VidIn CheckList

dormakaba Airport Exit Gate — Motor Assembly Replacement

12 min read

dormakaba PIL-M02 16 Airport Exit Gate — Motor Assembly Replacement

Applies to: dormakaba Airport Exit Gates — all VidIn technicians and subcontractors Purpose: Complete motor assembly replacement — from securing site access through functional testing Version: 1.0 | Last Updated: February 26, 2026 Owner: John Lang

Overview / Purpose

About This Document

This service document was written to facilitate the replacement of motor assemblies on the dormakaba PIL-M02 16 Airport Exit Gates. The procedure requires specific physical preparation and coordination with airport security.

Read this guide fully before scheduling service. There are logistical constraints — especially around airport access — that must be resolved before a service date is set.

⚠️ Before You Begin

Airport Access Requirements

  • You will be working on the secure (post-TSA) side of the airport. Each airport has its own access procedures and attitude — be prepared and pay close attention to instructions from your escort.
  • It is an inconvenience to airport staff to have you leave site to retrieve forgotten items. Do not plan on returning to your vehicle for forgotten items.
  • Have all required parts, tools, and supplies staged and ready before you enter security.
  • Do not wander off unescorted. Follow your escort at all times.

Power Requirements

Confirm the lane power-down procedure with the airport before the service date. The exact procedure may vary by site — see Step 2 below.

Scope of Work

  1. Power down the lane
  2. Record the current door gap
  3. Remove door cabling
  4. Remove the door
  5. Remove the motor plate assembly
  6. Replace the motor
  7. Reinstall the motor plate assembly
  8. Reinstall the door
  9. Restore cabling
  10. Power on and test

Required Tools & Materials

ItemQtyNotes
Replacement motor assembly1 per doorConfirm part number before ordering
Socket wrench set - Metric with extension and shallow sockets1For motor plate retaining bolts and door mounting bolts
Combination wrench set1For motor tensioning and jamb nuts
Zip tie cutters / side cutters1For removing cable zip ties
New zip ties - thinBagFor cable re-securing after reinstallation
Camera / phone1Document door gap and cable positions before disconnecting
Cable labelsPackFor labeling cables before disconnection

Confirm Parts

Verify the replacement motor assembly part number and any tool requirements with the dormakaba service manual before the service date.

Procedure

1 — Site Access & Coordination

  • Make contact with airport officials upon arrival
  • Obtain keys to the lanes
  • Have your escort notify airport security that alarms will be triggered during the repair — confirm this before starting work
  • Stage all tools and parts before proceeding through the security checkpoint
    • Don’t inconvenience your escort and security with unnecessary trips for forgotten items.
    • When working, all tools and parts must stay within the lane area of the PIL-M02 16 — away from anyone on the gate side of the airport

2 — Power Down the Lane

Confirm Power-Down Procedure

The exact power-down steps may vary by site. Verify with the airport before the service date. The procedure below is the general sequence — confirm with your site contact.

  • Place the lane in standby mode (if applicable)
  • Open the lane doors to the full-open position
  • Open the cabinet on the left side of the lane
  • Locate the power switch at the lower right of the cabinet interior
  • Switch the lane to the powered-off state
  • Confirm the lane is fully de-energized before proceeding

3 — Record Current Door Gap

  • Visually check and photograph the gap between the two doors
    • The doors may touch lightly but must not bind or overlap in any way
    • Any binding or overlap indicates a potential deeper issue at the lower ball assembly — stop and contact the PM before proceeding
  • Check that both doors are at the same height at the center and that they are in line (not tilted inward or outward)
    • Height and tilt issues can be corrected during reinstallation

4 — Open the Upper Cabinet Drawer

  • Unlock and slide the Upper Cabinet Drawer on the door to be serviced

    • This exposes the left and right door assemblies inside the upper section

  • Identify which door side (left or right) requires service

5 — Cable Removal

Photo Before Disconnecting

Before cutting any zip ties or removing any cables, photograph the cable positions on the circuit board. You may also want to tag each connection in some manner. This is your reference for reinstallation. Be aware that other locations may not have the same combinations of cable to reference.

  • Locate the cabling running to the circuit board

    • Cables are pushed into metal spring clips and secured with zip ties

  • Cut the zip ties securing the cables to the clips

  • Release the cables from the spring clips

  • Photograph or label the position of each cable on the circuit board before disconnecting

  • Disconnect each cable from the circuit board

  • Move the disconnected cables out of the way so the motor assembly plate can be removed freely

6 — Door Removal

Two-Person Operation Required

Door removal requires two technicians working in coordination. Do not attempt this alone. Keep the door as vertical as possible. Do not let the bottom of the door tip outward — this puts lateral stress on the lower ball assembly and can shift the ball out of position.

  • Remove the four bolts holding the upper door assembly to the drive gear
    • The door will remain in position after bolt removal — it does not drop
  • Rotate the door into its full open position
    • this lines up the cutout at the top with the motor housing for removal
  • Two-technician lift:
    1. Tech 1 lifts the motor plate assembly upward — it will move approximately ¼″ to ½″
    2. Tech 2 moves the door post away from the curved portion of the sheet metal, then out of the large toothed drive gear
    3. Tech 1 pauses, repositions, and lifts again near the center of the motor assembly plate
    4. Tech 2 continues sliding the door post outward over the rollers, then carefully passes the door assembly through the gap at the top of the door post
    5. Both technicians lift the door upward and away from the lower ball assembly

Lower Ball Assembly — Handle with Care

When clearing the lower ball, try to clear the top of the lower mount before tipping the door over. Do not twist or bend the lower ball assembly outward — this can cause the ball to shift, resulting in a door gap that is too narrow or causes the doors to overlap.

  • Set the door in a safe, stable position away from the work area

7 — Motor Plate Assembly Removal

Heavy Component — Two People Required

The motor plate assembly is relatively heavy. The technician removing it must carefully navigate several obstacles. Have a second person available to assist.

  • Have Tech 2 hold the motor plate assembly in place while Tech 1 removes the mounting hardware

  • Loosen and remove the four large retaining bolts

  • Carefully lower the motor plate assembly and set it in a clear work area

8 — Motor Replacement

  • Note and record the current tension on the toothed belt between the motor pulley and the drive pulley — this is your reinstallation target
  • Loosen the two locking (jamb) nuts on the tensioning bolts
  • Back off the two tensioning bolts to release belt tension
  • Disconnect the motor cable from the circuit board
  • Remove the four nuts holding the motor assembly to the motor plate
  • Remove the old motor assembly

Record Motor Info Before Discarding

Photograph and record the part number and serial number of both the old motor (for warranty tracking) and the new motor (for the service record). Do this before you leave the site.

  • Set the new motor in position on the motor plate
  • Thread in and hand-tighten the four mounting nuts — do not fully tighten yet
  • Reconnect the motor cable to the circuit board
  • Tighten the two tensioning bolts until belt tension matches the original tension recorded above
  • Tighten the two jamb nuts to lock the tensioning bolts in place
  • Torque the four mounting nuts to specification

9 — Motor Plate Assembly Installation

Two-Person Operation Required

Reinstallation requires two technicians — one to position and hold the plate, one to thread in the hardware.

Prior to installing take a close look at the four protruding rubber insulated hex nuts in the header, this part can be a bit frustrating.

  • Each must fit into slots cut in the motor plate assembly and when done correctly are flush on the back side of the entire assembly.
  • The best way to describe this is when you reach up above and behind the motor plate assembly the hex portion of the mount will be flush with the back of the plate.
  • Jiggling the plate can help seat one or more of the mounts allowing a Tech to start a bolt in place
    • Use as little pressure as needed to start the bolts so they don’t lift out of the slot
    • Hex nuts that don’t seat immediately can be maneuvered in place by loosing the bolt and reaching above the plate to turn the hex nut by hand
    • Other means is to put a little side pressure on a loose bolt and use it to twist the hex nut into the slot.
  • Tech 1 lifts and positions the motor plate assembly into alignment with the mounting points
    • Navigate carefully to avoid pinching cables or disturbing surrounding components
  • Tech 2 threads in the four large retaining bolts by hand while Tech 1 holds the plate in position
  • Once two bolts are in place in opposite corners and hand-tight, the plate is self-supporting, Tech 1 can release
  • Leave the four bolts only finger-tight — do not torque yet, as you will need to move the motor plate assembly to align the doors

10 — Door Reinstallation

Two-Person Operation Required

Door reinstallation is the reverse of removal and requires two technicians.

  • Two-technician reinstallation:

    1. Start with the door on its edge, post side down meeting stile (edge) upward and bearing in place

    2. With one technician at either end, lift the door by the post

    3. Tech 1 positions the door and guides the door post over the lower ball pin so that the bearing can slip onto the ball pin.

      • This can be at a shallower angle until the door is on the pin. Once the bearing has engaged the ball pin be cautous of putting to much lateral stress on the lower ball assembly it can shift the ball out of position.

    4. Tech 2 supports the and lifts the door to a near standing position on the pin. The post side of the door should be near the center of the lane with the meeting stile in the full open position and the lower edge of the door against the wall of the lane. Essentially the same position after it past the motor during removal.

    5. Tech 1 lifts the motor plate assembly while Tech 2 carefully slides the door post inward, threading it past the motor, rollers and while working around the curved sheetmetal, under the drive gear.

    6. Aligning the four bolt holes

      • be sure that the door and the door drive gear are in the same mode, either open or closed.

    7. Install and finger tighten the four mounting bolts securing the upper door assembly to the drive gear

Lower Ball Assembly — Handle with Care

When lowering the door onto the lower ball, expect to hear a pop as the bearing locks onto the ball pin.

11 - Door adjustments

  • Verify the door height and alignment matches the starting alignment
    • If the swing is off, the door swings too far in or doesn’t swing in far enough you can loosen the door bolts and twist the door into position
    • Doors should be at the same height, if not loosen the motor plate assembly and move it forward or backward to adjust.

12 — Cable Restoration

  • Route each cable back through the metal spring clips in its original position
    • Use the photos or labels from Step 5 as reference
  • Reconnect all cables to their original positions on the circuit board
  • Secure all cables with new zip ties
  • Verify no cables are pinched, strained, or routed near moving components

13 — Power-On and Testing

  • Restore power using the power switch in the left cabinet
  • Observe the lane as it powers up — listen and watch for any unusual sounds or movement
  • Test the door through a full open and close cycle
    • Door should move smoothly with no binding, grinding, or hesitation
  • Verify the door gap matches the original recorded measurement from Step 3
    • Adjust if needed before sign-off
  • Confirm alarm behavior is normal with airport security
  • Slide and lock the Upper Cabinet Drawer
  • Return lane keys to the appropriate airport contact
  • Document the completed repair — record motor part numbers (old and new), technician name, and date

Notes / Gotchas

Lessons Learned

  • Record everything before you touch it. Photograph cable positions, note door gap, note belt tension. The reinstallation depends on matching the pre-service state.
  • The lower ball assembly is the most common mistake point. Any outward torque when removing or reinstalling the door will shift the ball and change the door gap. Move carefully and clear the top of the lower mount before tipping the door.
  • Belt tension is critical. Too loose and the motor slips; too tight and it wears prematurely. Match the original tension exactly.
  • Two people are required for the motor plate and the door. Attempting either alone risks dropping the assembly or damaging components.
  • Airport security is unpredictable. Budget extra time for access coordination. Bring paperwork, credentials, and your professional demeanor. Rushing the checkpoint creates problems.
  • Part identification: Always photograph and record the part number and serial number of both the old motor and the new motor before leaving the site.

✏️ Edit Notes edit

  • [EDIT-1] Include a link to the image
  • [EDIT-2] Include a link to the image
  • [EDIT-3] Confirm steps to power down / up the system
  • [EDIT-4] Include a link to the image of the assembly
  • [EDIT-5] Draw diagram depicting the flush position
  • [EDIT-6] Add detailed door gap adjustment steps — how to measure, what to adjust, and acceptance criteria
  • [EDIT-7] find out how to tell the difference

Last updated: February 26, 2026 Owner: John Lang | jlang@vid-in.com

Graph View