BraunAbility Rampvan Manual

Toyota Minivans
Maintenance and Service Manual
33446 Rev B
February 2011
Toyota Minivans
Wheelchair-Accessible
Lowered Floor Conversion
featuring 2004 - 2010
featuring Toyota Minivans
featuring Toyota Minivans
®
Braun Rampvan®
Braun Rampvan
W
ARNING
ual
Man
Read manual
before servicing.
Failure to do so
may result in
serious bodily
injury and/or
property damage.
®
®
®

The Braun Rampvan®lowered
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Maintenance, lubrica-
tion, troubleshoot-
ing and service
procedures must be
performed as speci-
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service technician.
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result in serious
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W
ARNING
INTRODUCTION
Introduction
Rampvan® Operation Quick Reference Guide
One-Touch Control Activation
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Manual Operation
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Rampvan Operation Overview
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Power Operation
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Interior Mounted Switches
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or
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DOOR

Page 1
CONTENTS
Safety Precautions ............................................ 2
Towing ................................................................ 2
Maintenance and Service Requirements ........ 3
Maintenance and Lubrication Schedule ...... 4-7
Troubleshooting Diagnosis Chart ............... 8-13
Below Floor Obstructions ..........................14, 15
Auxiliary Power Supply ........... ....................... 16
Wiring Diagrams and Electrical Schematics
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Repair Parts
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Dimensions ...................................................... 42

Page 2
SAFETY PRECAUTIONS
Safety Precautions
Read this manual,
the Rampvan®oper-
ator’s manual and
supplements before
performing opera-
tion, maintenance or
service procedures.
Failure to do so may
result in serious
bodily injury and/or
property damage.
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Towing
Towing with a Rampvan®
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Page 3
MAINTENANCE and SERVICE
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QDQFHRUVHUYLFHSURFHGXUHV
&RQWDFW7KH%UDXQ&RUSRUDWLRQ
DW7+(/,)7®LIDQ\RIWKLV
LQIRUPDWLRQLVQRWXQGHUVWRRG
One-Touch Control System:
5DPSYDQ®SRZHUIXQFWLRQVDUH
PDQDJHGE\WKH2QH7RXFK
HOHFWURQLFFRQWUROV\VWHP7KH
FRQWUROV\VWHPFDQEHDFWLYDWHG
XVLQJWKH7R\RWDUHPRWHNH\OHVV
HQWU\WUDQVPLWWHUDQ\RIWKHLQWH-
ULRUPRXQWHGFRQWUROVZLWFKHVRU
WKHRSWLRQDOPDJQHWLFHQWU\
Braun Corporation Aftermarket
Control Systems Policy:7KH
%UDXQ&RUSRUDWLRQPDQXIDFWXUHV
GHGLFDWHGFRQWUROV\VWHPVIRULWV
SURGXFWV7KHVHFRQWUROV\V-
WHPVKDYHEHHQGHVLJQHGDQG
WHVWHGIRUXVHLQFRQMXQFWLRQZLWK
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FRQWUROV\VWHPVDUHWKHRQO\FRQ-
WUROV\VWHPVDXWKRUL]HGIRUXVH
ZLWK%UDXQSURGXFWV
'RQRWDWWHPSWWRLQWHUIDFHDIWHU-
PDUNHWFRQWUROV\VWHPVZLWKRXW
DXWKRUL]DWLRQIURP7KH%UDXQ
&RUSRUDWLRQ7RGRVRPD\UHVXOW
LQVHULRXVERGLO\LQMXU\DQGRU
SURSHUW\GDPDJH
Maintenance and Service Requirements

Page 4
MAINTENANCE and SERVICE
Maintenance and lu-
brication procedures
must be performed
DVVSHFLÀHGE\DQ
authorized service
technician. Failure
to do so may result
in serious bodily in-
jury and/or property
damage.
1RUPDOYHKLFOHPDLQWHQDQFHPXVW
EHSHUIRUPHGDVRXWOLQHGLQWKH
7R\RWDVXSSOLHGRZQHUҋVPDQXDO
7KLVPDLQWHQDQFHLVQRWWKH
UHVSRQVLELOLW\RI7KH%UDXQ&RU-
SRUDWLRQ5HIHUWRWKH:DUUDQW\
VHFWLRQRIWKLVPDQXDOIRUGHWDLOV
UHJDUGLQJ7KH%UDXQ&RUSRUDWLRQ
5DPSYDQ®:DUUDQW\
7KHPDLQWHQDQFHDQGOXEULFD-
WLRQSURFHGXUHVRXWOLQHGLQWKLV
VFKHGXOHPXVWEHSHUIRUPHGDW
WKHUHFRPPHQGHGVFKHGXOHG
LQWHUYDOVE\D%UDXQDXWKRUL]HG
VHUYLFHUHSUHVHQWDWLYH
,QÁRRU5DPS.HHSLQJWKHLQÁRRU
UDPSDQGUDPSFDVVHWWHDUHD
FOHDQLVWKHPRVWHIIHFWLYHSUH-
YHQWLYHPDLQWHQDQFHSUDFWLFHWR
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WKHVXUURXQGLQJDUHDEHIRUHDS-
SO\LQJOXEULFDQWV:KHQUHSODFLQJ
OXEULFDWHGFRPSRQHQWVEHVXUH
WROXEULFDWHGXULQJLQVWDOODWLRQ
SURFHGXUHV
$´GULÀOPµVW\OHRIOLJKWRLOVKRXOG
EHDSSOLHGZKHUH/LJKW2LOLV
FDOOHGRXWJRHVRQZHWDQGWKHQ
GULHV/XEULFDQWVRIWKLVW\SH
DUHDYDLODEOHWKDWGRQRWDWWUDFW
GXVWDQGRWKHUGHEULV8VHRI
LPSURSHUOXEULFDQWVFDQDWWUDFW
GLUWRURWKHUFRQWDPLQDQWVZKLFK
FRXOGUHVXOWLQZHDURUGDPDJH
WRFRPSRQHQWV$YRLGOXEULFDQWV
WKDWFDQOHDYHVWDLQV
6RPHOXEULFDQWVUHIHUHQFHGLQWKH
VFKHGXOHDUHDYDLODEOHIURP7KH
%UDXQ&RUSRUDWLRQSDUWQXPEHUV
SURYLGHGZKHUHVSHFLÀHG
$OOOLVWHGLQVSHFWLRQOXEULFDWLRQ
DQGPDLQWHQDQFHSURFHGXUHV
VKRXOGEHUHSHDWHGDW´PRQWKµ
LQWHUYDOVIROORZLQJWKHVFKHGXOHG
´PRQWKµPDLQWHQDQFH7KHVH
LQWHUYDOVDUHDJHQHUDOJXLGHOLQH
DQGZLOOYDU\DFFRUGLQJWRIUH-
TXHQF\RIXVHDQGFRQGLWLRQV
([SRVXUHWRVHYHUHFRQGLWLRQV
ZHDWKHUHQYLURQPHQWFRQWDPL-
QDWLRQKHDY\XVDJHHWFPD\UH-
TXLUHLQVSHFWLRQDQGPDLQWHQDQFH
SURFHGXUHVWREHSHUIRUPHGPRUH
RIWHQWKDQVSHFLÀHG
Maintenance and Lubrication Schedule
Discontinue Rampvan®use
immediatelyLIPDLQWHQDQFHDQG
OXEULFDWLRQSURFHGXUHVDUHQRW
SURSHUO\SHUIRUPHGRULIWKHUH
LVDQ\VLJQRIZHDUGDPDJH
LPSURSHURSHUDWLRQRUDQ\DEQRU-
PDOFRQGLWLRQ&RQWDFW\RXUVDOHV
UHSUHVHQWDWLYHRUFDOO7KH%UDXQ
&RUSRUDWLRQDW7+(/,)7®.
2QHRIRXUQDWLRQDO3URGXFW6XS-
SRUWUHSUHVHQWDWLYHVZLOOGLUHFW
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WHFKQLFLDQZKRZLOOLQVSHFW\RXU
5DPSYDQ®.

Page 5
MAINTENANCE and SERVICE
3 Months
Foldout Ramp: )ROGRXWUDPSVYDU\LQ
GHVLJQ'LVUHJDUGUHIHUHQFHVWRFRPSRQHQWV
QRWSUHVHQW
2XWERDUGUDPSH[WHQVLRQKLQJHDQGIDVWHQHUV
,QVSHFWUDPSLQERDUGSLYRWSRLQWVEROWVVFUHZV
DQGEXVKLQJVEHDULQJVIRUSRVLWLYHVHFXUHPHQW
ZHDURUGDPDJH
,QVSHFWUDPSIROGSLFNXSEHDULQJIRUSRVLWLYH
VHFXUHPHQWDOLJQPHQWZHDURURWKHUGDPDJH
,QVSHFWUDPSIROGDUPIRUSRVLWLYHVHFXUHPHQW
DOLJQPHQWZHDURURWKHUGDPDJH
,QVSHFWUDPSIROGDUPEHDULQJVORWIRUH[FHVVLYH
ZHDURUGDPDJH
,QVSHFWUDPSH[WHQVLRQFKDLQIRUSURSHUDOLJQ-
PHQWVHFXUHPHQWRURWKHUGHIHFWV
,QVSHFWUDPSÁRRUPRXQWLQJKDUGZDUHIRUVH-
FXUHPHQWORRVHRUPLVVLQJ
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DOLJQPHQWREVWUXFWLRQVFOHDQOLQHVVZHDURU
RWKHUGDPDJH
,QVSHFWGULYHEHOWLGOHUSXOOH\IRUVHFXUHPHQW
ORRVHSXOOH\ZLOOFDXVHGULYHV\VWHPWRVOLS
General Items
/RZHUSRZHUVOLGHGRRUWUDFN
:KHHOFKDLUDQGRFFXSDQWUHVWUDLQWEHOWVDQGWLH
GRZQWUDFN
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JDJHPHQWRIODWFKLQJPHFKDQLVPV
&OHDQDQGOXEULFDWHZLWK/LJKW2LO5HVHFXUH
RUUHSODFHIDVWHQHUVDVQHHGHG
&OHDQDQGOXEULFDWHZLWK/LJKW2LO7LJKWHQ
UHSODFHRUFRUUHFWDVQHHGHG
5HSODFHRUFRUUHFWDVQHHGHG,IEHDULQJ
UHWDLQLQJVFUHZLVQRWVHFXUHRULVUHPRYHGIRU
VHUYLFHDSSO\%OXH7KUHDG/RFNHU/RFWLWH
WRUHWDLQLQJVFUHZDQGWLJKWHQ
7LJKWHQUHSODFHRUFRUUHFWDVQHHGHG
5HSODFHLIQHHGHG
5HDOLJQUHVHFXUHUHSODFHRURWKHUZLVHFRUUHFW
DVQHHGHG
5HVHFXUHUHSODFHRUFRUUHFWDVQHHGHG
5HDOLJQUHPRYHREVWUXFWLRQFOHDQUHSODFHRU
RWKHUZLVHFRUUHFWDVQHHGHG8VHDLUFRPSUHV-
VRUWREORZRXWGHEULV
5HVHFXUHUHSODFHRUDGMXVWDVQHHGHG
,QVSHFWIRUREVWUXFWLRQVDQGFOHDQYDFXXPRU
EORZRXWGHEULVXVLQJFRPSUHVVRU
,QVSHFWIRUDQ\GHIHFWVVXFKDVFXWVIUD\LQJRU
DQ\PDOIXQFWLRQRIEHOWEXFNOHRUVHFXUHPHQW
KDUGZDUH&OHDQGLUWDQGGHEULVIURPWLHGRZQ
WUDFN5HSODFHLPPHGLDWHO\LIGDPDJHG
5HSODFHRUFRUUHFWDVQHHGHG
Maintenance and Lubrication Schedule

Page 6
Perform all procedures listed in previous section also
6 Months
Power Fold Ramps:
5DPSÁDSH[WHQVLRQFKDLQ
5HPRYHUDPSKRXVLQJFRYHUUHDUYHUWLFDOSDQHO
DQGLQVSHFW
7RSPRXQWEUDFNHWEROWVIRUVHFXUHPHQW
ORRVHRUPLVVLQJ
0RWRUPRXQWLQJEROWVIRUVHFXUHPHQWORRVH
RUPLVVLQJ
5DPSIROGDUPVHFXUHPHQWFROODUDQG
PRXQWLQJVFUHZV
0LFURVZLWFKHVVHFXUHPHQWDQGDGMXVWPHQW
0LFURVZLWFKZLUHVDQGWHUPLQDOVIRUVHFXUH-
PHQWRUGDPDJH
0DJQHWLFVZLWFKDSSOLFDEOHIRURQO\
3RZHU,QÁRRU5DPSV'HSOR\UDPSSODWIRUP
IURPFDVVHWWHDQGLQVSHFW
'ULYHEHOWDGMXVWPHQWVOLSSDJHDQGLGOHU
SXOOH\IRUVHFXUHPHQWDQGDOLJQPHQW
0RWRUPRXQWLQJEROWVIRUVHFXUHPHQWORRVH
RUPLVVLQJ
0LFURVZLWFKHVVHFXUHPHQWDQGDGMXVWPHQW
0LFURVZLWFKZLUHVDQGWHUPLQDOVIRUVHFXUH-
PHQWRUGDPDJH
/LQHDU%HDULQJ%ORFNV
Manual Fold Ramps:
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5HPRYHUDPSKRXVLQJFRYHUUHDUYHUWLFDOSDQHO
DQGLQVSHFW
7RSPRXQWEUDFNHWEROWVIRUVHFXUHPHQW
ORRVHRUPLVVLQJ
6SULQJKRXVLQJPRXQWLQJEROWVIRUVHFXUH-
PHQWORRVHRUPLVVLQJ
5DPSIROGDUPVHFXUHPHQWFROODUDQG
PRXQWLQJVFUHZV
Inspect power source:2(0EDWWHU\DP-
SHUHIXVH2(0HQJLQHFRPSDUWPHQWIXVHEORFN
DQGGULYHUVLGHXQGHUGDVKPRXQWHGIXVHEORFN
/XEULFDWHZLWK$QWL6HL]HR]FDXONWXEH
DYDLODEOHSHU%UDXQSDUWQR
5HVHFXUHDGMXVWPLFURVZLWFKHVUHSODFHGDP-
DJHGSDUWVRURWKHUZLVHFRUUHFWDVQHHGHG
1RWH6HH3UH)ROGRXW5DPSDQG
)ROGRXW5DPS([SORGHGYLHZVRQSDJHV%
%$DQG$
5HVHFXUHDGMXVWDOLJQUHSODFHGDPDJHGSDUWV
RURWKHUZLVHFRUUHFWDVQHHGHG1RWH6HH
,QÁRRU5DPS([SORGHG9LHZRQSDJHV$DQG
$
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ÁRRUWUDQVLWLRQÁDSWULPWRDFFHVV,QVHUWRLOLQ
WRSRIEORFNVXVLQJDÁH[QR]]OH
/XEULFDWHZLWK$QWL6HL]HR]FDXONWXEH
DYDLODEOHSHU%UDXQSDUWQR
5HVHFXUHUHSODFHGDPDJHGSDUWVRURWKHUZLVH
FRUUHFWDVQHHGHG
5HVHFXUHUHSDLURUUHSODFH
MAINTENANCE and SERVICE
Maintenance and Lubrication Schedule
Continued on next page

Page 7
MAINTENANCE and SERVICE
Maintenance and Lubrication Schedule
Continued from previous page
6 Months
Inspect kneel actuator assembly for:
$FWXDWRUPRXQWLQJSLQVHFXUHPHQWPLFUR-
VZLWFKDFWLYDWLRQEORFN
,QVSHFWFKDLQIRUPLVDOLJQPHQWZHDURU
GDPDJH
,QVSHFWFKDLQPDVWHUOLQNVIRUVHFXUHPHQW
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Page 11
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6HHDQG
&RQQHFWUHSDLURUUHSODFH
7LJKWHQUHSODFHRURWKHUZLVHFRUUHFWDV
QHHGHG
$GMXVWRUUHSODFH
5HSODFHPRWRU
6HH%UDXQ6HUYLFH&HQWHU
&RQQHFWUHSDLURUUHSODFH
5HDOLJQWLJKWHQUHSODFHGDPDJHGSDUWV
RURWKHUZLVHFRUUHFWDVQHHGHG
$GMXVWFDUULDJHKHLJKWDGMXVWPHQWVFUHZ
FORFNZLVHWRUDLVHFDUULDJHDQGFRXQWHU
FORFNZLVHWRORZHU
7LJKWHQUHSODFHRURWKHUZLVHFRUUHFW
DVQHHGHG5HDURXWERDUGUROOHULV
DGMXVWDEOH
&KHFNDQGFRUUHFW
7.20
Faulty
In (Stow)
Operation
7.10
No In
(Stow)
Operation
6HH
5DPS,Q6WRZPLFURVZLWFKRXWRI
DGMXVWPHQWRUGDPDJHG
6HHDQG
5DPS,Q6WRZPLFURVZLWFKKDU-
QHVVGLVFRQQHFWHGRUGDPDJHG
6HH
DQG
$GMXVWRUUHSODFH
&RQQHFWUHSDLURUUHSODFH

Page 12
11.20
Faulty
Operation
8.00
POWER
DOOR
(CLOSE)
6HHDQG
6HH
6HH
6HH
Foldout Ramps:
6HHDQG
,QÁRRU5DPSV
 6HH
DQG
9.00
KNEEL
SYSTEM
(RAISE)
10.10
No Operation
10.00
REMOTE
CONTROL
9.20
Faulty
Operation
9.10
No Raise
Operation
11.10
No Operation
FUNCTION SYMPTOM POSSIBLE CAUSE REMEDY
TROUBLESHOOTING
8.30
Faulty
Operation
8.40
Door Does
Not Close
Fully
8.50
Door Contacts
Ramp When
Closing
8.10
No
Close
Operation
8.20
Motor Runs - Door
Does Not Move
11.00
KNEEL
ELECTRICAL
OVERRIDE
6HH
DQG
6HH
6HH
6HH7R\RWDYHKLFOHRZQHUҋV
 PDQXDO
5HSODFHVZLWFK
6HHDQG
.QHHOHOHFWULFDORYHUULGHVZLWFK
GDPDJHG
6HH

Page 13
TROUBLESHOOTING
12.10
No
Operation
12.00
KNEEL
MECHANICAL
OVERRIDE
5HSODFHQXW.QHHOPRWRUUHOHDVHQXWPLVVLQJ
IURPDFWXDWRUPRWRUVKDIW
FUNCTION SYMPTOM POSSIBLE CAUSE REMEDY

Page 14
OEM
Wiring
Braun
Wiring
Heat &
AC Lines
Fuel
System
Brake
System
Color Key
BELOW FLOOR OBSTRUCTIONS
PXVWEHDYRLGHG2EVWUXFWLRQV
LQFOXGHZLULQJIXHOV\VWHP
EUDNHOLQHVHWF,QVWDOOHUVPXVW
EHDZDUHRIWKHVHREVWUXFWLRQV
Fuel
Return
Line
Battery
Fuse
Block
Emergency
Brake
Cable
Brake
Lines
Rear Heat
Lines
Fuel Fill
Tube
Fuel
Tank
Fuel Vapor
Line
Fuel Vent
Line
SDM
Module
Charcoal
Canister
Controller
(PMM)
Rear AC
Lines
Seat
Connector
Typical
Driver
&
Passenger
SIR
Module
Fuel Vent
Line
Main Fuel
Line
OEM
Wiring
Braun
Wiring
Heat &
AC Lines
Fuel
System
Brake
System
Color Key
5HIHUWRWKHDSSOLFDEOHLOOXVWUDWLRQ
ZKHQLQVWDOOLQJDIWHUPDUNHWHTXLS-
PHQWWRDYRLGFRQWDFWLQJRUGDPDJ-
LQJYLWDOFRPSRQHQWVXQGHUWKHÁRRU
:KHQLQVWDOOLQJDQHOHFWULFDOWLH
GRZQSRZHUVHDWRURWKHUDX[LO-
LDU\HOHFWULFDOGHYLFHLQDQ5DPS-
YDQ®REVWUXFWLRQVEHORZWKHÁRRU
Infloor
Rampvan®

Page 15
'ULOOLQJRUFXWWLQJLQWRVXFK
REVWUXFWLRQVPD\UHVXOWLQSRWHQ-
WLDOKD]DUGVDVZHOODVSURSHUW\
GDPDJH
Fuel
Return
Line
Battery
Fuse
Block
Emergency
Brake
Cable
Brake
Lines
Rear Heat
Lines
Fuel Fill
Tube
Fuel
Tank
Fuel Vapor
Line
Fuel Vent
Line
SDM
Module
Charcoal
Canister
Controller
(PMM)
Rear AC
Lines
Seat
Connector
Typical
Driver
&
Passenger
SIR
Module
Fuel Vent
Line
Main Fuel
Line
OEM
Wiring
Braun
Wiring
Heat &
AC Lines
Fuel
System
Brake
System
Color Key
OEM
Wiring
Braun
Wiring
Heat &
AC Lines
Fuel
System
Brake
System
Color Key
BELOW FLOOR OBSTRUCTIONS
Check for obstruc-
tions such as wires,
gas lines, exhaust,
etc. before drilling
or cutting through
ÁRRU)DLOXUHWRGRVR
may result in serious
bodily injury and/or
property damage.
1RWH6RPHZLULQJKDUQHVVHV
VKRZQPD\QRWEHSUHVHQW$YRLG
DOOKDUQHVVORFDWLRQV
Foldout
Rampvan®

Page 16
AUXILIARY POWER SUPPLY
5LVNRIHOHFWULFDOÀUH
Install and electrically
terminate Auxiliary
electrical device as
VSHFLÀHGE\GHYLFH
manufacturer.
Do not connect auxil-
iary devices to vehicle
battery. Doing so
may result in damage
to electrical system
and/or electronic
components.
'RQRWFRQQHFWDX[LOLDU\GHYLFHV
GLUHFWO\WRWKHYHKLFOHEDWWHU\
'RLQJVRPD\UHVXOWLQGDPDJHWR
HOHFWULFDOV\VWHPDQGRUHOHFWURQLF
FRPSRQHQWV
7ZRIXVHEORFNVDUHSURYLGHG
DVDQDX[LOLDU\SRZHUVRXUFHIRU
GHDOHULQVWDOOHGDX[LOLDU\HOHFWULFDO
GHYLFHV)XVHEORFNGHWDLOVDQG
VSHFLÀFDWLRQVDUHSURYLGHGEHORZ
7KHIXVHEORFNVDUHORFDWHGRQ
WKHGULYHUVLGHRIWKHGDVKFHQWHU
FRQVROH
Below Floor Obstructions:
:KHQLQVWDOOLQJDIWHUPDUNHWHTXLS-
PHQWLQDQ5DPSYDQ®REVWUXF-
WLRQVEHORZWKHÁRRUPXVWEH
DYRLGHG2EVWUXFWLRQVLQFOXGHZLU-
LQJIXHOV\VWHPEUDNHOLQHVHWF
,QVWDOOHUVPXVWEHDZDUHRIWKHVH
REVWUXFWLRQV
5HIHUWRWKHLOOXVWUDWLRQVRQSDJHV
DQGWRDYRLGFRQWDFWLQJRU
GDPDJLQJYLWDOFRPSRQHQWVXQGHU
WKHÁRRU
Fuse Blocks:
7ZRIXVHEORFNVDUHSURYLGHGIRU
XVHDVDQDX[LOLDU\SRZHUVRXUFH
RQH,JQLWLRQIXVHEORFNDQGRQH
%DWWHU\IXVHEORFN
7KH%DWWHU\IXVHEORFNSURYLGHV
SRZHUDWDOOWLPHVLQGHSHQGHQWRI
WKHYHKLFOHLJQLWLRQ7KH,JQLWLRQ
IXVHEORFNVXSSOLHVSRZHUZKHQ
WKHYHKLFOHLJQLWLRQLVRQRQO\
(DFKIXVHEORFNFDQDFFRPPR-
GDWHXSWRIRXU$72®W\SHIXVHV
7KHLQVWDOOHULVUHVSRQVLEOHIRU
VXSSO\LQJWKHFRUUHFWJDXJHZLUH
DQGIXVHIRUWKHSDUWLFXODUGHYLFH
WREHDWWDFKHGWRWKHIXVHEORFN
DVVSHFLÀHGE\WKHPDQXIDFWXUHU
RIWKHGHYLFH
1RWH,ILQVWDOOLQJDQDX[LOLDU\
HOHFWULFDOGHYLFHWKDWUHTXLUHV
PRUHWKDQDDPSHUHSRZHU
VRXUFHDQDOWHUQDWLYHSRZHU
VRXUFHPXVWEHSURYLGHG
1RWH7KHWRWDOPD[LPXPORDGIRU
HDFKEORFNPXVWQRWH[FHHG
DPSHUHV
F3 F4
F1 F2
29428
OPEN
F3 F4
F1 F2
29429
OPEN OPEN
OPEN OPEN
7KHIXVHEORFNDVVHPEO\LV
ORFDWHGXQGHUWKHGULYHUVLGH
GDVKERDUG
1RWH6HHEHORZÁRRUREVWUXF-
WLRQVLOOXVWUDWLRQVRQSDJHV
DQG
Battery Fuse Block Ignition Fuse Block

Page 17A Page 18A
Pre-2007 Power Door, Infloor Ramp and Kneel Wiring Diagram
To: OEM
Door (Module
Connector Side)
To: OEM
Door (Module
Connector Side)
To: OEM
Door (Module
Harness Side)
To: OEM
Door (Module
Harness Side)
Door
Open
Switch
Ramp
OUT
Switch
Transmission
Interlock
Switch
Fuse Block S-7105-1
50 AMP
E40142A
S-6104
36-4091-0
36-1026-1
RW-7704-1
S-7102-1
S-7116-1
36-1017-3
E90114A
SR-9161-1
S-7101-1
NOTE: Dashed lines indicate modified OEM door.
S-7130-1
RC50066A
36-1012-3
TO Battery (+)
TO OEM
Ingnition
Kneel Actuator RC50106A
Relay 1
OEM Door Relay Board 100380-001
Ramp
IN
Switch
Ground Stud
Body
Ground
Ground Stud
PMM Controller 35-4086-0
Magnetic
Entry
Switch
Kneel Override
Switch
35-8536-0
Yazaki
Connector
(N/A)
Ramp Motor
and Gear Box
EC40110A
6
13
42
15
16
1
-
-
+
+
K3
11
J1
9 9
8
6
13
42
15
16
1
-
-
8
+
+
K4
6
13
4
16
D3
100380-
Assy
11
Rev
J2
9
8
Omron
G8NW-
K5
1
12VDC
2
XXXXXX
JAPAN
1
11
K1
9
86
13
4
16
1
11
K2
D2
D1
IGN.
BAT.
25
30
F-3 F-3
F-4
F-2
F-4
F-1F-1 F-2
3
ON
OFF
PWR
DOOR
6
5
4
3
2
1
COLOR FUNCTIONNO.
16-COND WIRE CODE
7
8
9
10
11
12
13
14
15
16
WH/GY - 20G
NONE
WH/RD - 20G
NONE
BK - 18G
RD -16G
WH/BN - 20G
GY/YL - 20G
WH - 20G
WH/PU - 20G
BR/GN - 20G
BK - 20G
BK - 20G
GY/BK - 20G
YL - 20G
WH - 18G
Kneel Raised
N/A
Park Switch
N/A
L2G - Not Used
Logic Power
Kneel Lowered
Ramp Stowed
Ramp Deployed
Door Full Open
Door Closed
Latch Out - Gnd
Latch In - Gnd
Ramp Gate
Unlocked - N/A
Mag Switch
Lockout
Ramp Delay
Enable - Gnd
9 10 111213141516
12345678
2
1
COLOR FUNCTIONNO.
2-COND WIRE CODE
WH - 10G
RD - 12G
Ground
High Current
Power
12
2
1
COLOR FUNCTIONNO.
2-COND WIRE CODE
BK - 18G
BL - 18G
Ground
Park
2
1
COLOR FUNCTIONNO.
2-COND WIRE CODE
BK -20G
WH/RD - 20G
Ground
Park
12
2
1
COLOR FUNCTIONNO.
2-COND WIRE CODE
WH - 22G
WH - 22G
Mag Entry
Mag Ground
2
1
COLOR FUNCTIONNO.
2-COND WIRE CODE
WH/RD - 18G
RD - 18G
Mag Entry
Mag Ground
12
2
1
COLOR FUNCTIONNO.
2-COND WIRE CODE
BK (Switch)
BL (Switch)
Ground
Ramp Stowed
12
2
1
COLOR FUNCTIONNO.
2-COND WIRE CODE
BK/GY - 18G
WH - 18G
Ground
Ramp Stowed
12
2
1
COLOR FUNCTIONNO.
2-COND WIRE CODE
BK - 14G
RD - 14G
Ramp Motor 2
Ramp Motor 1
12
2
1
COLOR FUNCTIONNO.
2-COND WIRE CODE
BK - 14G
RD - 14G
Ramp Motor 2
Ramp Motor 1
12
2
1
COLOR FUNCTIONNO.
2-COND WIRE CODE
2
1
COLOR FUNCTIONNO.
2-COND WIRE CODE
BK - 16G
GN - 16G
Door Motor
Latch Solenoid
BK - 16G
GN - 16G
Door Motor
Latch Solenoid
12
2
1
COLOR FUNCTIONNO.
2-COND WIRE CODE
BL (Switch)
BK (Switch) Ground
Ramp Deployed
2
1
COLOR FUNCTIONNO.
2-COND WIRE CODE
BK - 20G
BN - 20G
Ground
Ramp Deployed
12
2
1
COLOR FUNCTIONNO.
2-COND WIRE CODE
BK - 20G
BN - 20G
2
1
COLOR FUNCTIONNO.
2-COND WIRE CODE
BK - 20G
WH - 20G
2
1
COLORNO.
2-COND WIRE CODE
BK - 16G
WH - 16G
2
1
COLOR FUNCTIONNO.
2-COND WIRE CODE
BK - 20G
WH/PU - 20G
Ground
Door Full Open
FUNCTION
Ground
Door Full Open
12
2
1
COLOR FUNCTIONNO.
2-COND WIRE CODE
NONE
WH/BN-20G Kneel Lowered
N/A
1
COLOR FUNCTIONNO.
2-COND WIRE CODE
PU - 20G
2 NONE N/A
Kneel Lowered
(Fake)
12
2
1
COLOR FUNCTIONNO.
2-COND WIRE CODE
2
1
COLOR FUNCTIONNO.
2-COND WIRE CODE
WH - 16G
GY - 16G
Door Motor
Latch Solenoid
BK - 16G
GN - 16G
Door Motor
Latch Solenoid
213
2
1
COLOR FUNCTIONNO.
3-COND WIRE CODE
BL/WH - 18G
WH - 18G
Kneel ON/OFF
3 BK - 18G Ground
Dash Operate
2
1
COLOR FUNCTIONNO.
3-COND WIRE CODE
WH/YL - 20G
WH/OR - 20G
Kneel ON/OFF
3 BK - 20G Ground
Dash Operate
2
1
COLOR FUNCTIONNO.
3-COND WIRE CODE
BK - 14G
LT GN - 14G
Kneel Override
3 NONE N/A
Kneel Motor 1
12
2
1
COLOR FUNCTIONNO.
2-COND WIRE CODE
BK - 16G
RD - 16G
Kneel Motor 2
Kneel Motor 1
2
1
COLOR FUNCTIONNO.
2-COND WIRE CODE
BK - 14G
RD - 14G
Kneel Motor 2
Kneel Motor 1
12
2
1
COLOR FUNCTIONNO.
2-COND WIRE CODE
BK - 16G
RD - 16G
Ground
Logic Power
21
2
1
COLOR FUNCTIONNO.
2-COND WIRE CODE
BK - 14G
RD - 14G
Ground
Logic Power
456
123
6
5
4
3
2
1 GY/BK - 20G
FRONT VIEW SHOWN REAR VIEW SHOWN
COLOR FUNCTIONNO.
9-COND WIRE CODE
7
8
9
BK - 20G
GY/YL - 20G
BK - 20G
WH - 20G
BK - 20G
DK BN - 14G
NONE
LT BN - 14G
Ramp Stowed
Ground
Ramp Stowed
Ramp Deployed
Ground
Ramp Deployed
Ground
Ramp Gate
Unlock
Ramp Motor 1
N/A
Ramp Motor 2
6
5
4
3
2
1
COLOR FUNCTIONNO.
9-COND WIRE CODE
7
8
9
NONE
WH - 18G
NONE
NONE
NONE
NONE
RD - 14G
NONE
BK - 14G
N/A
Ramp Stowed
N/A
N/A
N/A
N/A
Ramp Motor 1
N/A
Ramp Motor 2
123
123
12
2
1
COLOR FUNCTIONNO.
6-COND WIRE CODE
LT BN - 14G
DK BN - 14G
Ramp Motor 2
3 NONE N/A
4 LT BL - 14G PMM Door close
5 NONE N/A
6 YL - 14G Sleep Harness
Ramp Motor 1
2
1
COLOR FUNCTIONNO.
5-COND WIRE CODE
NONE
WH/BK - 18G
N/A
3 NONE N/A
4 NONE N/A
C-Pillar Ground
5 BK - 18G
C-Pillar Operate
2
1
COLOR FUNCTIONNO.
6-COND WIRE CODE
NONE
NONE
3 BN/BL - 20G
4 NONE N/A
5 WH/YL - 20G KneelON/OFF
6NONE
WH - 10G
LTGN - 14G
BK - 14G
LTBL - 14G
LTBN - 14G
DK BN - 14G DK BN - 14G
BN/BL - 20G
WH/GY - 20G
WH/BN - 20G WH/BN - 20G
GY/YL - 20G
WH - 18G
YL - 20G
GY/BK - 20G
BK - 20G
BK - 20G
BN/GN - 20G BN/GN - 20G
BK - 18G
WH/OR - 20G
WH/YL - 20G
WH/GY - 20G
WH/BN - 20G
GY/YL - 20G
WH - 18G
YL - 20G
LTGN - 14G
WH - 10G
RD - 12G
RD - 10G
BK - 14G
YL - 14G
LTBL - 14G
LTBN - 14G
DK BN - 14G
GY/BK - 20G
BK - 20G
BK - 20G
BN/GN - 20G
BK - 18G
WH/OR - 20G
WH - 18G
BL/WH - 18G
BL - 18G
RD - 10G
RD - 10G BK - 14G
BK - 14G
RD - 12G RD - 12G
WH - 22G
RD - 12G WH - 22G
BK - 18G
BK - 18GBK - 18G
BK - 18G
RD - 16G
WH/RD - 20G
WH/OR - 20G
RD - 16G
WH/YL - 20G
WH/RD - 20G
WH/OR - 20G
YL - 14G
BK - 14G
LTGN - 14G
WH - 10G
RD - 12G
WH - 10G
BK - 12G
BK - 20G BK - 20G BK - 14G
WH - 18G
BK - 18G
YL - 20G
WH/RD - 18G
LT BL - 14G
LTBN - 14G
DK BN - 14G
WH - 12G
BK - 14G
RD - 12G
YL - 14G
BK - 16G
WH/BK - 18G
BK - 18G
BK/GY - 18G
RD - 12G
YL - 14G
BK - 14G
LTGN - 14G
BK - 14G
LTBL - 14G
LTBN - 14G
GY/BK - 20G
BN/BL - 20G
GY/YL - 20G
WH/GY - 20G
WH/OR - 20G
RD - 12G
WH/RD - 18G
YL - 14G
WH/RD - 18G
RD - 18G
DK BN - 14G
BN/GN - 20G
WH - 12G
BK - 14G
BK - 14G
LTBL - 14G
LTBN - 14G
GY/BK - 20G
BN/BL - 20G
WH/BN - 20G
GY/YL - 20G
WH/PU - 20G
WH - 20G
WH/PU - 20G
WH - 20G
WH/PU - 20G
WH - 20G
WH/PU - 20G
WH - 20G
WH/OR - 20G
BK - 16G
WH - 16G
BK - 20G
WH/PU - 20G
BK - 20G
WH/PU - 20G
BK - 16G
GN - 16G
DK BL - 20G
LTGN - 20G
YL - 20G
BK - 14G
RD - 14G
DK BL - 20G
GN - 16G
BK - 16G
LTGN - 20G
YL - 20G
BK - 14G
GY/YL - 20G
TN/WH - 20G
BN - 16G
BN - 16G
PK - 20G
WH - 16G
GY - 16G
WH - 16G
GY - 16G
DK BL - 20G
LTGN - 20G
YL - 20G
BK - 14G
RD - 14G
BN - 20GBN - 20G
BK - 20G
BN - 20G
BK - 20G
BN - 20G
BK - 20G
WH - 20G
RD - 12G
WH/RD - 18G
N/A
N/A
N/A
PMM Operate
21 21
12
12
12
12
1
COLORNO.
2-COND WIRE CODE
BN - 20G
2
1
COLOR FUNCTION
FUNCTION NO.
2-COND WIRE CODE
NONE
BN - 20G
NA
Ramp Deployed
2NONE NA
Ramp Deployed
(Fake)
12 12
12
12
12
12
2
1
COLOR FUNCTIONNO.
6-COND WIRE CODE
WH/BK - 18G
BN/BL - 20G
3 WH/RD - 18G
4 LT BL - 14G
5NONE
6 BN/GN - 20G
2
1
COLOR FUNCTIONNO.
6-COND WIRE CODE
WH/OR -20G
WH - 20G
3 WH/OR - 20G Mag Operate
4 OR - 20G PMM Door Close
5 NONE N/A
6 YL - 20G Door Closed
PMM Trigger
C-Pillar Operate
Mag Operate
PMM Door Close
N/A
Door Closed
PMM Trigger
C-Pillar Operate
654
321
321
654
12345
2
1
COLOR FUNCTIONNO.
8-COND WIRE CODE
WH - 12G
RD - 12G
Kneel Motor 2
3 BK - 14G Kneel Override
4 NONE N/A
N/A
5NONE
N/A
6NONE
N/A
7NONE
N/A
8NONE
Battery
123
456
789
6
5
4
3
2
1 LT GN - 20G
COLOR FUNCTIONNO.
9-COND WIRE CODE
7
8
9
DK BL - 20G
BK - 20G
BN - 20G
PU - 20G
OR - 20G
PK - 20G
WH - 20G
TN/WH - 20G
Handle Switch
Door Operate
Ground
Ramp Deploy
Kneel Lower
PMM Door Close
Battery
PMM Operate
Ramp Stow
123
456
789
123456789
4
3
2
1 WH - 16G
COLOR FUNCTIONNO.
4-COND WIRE CODE
GY - 16G
GN - 16G
BK - 16G
Latch Solenoid
Door Motor
Door Motor
Latch Solenoid
1234
2
1
COLOR FUNCTIONNO.
6-COND WIRE CODE
BK - 14G
RD - 14G
3 YL - 20G Door Closed
4 LT GN - 20G HandleSwitch
5 DK BL - 20G B-Pillar Operate
6NONE N/A
Battery
Ground 2
1
COLOR FUNCTIONNO.
6-COND WIRE CODE
WH/BK - 16G
BK - 16G
3 YL/RD - 20G
4 WH/RD - 20G
5 LT BL - 20G
6NONE
123
456
123
456
123
456
123
456
123456
36
25
14
87
36
25
14
87
Ground
Ramp Deployed
Ground
Ramp Deployed
Door Closed
Handle Switch
B-Pillar Operate
N/A
Battery
Ground
2
1
COLOR FUNCTIONNO.
6-COND WIRE CODE
BK - 14G
RD - 14G
3 YL - 20G Door Closed
4 LT GN - 20G HandleSwitch
5 DK BL - 20G B-Pillar Operate
6NONE N/A
Battery
Ground 2
1
COLOR FUNCTIONNO.
6-COND WIRE CODE
WH/BK - 16G
BK - 16G
3 YL/RD - 20G
4 WH/RD - 20G
5 LT BL - 20G
6NONE
Door Closed
Handle Switch
B-Pillar Operate
N/A
Battery
Ground
Operate Signal Tap
Pass. Body Harness
Cavity 12 BJ1 (BL Wire)
33227A
WH/OR - 20G
2
1
COLOR FUNCTIONNO.
2-COND WIRE CODE
NONE
WH/OR - 20G
N/A
Operate
12
2
1
COLOR FUNCTIONNO.
2-COND WIRE CODE
NONE
WH/OR - 20G
N/A
B-Pillar Operate
12
KEY
DK
GY
GN
BR
BL
BK
LT
PU
WH
YL
??G
DARK ?? WIRE
GRAY
GREEN WIRE
BROWN WIRE
BLUE WIRE
BLACK WIRE
LIGHT ?? WIRE
TN TAN WIRE
PURPLE WIRE
RD RED WIRE
WHITE WIRE
YELLOW WIRE
WIRE GAUGE
Kneel
ON/OFF
Switch
31022
Dash
Door
Switch
20-0022-0
Kneel
RAISED
Switch
35-8419-0
Kneel
LOWERED
Switch
35-8418-0
2
1
COLOR FUNCTIONNO.
6-COND WIRE CODE
BK - 18G
WH/BN - 18G
3 WH - 12G Kneel Motor 2
4 BK - 18G Ground
5 WH/GY - 20G Kneel Raise
6 LT GN - 14G Kneel Motor 1
Kneel Lower
Ground
2
1
COLOR FUNCTIONNO.
6-COND WIRE CODE
BL (Switch 2)
BL (Switch 1)
3 BK - 16G
4 BK (Switch 1)
5 BK (Switch 2)
6 RD - 16G
654
321
321
654
Kneel Motor 2
Ground
Kneel Raise
Kneel Motor 1
Kneel Lower
Ground

Page 17B Page 18B
Unfold for:
Pre-2007 Power Door,
Infloor Ramp and Kneel
Wiring Diagram
Pre-2007 Power Door, Infloor Ramp and Kneel Electrical Schematic
M
RAMP
IN
SWITCH
RAMP
MOTOR
WH - 10G
LT GN - 14G
BK - 14G
LT BL - 14G
LT BN - 14G
DK BN - 14G DK BN - 14G
BN/BL - 20GBN/BL - 20G
WH/GY - 20G
WH/BN - 20G WH/BN - 20G
GY/YL - 20G
WH - 18G
YL - 20G
GY/BK - 20G
BK - 20G
BK - 20G
BN/GN - 20G BN/GN - 20G
BK - 18G
WH/OR - 20G
WH/YL - 20G
WH/GY - 20G
WH/BN - 20G
GY/YL - 20G
WH - 18G
YL - 20G
LT GN - 14G
WH - 10G
RD - 12G
RD - 12G
BK - 14G
YL - 14G
LT BL - 14G
LT BN - 14G
DK BN - 14G
GY/BK - 20G
BK - 20G
BK - 20G
BN/GN - 20G
BK - 18G
WH/OR - 20G
WH/OR - 20G
WH - 18G
BL/WH - 18G
BL - 18GRD - 6G
WH - 22G
BK - 18G
BL - 18G
BL (Switch 2)
BL (Switch 1)
BK (Switch 2)
BK (Switch 1)
BK - 18G
WH/OR - 20G
WH/YL - 20G
WH/RD - 20G
BK - 20G
BK - 20G
RD - 16G
WH/RD - 20G
WH/OR - 20G
RD - 10G
WH/RD - 20G
WH/OR - 20G
RD - 16G
WH/YL - 20G
RD - 10G
WH/RD - 20G
BK - 20G
RD - 16G RD - 10G
RD - 10G
30 AMP 25 AMP3 AMP
RD - 12G
BK - 14G
RD - 12G
BK - 14G
YL - 14G
BK - 14G
LT GN - 14G
WH - 10G
RD - 12G
WH - 10G
BK - 20G BK - 20G BK - 14G
WH - 18G
BK - 18G
YL - 20G
WH/RD - 18G
WH - 10G
BK - 14G
WH - 18G
BK - 18G
YL - 20G
RD - 18G
LT BL - 14G
LT BN - 14G
DK BN - 14G
WH - 12G
BK - 14G
RD - 12G
YL - 14GYL - 14G
BK - 16G
WH/BK - 18G
BK - 18G
RD - 12G
YL - 14G
BK - 14G
LT GN - 14G
BK - 14G
LT BL - 14G
LT BN - 14G
GY/BK - 20G
BN/BL - 20G
GY/YL - 20G
WH/GY - 20G
WH/OR - 20G
RD - 12G
WH/RD - 18G
YL - 14G YL - 14G
WH/RD - 18G
RD - 18G
WH - 22G
WH - 22G
DK BN - 14G
BN/GN - 20G
WH - 12G
BK - 14G
BK - 14G
LT BL - 14G
LT BN - 14G
GY/BK - 20G
BN/BL - 20G
WH/BN - 20G
WH - 18G
BK/GY - 18G
WH - 18G
BK (Switch)
BL (Switch)
RD - 14G
BK - 14G BK - 14G
RD - 14G
BK - 14G
RD - 14G
GY/YL - 20G
WH/PU - 20G
WH - 20G
WH/PU - 20G
WH - 20G
WH/PU - 20G
WH - 20G
WH/PU - 20G
WH - 20G
WH/OR - 20G
BK - 16G
WH - 16G
BK - 20G
WH/PU - 20G
BN - 20G
BK - 16G
GN - 16G
DK BL - 20G
LT GN - 20G
YL - 20G
BK - 14G
RD - 14G
DK BL - 20G
GN - 16G
BK - 16G
LT GN - 20G
YL - 20G
BK - 14G
GY/YL - 20G
TN/WH - 20G
BN - 16G
BN - 16G
PK - 20G
WH - 16G
GY - 16G
BL (Switch 1)
BK - 16G
BL (Switch 2)
BK (Switch 1) BK (Switch 2)
RD - 16 G
BL (Switch 1)
BK - 16G
BK (Switch 1)
RD - 16 G
WH/BN - 18G
BK - 18G
WH - 12G
BK - 18G
WH/GY - 20G
LT GN - 14G
WH - 20GBN/BL - 20G
GY/YL - 20GGY/YL - 20G
WH/OR - 20GWH/OR - 20G WH/OR - 20GWH/BK - 18G WH/OR - 20GWH/RD - 18G
OR - 20GLT BL - 14G
YL - 20GBN/GN - 20G
PU - 20G
BN - 20G
WH/BR - 20G
WH - 20G
BK - 20G
WH - 16G
GY - 16G
DK BL - 20G
LT GN - 20G
YL - 20G
BK - 14G
RD - 14G
RD - 12G
WH/RD - 18G
BK - 18G
DK BN - 14G
BN/GN - 20G
WH - 12G
BK - 20G
BK - 14G
BK - 14G
LT BL - 14G
LT BN - 14G
GY/BK - 20G
BN/BL - 20G
WH/BN - 20G
GY/YL - 20G
GY/YL - 20G
WH/PU - 20G
WH - 20G
WH - 20G
WH/OR - 20G
RD - 12G
WH/RD - 18G
BN - 20G
M
M
_
IGN.
50 AMP
BAT.
BK - 20G
BN - 20G
BK - 20G
BN - 20G
BK (Switch)
BL (Switch)
RAMP
OUT
SWITCH
COM
NO
TRANSMISSION
INTERLOCK
SWITCH
FUSE BLOCK
TO OEM
IGNITION
DASH
DOOR
SWITCH
KNEEL
ON/OFF
SWITCH
COM
NO
COM
NO
C-PILLAR
DOOR
SWITCH
KNEEL
OVERRIDE
SWITCH
DOOR
OPEN
SWITCH
TO OEM DOOR
(MODULE
HARNESS SIDE)
TO OEM DOOR
(MODULE
HARNESS SIDE)
TO OEM DOOR
(MODULE
CONNECTOR SIDE)
TO OEM DOOR
(MODULE
CONNECTOR SIDE)
COM
NO
COM
NO
85 86
30 87
87A
85 86
30 87
87A
KNEEL
RAISED
SWITCH
COM
NO
KNEEL
LOWERED
SWITCH
KNEEL
ACTUATOR
PMM CONTROLLER
35-4086-0
OEM DOOR RELAY BOARD
RELAY 1
COM
NO
MAGNETIC
ENTRY SWITCH
GRD
GRD
GRD
COM
NO
DRAWING NOTES
Junctions only occur at intersections with junctions symbol.
All other intersections are wire crossings with out junctions!
BATTERY
JUNCTION
CHASSIS GROUND
FUSE
MOTOR
DESCRIPTION SYMBOL
CONNECTOR
COM
NO
NC
COM
NO
85 86
30 87
87A
NC SWITCH
NO SWITCH
MOMENTARY SWITCH
MOMENTARY SWITCH
RELAY
DESCRIPTION SYMBOL
GRD
12
12
12
1
3456789
10111213141516
2
21
21
11
23
2
1
13
54
5
6
64
21
2
3
31
3456
65
6
4321
5432178910111213141516
21 21
12 12
21 2
3 31
65
6
4321
543
12
12
21
12
1
3456
2
12
12
12
12
3456
98
9
7654
876
12
1
34
23454
321
321
65 6
4321
54321
65 6
4321
54321
21 21
21 21
21 21
21 21
21 21
21 21
21 21
21 2
3 3
4 4
5 5
6 6
7 7
8 8
9 91
21 21