat detector)
(ADJUSTABLE PEDALS MORTOR FORWARD)
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
4
5
10
16
23
29
34
1
2
3
1
BODY SIDE CONNECTOR #A16015-ND
Pins: A25033-ND QTY 3
RD (12 GA.) - CAV 1
TO PASSENGER SIDE
SEAT PLUG
OR/RD (12 GA.)
BODY SIDE CONNECTOR # A1364-ND
Pins: A1648-ND QTY 23
A1341-ND QTY 4
28
33
37
9
15
22
TOP
BODY SIDE
OR/RD (14 GA.) - CAV 2
OR/RD (12 GA.)
RELOCATED OEM CIRCUIT BREAKER
(ADJUSTABLE PEDAL SENSOR )
WT/GY (20 GA.) - CAV 25 (CAN BUS +)
VT/LB (20 GA.) - CAV 26
WT/OR (20 GA.) - CAV 24 (CAN BUS -)
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)
WT/OR (20 GA.) - CAV 3 (CAN BUS -)
OR/LB (20 GA.) - CAV 2
LG/WT (20 GA.) - CAV 1
Updated on 6/3/2014
2011-2014 Chrysler Minivan
C376/
I405 Drivers Side with POWER & HEAT & MEMORY With Seat Detector
2011-2014
driver ’S Side MeMorY
Page 62
13
11
9
7
5
3
1
4
1
8
6
4
2
14
12
10
1
5
11
19
4
10
18
24
WT/GY (20 GA.) - CAV 4 (CAN BUS +)
(SEAT BELT BUCKLE SWITCH)
(R.F. HEATED SEAT TEMP SENSE)
(SEAT BELT RETRACTOR TENSIONER LINE 2)
(HEATED STEERING WHEEL RETURN)
(RT. FRONT SEAT HEATER CONTROL)
(FUSED OUTPUT)
(SEAT POS SENSOR VOLTAGE)
(HEATED STEERING WHEEL)
(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
SEAT SIDE CONNECTOR
3
2
#A16019-ND
PINS: A25032-ND 3 per van
1
SEAT SIDE CONNECTOR
# A 1359-ND
28
33
37
4
PINS: A1650-ND QTY 9
A1661-ND QTY18
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 )
WT/GY (20 GA.) - CAV 25 (CAN BUS +)
VT/LB (20 GA.) - CAV 26
WT/OR (20 GA.) - CAV 24 (CAN BUS -)
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)
LG/YL (18 GA.) - CAV 17
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)
(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)
WT/OR (20 GA.) - CAV 3 (CAN BUS -)
OR/LB (20 GA.) - CAV 2
LG/WT (20 GA.) - CAV 1
Updated on 6/3/2014
C376/
2011-2014 Chrysler Minivan
I405 Drivers Seat with POWER & HEAT-& MEMORY With Seat Detector
2011-2014
driver ’S Side MeMorY
Page 63
SEAT DETECTOR V 4.40
SEAT SENSOR
YL/GN
POWER
RD
GROUND
BK
LB/GY
SEAT BELT
SEAT POS SENSOR
WT/LB
SEAT POS SENSOR +
VT/LB
PK/DB
HEADREST +
BK/RD
HEADREST GND
SEAT BELT RETRACTOR Ln2 LB/YL
SEAT BELT RETRACTOR Ln1 LB/DG
SEAT THORAX SQUIB 1 Ln 2 VT/LB
SEAT THORAX SQUIB 1 Ln 1 GY/LG
#11134-001ASM-PS
From Drivers
Side seat
OR/RD (12 GA.)
Body Side
Wires
To Chassis
GND
2.4 OHM
2.4 OHM
1K
510 ohm
510 ohm
YL/GN (20 GA.) - CAV 17
(SEAT THORAX SQUIB 1 LINE 1)
(SEAT BELT RETRACTOR TENSIONER LINE 1)
(SEAT THORAX SQUIB 1 LINE 2)
LB/DG (18 GA.) - CAV 19
VT/LB (18 GA.) - CAV 20
GY/LG (18 GA.) - CAV 21
(SEAT BELT RETRACTOR TENSIONER LINE 2)
LB/YL (18 GA.) - CAV 18
(SEAT OCCUPANT DETECTION RETURN)
LB/DG (20 GA.) - CAV 8
LB/LG (20 GA.) - CAV 9
(SEAT BELT SWITCH SENSE)
(SEAT OCCUPANT DETECTION SIGNAL)
LB/GY (20 GA.) - CAV 7
(HEAD REST GROUND)
(SEAT BELT BUCKLE SWICHT SENSE)
(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)
WT/LB (20 GA.) - CAV 2
BK/RD (20 GA.) - CAV 5
(GROUND)
BK (12 GA.) CAV 1
(Seat sensor wire for seat detector)
21
BODY SIDE CONNECTOR #A16031-ND
Pins: A25032-ND QTY 2
Pins: A1648-ND QTY 12
A1650-ND QTY 4
20
19
15
3
8
14
22
1
9
4
2
TOP
Updated on 6/3/2014
2011-2012 Chrysler Minivan
C378 Passenger Side with MANUAL SEAT With Seat Detector
BODY SIDE
2011-2012
PaSSenger ’S Side Manual
7
1
1
Page 64
4
14
8
BK/RD
LG/YL
LG/DG
GY/LG (18 GA.) - CAV 21
LB/DG (18 GA.) - CAV 19
VT/LB (18 GA.) - CAV 20
LB/YL (18 GA.) - CAV 18
BK (20 GA.) - CAV 17
(Seat sensor wire for seat detector)
(SEAT OCCUPANT DETECTION RETURN)
(SEAT THORAX SQUIB 1 LINE 1)
(SEAT BELT RETRACTOR TENSIONER LINE 1)
(SEAT THORAX SQUIB 1 LINE 2)
(SEAT BELT RETRACTOR TENSIONER LINE 2)
LB/LG (20 GA.) - CAV 9
(SEAT BELT SWITCH SENSE)
(SEAT OCCUPANT DETECTION SIGNAL)
LB/GY (20 GA.) - CAV 7
(SEAT BELT BUCKLE SWICHT SENSE)
LB/TN (20 GA.) - CAV 6
LB/DG (20 GA.) - CAV 8
(HEAD REST GROUND)
(PASS SEAT POS SENSOR DATA)
(HEAD REST PASS SOLENOID +)
(PASS SEAT POS SENSOR VOTAGE)
BK/RD (20 GA.) - CAV 5
VT/LB (20 GA.) - CAV 3
PK/DB (20 GA.) - CAV 4
WT/LB (20 GA.) - CAV 2
TOP
9
20
15
2
4
PINS: A1661- ND QTY 9
A1341- ND QTY 4
# A16037-ND
22
1
SEAT SIDE CONNECTOR
21
19
8
14
3
Updated on 6/3/2014
2011-2012 Chrysler Minivan
C378 Passenger Seat with MANUAL - With Seat Detector
SEAT SIDE
2011-2012
PaSSenger ’S Side Manual
Page 65
SEAT DETECTOR V 4.40
SEAT SENSOR
YL/GN
POWER
RD
GROUND
BK
LB/GY
SEAT BELT
SEAT POS SENSOR
WT/LB
SEAT POS SENSOR +
VT/LB
PK/DB
HEADREST +
BK/RD
HEADREST GND
SEAT BELT RETRACTOR Ln2 LB/YL
SEAT BELT RETRACTOR Ln1 LB/DG
SEAT THORAX SQUIB 1 Ln 2 VT/LB
SEAT THORAX SQUIB 1 Ln 1 GY/LG
#11134-001ASM-PS
OR/RD (14 GA.)
From Drivers
Side seat
Body Side
Wires
2.4 OHM
2.4 OHM
1K
510 ohm
510 ohm
BK (12 GA.) - CAV 1
YL/GN (20 GA.) - CAV 17
(SEAT OCCUPANT DETECTION SIGNAL)
LB/GY (20 GA.) - CAV 7
LB/DG (20 GA.) - CAV 8
RD (20 GA.) - CAV 22
(FUSED B+)
(SEAT THORAX SQUIB 1 LINE 1)
OR/RD (14 GA.) - CAV 22
GY/LG (18 GA.) - CAV 21
(SEAT BELT RETRACTOR TENSIONER LINE 1)
(SEAT THORAX SQUIB 1 LINE 2)
LB/DG (18 GA.) - CAV 19
VT/LB (18 GA.) - CAV 20
(RIGHT FRONT HEATED SEAT TEMP SENSE)
TN/DB (20 GA.) - CAV 12
(SEAT BELT RETRACTOR TENSIONER LINE 2)
(RIGHT FRONT SEAT HEATER CONTROL)
LG/VT (20 GA.) - CAV 11
LB/YL (18 GA.) - CAV 18
(SEAT OCCUPANT DETECTION RETURN)
(HEATED SEAT SENSOR RETURN)
TN/WT (20 GA.) - CAV 10
LB/LG (20 GA.) - CAV 9
(SEAT BELT SWITCH SENSE)
(HEAD REST GROUND)
(SEAT BELT BUCKLE SWICHT SENSE)
LB/TN (20 GA.) - CAV 6
(PASS SEAT POS SENSOR DATA)
(HEAD REST PASS SOLENOID +)
VT/LB (20 GA.) - CAV 3
PK/DB (20 GA.) - CAV 4
BK/RD (20 GA.) - CAV 5
(PASS SEAT POS SENSOR VOTAGE)
WT/LB (20 GA.) - CAV 2
(GROUND)
(Seat sensor wire for seat detector)
2
22
1
21
19
14
3
8
BODY SIDE CONNECTOR #A16031-ND
Pins: A25032-ND QTY 2
Pins: A1648-ND QTY 12
A1650-ND QTY 4
20
15
9
4
TOP
Updated on 6/3/2014
2011-2012 Chrysler Minivan
C378 Passenger Side with POWER & HEAT - With Seat Detector
BODY SIDE
2011- (earlY) 2012
PaSSenger ’S Side PoWer & heaT
14
8
BK/RD
LG/YL
LG/DG
(GROUND)
(SEAT BELT SWITCH SENSE)
(SEAT BELT BUCKLE SWICHT SENSE)
(HEAD REST GROUND)
(PASS SEAT POS SENSOR DATA)
(HEAD REST PASS SOLENOID +)
(PASS SEAT POS SENSOR VOTAGE)
GY/LG (18 GA.) - CAV 21
(SEAT THORAX SQUIB 1 LINE 1)
(SEAT BELT RETRACTOR TENSIONER LINE 1)
(SEAT THORAX SQUIB 1 LINE 2)
LB/DG (18 GA.) - CAV 19
VT/LB (18 GA.) - CAV 20
(FUSED B+)
(Seat sensor wire for seat detector)
(SEAT BELT RETRACTOR TENSIONER LINE 2)
OR/RD (14 GA.) - CAV 22
(RIGHT FRONT HEATED SEAT TEMP SENSE)
TN/DB (20 GA.) - CAV 12
BK (20 GA.) - CAV 17
(RIGHT FRONT SEAT HEATER CONTROL)
LG/VT (20 GA.) - CAV 11
(SEAT OCCUPANT DETECTION RETURN)
TN/WT (20 GA.) - CAV 10 (HEATED SEAT SENSOR RETURN)
LB/LG (20 GA.) - CAV 9
LB/DG (20 GA.) - CAV 8 (SEAT OCCUPANT DETECTION SIGNAL)
LB/GY (20 GA.) - CAV 7
LB/TN (20 GA.) - CAV 6
BK/RD (20 GA.) - CAV 5
VT/LB (20 GA.) - CAV 3
PK/DB (20 GA.) - CAV 4
WT/LB (20 GA.) - CAV 2
LB/YL (18 GA.) - CAV 18
BK (12 GA.) - CAV 1
TOP
9
20
15
2
4
PINS: A1661- ND QTY 11
A1341- ND QTY 5
A25033-ND QTY 2
# A16037-ND
22
1
SEAT SIDE CONNECTOR
21
19
8
14
3
Updated on 6/3/2014
2011-2012 Chrysler Minivan
C378 Passenger Seat with POWER & HEAT - With Seat Detector
SEAT SIDE
7
1
1
Page 66
4
2011- (earlY)2012
PaSSenger ’S Side PoWer & heaT
Page 67
SEAT DETECTOR V 4.40
SEAT SENSOR
YL/GN
POWER
RD
GROUND
BK
LB/GY
SEAT BELT
SEAT POS SENSOR
WT/LB
SEAT POS SENSOR +
VT/LB
PK/DB
HEADREST +
BK/RD
HEADREST GND
SEAT BELT RETRACTOR Ln2 LB/YL
SEAT BELT RETRACTOR Ln1 LB/DG
SEAT THORAX SQUIB 1 Ln 2 VT/LB
SEAT THORAX SQUIB 1 Ln 1 GY/LG
OCCUPANT DETECT SIG LB/DG
OCCUPANT DETECT RET LB/LG
#11134-001ASM-PS
OR/RD (14 GA.)
From Drivers
Side seat
Body Side
Wires
1K
2.4 OHM
2.4 OHM
1K
510 ohm
510 ohm
BK (12 GA.) - CAV 1
YL/GN (20 GA.) - CAV 17
(SEAT BELT RETRACTOR TENSIONER LINE 2)
RD (20 GA.) - CAV 22
OR/RD (14 GA.) - CAV 22
GY/LG (18 GA.) - CAV 21
(FUSED B+)
(SEAT THORAX SQUIB 1 LINE 1)
LB/DG (18 GA.) - CAV 19 (SEAT BELT RETRACTOR TENSIONER LINE 1)
VT/LB (18 GA.) - CAV 20
(SEAT THORAX SQUIB 1 LINE 2)
LB/YL (18 GA.) - CAV 18
TN/DB (20 GA.) - CAV 12 (RIGHT FRONT HEATED SEAT TEMP SENSE)
LG/VT (20 GA.) - CAV 11 (RIGHT FRONT SEAT HEATER CONTROL)
LB/LG (20 GA.) - CAV 9 (SEAT OCCUPANT DETECTION RETURN)
TN/WT (20 GA.) - CAV 10 (HEATED SEAT SENSOR RETURN)
LB/DG (20 GA.) - CAV 8 (SEAT OCCUPANT DETECTION SIGNAL)
(SEAT BELT SWITCH SENSE)
(SEAT BELT BUCKLE SWICHT SENSE)
LB/GY (20 GA.) - CAV 7
(HEAD REST GROUND)
LB/TN (20 GA.) - CAV 6
(PASS SEAT POS SENSOR DATA)
(HEAD REST PASS SOLENOID +)
VT/LB (20 GA.) - CAV 3
PK/DB (20 GA.) - CAV 4
BK/RD (20 GA.) - CAV 5
(PASS SEAT POS SENSOR VOTAGE)
WT/LB (20 GA.) - CAV 2
(GROUND)
(Seat sensor wire for seat detector)
22
1
21
19
14
3
8
BODY SIDE CONNECTOR #A16031-ND
Pins: A25032-ND QTY 2
Pins: A1648-ND QTY 12
A1650-ND QTY 4
20
15
9
4
2
TOP
Updated on 6/3/2014
2011-2012 Chrysler Minivan
C378 Passenger Side with POWER & HEAT - With Seat Detector
BODY SIDE (W/ OCCUPANT DETECTION CIRCUIT)
2011- (laTe) 2012
PaSSenger ’S Side PoWer & heaT
14
8
BK/RD
LG/YL
LG/DG
(GROUND)
(RIGHT FRONT HEATED SEAT TEMP SENSE)
TN/DB (20 GA.) - CAV 12
GY/LG (18 GA.) - CAV 21
(SEAT THORAX SQUIB 1 LINE 1)
(SEAT BELT RETRACTOR TENSIONER LINE 1)
(SEAT THORAX SQUIB 1 LINE 2)
LB/DG (18 GA.) - CAV 19
VT/LB (18 GA.) - CAV 20
(FUSED B+)
(Seat sensor wire for seat detector)
(SEAT BELT RETRACTOR TENSIONER LINE 2)
OR/RD (14 GA.) - CAV 22
(RIGHT FRONT SEAT HEATER CONTROL)
LG/VT (20 GA.) - CAV 11
BK (20 GA.) - CAV 17
(SEAT OCCUPANT DETECTION RETURN)
(HEATED SEAT SENSOR RETURN)
TN/WT (20 GA.) - CAV 10
LB/LG (20 GA.) - CAV 9
(SEAT BELT SWITCH SENSE)
(SEAT OCCUPANT DETECTION SIGNAL)
LB/GY (20 GA.) - CAV 7
(SEAT BELT BUCKLE SWICHT SENSE)
LB/TN (20 GA.) - CAV 6
LB/DG (20 GA.) - CAV 8
(HEAD REST GROUND)
(PASS SEAT POS SENSOR DATA)
(HEAD REST PASS SOLENOID +)
(PASS SEAT POS SENSOR VOTAGE)
BK/RD (20 GA.) - CAV 5
VT/LB (20 GA.) - CAV 3
PK/DB (20 GA.) - CAV 4
WT/LB (20 GA.) - CAV 2
LB/YL (18 GA.) - CAV 18
BK (12 GA.) - CAV 1
TOP
9
20
15
2
4
PINS: A1661- ND QTY 11
A1341- ND QTY 5
A25033-ND QTY2
# A16037-ND
22
1
SEAT SIDE CONNECTOR
21
19
8
14
3
Updated on 6/3/2014
2011-2012 Chrysler Minivan
C378 Passenger Seat with POWER & HEAT - With Seat Detector
SEAT SIDE (W/ OCCUPANT DETECTION CIRCUIT)
7
1
1
Page 68
4
2011-(laTe) 2012
PaSSenger ’S Side PoWer & heaT
Page 69
SEAT DETECTOR V 4.40
SEAT SENSOR
YL/GN
POWER
RD
GROUND
BK
LB/GY
SEAT BELT
SEAT POS SENSOR
WT/LB
SEAT POS SENSOR +
VT/LB
PK/DB
HEADREST +
BK/RD
HEADREST GND
SEAT BELT RETRACTOR Ln2 LB/YL
SEAT BELT RETRACTOR Ln1 LB/DG
SEAT THORAX SQUIB 1 Ln 2 VT/LB
SEAT THORAX SQUIB 1 Ln 1 GY/LG
OCCUPANT DETECT SIG
LB/DG
OCCUPANT DETECT RET
LB/TN
#11134-001ASM-PS
OR/RD (14 GA.)
From Drivers
Side seat
Body Side
Wires
To Chassis
GND
1K
2.4 OHM
2.4 OHM
1K
510 ohm
510 ohm
RD (20 GA)
YL/GN (20 GA.) - CAV 17
(SEAT BELT SWITCH SENSE)
(SEAT BELT RETRACTOR TENSIONER LINE 2)
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
BODY SIDE CONNECTOR #A16031-ND
Pins: A25032-ND QTY 2
Pins: A1648-ND QTY 10
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+)
(SEAT THORAX SQUIB 1 LINE 1)
LB/DG (18 GA.) - CAV 19 (SEAT BELT RETRACTOR TENSIONER LINE 1)
VT/LB (18 GA.) - CAV 20
(SEAT THORAX SQUIB 1 LINE 2)
LB/YL (18 GA.) - CAV 18
LB/TN (20 GA.) - CAV 9 (SEAT OCCUPANT DETECTION RETURN)
LB/DG (20 GA.) - CAV 8 (SEAT OCCUPANT DETECTION SIGNAL)
LB/GY (20 GA.) - CAV 7
(HEAD REST GROUND)
(HEAD REST PASS SOLENOID +)
PK/DB (20 GA.) - CAV 4
BK/RD (20 GA.) - CAV 5
(GROUND)
BK (12 GA.) - CAV 1
(Seat sensor wire for seat detector)
Updated on 6/3/2014
2013-2014 Chrysler Minivan
I406/C378 Passenger Side with MANUAL- With Seat Detector
BODY SIDE (W/ OCCUPANT DETECTION CIRCUIT)
2013-2014
PaSSenger ’S Side Manual
8
7
1
14
Page 70
BK/RD
LG/YL
LG/DG
GY/LG (18 GA.) - CAV 21
LB/DG (18 GA.) - CAV 19
VT/LB (18 GA.) - CAV 20
LB/YL (18 GA.) - CAV 18
BK (20 GA.) - CAV 17
(SEAT THORAX SQUIB 1 LINE 1)
(SEAT BELT RETRACTOR TENSIONER LINE 1)
(SEAT THORAX SQUIB 1 LINE 2)
TOP
PINS: A1661- ND
A1341- ND
# A16037-ND
22
1
9
20
15
2
4
QTY 6
QTY 4
SEAT SIDE CONNECTOR
21
19
8
14
3
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
(Seat sensor wire for seat detector)
(SEAT OCCUPANT DETECTION RETURN)
(SEAT BELT RETRACTOR TENSIONER LINE 2)
LB/TN (20 GA.) - CAV 9
(SEAT BELT SWITCH SENSE)
(SEAT OCCUPANT DETECTION SIGNAL)
LB/GY (20 GA.) - CAV 7
(HEAD REST GROUND)
(HEAD REST PASS SOLENOID +)
LB/DG (20 GA.) - CAV 8
BK/RD (20 GA.) - CAV 5
PK/DB (20 GA.) - CAV 4
Updated on 6/3/2014
2013-2014 Chrysler Minivan
I406A/C378 Passenger Seat with MANUAL - With Seat Detector
SEAT SIDE
2013-2014
PaSSenger ’S Side Manual
Page 71
SEAT DETECTOR V 4.40
SEAT SENSOR
YL/GN
POWER
RD
GROUND
BK
LB/GY
SEAT BELT
SEAT POS SENSOR
WT/LB
SEAT POS SENSOR +
VT/LB
PK/DB
HEADREST +
BK/RD
HEADREST GND
SEAT BELT RETRACTOR Ln2 LB/YL
SEAT BELT RETRACTOR Ln1 LB/DG
SEAT THORAX SQUIB 1 Ln 2 VT/LB
SEAT THORAX SQUIB 1 Ln 1 GY/LG
OCCUPANT DETECT SIG
LB/DG
OCCUPANT DETECT RET
LB/TN
#11134-001ASM-PS
OR/RD (14 GA.)
From Drivers
Side seat
Body Side
Wires
To Chassis
GND
1K
2.4 OHM
2.4 OHM
1K
510 ohm
510 ohm
RD (20 GA)
YL/GN (20 GA.) - CAV 17
(SEAT BELT SWITCH SENSE)
(SEAT BELT RETRACTOR TENSIONER LINE 2)
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
BODY SIDE CONNECTOR #A16031-ND
Pins: A25032-ND QTY 2
Pins: A1648-ND QTY 10
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+)
(SEAT THORAX SQUIB 1 LINE 1)
LB/DG (18 GA.) - CAV 19 (SEAT BELT RETRACTOR TENSIONER LINE 1)
VT/LB (18 GA.) - CAV 20
(SEAT THORAX SQUIB 1 LINE 2)
LB/YL (18 GA.) - CAV 18
LB/TN (20 GA.) - CAV 9 (SEAT OCCUPANT DETECTION RETURN)
LB/DG (20 GA.) - CAV 8 (SEAT OCCUPANT DETECTION SIGNAL)
LB/GY (20 GA.) - CAV 7
(HEAD REST GROUND)
(HEAD REST PASS SOLENOID +)
PK/DB (20 GA.) - CAV 4
BK/RD (20 GA.) - CAV 5
(GROUND)
BK (12 GA.) - CAV 1
(Seat sensor wire for seat detector)
Updated on 6/3/2014
2013-2014 Chrysler Minivan
I406/C378 Passenger Side with MANUAL- With Seat Detector
BODY SIDE (W/ OCCUPANT DETECTION CIRCUIT)
2013-2014 PaSSenger ’S Side PoWer & heaT
8
7
1
14
Page 72
BK/RD
LG/YL
LG/DG
(RIGHT FRONT SEAT HEATER CONTROL)
(RIGHT FRONT HEATED SEAT TEMP SENSE)
TN/WT (20 GA.) - CAV 10
LG/VT (20 GA.) - CAV 11
TN/DB (20 GA.) - CAV 12
LB/YL (18 GA.) - CAV 18
GY/LG (18 GA.) - CAV 21
(FUSED B+)
(SEAT THORAX SQUIB 1 LINE 1)
(SEAT BELT RETRACTOR TENSIONER LINE 1)
(SEAT THORAX SQUIB 1 LINE 2)
(SEAT BELT RETRACTOR TENSIONER LINE 2)
OR/RD (14 GA.) - CAV 22
3
TOP
9
20
15
2
4
PINS: A1661- ND QTY 9
A1341- ND QTY 4
A25033-ND QTY 2
# A16037-ND
22
1
SEAT SIDE CONNECTOR
21
19
8
14
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
(Seat sensor wire for seat detector)
BK (20 GA.) - CAV 17
(SEAT OCCUPANT DETECTION RETURN)
(HEATED SEAT SENSOR RETURN)
LB/TN (20 GA.) - CAV 9
(SEAT BELT SWITCH SENSE)
(SEAT OCCUPANT DETECTION SIGNAL)
LB/GY (20 GA.) - CAV 7
(HEAD REST GROUND)
(HEAD REST PASS SOLENOID +)
(GROUND)
LB/DG (20 GA.) - CAV 8
BK/RD (20 GA.) - CAV 5
PK/DB (20 GA.) - CAV 4
LB/DG (18 GA.) - CAV 19
VT/LB (18 GA.) - CAV 20
BK (12 GA.) - CAV 1
Updated on 6/3/2014
2013-2014 Chrysler Minivan
I406A/C378 Passenger Seat with POWER & HEAT - With Seat Detector
SEAT SIDE
2013-2014
PaSSenger ’S Side PoWer & heaT
oTc Wiring (WiTh The door oPen liMiT SWiTch)
ROLLX VANS ONE TOUCH CONT
ITF Harness V6/ OTC Board V8 MOD
TIPM
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
(Fuse box
under hood)
BK
DB / YL (20 GA.)
BK (20 GA.
BK (20 GA.)
CUT
Twisted pairs run down B-Pillar
1
BACK SIDE
WT/OR
WT/GY
WT/OR (CAV 5)
(Chrysler Door Ajar Circuit)
N/C
BK (10 GA.)
(User switch)
(Neutral Safety)
(Door Open Limit)
(Door Closed Limit)
DB (20 GA.)
BLACK
DG (20 GA.)
INPUTS
VT/YL (CAV 11)
WT / RD (20 GA.)
WT / RD (20 GA.)
N/C
BACK SIDE
14
WT/GY (CAV 12)
WT/GY
N/C
1
Passenger’s side Door snake
(B-Pillar)
WT/OR
BLACK
DOOR DISABLE
16
DMRR
Door Module Right Rear
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
BACK SIDE
OUTPUTS
12
RD / WT
YL / WT (20 GA.)
N/C
N/C
RD /
YL / BK
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
YL (12 GA.)
4
1
BK GY
(-) (+)
KNEEL SYSTEM
Italic Font = OEM Wire
Rollx Vans, Inc.
DRAWING #:
12361
6591 West Highway 13
REVISION:
V-8.00 My11 Chrysler
UP LIMIT
YL / WT
Savage, MN 55378
DRAWN BY:
Jason Hodgkins
952.890.7851
CHECKED BY:
Lynn Ringdahl
COPYRIGHT 2008
1
OEM B-PILLAR SWITCH
(Rollx Vans uses this to
operate the door)
* = For pictures of location see
Important Information and Location
Section in Service Manual
NONE
6
5
(OEM CAV #4) PASSENGER DOOR MODULE
(Rollx Vans uses this to
unlock the door)
RD (12 GA.)
SCALE:
10
BK
YL / DG
NC
NO
SWITCHES
* KNEEL LIMIT
(#6X284)
DOWN LIMIT
2
2
NC
1
1
NO
3
3
COM
COM
BK
RD (12 GA.)
REVISION HISTORY:
08330-001 INITIAL RELEASE. 11/25/2008
YL (12 GA.)
Page 73
BL (20 GA.)
BLACK
SHUNT, 2005 HONDA
CAN BUS
#WM4814-ND-H ASM
16
RESET
oTc Wiring (WiTh The door oPen liMiT SWiTch)
NTROLLER WIRING DIAGRAM BuilT Before 8/26/2013
OD E-F (W/ Limit Switch)
Compustar Remote
ROLLX VANS USER / RESET SWITCHES
(ASM #03220-005)
D-PILLAR
DASH
RESET SWITCH (8/21/06)
12/27/12
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.)
.)
0 GA. X 3)
DB (20 GA.)
BK (20 GA.)
BK (20 GA.)
IN
BK (20 GA.)
WT / RD (20 GA.) X 3
*
BK (20 GA. X 3)
C309
7
OR (20 GA.)
14
ar
FUSE PANEL
(BEHIND GLOVE BOX)
1N4007
DIODES
1 AMP
REMOTE
1 AMP
DOOR DETECTOR
1 AMP
CONTROLLER PWR
)
BL (20 GA.)
RD (20 GA.)
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
3
COM
YL / BK
L/RD
NO
COM
SWITCHES
* RAMP LIMIT
(#6X284)
BK
DB
#310-1059
ITF RAMP
*RELAY BOARD #OTCV8 RELAY BD
J2
OR (20 GA.)
RD (20 GA.)
BL (20 GA.)
Rollx Vans Remote Reciever
OUTPUTS
ASM #03295-003
ANTENNA RUNS
UP PASSENGER
“D” PILLAR
YL (12 GA.)
6
RAMP
ENABLE
GND (To Body)
RD (12 GA.)
BK
BK (12 GA.)
KNL DN
KNL UP
BK (12 GA.)
1
4
8
13
17
21
12
16
20
23
BK (10 GA.)
RAMP UP
PWR OVERRIDES
2
RD (10 GA.)
RAMP DN
INPUTS
DB
BA
# 08044-002
D
3
7
GN/DB
(OEM CAV 9)
ASM #03220-005
RD (-)
YL (+)
J1
N
CM6200
3
R
P
Neutral Safety
NC
RD (14 GA.)
RD
RD / BK
2
1
1
BK (20 GA.)
NO
2
RD (10 GA.)
NC
DB (20 GA.)
D / WT (20 GA.)
OR/RD (20 GA.)
BK (20 GA.)
DOWN
LIMIT
+
*(To Inition Hot)
located under
steering column
RD / DG (20 GA.)
-
RD (8 GA.)
NC
NO
2
1
3
COM
DOOR OPEN LIMIT SWITCH
(Passenger side lower door track)
Page 74
POWER OVERRIDE BUS
8
1
)
oTc Wiring (WiTh The door deTecTor)
ROLLX VANS ONE TOUCH C
ITF Harness V6/ OTC Board V8 MOD
* = For pictures of location see
Important Information and Location
Section in Service Manual
*UNIVERSAL DOOR
DETECTOR
(13104-001ASM)
Italic Font = OEM Wire
LOCATION:
Passengers D-PILLAR
12
BACK SIDE
N/C
(Door Closed Status In)
VT (20 GA.) (QUAD B + IN)
BL (20 GA.) (QUAD A + IN)
PK (20 GA.) (GND)
N/C
1
4
1
OR/RD (20 GA.) (Door Open Status out)
BL/YL (20 GA.) (Reset)
BK (20 GA.)
(GND)
KNEEL DISABLE (ON / OFF) SWITCH
(ASM #03220-001)
VT
LOCATION:
Passengers C-PILLAR
(V BAT)
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
BLACK
1
LB/WT (20GA.)
BACK SIDE
BK (10 GA.)
DB (20 GA.)
N/C
BACK SIDE
BLACK
INPUTS
WT/GY (CAV 12)
WT / RD (20 GA.)
WT / RD (20 GA.)
N/C
(User switch)
DG (20 GA.)
(Neutral Safety)
OR / RD (20 GA.)
(Door Open Limit)
VT / YL (20 GA.)
(Door Closed Limit)
SWITCHES
* RAMP LIMIT
(#6X284)
RD / DG (20 GA.)
RD / WT (20 GA.)
N/C
NC
NO
YL / DG (20 GA.)
2
2
UP
LIMIT
DOWN
LIMIT
1
3
COM
YL / WT (20 GA.)
1
3
N/C
BK (20 GA.)
BACK SIDE
OUTPUTS
YL/RD
(Door Control)
RD/DB
1
5
(Unlock Output)
BLACK
RD (12 GA.)
N/C
YL (12 GA.)
ECN # 13196
Rollx Vans, Inc.
Effective Stock # 47397
6591 West Highway 13
Effective Start Date: 8/26/2013
Savage, MN 55378
DRAWING #: 13266
952.890.7851
DRAWN BY:
COPYRIGHT 2008
(VT/YL)
BK
BK
(Rollx Vans uses this to
unlock the door)
(OEM CAV #4)
LOCATION:
Passenger front door
BK
Jason Hodgkins
6 PASSENGER DOOR MODULE
10
N/C
LG / WT (20 GA.)
BK GY
(-) (+)
(CAV #1)
1
4
KNEEL SYSTEM
OEM B-PILLAR SWITCH
(Rollx Vans uses this to
operate the door)
YL / WT
BK
UP LIMIT
NC
NO
COM
SWITCHES
* KNEEL LIMIT
(#6X284)
DOWN LIMIT
2
2
NC
1
1
NO
3
3
BK
COM
YL / DG
RD (12 GA.)
REVISION HISTORY:
08330-001 INITIAL RELEASE. 11/25/2008
YL (12 GA.)
Page 75
NO
RD
RD / BK
YL / BK
YL / BK (20 GA.)
YL / RD (20 GA.)
OR (20 GA.)
RD / DB (20 GA.)
BLACK
NC
COM
RD
(20 GA.)
RD / BK (20 GA.)
1
RAMP MOTOR
WT/OR (CAV 5)
LB/VT (20GA.)
N/C
1
12
(Chrysler Door Ajar Circuit
LOCATION:
Passengers B-PILLAR Solder
WT/GY (20GA.)
N/C
1
14
Solder
WT/OR (20GA.)
BLACK
DOOR DISABLE
16
SHUNT, 2005 HONDA
CAN BUS
#WM4814-ND-H ASM
16
PSDMR
Power Sliding Door Module Rig
oTc Wiring (WiTh The door deTecTor)
9/23/2013
H CONTROLLER WIRING DIAGRAM
MOD F (W/ Door Detector)
DASH
RESET SWITCH (8/21/06)
4
DB
BK
BuilT afTer 8/26/2013
ROLLX VANS USER / RESET SWITCHES
(ASM #03220-005)
D-PILLAR
DB
DASH
C-PILLAR
BK
BK
DB
BK
DB
1
DB (20 GA.)
BK (20 GA.)
BK (20 GA. X 3)
LOCATION:
Back side of the lower slider door track
R
odule Right
BK (20 GA. X 3)
DB / YL (20 GA.)
DMRR
Door Module Right Rear
ITF RAMP OVERRIDE
SWITCH
(DRIVER SIDE B
PILLAR) #05175-001
BK (20 GA.)
OUT
* FUSE PANEL
(BEHIND GLOVE BOX)
1 AMP
REMOTE
1 AMP
IN
DOOR DETECTOR
1 AMP
CONTROLLER PWR
7
Circuit)
14
Passenger’s side Door snake
(B-Pillar)
C309
VT/YL (CAV 11)
OR (20 GA.)
Nuetral
Safety
Ignition
Hot
1N4007
DIODES
8
1
LOCATION:
Passengers B-PILLAR
BL (20 GA.)
RD (20 GA.)
11DQ05-ND
DIODE
BK (8 GA.)
40A
FUSE
/ BK
/ BK
RD (14 GA.)
RD (-)
BK (20 GA.)
ITF RAMP
RD (10 GA.)
#310-1059
DB (20 GA.)
CHES
GN/DB
(OEM CAV 9)
*RELAY BOARD #OTCV8 RELAY BD
BK (10 GA.)
KNL DN
OR (20 GA.)
PWR OVERRIDES
RD (20 GA.)
BL (20 GA.)
INPUTS
OUTPUTS
YL (12 GA.)
6
RAMP
ENABLE
D
2
BK
1
4
8
13
17
21
7
12
16
20
23
LOCATION:
On the transmission
RD (10 GA.)
RAMP UP
KNL UP
N
GND (To Body)
Rollx Vans Remote Reciever
CM6200
J2
RAMP DN
DB
ASM #03220-005
J1
R
P
Neutral Safety3
RD
# 08044-002
+
*(To Inition Hot)
located under
steering column
YL (+)
B
-
RD (8 GA.)
ASM #03295-003
LOCATION:
Passenger’s side D-Pillar
ANTENNA RUNS
UP PASSENGER
“D” PILLAR
BK (12 GA.)
RD (12 GA.)
Page 76
POWER OVERRIDE BUS
DG (20 GA.)
oTc Wiring (WiTh The door deTecTor no can BuS)
ROLLX VANS ONE TOUCH CONT
ITF Harness V6/ OTC Board V8 MOD
* = For pictures of location see
Important Information and Location
Section in Service Manual
12
N/C
BACK SIDE
*UNIVERSAL DOOR
DETECTOR
(13104-001ASM)
Italic Font = OEM Wire
LOCATION:
Passengers D-PILLAR
(Door Closed Status In)
VT (20 GA.) (QUAD B + IN)
N/C
1
4
BL (20 GA.) (QUAD A + IN)
PK (20 GA.) (GND)
1
OR/RD (20 GA.) (Door Open Status out)
BL/YL (20 GA.) (Reset)
BK (20 GA.)
(GND)
KNEEL DISABLE (ON / OFF) SWITCH
(ASM #03220-001)
VT
LOCATION:
Passengers C-PILLAR
(V BAT)
BK
TIPM
(Fuse box
under hood)
4
N/C
VT (20 GA.)
PSDMR
Power Sliding Door Module Rig
BK (20 GA.)
DB / YL (20 GA.)
N/C
1
(Chrysler Door Ajar Circuit
WT / RD (20 GA.)
WT / RD (20 GA.)
BK (10 GA.)
DB (20 GA.)
BLACK
INPUTS
BACK SIDE
14
N/C
N/C
VT / YL (20 GA.)
(Door Closed Limit)
SWITCHES
* RAMP LIMIT
(#6X284)
RD / DG (20 GA.)
RD / WT (20 GA.)
NC
YL / DG (20 GA.)
COM
NO
2
2
UP
LIMIT
DOWN
LIMIT
1
3
1
3
YL/RD
(Door Control)
RD/DB
BLACK
1
5
RD (12 GA.)
BK
BK
YL (12 GA.)
ECN # 14078
Rollx Vans, Inc.
Effective Stock # 47655
6591 West Highway 13
Effective Start Date: 3/17/2014
Savage, MN 55378
DRAWING #: 14072
952.890.7851
DRAWN BY:
COPYRIGHT 2008
Jason Hodgkins
6 PASSENGER DOOR MODULE
10
BK
(Unlock Output)
(Rollx Vans uses this to
unlock the door)
(OEM CAV #4)
LOCATION:
Passenger front door
(OEM CAV #1)
BK GY
(-) (+)
1
4
KNEEL SYSTEM
OEM B-PILLAR SWITCH
(Rollx Vans uses this to
operate the door)
YL / WT
BK
YL / DG
UP LIMIT
NC
NO
SWITCHES
* KNEEL LIMIT
(#6X284)
DOWN LIMIT
2
2
NC
1
1
NO
3
3
COM
COM
BK
RD (12 GA.)
REVISION HISTORY:
08330-001 INITIAL RELEASE. 11/25/2008
YL (12 GA.)
Page 77
NO
RD
RD / BK
YL / BK
N/C
LG / WT (20 GA.)
NC
COM
BK (20 GA.)
YL / BK (20 GA.)
YL / RD (20 GA.)
OR (20 GA.)
RD / DB (20 GA.)
BLACK
BACK SIDE
OUTPUTS
(Neutral Safety)
(Door Open Limit)
RD
(20 GA.)
RD / BK (20 GA.)
1
RAMP MOTOR
DG (20 GA.)
OR / RD (20 GA.)
YL / WT (20 GA.)
1
12
(User switch)
oTc Wiring (WiTh The door deTecTor no can BuS)
3/13/2014
NTROLLER WIRING DIAGRAM
OD F (Dropped the CAN BUS)
DASH
RESET SWITCH (8/21/06)
4
DB
BK
BuilT afTer 3/17/2014
ROLLX VANS USER / RESET SWITCHES
(ASM #03220-005)
D-PILLAR
DB
DASH
C-PILLAR
BK
BK
DB
BK
DB
1
DB (20 GA.)
BK (20 GA.)
BK (20 GA. X 3)
LOCATION:
Back side of the lower slider door track
R
odule Right
BK (20 GA. X 3)
DB / YL (20 GA.)
DMRR
Door Module Right Rear
ITF RAMP OVERRIDE
SWITCH
(DRIVER SIDE B
PILLAR) #05175-001
BK (20 GA.)
OUT
* FUSE PANEL
(BEHIND GLOVE BOX)
1 AMP
REMOTE
1 AMP
IN
DOOR DETECTOR
1 AMP
CONTROLLER PWR
7
Circuit)
14
Passenger’s side Door snake
(B-Pillar)
C309
VT/YL (CAV 11)
OR (20 GA.)
Nuetral
Safety
Ignition
Hot
1N4007
DIODES
8
1
LOCATION:
Passengers B-PILLAR
BL (20 GA.)
RD (20 GA.)
11DQ05-ND
DIODE
BK (8 GA.)
40A
FUSE
/ BK
/ BK
RD (14 GA.)
BK (20 GA.)
ITF RAMP
RD (-)
RD (10 GA.)
#310-1059
DB (20 GA.)
CHES
GN/DB
(OEM CAV 9)
*RELAY BOARD #OTCV8 RELAY BD
RAMP UP
KNL DN
OR (20 GA.)
PWR OVERRIDES
RD (20 GA.)
BL (20 GA.)
INPUTS
OUTPUTS
YL (12 GA.)
6
RAMP
ENABLE
D
2
BK
1
4
8
13
17
21
7
12
16
20
23
LOCATION:
On the transmission
RD (10 GA.)
BK (10 GA.)
KNL UP
N
Rollx Vans Remote Reciever
CM6200
J2
RAMP DN
DB
ASM #03220-005
J1
R
P
Neutral Safety3
RD
# 08044-002
+
*(To Inition Hot)
located under
steering column
YL (+)
B
-
RD (8 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 78
POWER OVERRIDE BUS
DG (20 GA.)
oTc Wiring (WiTh Wing WindoW inTerface)
ROLLX VANS ONE TOUCH CON
ITF Harness V7/ OTC Board V8 MO
* = For pictures of location see
Important Information and Location
Section in Service Manual
Italic Font = OEM Wire
PSDMR
Power Sliding Door Module Right
LOCATION:
Back side of the lower slider door track
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
4
1
12
N/C
BACK SIDE
*UNIVERSAL DOOR
DETECTOR
(13104-001ASM)
VT (20GA.)
N/C
1
(V BAT)
WT / RD (20 GA.)
WT / RD (20 GA.)
(V BAT)
(V BAT)
N/C
C309
OR / RD (20 GA.)
(Door Open Limit)
VT / YL (20 GA.)
(Door Closed Limit)
(Ramp Up Limit)
(Ramp Down Limit)
SWITCHES
* RAMP LIMIT
(#6X284)
NC
NO
YL / DG (20 GA.)
2
2
N/C
(Ramp Down)
(Ramp Up)
(Kneel Down)
(Kneel Up)
(Door Control)
(VT/YL)
BK (20GA.)
BK (20GA.)
YL (12 GA.)
Effective Stock #: 01060
Savage, MN 55378
DRAWING #: 14083
952.890.7851
DRAWN BY:
COPYRIGHT 2008
Jason Hodgkins
1
YL / WT
6591 West Highway 13
Effective Start Date: 4/14/2014
BK GY
(-) (+)
KNEEL SYSTEM
OEM B-PILLAR SWITCH
(Rollx Vans uses this to
operate the door)
Rollx Vans, Inc.
ECN # 14112
(Rollx Vans uses this to
unlock the door)
(CAV #1)
4
BK
UP LIMIT
NC
NO
COM
SWITCHES
* KNEEL LIMIT
(#6X284)
DOWN LIMIT
2
2
NC
1
1
NO
3
3
BK
COM
YL / DG
RD (12 GA.)
REVISION HISTORY:
08330-001 INITIAL RELEASE. 11/25/2008
YL (12 GA.)
Page 79
NO
(OEM CAV #4)
LOCATION:
Passenger front door
BK (20GA.)
N/C
1
5
(Unlock Output)
NC
COM
6 PASSENGER DOOR MODULE
10
RD (12 GA.)
3
(Ramp Enable)
N/C
LG / WT (20 GA.)
1
BK (20 GA.)
YL / BK (20 GA.)
YL / RD (20 GA.)
OR (20 GA.)
RD / DB (20 GA.)
BLACK
UP
LIMIT
DOWN
LIMIT
1
3
COM
RD
(20 GA.)
RD / BK (20 GA.)
BACK SIDE
8
YL / WT (20 GA.)
BLACK
1
VT/YL (CAV 11)
(Neutral Safety)
RD / DG (20 GA.)
RD / WT (20 GA.)
1
OBSTACLE DET.
DMRR
Door Module Right R
Passenger’s side Door sn
(B-Pillar)
BK (10 GA.)
BLACK
BACK SIDE
INPUTS
OUTPUTS
12
BK (20GA.)
(User switch)
DG (20 GA.)
1
DB
(Chrysler Door Ajar Circuit)
Status out)
(Reset)
(GND)
(GND)
WT / RD (20 GA.)
DB (20 GA.)
14
BL/YL (20GA.)
BK (20GA.)
(Door Closed Status In)
A.)
0G
VT (20 GA.)
L (2
(QUAD B + IN)
Y
/
VT
BL (20 GA.)
(QUAD A + IN)
(Door Open
A.)
20 G
BL/YL (20 GA.)
RD (
OR/
PK (20 GA.)
BK (20 GA.)
LOCATION:
Behind OTC Board
BK
DB
BK
PK (20GA.)
N/C
4
Door Detector Extension
LOCATION: 66”
Passengers C-PILLAR
VT (20GA.)
BL (20GA.)
4
N/C
BACK SIDE
WING WINDOW FLAPPER
BLACK
N/C
DA
1
1
16
RO
KNEEL DISABLE (ON / OFF) SWITCH
(ASM #03220-001)
DASH
RESET SWITCH
OTC WIRING (With Wing Window Interface)
3/24/2014
ONTROLLER WIRING DIAGRAM
MOD H (W/ Wing Window Interface)
Right Rear Wing
Window Motor
ROLLX VANS USER / RESET SWITCHES
(ASM #03220-005)
D-PILLAR
BK
DB
BK
VT/BL
VT/YL
e Door snake
r)
OR / BL
Rear Window Signal
BL /YL
OR / YL
Rear Window Return
OR / YL
ITF RAMP OVERRIDE SWITCH
#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
WT/RD (20GA.X2)
BK (20GA.)
BK (20GA.)
uit)
BL (20 GA. X 3)
GA.)
BL
BL
BK (20GA.)
BK (20GA.)
To Driver’s side
Window Switch
OR / BL
#14044-001ASM
DB (20 GA.)
RR
e Right Rear
Wing Window Interface
CUT
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
*RELAY BOARD #OTCV8 RELAY BD
BK (10 GA.)
RAMP UP
YL/RD
KNL UP
BK (12 GA.)
RD/DB
1
#3
(Ramp Enable)
(Ramp Up)
(Ramp Down)
BL (20 GA.)
OR (20 GA.)
RD (20 GA.)
6
P
R
AM
RD
YL
)
(+
DB (20 GA.)
1
0-
(-)
(Ramp -)
9
05
(Kneeler +)
(Kneeler -)
PWR OVERRIDES
(Ramp +)
OUTPUTS
INPUTS
(User switch)
RD (12 GA.)
RAMP
ENABLE
F
IT
*(To Inition Hot)
located under
steering column
RD (12 GA.)
R
N
D
P
Neutral Safety3
GN/DB
(OEM CAV 9)
OTC BOARD
DB
ASM #03220-005
KNL DN
(Remote Pwr.)
YL / BK
BK (12 GA.)
(Remote Gnd.)
RD / BK
RD
Programming
Switch
BK
7
12
16
20
23
GN/WT
RD
ASM #03295-003
ANTENNA RUNS
UP PASSENGER
“D” PILLAR
Page 80 1
4
8
13
17
21
Rollx Vans Remote Reciever
LOCATION:
Passenger’s side D-Pillar
RD (12 GA.)
2
LOCATION:
On the transmission
GN
BK
BK (12 GA.)
-
+
PK/GN (20 GA.)
CM6200
RAMP DN
BK (20 GA.)
RD (10 GA.)
RD (8 GA.)
FUSE
RD (14 GA.)
J2
GND (To Body)
J1
11DQ05-ND
DIODE
YL (12 GA.) (Ramp +)
RD
# 08044-002
POWER OVERRIDE BUS
BK
DB
Rear Window Return OR / YL
BK
DB
3
1
Rear Window Signal OR / BL
C-PILLAR
DASH
LOCATION:
Right Rear D-Pillar
rollX vanS PoWer door (MoTor Bar) Wiring
Rollx Vans Power Door (Mo
Touchtronic Power Touch 1550
2
1
3
DOOR LOCK LIMIT SWITCH #6X284 IN
PASSENGER DOOR
(WHEN CLOSED, SENDS POWER TO
HARDWIRED SWITCHES)
NC
NO
COM
VT (14)
RAMP UP
LIMIT SWITCH
#03220-004
RMP
DWN
NC NO
COM
RAMP
POWER SWITCH
ON
DB (14 GA.)
WT (14 GA.)
CLOSE
RD (14)
-
RD (10 GA.)
YL (14 GA.)
DG (14 GA.)
BK (14)
+
BR (14 GA.)
WT (14)
RD (10)
FUSE
30 A
OFF
FUSE
15 A
KNEEL
TN (16 GA.)
26 24 25
DG/DB (OEM CAV 8)
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
87A
87
FIREWALL
C
USE
OPEN
DOOR
1
6
COM
DASH KNEEL
DOWN L.E.D.
TRS T3 SIGNAL
5
NC NO
DASH USER
SWITCH
#8981K520
NEUTRAL
SAFETY 3.3L
10
OPEN
BK (16 GA.)
26 24 25
Soldier all
remote
connections
BR (14 GA.)
RD (14 GA.)
FUSE
10 A
FUSE
1A
BR
DG
CHASSIS
GROUND
RAMP
VT (16 GA.)
OEM VT/DG (14)
FOR DOOR AJAR
PNK #10 (12V IN)
RD (16 GA.)
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)
GRY/RED #2
WHT/RED #1
TOUCHTRONICS
MODULE (#P1510-R)
YL (20)
10 AMP CIRCUIT BR
OR
15 AMP GLASS F
CLOSE
ROLLX VANS
REMOTE
(BEHIND
GLOVE BOX)
85
87
RD (14 GA.)
BK (14 GA.)
DOOR OPEN
DOOR
LOC
Page 81
rollX vanS PoWer door (MoTor Bar) Wiring
7/9/2013
Motor Bar) Wiring Diagram v2
50-R Remote System (Jan. 2011)
YL (16 GA.)
TO OEM
DOOR AJAR
NC
VT (14)
NO
MOTOR BAR
C PILLAR
USER SWITCH
#310-1059
YL
DB
COM
KNEELER
BK (14 GA.)
85
DOOR CLOSE
BR
PK (14 GA.)
87A
87
85
RAMP DOWN
30
86
87A
87
85
RAMP UP
30
86
87A
87
85
KNEEL DOWN
87
85
WT (16 GA.)
KNEEL UP
RELAYS (#5-1393302-8)
LOCATED IN OEM SPARE TIRE KIT COMPARTMENT
Page 82
YL (14 GA.)
YL (14 GA.)
86
BR (14 GA.)
87A
87
30
BR
KNEEL DN
LIMIT SWITCH
#03220-013
OR (16 GA.)
86
YL
JONES BLOCK
#3-142
A.)
30
DG
DG (14 GA.)
DB (14 GA.)
.)
COM
COM
YL (14 GA.)
NC NO COM
TO DASH
L.E.D.
KNEEL UP LIMIT
SWITCH
#03220-014
NC
NO
NC
NO
YL (16 GA.)
A
BK
(-)
*
TN (16 GA.)
86
DG
GY
(+)
GY (16 GA.)
30
12
11
13
DG
RD
RD (16 GA.)
COM
NC
NO
Toggle Switch
#4X203
ITCH
DOOR OPEN
LIMIT SWITCH
(CHERRY)
#E19-50H
YL
DG (16 GA.)
WT
DOOR
BR(16 GA.)
13 11 12
OPEN
CLOSE
UIT BREAKER
R
ASS FUSE
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 83
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
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