PlugSlidingDoor IM PS1600002

Plug Sliding Door System
Installation Manual
IM Version
Release date
3.2
2021-05-10
Document ID PS1600002
Project name Plug Sliding Door System 1
Project ID PS1
File name PlugSlidingDoor_IM_PS1600002.PDF

Template version 20210311R1.8
Plug Sliding Door System Revision history
Installation Manual
Revision history
Revision Date By Description
Prepared: Torque setting catch block adjusted from 26±2Nm to 20±2Nm pos 12.
3.2 2021-05-10
M.Stoelinga Adjusted revision history details.
Prepared:
3.1 2021-03-26 Torque setting can be checked by checking the torque marking.
M.Stoelinga
Acronyms added.
Adjusted torque setting order.
Adjusted torque setting value of the shaft coupler from 13±1Nm to
22±2Nm pos 3.
Prepared:
3.0 2021-03-19 Added door movement and open position to Description of the door
M.Stoelinga
system.
Changed service e-mail address.
Minor change in the order of the door leaf adjustment.
Minor text changes.
Minor text and layout improvements
Prepared:
2.1 2019-10-24 Reference adjustment TS 155
M. Stoelinga
Changed chapter "Contact" to appendix
Document structure changed.
Adjusted overview.
Installation chapter added to heading 1.
Prepared:
2.0 2019-07-19 Added microswitch position sub chapter.
M.Sandtmann
Textual and lay-out update.
Added caution to mount the door leaves.
Door leaves closed position added note.
Prepared:
1.0 2019-04-26 Initial version
M.Sandtmann
PlugSlidingDoor_IM_PS1600002.PDF(3.2) 2021-05-10 page 2 of 32

Plug Sliding Door System Preface
Installation Manual
Preface
The Quality System of Ventura Systems is accredited to EN ISO 9001:2015.
All rights reserved. Disclosure to third parties of this document or any part thereof, or the use of any information contained
therein for purposes other than provided for by this document, is not permitted, except with prior and express written
permission from Ventura Systems.

Plug Sliding Door System Table of contents
Installation Manual
Table of Contents
1 Introduction ........................................................................................................................................................................................... 6
1.1 Purpose........................................................................................................................................................................................... 6
1.2 Scope .............................................................................................................................................................................................. 6
1.3 Definitions ...................................................................................................................................................................................... 6
1.4 Acronyms and Abbreviations ......................................................................................................................................................... 6
1.5 References ...................................................................................................................................................................................... 6
1.5.1 External documents ................................................................................................................................................................ 6
1.5.2 Ventura Systems documents .................................................................................................................................................. 6
1.6 Overview......................................................................................................................................................................................... 6
2 Door installation safety ......................................................................................................................................................................... 7
2.1 General ........................................................................................................................................................................................... 7
2.2 Disclaimer ....................................................................................................................................................................................... 7
2.3 Safety alert symbols ....................................................................................................................................................................... 8
2.4 Safety instructions .......................................................................................................................................................................... 9
3 Door assembly kits............................................................................................................................................................................... 10
3.1 Unpacking instructions ................................................................................................................................................................. 10
3.2 Included kits ................................................................................................................................................................................. 10
3.3 Storage instructions ..................................................................................................................................................................... 11
3.4 Required documentation ............................................................................................................................................................. 11
3.5 Required tools .............................................................................................................................................................................. 11
3.6 Description of the door system .................................................................................................................................................... 12
4 Installation ........................................................................................................................................................................................... 13
4.1 Mount the door mechanism ........................................................................................................................................................ 13
4.2 Mount the door shafts and bottom supports .............................................................................................................................. 14
4.3 Mount the door arms ................................................................................................................................................................... 16
4.4 Mount the door leaves ................................................................................................................................................................. 17
4.5 Door leaves parallel with each other ........................................................................................................................................... 19
4.6 Door leaves parallel with the step edge ...................................................................................................................................... 20
4.7 Height adjustment door leaves .................................................................................................................................................... 21
4.8 Door leaves in open position clearance and prevent shaking ..................................................................................................... 22
4.9 Door leaves in fully open position ................................................................................................................................................ 23
4.10 Door leaves closed position ....................................................................................................................................................... 24
4.11 Door leaves glass flush with the outside of the vehicle............................................................................................................. 26
4.12 Door leaves closed position and catch wedge ........................................................................................................................... 27
5 Torque Settings.................................................................................................................................................................................... 29
6 Operational checks .............................................................................................................................................................................. 31
6.1 Operation and controls ................................................................................................................................................................ 31
6.2 Safety checks ................................................................................................................................................................................ 31
Appendix A - Contact .............................................................................................................................................................................. 32
List of Figures
Figure 1: Door mechanism ..................................................................................................................................................................... 10
Figure 2: Mounting kit ............................................................................................................................................................................ 10
Figure 3: Left door leaf ........................................................................................................................................................................... 10
Figure 4: Right door leaf ......................................................................................................................................................................... 10
Figure 5: Overview PS1 door system in closed position ........................................................................................................................ 12
Figure 6: Overview PS1 door system in open position .......................................................................................................................... 12
Figure 7: Measure the portal ................................................................................................................................................................. 13
Figure 8: Mount adapter and portal finishing ........................................................................................................................................ 13
Figure 9: Positioning of the mechanism................................................................................................................................................. 14
Figure 10: Required parts for this step .................................................................................................................................................. 14
Figure 11: Connecting the door shaft onto the top bracket.................................................................................................................. 14
Figure 12: Securing the bottom support ................................................................................................................................................ 15
Figure 13: Linking the connection rod ................................................................................................................................................... 15
Figure 14: End result of this step ........................................................................................................................................................... 15
Figure 15: Required parts of this step .................................................................................................................................................... 16
Plug Sliding Door System Table of contents
Installation Manual
Figure 16: Connecting the door arms onto the door mechanism ......................................................................................................... 16
Figure 18: Required parts for this step .................................................................................................................................................. 17
Figure 19: Fitting the door leaf on the door shaft ................................................................................................................................. 17
Figure 20: Checking connection ............................................................................................................................................................. 17
Figure 21: Connecting the door arms onto the door mechanism ......................................................................................................... 17
Figure 22: Mount door leaf to door arms .............................................................................................................................................. 18
Figure 24: Door leaves parallel with each other .................................................................................................................................... 19
Figure 25: Adjustment bolt..................................................................................................................................................................... 19
Figure 26: adjusting inward/outward position door leaves ................................................................................................................... 20
Figure 27: Door leaves parallel with step edge ...................................................................................................................................... 20
Figure 28: Door leaves height adjustment ............................................................................................................................................. 21
Figure 29: Connection rod...................................................................................................................................................................... 22
Figure 30: Space between rail and door shaft ....................................................................................................................................... 22
Figure 31: End Stop ................................................................................................................................................................................ 22
Figure 32: Door leaves fully open position ............................................................................................................................................ 23
Figure 33: Door leaves closed position .................................................................................................................................................. 24
Figure 34: Adjusting door leaves closed position .................................................................................................................................. 25
Figure 35: Distance between door leaves .............................................................................................................................................. 25
Figure 36: Door front view ..................................................................................................................................................................... 26
Figure 37: Adjusting upper corners, glass flush with vehicle body........................................................................................................ 27
Figure 38: Adjusting bottom corners, glass flush with vehicle body ..................................................................................................... 27
Figure 39: Door leaves closed position .................................................................................................................................................. 27
Figure 40: Adjusting door leaves closed position .................................................................................................................................. 28
Figure 41: Distance between door leaves .............................................................................................................................................. 28
Figure 42: mark the fasteners with a torque marker............................................................................................................................. 29
Figure 43: torque setting overview. ....................................................................................................................................................... 29
Figure 44: World map Ventura locations ............................................................................................................................................... 32
List of Tables
Table 1: Acronyms and abbreviations ...................................................................................................................................................... 6
Table 2: External documents .................................................................................................................................................................... 6
Table 3: Ventura Systems documents ...................................................................................................................................................... 6
Table 4: General contact information .................................................................................................................................................... 32
Table 5: Parts contact information......................................................................................................................................................... 32

Plug Sliding Door System Introduction
Installation Manual Purpose
1 Introduction
1.1 Purpose
This installation manual describes installation procedures for the Ventura plug slide door system. Together with the
commissioning manual and the system drawings makes a complete set of installation documentation. It is important to follow all
instructions. All instructions must be conducted without air pressure/electric power unless mentioned otherwise. The instructions
should be executed for both door leaves when the system contains two door leaves. A well-adjusted door system is less vulnerable
to failure. The right maintenance is crucial for the durability of the door system.
1.2 Scope
The purpose of this document is to guide trained mechanics trough the installation steps of the plug slide door system.
1.3 Definitions
No definitions.
1.4 Acronyms and Abbreviations

Abbreviation Description
DCU Door Control Unit
IATF International Automotive Task Force
ISO International Standardization Organization
HQ Headquarters
PS Plug Slide door system
QM Quality Manual
TS Technical Specification (TS155)
Table 1: Acronyms and abbreviations
1.5 References
1.5.1 External documents
Reference Description Date
IATF 16949:2016 Automotive quality management system standard 2016-10-01
ISO 9001:2015 ISO Standard for Quality Management Systems – Requirements. 2015-10-01
TS 155 Rev 2 Bus door safety systems 2017-11-23
Table 2: External documents
1.5.2 Ventura Systems documents

Reference Type Description Revision Date
QM000001 DG Documentation Guideline 4.0 2021-01-04
Table 3: Ventura Systems documents
1.6 Overview
Section 1 gives an introduction, definitions and overview of this document.
Section 2 contains the general door system safety instructions, safety symbols and disclaimer.
Section 3 contains information about the door assembly kit.
Section 4 contains the installation instructions.
Section 5 contains the torque settings.
Section 6 contains operational checks before applying power.

Plug Sliding Door System Door installation safety
Installation Manual General
2 Door installation safety

2.1 General
Safety of the operator and bystanders is one of the main concerns in designing and developing a new piece of equipment.
Ventura's door systems have the proper safety features for common use of the system. An accident can often be avoided by
recognizing potentially hazardous situations before an accident occurs. As you install, operate, or maintain the door system, you
must be alert to potential hazards. Make sure you have the necessary training, skills and tools to perform any assembly, or
maintenance procedures. Improper operation and maintenance of this door system may result in a dangerous situation that may
cause injury or death.
Ventura Systems cannot anticipate every possible circumstance that may involve a potential hazard. The warnings in this
document and on the product are not all-inclusive. If a method of installation or operation is used, which is not specifically
recommended by Ventura Systems, you must satisfy yourself that it is safe for you and for others. You should also ensure that the
door system will not be damaged or be made unsafe by the installation and/or operational methods you choose. The information,
specifications and illustrations in this document are based on the information that was available at the time this document was
written and can change at any time without notice.
2.2 Disclaimer
The information contained in this document is based upon reliable technical data at the time the document was published. These
instructions are intended for use by persons having the technical knowledge to install, maintain or repair this door system. The
instructions are to be used at the mechanic’s own discretion and risk. Ventura Systems assumes no responsibility for results
obtained or damage incurred from the use of this material either in whole or in part by the installer. This document provides basic
instructions for handlings of the door system in a step-by-step sequence that will work in most situations. While effort has been
made to ensure the information in this document is correct and complete, we would appreciate it if you would contact us in case
of errors.

Installation Manual Safety alert symbols
2.3 Safety alert symbols

This document contains safety messages which alert you to potential personal injury hazards. Obey all safety messages in this
document to avoid possible injury or death. The following key words and layouts calls for your attention: DANGER, WARNING,
CAUTION and NOTICE. Below are examples of these safety messages. The NOTE message is used for additional information but
these are not threatening for the mechanic, bystanders, nor the door system.
DANGER! NOTICE
Indicates an imminently hazardous situation which, if Indicates that equipment or property damage can
not avoided, will result in death or serious injury. This result if instructions are not followed.
signal word is limited to the most extreme situations.
NOTE
WARNING!
Additional information important but not
Indicates a potentially hazardous situation which, if threatening for people or to the system.
not avoided, could result in death or serious injury.
CAUTION!
Indicates a potentially hazardous situation which if

not avoided, may result in minor or moderate injury.

Installation Manual Safety instructions
2.4 Safety instructions

WARNING! NOTICE
This door system is designed for a specific Do not modify the door system or safety devices.
application; Unauthorized modifications may impair its function
DO NOT modify or use this unit for any application and safety.
other than for which it was designed.
If equipment has been altered in any way from the
original design, Ventura Systems does not accept
Door systems operated improperly or by untrained any liability for injury or warranty.
personnel is dangerous. Lack of operation knowledge
may cause high risk. If replacement of parts is necessary, genuine factory
replacement parts must be used to restore the door
system to its original specifications.
Do not install this door system if it is damaged. If you
are in doubt if the door system has a defect,
*always disconnect the air and/or electric power
immediately stop the installation and contact
while replacing parts. Safety features may not be
Ventura Systems.
active while replacing parts.
Do not connect the door system to air or electric Ventura Systems will not accept responsibility for
supply during the maintenance process. If the damages as a result of the use of unapproved parts.
manual states otherwise, follow the manual.
While working on the Ventura door systems wear
appropriate personal protective equipment.
This list may include but is not limited to:
Do not attempt to install the door system under • Protective shoes with slip resistant soles
influence of drugs or alcohol. • Protective goggles, glasses or face shield
• A hard hat
Follow the regional and country laws and safety

precautions.

Plug Sliding Door System Door assembly kits
Installation Manual Unpacking instructions
3 Door assembly kits

A complete door system consists of three to four assembly kits. A mounting kit, one/two door leaves and a door mechanism. Also,
you should have a full set of documentation. A set of documentation contains a mechanical installation manual, commissioning
manual, system drawing, repair manual, maintenance manual and parts overview.
3.1 Unpacking instructions

Unpack the door system carefully. Watch for possible damage that may have occurred during shipment. Make sure all electrical or
pneumatic components and wiring are not damaged. Check if all electrical and pneumatic connections are still fixed. If anything is
damaged, replace these parts. Otherwise, continue the installation.
NOTICE
Do not remove the factory installed white zip ties. If the manual states otherwise, follow the manual. Never remove black zip
ties.
Read and follow the instructions written on the parts to see which zip ties are not allowed to be removed.
3.2 Included kits
Figure 1: Door mechanism Figure 2: Mounting kit
Figure 3: Left door leaf Figure 4: Right door leaf

Installation Manual Storage instructions
3.3 Storage instructions

If the equipment is not installed immediately, store in a clean and dry location. Care should be taken moving the equipment from
a warm to a cold location, as condensation may occur. If condensation does occur, and the equipment is wet, allow it to dry
thoroughly before applying power. Store the Ventura door system following these instructions.
• Stack the crates to a maximum of 3.
• Prevent external load.
• Do not store under humid or wet conditions.
• Do not stack any other product on top of the crates.
• Store the crates horizontal.
• Protect the door system from dust and dirt.
3.4 Required documentation

Use the right documentation as guidance for the installation, commissioning and maintenance of the door system.
Installation documentation:
• Commissioning manual
• Door system drawing
• Door mechanism installation manual
• Optional: DCU system manual
After sales documentation:
• Maintenance manual
• Repair manual
• Parts overview
3.5 Required tools

It is important to use (calibrated) tools of good quality to prevent damage to the door system and prevent personal injury. No
special tools are necessary. There is a tool which could help with the adjustments of the door.
Tool Usage
Door speed adjustment (cylinder)
Allen key set (metric)
and door alignment adjustment.
Socket or wrench set Door installation and cylinder rod
(metric) adjustment

Installation Manual Description of the door system
3.6 Description of the door system
The illustration of the door system to the right represents the

plug slide door.
1. Door mechanism
2. Door shaft left
3. Door shaft right
4. Bottom support left
5. Bottom support right
6. Door leaf left
7. Door leaf right
8. Door arm left
9. Door arm right
10. Portal
Figure 5: Overview PS1 door system in closed position
Motion of the door system

The plug slide door opens in 2 steps. The first step plugs the
doors out of the vehicle. Then the doors slide open along the
vehicle. In some variations the door closest to front of the
vehicle opens with a minor angle so the door will not hit
exterior parts of the vehicle. Examples are mirrors or tires.
NOTICE
The portal is including all covers, strips etc. which
are not part of the Ventura Systems door system.
Left and right are defined looking from the inside

of the vehicle.
Illustrations or images in the manual may differ

from reality. Electrical and pneumatic systems have
the same mechanical installation.
Figure 6: Overview PS1 door system in open position

Plug Sliding Door System Installation
Installation Manual Mount the door mechanism
4 Installation
Execute the following steps to install the system.
4.1 Mount the door mechanism

WARNING! CAUTION!
Falling hazard. The door mechanism is heavy. We advise to lift this
The door mechanism is heavy. It is the installer’s piece with a lifting tool, or with two persons to
responsibility to securely fasten the door mechanism prevent personal injury and to prevent damage to the
to the portal. Severe injury and possible death can mechanism.
occur if the mechanism falls.
Check the portal size.

• The height of the portal needs to be within tolerance
over the complete width of the portal (1, 2).
• The width of the portal needs to be within tolerance
over the complete height of the portal (3, 4).
• Check the portal diagonals by measuring 5 and 6.
• Check the mounting points at the system drawing 0.3A
• Check the mounting point dimensions according to
system drawing. 2.2B.
Figure 7: Measure the portal
Mount adapter brackets and portal finishing

• If the brackets are not already pre-mounted to the
door mechanism, mount the adapter brackets to the
door mechanism before installing to the portal.
Alternatively, first mount the adapter brackets to the
portal.
• When choosing to mount the adapter brackets first to
the portal, a custom jig for precise fitment is advised.
• Install the portal sealing on the inside of the portal if
applicable.
Figure 8: Mount adapter and portal finishing

Installation Manual Mount the door shafts and bottom supports
Mount the door mechanism,

onto the mounting points.
• Position the door mechanism in the center of the
portal. Measurements 1 and 2 have to be equal with a
tolerance of 2 mm.
• Level the mechanism to the portal and measurements
3 and 4 must be equal with a tolerance of 2 mm.
• Check if the mechanism is mounted level. Check if the
measurements 3 and 4 are equal and according to
Door system drawing: 2.2.
• When level and centered, tighten the fasteners.
Figure 9: Positioning of the mechanism
4.2 Mount the door shafts and bottom supports
Required parts for this step:

1. 1x door shaft left
2. 1x door shaft right
3. 1x bottom support left
4. 1x bottom support right
The following steps represent the left side of the door system.
Repeat these steps for the right side of the door system after
completing the installation of the left side.
Figure 10: Required parts for this step
Mount the door shaft onto the mechanism

• Clean bearing bush and apply multi-purpose grease on
the pivot bolt of the top bracket.
• Fit the top of the door shaft onto the pivot bolt on the
top bracket.
• Hold the door shaft and move on to the next step.
Figure 11: Connecting the door shaft onto the top bracket

Installation Manual Mount the door shafts and bottom supports
Securing the door shaft

• Clean the bearing bush and apply multi-purpose
grease on the pivot bolt of the bottom support.
• Fit the door shaft over the pivot bolt on the bottom
support and hold the door shaft and bottom support.
• Move the bottom support into position while holding
both the bottom support and door shaft.
• Use self-supplied fasteners for mounting the bottom
support to the portal.
Figure 12: Securing the bottom support
Linking the connection rod.

• Connect the connection rod with the upper lever of
the door shaft.
• Fasten the connection rod to the door shaft, make
sure to place a lock disc (1) on both sides of the
connection to the door shaft.
Figure 13: Linking the connection rod
End result of this step:

1. The door shafts left and right are connected to the
door mechanism.
2. The bottom supports are in place with the pivot bolt
inside the bearing bush and mounted to the portal.
3. The connection rods are connected from the
mechanism onto the door shafts
4. Both left and right sides are in place.
Figure 14: End result of this step

Installation Manual Mount the door arms
4.3 Mount the door arms

1. 1x door arm left
2. 1x door arm right
Figure 15: Required parts of this step
Mounting the door arms

• Use the cable tie on the end of the spiral cable to pull
the spiral cable through the door arms. Do not cut-off
the cable tie afterwards.
• Mount the door arms with the supplied fasteners.
Make sure the fasteners are fitted nominal into the
slotted holes to ensure the door arm is mounted as
straight as possible onto the bearing house.
Figure 16: Connecting the door arms onto the door mechanism

1. The left and right door arms are connected to the door
mechanism.

Installation Manual Mount the door leaves
4.4 Mount the door leaves

1. 1x door leaf left
2. 1x door leaf right
3. Scissor
4. Hex key M6
5. Torx T50
The following steps represent the left side of the door system.
Repeat these steps for the right side of the door system after
completing the installation of the left side.
CAUTION!
The door leaves are heavy. We advise to install the door leaves
with two persons to prevent personal injury and prevent severe
damage to the door system. Figure 18: Required parts for this step
Fitting the door leaf onto the door shaft

• loosen the lever block (1) and rotate it. Fit the door leaf
over the guide roller and lower lever.
• Place the door leaf over the door shaft lower lever and
make sure the guide roller on the lower lever fits well
inside the door leaf guiding rail.
• Rotate the lever block (1) to lock the door leaf in place.
Figure 19: Fitting the door leaf on the door shaft
Checking connection
• The door mechanism is always shipped with a cable tie
(1) which secures the right side bearing house to the
drive bracket. Without this cable tie (1) this connection
can be made undone when the bearing house is being
tilted.
• Make sure the pin (2) on the drive bracket is inside the
drive bracket hole. If not, then tilt the door arm and
put the pin (2) through the hole. The pin (2) needs to
protrude the drive bracket bush at least 1mm. Figure 20: Checking connection
Connecting the sensitive edge

• Connect the connector of the sensitive edge on the
door leaf to the spiral cable that runs through the door
arm.
• Put the cable tie on the end of the spiral cable inside
the door leaf or door arm. Do not cut-off the cable tie.
Figure 21: Connecting the door arms onto the door mechanism

Installation Manual Mount the door leaves
Mount door leaves to door arms

• Mount the top of the door leaf onto the door arm
using the supplied fasteners and make sure there is not
any loose cable caught between the door leaf and the
door arm.
• Check if the connection between the drive bracket and
the bearing house is still correct. The pin (2) needs to
protrude the drive bracket bush at least 1mm.
• Remove the cable tie (1) which ties the drive bracket to
the actuator/cylinder. See image "checking
Figure 22: Mount door leaf to door arms
connection"

1. The door leaves are connected to the door shafts.
2. The door leaves are connected onto the door arms.
3. Both the left and right door leaf are in place.

Installation Manual Door leaves parallel with each other
4.5 Door leaves parallel with each other

Put the door system in almost closed position where the door leaves are not yet moving inwards. Then check if the door leaves are
parallel with each other and if a straight line of sight is visible.
Position 1 Position 2
Figure 25: Adjustment bolt
Figure 24: Door leaves parallel with each other
If the door leaves are not parallel (1) to each other, adjust this by following the next steps. These steps are the same for both a
type A door and a type B door.
1. Loosen the rotation point (2) slightly and fully loosen the other 3 fasteners which hold the door leaf to the door arm.
2. Adjust the door leaves by turning the adjust bolts (3) until they are parallel with each other and a straight line of sight is
visible.
3. Tighten the fasteners

Installation Manual Door leaves parallel with the step edge
If one of the door leaves is more inward or outward then the

other. Follow the next steps to place them parallel to each
other.
1. Loosen the bolts connecting the door arms to the door
mechanism
2. Adjust the inward/outward position by adjusting the
door arms using the slotted holes in the door arms.
Figure 26: adjusting inward/outward position door leaves
4.6 Door leaves parallel with the step edge

Put the doors in an almost closed position and check if the door leaves are parallel with the step edge (1)
Figure 27: Door leaves parallel with step edge
If the door leaves and the step edge (1) are not parallel to each other, fix this by following the next steps.
1. Loosen the rotation point (2) slightly and also fully loosen the other 3 fasteners.
2. Rotate the door leaf until it is parallel with the step edge.

Installation Manual Height adjustment door leaves
4.7 Height adjustment door leaves

Put the door system in closed position. Then check if the height between the door leaves and portal is correct.
NOTE
Make sure to loosen the bottom support and top bracket when lowering or increasing the height of the door mechanism to
prevent damage to the plastic bearing bushes fitted inside the door shaft.
Figure 28: Door leaves height adjustment
If distance 1 is not 50±2mm and parallel, adjust the height of the door leaves by moving the door mechanism up or down
following the next steps.
1. Loosen the fasteners (2) that hold the door mechanism to the adapter bracket.
2. Loosen the bottom support (4) and top bracket (3)
3. Level the door mechanism and make sure there is 50±2mm of space between the portal and the top of the door leaves.
4. Tighten the fasteners (2)
5. Remove any vertical play in the door shaft by adjusting the bottom support (4) and top bracket (3)

Installation Manual Door leaves in open position clearance and prevent
shaking
4.8 Door leaves in open position clearance and prevent shaking
To prevent shaking door leaves at the end of the door open movement, the following conditions have to be achieved:
• The bearing house has to touch the rubber at the end of the movement.
• The guide roller on the lower level of the door shaft must touch the end of the guiding rail of the door leaf.
• The end stop underneath the door shaft has to touch the bottom support.
NOTE
Check if there is 4 to 8mm of space between the door shaft lower lever and the door leaf rail across the full movement of the
door leaf (position 2). The lever block as discussed in step 4 should prevent the guiding roller from coming out of the door leaf
rail.
Position 1 Position 2 Position 3
Figure 29: Connection rod Figure 30: Space between rail and door shaft Figure 31: End Stop
Adjust door leaf rail clearance

The guiding rail of the door leaf may not touch the door shaft lower lever. There should be 4 to 8mm of space across the full
movement of the door leaf (position 2).
• Adjust the height of the door shaft by lowering or raising the bottom support and top bracket.
• Make sure there is no vertical play in the door shaft.

Installation Manual Door leaves in fully open position
Adjust the door leaf fully open position
Check if the guiding roller on the door shaft lower lever is touching the end of the door leaf rail. Also check if the end stop is
touching the bottom support (position 3).
• Adjust the connection rod so the end stop touches the bottom support and the guiding roller touches the end of the
guiding rail (position 1)
4.9 Door leaves in fully open position
Figure 32: Door leaves fully open position
Check if both bearing houses (2) move against the rubbers (1) in fully open position. There may not be any space between these
parts (4). If there is space between the rubber (1) and the bearing house (2), follow the next steps.
1. Put the door leaves in open position by hand.
2. Check if the bearing house (2) touches the rubber (1) on the end of the movement. If not, check if the door mechanism is
centered (See step 1).
3. Loosen the tension bracket (3).
4. Push the left door leaf so it will move into fully open position until the bearing house (2) is touching the rubber (1) on the
end.
5. Hand-tighten the tension bracket (3).

Installation Manual Door leaves closed position
4.10 Door leaves closed position

In this step check all measurements while having power on the system. Check if the space (2) between the door leaves is conform
following the system drawing at the top of the door leaves. The space has to be the same at the bottom eventually, but has to be
adjusted in step 12 by adjusting the catch wedge.
WARNING!
Remove the power and/or pressure from the system before making any adjustment.
NOTE
Moving the right camroller to the left side will reduce pressure and moving to the right side will increase pressure between the
door leaves.
Figure 33: Door leaves closed position

Installation Manual Door leaves closed position
Figure 35: Distance between door

Figure 34: Adjusting door leaves closed position leaves
If the space (2) between the door leaves is not as described in the system drawing at the top of the door leaves. Adjust this by
following the next steps.
1. Loosen the 3 fasteners on the bearing house drive bracket.
2. The camroller bracket (3) between the bearing house and drive bracket can now move through the slotted holes,
changing the space (2) between the door leaves. Adjust the space between the door leaves at the top to the distance
described in the system drawing.

Installation Manual Door leaves glass flush with the outside of the vehicle
4.11 Door leaves glass flush with the outside of the vehicle
This step is important for getting a tight seal between the rubbers of the door and the bus. Put the doors in closed position (with
power) and check if the glass of the door leaves is flush with the outside of the vehicle.
WARNING!
NOTE
Do not use the connection rod to adjust the inward/outward position of the door leaves.
Figure 36: Door front view

Installation Manual Door leaves closed position and catch wedge
Figure 37: Adjusting upper corners, glass flush with vehicle Figure 38: Adjusting bottom corners, glass flush with vehicle
body body
Adjust the doors to fit properly in all corners. Follow the next step to adjust the doors to be aligned with the portal in the upper
corners.
• To adjust the inward/outward position of the door mechanism (1) loosen the top fasteners that hold the door mechanism
to the adapter brackets. When lose, the position of the door mechanism can be adjusted inward and outward.
Follow the next step to adjust the doors to be aligned with the portal in the bottom corners.
• Adjust inward/outward position door leaves by adjusting the position of the door shaft (2) on the bottom support. Loosen
the fastener and move the pivot inwards or outwards.
4.12 Door leaves closed position and catch wedge

In this step check all measurements while having power on the system. The space (2) between the door leaves vertical profiles
should be perfect after adjusting the space in step 10. Check if the space (2) between the door leaf vertical profiles is conform
following the system drawing at the bottom of the door leaves.
WARNING!
Figure 39: Door leaves closed position

Installation Manual Door leaves closed position and catch wedge
Figure 40: Adjusting door leaves closed position Figure 41: Distance between door leaves
Adjusting the catch wedge height (4)

• Loosen the fasteners which hold the catch wedge (4) to the door leaf.
• Slide the catch wedge (4) up or down through the slotted hole until the wedge on the catch wedge (4) is at the right
height to be caught by the catch block (3).
• Tighten the fasteners.
Adjusting the space (2) between the door leaves
• Loosen the fasteners on the catch block (3).
• Adjust the catch blocks equally:
o Decrease space (2) = move the catch block (3) outwards
o Increase space (2) = move the catch block (3) inwards
• Tighten the fasteners.

Plug Sliding Door System Torque Settings
Installation Manual
5 Torque Settings
All generic plug slide settings that require torque tightening are in this chapter. Check all mentioned fasteners on the correct
torque settings. In case of a double leaf system, check both sides. The torque settings of marked fasteners may be verified by
checking if the marking is intact.
The fasteners which connect Ventura parts onto the vehicle are, in most cases, non-Ventura parts. Therefor the torque of these
fasteners is not defined by Ventura.
After setting a part to torque specification, mark the connection

with a torque marker.
Figure 42: mark the fasteners with a torque marker.
The position in the system overview have details in the following part of this manual. In the second part the torque settings are
described.
Figure 43: torque setting overview.

Plug Sliding Door System Torque Settings
Installation Manual
121±9 Nm, 2 per side 22±2 Nm, 2 per side 22±2 Nm, 2 per side
22±2 Nm, 3pc 9±1 Nm, 2pc 45±4 Nm, 4 per side

Plug Sliding Door System Operational checks
Installation Manual Operation and controls
6 Operational checks
Execute these checks before applying power.
WARNING!
Applying power to an unchecked system may result in a potentially hazardous situation which, if not avoided, could result in
death or serious injury.
No. Check Verified by Approved

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

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

These checks are all with power and/or pressure.
1. All emergency buttons are functioning.
2. Check pneumatic obstruction detections. (if applicable)
Apply an obstruction while closing. Doors open again. Test left and right separately.
3.
*CAUTION!
Apply an obstruction while opening. Doors go to half open position. Test left and
4.
right separately. (if applicable) *CAUTION!
5. Check if the mechanism goes overcenter in closed position. (if applicable)
CAUTION!
Do not use body parts to apply an obstruction.

Plug Sliding Door System Operational checks
Installation Manual Safety checks
Appendix A - Contact
Figure 44: World map Ventura locations
Ventura Systems Ventura Systems Ventura Systems Inc

Ventura Systems HQ
Asia Pacific Australia North America
Unit 10 on the 13/F
De Marne 216 PO Box 284 160 Gibson Ct
Fotan Industrial Centre
8701MH Bolsward Sanctuary Cove QLD 4212 NC 28034
26-28 Au Pui Wan Street
The Netherlands Australia Dallas
Hong Kong
+31 (0) 51 557 7750 +852 2712 6001 +1 704-691-0311
+31 (0) 51 557 3410 +852 2512 2325 +1 704-691-0313

support@venturasystems.com info@venturasystems.hk info@venturasystems.com.au info@venturasystems.com
www.venturasystems.com
Table 4: General contact information
Ventura Systems Ventura Systems Inc

Ventura Systems HQ Ventura Systems Australia
Asia Pacific North America
parts@venturasystems.com info@venturasystems.hk info@venturasystems.com.au info@venturasystems.com
+31 (0) 515 577485
Table 5: Parts contact information
Contact your local Agent for parts.

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1.4 Acronyms and Abbreviations

1.5.2 Ventura Systems documents

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2 Door installation safety

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2.3 Safety alert symbols

Indicates a potentially hazardous situation which if

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2.4 Safety instructions

Follow the regional and country laws and safety

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3 Door assembly kits

3.1 Unpacking instructions

3.2 Included kits

Figure 1: Door mechanism Figure 2: Mounting kit

Figure 3: Left door leaf Figure 4: Right door leaf

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3.3 Storage instructions

3.4 Required documentation

3.5 Required tools

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3.6 Description of the door system

The illustration of the door system to the right represents the

Figure 5: Overview PS1 door system in closed position

Motion of the door system

Left and right are defined looking from the inside

Illustrations or images in the manual may differ

Figure 6: Overview PS1 door system in open position

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4.1 Mount the door mechanism

Check the portal size.

Figure 7: Measure the portal

Mount adapter brackets and portal finishing

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Mount the door mechanism,

4.2 Mount the door shafts and bottom supports

Required parts for this step:

Figure 10: Required parts for this step

Mount the door shaft onto the mechanism

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Securing the door shaft

Figure 12: Securing the bottom support

Linking the connection rod.

Figure 13: Linking the connection rod

End result of this step:

Figure 14: End result of this step

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4.3 Mount the door arms

Required parts for this step:

Figure 15: Required parts of this step

Mounting the door arms

End result of this step:

Figure 17: End result of this step