EXE User Manual (Snap-on)
Contents
1. and continues to make a noise for as long as rocker switch is held down or door open fully auto check that there is no obstruction in the step unit preventing it deploying such as a piece of gravel trapped in the slides gear mesh of twin arm types remove lower cover and disconnect the link arm s from the tread Check that the tread can slide out easily and check gear meshing point of gear arms on twin arm units are free of any particles that could be jamming them If it is clear that there is no external contamination preventing the step moving then the gearbox of the motor has failed and a new motor unit will be required Page 9 If step motor starts then cuts out with a small movement of the tread Check that the door handbrake lead is connected properly to the switches and these are earthing when the door is open handbrake applied make sure ignition is also switched on If these are correct then the control unit is faulty and will need replacing If step motor is silent unplug the step loom plug at the rear of the step unit and apply a separate 12v supply across the two power pins in the step loom plug see diag below If the step motor remains silent the motor has failed and will have to be replaced If step motor makes a noise but the step does not move reverse the polarity and check that the step deploys If the step does not deploy but the motor still makes a noise go back to stage above to check for objects2. other lead to each of the power pins in the step loom plug in turn as shown in diagram below If there is a circuit from either pin to the step case there is a short in one of the step motor wires within the step unit remove lower cover of step and check the wires from the motor have not been trapped or become frayed and are shorting out on the case Test 2 Do a visual check on all wire connections to the rocker switch fail safe multi plug connectors to the control unit power switch fully auto and also check the door switch is earthing when the door is opened hand brake is earthing when applied Also check the main power lead and earth leads from the control unit are connected properly If these all appear to be correct proceed to Test 3 Test 3 With someone listening close to the step underneath the vehicle check for any sound coming from the step motor when the rocker switch is pressed door is opened to deploy the step make sure door is open handbrake applied ignition on step power switch is on fully auto only Note if the step is wired up as fully auto 1 close the door for 1 mins before carrying out this test to allow the thermal switch on the step motor to cool and reconnect if the motor has been trying to deploy the step for some time but has been prevented by some obstruction It will have switched off automatically and will not reconnect until the thermal switch has cooled down If step motor is making a noise
3. that may be trapped in the step mechanism above If step can be deployed and stowed by applying a direct 12v supply to the step power pins but ceases to operate when the plug is reconnected and operated by normal methods deploy step using the direst power supply to the pins then reconnect the plug and see if the step will close If the step will close but does not deploy the deployed micro switch may have failed this is the micro switch that is activated by the motor arm when the step is fully deployed With the step in any position other than fully deployed use a circuit tester and check for a circuit across the deployed microswitch pin and common return pin see diag below If there is a circuit the micro switch is operating correctly and there is a fault in the step control box This will have to be replaced If there is no circuit the deployed micro switch has failed and will have to be replaced Diag I plug from step Deploy m switch M switch common return NYS SIEDS Page 10 SENES AVS STEPS EXE600 Emergency Stow Procedure In the unlikely event that your step should stop in the out position please follow the procedure detailed below On the underside of the step you Pull the R clips out and retain Remove the steel and nylon washers will find 2 arms attached to the them you will need them later aluminium tread Remove the arms and fold them The arms need to be crossed over to Push
4. the step in and insert the R in and under the step fully stow inside the case clip into the holes in underside of the case on both sides TE The R clip needs to be fully When fully through the holes the pushed through the holes pins will holds in the tread Page 11 EX SERIES 600 750 1000 1200 Electric Cassette Steps Useful Information to Keep Step Serial No Nearest Service Agent Next Service Due Other details SIEpS rope Langest Step Specials avs Page 26
5. where possible 3 Remove step from vehicle 4 Remove tread plate and lower panel 5 Remove guide rods Cassette steps only 6 Clean inside of case T Inspect micro switches and clean lube or replace 8 Inspect tread plate linkage to motor Check nylon bearings 9 Inspect and clean replace stainless steel tubes and rollers as necessary 10 Check nylon guides for wear Replace as necessary 11 Inspect connections to micro switches and motor including grommets in case 12 Inspect and clean tread plate 13 Supply and fit weatherproofing kit if not fitted 14 Replace side arm mounting bolts and Loctite as required 14 Lubricate all parts 15 Replace cover 16 Refit step Leave fitting hand tight only 17 Connect electrics as required Use waterproof connections is required 18 Operate step approx 10 times 19 Refit lower panel and tighten fittings 20 Test again and weight test 150Kg 21 Compile report 22 Update customer Service Record book In blue pack provided with Step For details of other service agents in your area contact AVS or see details on our web site www avssteps co uk We recommend SILICONE SPRAY be used as a lubricant DO NOT USE GREASE Service interval is recommended 6 months maximum Steps should be cleaned monthly or more frequently depending on operating conditions Cleaning instructions are available on request on our web site and in the SERVICE DOCUMENTS provided with every step TEL 01948 7810
6. 00 FAX 01948 780099 www avssteps co uk Page 6 FAULT FINDING INSTRUCTIONS STEP TYPE Electric T and E Last Updated 25 06 07 TITLE Step Failure Diagnostics Revision 1 AVS STEP FAILURE IN OPEN POSITION Test 1 With side door open hand brake on ignition on step switch on fully auto Listen closely to step underneath the vehicle when someone tries to close it by operating the rocker switch fail safe or closing the side door fully auto For fully auto steps make sure the side door is open for at least five minutes first to allow the motor thermal switch to cool if the step is jammed in any way and the motor has been trying to close the step The switch will automatically switch off the motor and needs to cool before it will reconnect If no noise from the step go to test 2 If step makes a noise but does not move go to test 3 Test 2 Check 10 amp fuse in power lead to in control box If blown replace and recheck step operation If fuse does not blow again immediately or has not failed proceed to test 4 If fuse blows immediately on attempted operation of the step Pull apart the loom connection plug at back of step unit and check state of the internal pin connectors If pins show signs of water contamination clean and re connect plug and retest step operation If pins OK retry operating step with 5 pin plug still disconnected if fuse still blows there is a short in the loom from the step plug back to th
7. EX SERIES 600 Electric Cassette Steps Owners Manual EXE600HZ AVS Marketing Ltd Offices 5 to 7 Mereside Ind Park Fenns Bank Whitchurch Shropshire SY13 3PA SE G Tel 01948 781000 Fax 01948 780099 of Europe s Largest I Step Specialist Email Sales avssteps co uk Web www avssteps co uk OPERATING INSTRUCTIONS STEP TYPE VEHICLE TYPE SIDE ENTRANCE COUNTRY OFF On Off switch ON AVS Electric steps Last Updated 09 07 06 Revision no 0 Operating AVS Electric Steps FULLY AUTOMATIC The step opens and closes as the nearest door is opened and closed The step can be switched of in the deployed or stowed position by using the on off switch usually mounted on the dash board By switching the step off it will not stow or deploy when the door is opened and closed The red warning light will continue to flash if the step is not stowed even if the on off switch if in the off position You may wish to isolated the step in the open position with the door closed to allow it to be cleaned Page 4 CLEANING INSTRUCTIONS STEP TYPES Last Updated 09 07 06 Version 2 Cleaning AVS Steps Steps should be cleaned at least once per month and more often if conditions dictate By using a power hose or even a standard hose frequently ensure no build up of material inside the step The step will self clean if the mud and dirt is lubricated with a power wash Remember to clean not just the tr
8. e control box check loom wires back to control box have not been trapped or become frayed anywhere obvious If fuse does not blow with plug disconnected the short is between the step plug and the step motor unit test with a circuit tester earthed to step case and the other lead to each of the power pins in the step loom plug in turn as shown in diagram below If there is a circuit from either pin to the step case there is a short in one of the step motor wires probably within the step unit remove lower cover of step and check the wires from the motor have not been trapped or become frayed and are shorting out on the case Test 3 If step motor is making a noise and continues to make a noise for as long as rocker switch is held down or door closed fully auto check that there is no obstruction in the step unit preventing it closing such as a piece of gravel trapped in the slides gear mesh of twin arm types remove lower cover and disconnect the link arm s from the tread Check that the tread can slide in and out easily and check gear meshing point of gear arms on twin arm units are free of any particles that could be jamming them If it is clear that there is no external contamination preventing the step moving then the gearbox of the motor has failed and a new motor unit will be required Test 4 Unplug step from body loom at plug at rear of step unit With a circuit tester and step unit still deployed check that there is
9. ead the bit you stand on but the side of the step too After cleaning the step should be allowed to dry When dry a day or two later perhaps apply silicone spray to help lubricate the movement of the step DO NOT USE GREASE Avoid use of oil it will simply wash away If the conditions are particularly bad daily cleaning may be required Every 6 months the bottom cover should be removed completely and the inside of the step physically cleaned particularly either side the stainless steel tubular runners This can be done as part of the service routine Failure to clean the steps regularly or to service the steps may result in the failure of the step in service This will not be covered under warranty We recommend that mud flaps are fitted to your vehicle Your step serial number is on the front RHS of the tread This will tell AVS exactly what type of step you have For more information contact AVS on SALES AFTERSALES Tel 01948 880010 01948 780238 Fax 01948 880020 01948 780458 Silicone Spray is supplied by Rocol on 0113 232 2700 www rocol com Applying Silicone Spray after the step has dried AaYS SICOS Europes ange I Sep Specs Page 5 STEP SERVICE ROUTINE STEP TYPE All AVS steps Last Updated 19 6 06 TITLE Service Routine Revision no 1 AVS Service Routine EVERY 12 MONTHS AVS Electric or Manual Steps 1 Note step serial no and start report 2 Disconnect electrical connections
10. hen there is a fault with the switch and it will have to be replaced If the step still does not close Do a thorough check on the multi plug connectors to the control unit if these are in order it is likely that the control unit has failed Diag I unction View of pins in l ower to motor plug from step tow m switch eploy m switch Power to motor M switch common return Page 8 FAULT FINDING INSTRUCTIONS STEP TYPE Electric T andE Last Updated 25 06 07 TITLE Step Failure Diagnostics Revision 1 STEP FAILURE IN STOWED POSITION Test 1 With side door open hand brake on ignition on step switch on Check 10 amp fuse in power lead to in control box If blown replace and recheck step operation If fuse does not blow again immediately or has not failed proceed to test 2 If fuse blows immediately on attempted operation of the step Pull apart the loom connection plug at back of step unit and check state of the internal pin connectors If pins show signs of water contamination clean and re connect plug and retest step operation If pins OK re try operating step with plug still disconnected if fuse still blows there is a short in the loom from the step plug back to the control box check loom wires back to control box have not been trapped or become frayed anywhere obvious If fuse does not blow with plug disconnected the short is within the step unit test with a circuit tester earthed to step case and the
11. no circuit between the stowed micro switch pin and the micro switches common return pin in the step loom plug see diag below If there is a circuit the stowed micro switch has stuck closed or has failed closed Remove bottom cover of step and check the stowed micro switch the one that would be activated when the step is closed is not damaged if damaged it will need replacing S SICOS Page Test 5 At the unplugged step loom plug at the back of the step unit or inside vehicle on BA type steps apply a 12v supply across the two power pins see diag below If the step remains dead it is likely that the motor has failed Check first that the leads from the plug to the motor are OK particularly within the step unit if OK then the motor has failed and will require replacing If the motor starts to buzz but the step does not move reverse the polarity across the power pins and see if the step then closes If the step can be deployed and stowed by applying the direct 12v supply across the power pins reversing it to change the step direction the fault lies either in the control unit rocker switch fail safe or in the vehicle loom Go to test 6 Test 6 Fail safe only First check the wire terminal connections of the blue wires to the rocker switch If they appear to be OK unplug the two blue wires or blue and blue white wires from the rocker switch and with a piece of wire connect them together If the step closes t
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