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Kwikee Steps Service Manual

1. Extended Profile Retracted Profile Series 37 Rise 7 Run 8 5 Bolt pattern Call Retracted Profile PRODUCT SERVICE TRAINING To determine which step you have look for a sticker on the S TEPS underside of the top tread or mouting surface If you can t locate it measure the step and use these drawings to identify the step Series 38 Rise 4 Run 10 75 Bolt pattern 8 x 22 Series 39 Rise 7 Run 10 Bolt pattern 7 5 x 20 5 as Double Tread Step Series Series 22 pra Rise 8 Run 8 Bolt pattern 9 x 25 5 Series 32 Rise 7 Run 9 Bolt pattern 8 x 22 Series 34 Rise 7 Run 9 Bolt pattern 8 x 26 Series 40 n Rise 8 Run 9 Bolt pattern 8 x 26 Series 42 Rise 6 Run 9 Bolt pattern 18 x 29 Extended Profile 32 25 10 75 Extended Profile Retracted Profile 8 213 p 11 38 t Si 35 EAD E Retracted Profile Retracted Profile Extended Profile Retracted Profile Engineered Solutions for RVs Currently Kwikee makes 19 different styles of electric steps 10 with S single treads 5 with double treads and 4 with triple treads Each TE PS style is identified by a Series number Triple Tread Step Series Series 23 D Rise 8 Run 8 Bolt pattern 9 x 25 25 Series 24 Rise 8 Run 9 Bolt pattern 8 x 26 Extended Profile Retracted Profile Series 25 7 Drop Rise 7 Run 8 Bolt pattern 8
2. 230 Davidson Ave Cottage Grove OR 97424 800 736 9961 www kwikee com REV 4_2 05 PRODUCT SERVICE TRAINING 40 SERIES Step Replacement Guide PAGE RISE 8 RUN 10 P n Motor Assembly Drawing and Parts Key Numbers Mounting bolt pattern 12 87 x 20 5 Part 904000016 24 tread with High torque Motor and Switch Kit 905316000 Part 904008025 24 tread with High torque Motor Control Unit and Switch Kit 905325000 CHART 1 Replacement Parts Kits for Series Steps 22 23 30 32 33 34 35 36 38 and 40 Parts Description Replacement Key Kit Part 1 Control Unit only n a Step Frame only 908040000 Retracted Profile sa Seep Light only STEP SERIES NUMBER 3 Cotter and Clevis pin To determine correct 1 4 IMGL A Control Replacement Kit 909770000 9095 10000 Control IMGL Integrated Motor Gear Box Linkage A Cotter and Clevis pin Four way pigtail Fasteners replacement part numbers it is necessary to know the Step Series Number It is located in the Owners Manual and printed under the top step Door Switches Part Part Description White Black Closed Open 905312000 905323000 Magnetic small rectangular 905314000 905324000 Magnetic 3 4 core round 905306000 905326000 Magnetic large rectangular 905307000 905327000 Magnetic 3 8 core round 905302000 905328000 Plated plunger switch If you can not locate the number me
3. battery terminal clamping bolt NOTE Some vehicles have a distribution block located near the battery that is connected directly to the battery The red and white wires may be connected here instead of the battery clamping bolt WARNING Do not connect this wire into any other circuit in the vehicle Tie any loose wires in place with the wire ties Step 15 At the step attach the four way Packard style connector from the wiring harness to the connector from the step control unit Step 16 Reconnect the vehicle battery Step 17 Place the Caution Stand Clear sticker on the outside of the van on the window glass or near the door handle where it will be easily seen fhe 230 Davidson Avenue Cottage Grove Oregon 97424 9545 541 942 3888 www kwikee com Page 2 Understep lig not available on all step models 12 AWG green ground to step top Y j A Step Wiring Two way 12 AWG green ground wire connector must be securely attached to the chassis for step to operate Fuse block IMPORTANT The yellow wire must go to a terminal marked IGN ignition or to another terminal that is hot when the ignition is tumed on 16 AWG purple optional step light switch may be connected to porch light 6 amp maximum fuse or circuit breaker required Oe Four way connector 16 AWG brown 16 AWG yellow ___ 12 AWG red g 16 AWG white Vehicle Wiring Ch 20 amp fuseor _ Chassis grou
4. Avoid contact with the skin A eyes and clothing 12 volt automotive batteries produce hydrogen gas which is explosive keep cigarettes open flames and sparks away from the battery at all times 5 To supply power attach the red wire from pigtail to positive post 6 With the power and ground connections complete all functions of the control unit can be checked at the four wires of the pigtail The brown wire is the door switch the white wire is the power switch and the yellow wire is the ignition override 7 To extend the step touch the white wire to the battery s positive post The step should extend and remain extended 8 To retract the step hold the white wire to the battery s positive terminal and touch the brown wire to the negative terminal IMPORTANT INSTALLER NOTES Be sure that all ground connections are securely fastened with good metal to metal contact A good ground is required for proper step operation Owner s Manual Maintenance Page 7 FIGURE 4 Wiring diagram for step with control unit geundtosteptop 12 AWG groen ground wro u urely Step Wiring the chassis for step to operate 16 AWG purple y P optional step light switch LY may be connected to porch light Two way if connector Fuse block IMPORTANT ZH Control The yellow wire must go to a terminal marked IGN ignition or to another terminal that is hot when the ignition is tu
5. Delco Field wound motor part number 8002 8279 8278 8287 requires the IMGL and Control Unit included in the Replacement Kit Table of Contents IMGL Replacement 1 Control Unit Replacement 2 Series 23 amp 24 4 Motor Replacement 214 IMGL Assembly and Control Replacement Instructions Page 2 CONTROL UNIT Instructions for removing and IMGL Assembly Drawing and Parts Key Numbers replacing the control unit FIGURE 1 Aor unit 909510000 requires a normally open switch If you are replacing a 9513 9516 9590 control unit you MUST also replace the door switch The new control will not work with older normally closed switches Proceed to the following steps after completing IMGL Assembly Removal steps 1 3 1 Controls prior to the 4 way Packard style connector Cut the molded rubber 4 way connector pigtail off just above the vehicle half of the butt connectors Since all manufacturers use different colored wires for vehicle wiring take a moment to note what color wires from the vehicle are connected to the white red brown and yellow wires of the pigtail Strip the vehicle wires back and connect the new Packard style pigtail connector to the vehicle wiring using heat shrink insulated butt connectors Make sure that the vehicle wires that were connected to the old pigtail are reattached to the new pigtail in the identical way NOTE Van steps using door switch only operation will have two wires coming from the v
6. There are three IMGLs one with each of the three linkages for Kwikee steps A LINKAGE IMGL fits 22 23 30 32 33 34 35 36 38 and 40 Series Steps B LINKAGE IMGL fits 28 31 37 and 39 Series Steps C LINKAGE IMGL fits 26 Series Steps Kwikee manufactures a complete Replacement Kit for each of the three linkages These kits include the IMGL integrated motor gear box linkage the 9510 Control Unit a four way pigtail a fastener kit and installation documentation Repart Kit Part Linkage 909770000 A LINKAGE IMGL Fits Step Series 22 23 30 32 33 34 35 36 38 40 909772000 B LINKAGE IMGL 28 31 37 39 909774000 C LINKAGE IMGL CONTROL UNIT REPLACEMENT For steps that already have the IMGL 909510000 Control the 909510000 Control Unit can be replaced with the same part number but steps with any other Control Unit require a full replacement kit as listed above The 909510000 Control Unit will not work correctly with any motor gearbox configurations other than the IMGL 26 PAGE Engineered Solutions for RVs NCREASED PERFORMANCE RELIABILITY PRODUCT IMPROVEMENT BULLETIN Kwikee Products Company Inc 230 Davidson Avenue Cottage Grove Oregon 97424 9545 Electric Step Improvements Applies to Kwikee Step Series 22 23 26 28 30 31 32 33 34 35 36 37 38 39 and 40 Kwikee announces the replacement of speci
7. house hold and industrial uses in addition to lubricating the steps It sprays on and into hard to reach places changing from a penetrating fluid to a tough protective grease in a matter of minutes The cured film is impervious to moisture and withstands temperatures above 400 F 204 C The formula also contains additives to prevent rust and reduce wear b ae FIGURE 1 FIGURE 3 DIAGRAM NOTES Fig 1 amp 3 Square shaft bearing lubricate around outside and under bearing head Fig 4 On step models equipped with plastic cover this cover will have to be removed to lubricate center bearing Lubricate bearings under cover every 90 days Figure 4 also shows bushing in bushing lubrication Maintain clean dry electrical connections at the two and four way connectors and any butt connectors leading to the vehicle Apply a small dab of di electric grease at the connections and replace corroded butt connectors to maintain a good electrical source for the step FIGURE 4 FIGURE 5 PAGE Engineered Solutions for RVs MAINTENANCE ADJUSTING THE CAM STOP Applies to the 24 25 27 32 34 35 36 38 and 40 Series Steps UAGE When the cam stops are out of adjustment the step may feel loose or mushy when stepped on If the cam stops are not properly adjusted the step may not extend fully to the locked out position Using a step with loose or out of adjustment
8. the above limitation or exclusion may not apply to you Before using user shall determine the suitability of the product for its intended use and user assumes all risk and liability whatsoever in connection there with 6 Kwikee will not under any circumstances reimburse the cost of warranty parts purchased from sources other than Kwikee Products Company Inc 7 This warranty gives you specific legal rights and you may have other rights which vary from state to state WARRANTY GUIDELINES AND PROCEDURES 1 Replace only those parts that are actually defective Motors gear cases gears linkage assemblies and control units are all replaceable as individual parts If you exchange a complete assembly when only the replacement of an individual part is required the non defective parts will be returned and only the defective part will be credited to you or replaced 2 Do not use conversion kits for warranty repairs Conversion kits are intended for the conversion of older steps with field wound motors to the newer permanent magnet motor system 3 A Returned Goods Authorization RGA number must be obtained before any parts or claims are sent in Call Kwikee s Service Line at 1 800 736 9961 for an RGA number 4 Our warranty does not cover travel time mileage or other incidental costs It is limited solely to the replacement of defective parts under warranty Owner s Manual 880 Kwikee Electric Steps The eae o S en aa SE NOTE a
9. x 22 Extended Profile Retracted Profile Series 25 S 4 2 10 8 Drop iN EN a re ADAI i Fam 9 42 Rise 8 Run 9 es i Bolt pattern 8 x 22 E 18 45 L 18 45 11 38 11 15 9 01 9 01 Extended Profile Retracted Profile Series 44 Rise 8 Run 9 Bolt pattern 8 x 22 Extended Profile Retracted Profile PRODUCT SERVICE TRAINING PAGE STEPS IMPROVEMENTS In October of 2004 Kwikee began shipping steps with an integrated motor gear box linkage IMGL Steps with the IMGL require a 909510000 Control Unit This section of the Service Training will cover repairs to steps that have the IMGL 9510 configuration Steps shipped prior to October of 2004 may have a variety of motor control unit configuration IMGL integrated motor gear box linkage Any steps except the 42 and 44 Series regardless of the original motor control unit combination can be repaired using the current IMGL 9510 parts and procedures If you are needing to repair a 42 or 44 Series please call our Customer Service Department at 1 800 736 9961 Please note if you are replacing the IMGL on a step that has any control other than a 909510000 Control Unit you must also change the control unit Previous Control Units will not work correctly with the IMGL and the 9051 Control Unit will not work correctly with previous motor gear gox linkage configurations
10. 3 number measure the step and refer to the dimensioned D Switch R oor Switches drawings above Confirm that Part Part Description White Black Closed Open 905312000 905323000 Magnetic small rectangular 1905314000 905324000 Magnetic 3 4 core round 905306000 905326000 Magnetic large rectangular 905307000 905327000 Magnetic 3 8 core round 905302000 905328000 Plated plunger switch you are using the correct step series replacement parts guide Used for all color controls manufactured prior to 2 99 Does NOT include black 909506000 909507000 Used for black controls since 2 99 including 909506000 909507000 and 909508000 Rocker Style Power Switch Part Description 905305000 For all fully automatic steps Self Center Rocker Switch Part Description 905316000 For steps NOT equipped with control units KWIKEE PRODUCTS COMPANY INC 230 Davidson Ave Cottage Grove OR 97424 800 736 9961 www kwikee com REV 4_2 05 Retracted Profile STEP SERIES NUMBER To determine correct replacement part numbers it is necessary to know the Step Series Number t is located in the Owners Manual and printed under the top step If you can not locate the number measure the step and refer to the dimensioned drawings above Confirm that you are using the correct step series replacement parts guide KWIKEE PRODUCTS COMPANY INC 39
11. A Cotter and Clevis pin Four way pigtail Fasteners Part Part Description White Black Closed Open 905312000 905323000 905314000 905324000 905306000 905326000 905307000 905327000 905302000 905328000 Magnetic small rectangular Magnetic 3 4 core round Magnetic large rectangular Magnetic 3 8 core round Plated plunger switch Used for all color controls manufactured prior to 2 99 Does NOT include black 909506000 909507000 Used for black controls since 2 99 including 909506000 909507000 and 909508000 Rocker Style Power Switch Part 905305000 Description For all fully automatic steps Self Center Rocker Switch Description For steps NOT equipped with control units 230 Davidson Ave Cottage Grove OR 97424 800 736 9961 www kwikee com REV 4_2 05 PAGE Available with brackets for Van applications a Mounting 2 bolt hole Location for location bracket Extended Profile Retracted Profile STEP SERIES NUMBER To determine correct replacement part numbers it is necessary to know the Step Series Number It is located in the Owners Manual and printed under the top step If you can not locate the refer to the dimensioned drawings above Confirm that you are using the correct step series replacement parts guide number measure the step and 37 SERIES Step Replace
12. Magnetic large rectangular R 1905307000 905327000 Magnetic 3 8 core round you are using the correct step 905302000 905328000 Plated plunger switch ReneS replacement parts Used for all color controls manufactured prior to 2 99 guide Does NOT include black 909506000 909507000 Used for black controls since 2 99 including 909506000 909507000 and 909508000 Rocker Style Power Switch Part Description 905305000 For all fully automatic steps Self Center Rocker Switch Part Description 905316000 For steps NOT equipped with control units KWIKEE PRODUCTS COMPANY INC 230 Davidson Ave Cottage Grove OR 97424 800 736 9961 www kwikee com REV 4_2 05 PRODUCT SERVICE TRAINING PAGE 30 SERIES Step Replacement Guide Available with brackets for Van applications RISE 7 5 RUN 16 75 Mounting bolt pattern 6 x 31 RV or VAN Part 903000016 36 tread with Motor and no control unit RV or VAN Part 903006000 36 tread with Motor and Control Unit VAN Part 903006002 36 tread includes Wiring Kit 907541000 and Door Switch 905323000 VAN Part 909315000 Plastic Splash Cover Motor Assembly Drawing and Parts Key Numbers BIF nar Extended Profile 21 75 625 9 25 6 25 TA 7 25 a Retracted Profile CHART 1 Replacement Parts Kits for Series Steps 22 23 30 32 33 34 35 36 38 and 40 STEP SERIES NUMBER To
13. SERIES Step Replacement Guide RISE 7 RUN 10 Mounting bolt pattern 7 5 x 20 5 Part 903900016 23 75 tread with Motor and Switch Kit 905316000 Part 903906025 23 75 tread with Motor Control Unit and Switch Kit 905325000 CHART 1 Replacement Parts Kits for Series Steps 22 23 30 32 33 34 35 36 38 and 40 Parts Description Replacement Key Kit Part 1 Control Unit only n a Step Frame only 908039000 n a Step Light only 909004000 2 Cotter and Clevis pin 1 4 IMGL B Control Replacement Kit 909772000 9095 10000 Control IMGL Integrated Motor Gear Box Linkage A Cotter and Glevis pin Four way pigtail Fasteners Door Switches Part Part Description White Black Closed Open 905312000 905323000 905314000 905324000 905306000 905326000 905307000 905327000 905302000 905328000 Magnetic small rectangular Magnetic 3 4 core round Magnetic large rectangular Magnetic 3 8 core round Plated plunger switch Used for all color controls manufactured prior to 2 99 Does NOT include black 909506000 909507000 Used for black controls since 2 99 including 909506000 909507000 and 909508000 Part 905305000 Description For all fully automatic steps Self Center Rocker Switch Part Description 905316000 For steps NOT equipped with control units Engineered Solutions for RVs Motor Assembly Drawing and Parts Key Numbers
14. Test Procedures have been provided to troubleshoot and test all of the Kwikee automatic electric step functions They are designed to initially check the step s basic functions separately from the RV wiring to determine whether or not the step is malfunctioning The following procedures test the various components of the step until the source of the malfunction is located Using these procedures will shorten and reduce the time spent troubleshooting Some portions of the test procedures require additional equipment This equipment includes a voltmeter a well charged 12 volt DC automotive battery and a 4 way connector pigtail Part 909306000 available from Kwikee Products Company Read the entire procedure prior to testing If you need assistance contact Kwikee s Service Line at 1 800 736 9961 Owner s Manual 880 Kwikee Electric Steps TESTING THE STEP 1 Inspect the step for visible damage that might restrict the step s operation 2 Obtain a 4 way pigtail connector part 909306000 from Kwikee 3 Disconnect 4 way connector on underside of step and connect step half of the connector to the four way connector pigtail See Figures 10 11 and 12 Page 10 11 4 Seta fully charged 12 volt DC automotive battery beside the step ATTENTION Do not allow the battery terminals to come in contact with the step Complete a ground for the step tests by connecting a 10 gauge wire from the negative battery pos to the green ground wire
15. Wiring diagram for step with cont of unit 10 If any of the step functions do y Understep light not work the source of the SS not available on Car Sn all step models Ww malfunction is either in the control 4 Motors SJ LEN S unit and or the motor Proceed to the Testing the Motor section on Page 11 Step Wiring f i Ifall of the step functions do work By PO teal ree ae SAS the malfunction is either in the e a PAS So door switch power switch or the IMPORTANT S y 4 Fi i a vehicle wiring Proceed to Testing purple gt the 4 way Connector section on when the ignition is tumed on optional step light switch 2 y may be connected Page Ll ctor to porch light anne 6 amp maximum fuse or AN os a Aa circuit breaker required as ANg brown moa poe 1 Ez A aL a 6 2 AWG red Vehicle Wiring a Chassis ground 3 6 AWG white Normally OPEN magnetic door switch 20 amp fuse or curcult breaker required a O Wis ws FIGURE 11 Wiring diagram for steps with door switch only operation FIGURE 12 Wiring diagram for W R steps without control unit 12 AWG green ground wire must be securely attached to the chassis for step to operate Q optional step light switch may be connected __ 12 AWG red Vehicle Wiring Chassis ground 20 amp fuse or curcuit breaker required s f OPEN Big s switch box switch IMPORTANT If the switch is OFF the step will no
16. a i round wire green ground wire Ground wire green ground wire m sst be eltached t vehiclo must be attached to vehicle sh chassis a good ground is needed chassis a good ground is needed for proper step operation for proper step operation is be Voltmeter should read lt i 12 volts DC when door is closed Voltmeter should read Voltmeter should read 12 volts DC power on 0 volts DC when door Voltmeter should is open read 12 volts DC 0 volts DC power off pe For Steps with and without Control Unit Troubleshooting and Testing Procedures Page 11 15 To check the ignition override system connect a voltmeter between the yellow wire from the 4 way connector vehicle half and the ground terminal on the end of the control unit s green ground wire see Figure 16 on Page 12 The voltage reading should be approximately 12 volts DC when ignition is on and zero 0 volts when ignition is off If the reading is zero when the ignition is on check all terminal connections wiring and the vehicle s ignition fuse NOTE The step wiring circuit must be independent No other device i e alarm systems step well lights etc can be connected to the step wiring circuit Any device connected to the steps wiring can cause the step to malfunction and will void the warranty 16 For steps equipped with door switch only operation Connect the white jumper wire from the vehicle half of the four way connector and the ground termi
17. a poor ground If the voltage reading is zero 0 volts check the step fuse circuit breaker all connections and the condition of the wiring between the battery and the plug including the ground connection at the chassis 13 To check the power switch connect a voltmeter between the white wire from the 4 way connector vehicle half and the terminal at the end of the control unit s green ground wire see Figure 14 The reading should be a minimum of 12 volts DC the same as in Step 12 when the switch is on and zero 0 volts DC when the switch is off If the voltmeter reads zero 0 volts when the power switch is on there is a problem in the power switch circuit Check the 6 amp in line fuse the power switch itself and the condition of the circuit s wiring and terminal connections 14 To check the door switch connect a voltmeter between the red wire from the 4 way connector vehicle half and the brown in the same connector see Figure 15 The voltage should be a minimum of 12 volts DC the same as in step 12 when the door is closed and zero 0 volts when the door is open If the readings are incorrect there is a problem with the switch Check the door switch and the condition of the circuit s wiring and terminal connections FIGURE 13 Check main FIGURE 14 Check power switch FIGURE 15 Check door switch power source 4 way connector 4 way connector vehicle side 4 way connector vehicle side i vehicle side a
18. all wires meet the minimum requirements specified in Figures 10 11 and 12 on Page 10 The step test procedures on Page 9 are provided to troubleshoot and test all Kwikee automatic electric step functions The procedures are designed to initially check the basic functions of the step separately from the RV wiring to determine whether or not the step is malfunctioning The procedures test various components of the step until the source of the malfunction is located Using the procedures will shorten and reduce the time spent troubleshooting Some portions of the test procedures require additional equipment This equipment includes voltmeter well charged 12 volt DC automotive battery 4 way connector pigtail Part 909306000 available from Kwikee Read the entire procedure prior to testing If you need assistance contact Kwikee s Service Line at 1 800 736 9961 Owner s Manual 888 Kwikee Electric Steps TESTING THE STEP 1 Inspect the step for visible damage that might restrict step operation 2 Obtain a 4 way pigtail connector part 909306000 from Kwikee 3 Disconnect 4 way connector on underside of step and connect the step half of the connector to the four way connector pigtail See Figures 10 11 and 12 on Pages 10 and 11 4 Seta fully charged 12 volt DC automotive battery beside the step ATTENTION Do not allow the battery terminals to come in contact VAN STEPS If the van step is equipped with a splash
19. complete mounting instructions are included with the step mounting brackets Step 4 Route and attach the brown wire from the wiring harness to the door switch using a blue butt connector Step 5 Tie any loose wires in place with the wire ties If necessary the wire ties can be held in place with a 6 or 8 sheet metal screw not supplied Step 6 Under the hood feed the white and yellow wires from the wring harness and one end of the separate white 16 ga wire not supplied through the firewall and into the passenger compartment This may be done through an existing rubber grommet around the speedometer cable or by drilling a hole WARNING Do not drill a hole unless you are absolutely sure there is nothing on the other side of what you are drilling through Do not feed wires through the firewall where there may be moving parts Grommet the hole to avoid damaging the wiring Step 7 Locate and cut a 15 32 diameter hole in the dash to mount the override switch Before you drill the hole be sure that there is enough room to mount the switch behind your hole location Do not install the switch at this time Step 8 Route both white wires to the power switch location cut to length leave a little slack and connect them to the switch using the 1 4 blue female push on terminals Tie any loose wires in place with the wire ties Step 9 Mount the override switch in the dash by inserting it through the hole in the dash from the back
20. cover remove the cover to access motor assembly and control unit If step is locked in retracted up position and the plastic cover can not be removed disassemble the step tread to access the plastic cover To disassemble the tread remove the 8 1 4 20 x 1 long hex head bolts in tread side rails connects tread and sliding blocks to side rail This allows the tread to drop out of the way and the plastic cover to be accessible Reassemble the tread after removing the cover Reinstall the cover after testing procedures and any necessary repairs are complete Fully extend the step to reinstall the cover Be sure that the four way connector exits the notch in the plastic cover when reassembling For Steps with and without Control Unit WARNING 12 volt automotive batteries contain sulfuric acid which can cause severe burns Avoid contact with the skin eyes and clothing 12 volt automotive batteries produce hydrogen gas which is explosive keep cigarettes open flames and sparks away from the battery at all times with the step Complete a ground for the step tests by connecting a 10 gauge wire from the negative battery post to the green ground wire of the control unit 5 To supply power attach the red wire from the pigtail to the battery s positive post The step will extend IMPORTANT INSTALLER NOTES Be sure that all ground connections are securely fastened with go
21. fuse or curcuit breaker required a k Normally OPEN magnetic door switch i Battery disconnect box switch IMPORTANT Ifthe switch is OFF the step will not operate Page 10 Troubleshooting and Testing Procedures Owner s Manual 880 Kwikee Electric Steps TESTING THE MOTOR 11 Disconnect the two way connector between the step motor and the control unit Connect the motor s red wire to the positive terminal of the battery and touch the motor s yellow wire to the negative terminal of the battery to extend the step To retract the step reverse the connections If the step extends and retracts during this test the condition of the step motor is good NOTE On steps with control unit 909507000 reverse the red and yellow wire connections to perform the aforementioned test WARNING Do not leave the wires connected during this test once the step has cycled A either in or out Failure to remove the wires from the battery will burn out the motor voiding any warranty TESTING THE 4 WAY CONNECTOR 12 To check the main power source connect a voltmeter between the red wire from the 4 way connector vehicle half and the ground terminal at the end of the control unit s green ground wire see Figure 13 The reading should be a minimum of 12 volts DC If the voltage reading is low there may be a loose or corroded connection at the battery a low charge level on the battery itself or
22. gear box linkage 909510000 printed on the control sticker identifies a 909510000 Control Unit PRODUCT SERVICE TRAINING 22 SERIES Step Replacement Guide PAGE RISE 8 RUN 8 Motor Assembly Drawing and Parts Key Numbers Mounting bolt pattern 9 x 25 25 Part 902200016 24 tread with Motor and Switch Kit 905316000 Part 902206025 24 tread with Motor Control Unit and Switch Kit 905325000 CHART 1 Replacement Parts Kits for Series Steps 22 23 30 32 33 34 35 36 38 and 40 Parts Description Replacement Key Kit Part 1 Control Unit only Retracted Profile n a Step Frame only 908022000 STEP SERIES NUMBER ma __ Step Lightonly 909004000 To determine correct 3 Cotter and Clevis pin replacement part numbers it 14 IMGL A Control Replacement Kit 909770000 9095 10000 Control IMGL integrated Motor Gear Box Linkage A Cotter and Clevis pin Four way pigtail Fasteners is necessary to know the Step Series Number Itis located in the Owners Manual and printed under the top step Door Switches Part White Black Closed Open 905312000 905323000 Magnetic small rectangular 905314000 905324000 Magnetic 3 4 core round 905306000 905326000 Magnetic large rectangular 905307000 905327000 Magnetic 3 8 core round 905302000 905328000 Plated plunger switch Description If you can not locate the number measure the step and refer to the dimensio
23. j ree assembly should already be removed from the step top as previously described 1 Ifthe step frame is mounted flush against the step mounting surface amas m l ja ET emt ERST the step will have to be removed to ba access the top side of the step frame i 1E opil lock washer t3 2 The hole pattern for the new IMGL assembly does not line up properly with the old mounting holes See Figure 3 for a mounting diagram for the 23 Series Step and Figure 4 for the 34 Series Step NOTE All four mounting bolts must be used to attach the motor assembly to the step frame or the step may not operate properly and damage to the step may occur 3 Bolt down the motor assembly and install the clevis pin and cotter pin as described in IMGL Assembly replacement step 8 on Page 1 4 Remount the step to the vehicle NOTE If you are installing a control unit It will be easier to do this while the step is FIGURE 4 34 Series Step removed from the vehicle See Figure 4 for important information a 1 4 20 hex nut 4 on remounting 34 Series steps flush against the step mounting surface NOTE A Ifthe step is mounted flush against the mounting surface the step must be removed from the vehicle before 414 flat wath pa af as h ws gt at washers drilling the 9 32 dia hole for attaching the Ws 7 see NOTE B motor assembly lt NOTE B The 1 4 flat washers are used to shim the permanent magnet motor assembly away from the step
24. of the control unit WARNING 12 volt automotive batteries contain sulfuric acid which can cause severe burns Avoid contact with the skin eyes and clothing 12 volt automotive batteries produce hydrogen gas which is explosive keep cigarettes open flames and sparks away from VAN STEPS If the van step is equipped with a splash cover remove the cover to access motor assembly and control unit If step is locked in retracted up position and the plastic cover can not be removed disassemble the step tread to access the plastic cover To disassemble the tread remove the 8 1 4 20 x 1 long hex head bolts in tread side rails connects tread and sliding blocks to side rail This allows the tread to drop out of the way and the plastic cover to be accessible Reassemble the tread after removing the cover Reinstall the cover after testing procedures and any necessary repairs are complete Fully extend the step to reinstall the cover Be sure that the four way connector exits the notch in the plastic cover when reassembling For Steps with and without Control Unit the battery at all times 5 To supply power attach the red wire from the pigtail to the battery s positive post IMPORTANT INSTALLER NOTES Be sure that all ground connections are securely fastened with good metal to metal contact A good ground is required for proper step operation 6 With the power and
25. or motors Cut wires will automatically void the warranty as Kwikee will have no way of testing or verifying your claim Do not deviate from any of the guidelines listed above For questions regarding these warranty procedures technical assistance call 1 800 736 9961 Shipping charges for returning parts to Kwikee shall be the responsibility of the customer Kwikee will pay shipping charges when returning warrantable goods to the customer Kwikee will not accept C O D shipments of any returned goods Kwikee Products Company Inc o 230 Davidson Avenue e Cottage Grove Oregon 97424 9545 541 942 3888 FAX 541 942 5515
26. overheating If zero voltage is present the control unit has shut off and is normal If the step does not work or operates erratically such as extending part way and shutting off the first item that should be checked is the vehicle s battery Low supply voltage may cause erratic operation of the step Poor ground connections may also cause erratic operation of the step Check battery voltage and condition A battery in good condition and properly charged will have a no load voltage of approx 12 6 volts Check the voltage at the battery and at the four way connector at the control unit Insure that all battery and step control unit connections are clean and secure Recharge or replace the battery as necessary and retest the step for proper operation The step may also operate erratically if the step is being operated directly from a converter and the output from the converter is not adequate or properly filtered for clean DC voltage The converter must be capable of producing a minimum of 30 amps for proper step operation If the ground to the control unit is lost either between the step control unit and the vehicle chassis the long green ground wire or between the vehicle battery and the ground negative battery cable the step will not function Make sure the battery terminals and all wire connections are clean and tight Verify that all wires meet the minimum requirements specified in Figures 10 11 and 12 on Page 10 The following Step
27. particular purpose or the suitability of this product for use with other products In no event shall Kwikee be liable for incidental consequential or property damage arising from the purchase and or use of this product or any claim hereunder This warranty is in lieu of all other express and implied warranties Kwikee neither assumes nor authorizes any other person to assume any liability for warranty claims not provided herein This warranty gives you specific legal rights including other rights that may vary from state to state Some states do not allow limitations on implied warranties and exclusion or limitation of incidental or consequential damages therefore the limitations and exclusions contained herein may not apply to you Any questions regarding warranty claims should be directed to your dealer or contact Kwikee Customer Service Representative 230 Davidson Ave Cottage Grove Oregon 97424 Contact Kwikee Customer Service by telephone at 1 800 736 9961 WARRANTY PERIODS PRODUCT PARTS LABOR Electric and Manual Steps Two 2 years Two 2 years One 1 year on finish Level Best Leveling Stabilizing System Five 5 years Two 2 years DigiSync Room Slide One 1 years One 1 year Cargo Slides One 1 years One 1 year Utility Trays One 1 years One 1 year Warranty periods may vary See manufacturer of RV warranty information for details NOTE Any parts returned for warranty service repair with wires
28. readings are incorrect there is a problem with the switch Check the door switch and the condition of the circuit s wiring and terminal connections FIGURE 6 Check power source 4 way connector vehicle side Ground wire green ground wire must be attached to vehicle chassis a good ground is needed for proper step operation Voltmeter should read 12 volts DC Page 10 Troubleshooting and Testing Procedures Kwikee 42 Series Step FIGURE 7 Check power switch 4 way connector vehicle side Ground wire green ground wire must be attached to vehicle chassis a good ground is needed for proper step operation Voltmeter should read 12 volts DC power on 0 volts DC power off FIGURE 9 Check ignition override 4 way connector vehicle side Ground wire green ground wire must be attached to vehicle chassis a good ground is needed for proper step operation Voltmeter should read 12 volts DC ignition on 0 volts DC ignition off Owner s Manual FIGURE 8 Check door switch 4 way connector vehicle side Voltmeter should read 12 volts DC when door is closed Voltmeter should read 0 volts DC when door is open FIGURE 10 Check connector 4 way connector vehicle side Ground wire green ground wire must be attached to vehicle chassis a good ground is needed for proper step operation Voltmeter should read minimum of 12 volts DC Troubleshooting and Testing Procedur
29. 0 For all fully automatic steps Self Center Rocker Switch Part Description For steps NOT equipped with control units KWIKEE PRODUCTS COMPANY INC 230 Davidson Ave Cottage Grove OR 97424 800 736 9961 www kwikee com REV 4_2 05 PRODUCT SERVICE TRAINING 488 9 38 10 75 Extended Profile 2 13 11 384 413 SX 575 Retracted Profile STEP SERIES NUMBER To determine correct replacement part numbers it is necessary to know the Step Series Number It is located in the Owners Manual and printed under the top step If you can not locate the number measure the step and refer to the dimensioned drawings above Confirm that you are using the correct step series replacement parts guide KWIKEE PRODUCTS COMPANY INC PAGE 36 SERIES Step Replacement Guide RISE 5 RUN 10 75 Motor Assembly Drawing and Parts Key Numbers Mounting bolt pattern 8 x 26 Part 903600016 30 tread with Motor and Switch Kit 905316000 Part 903606025 30 tread with Motor Control Unit and Switch Kit 905325000 CHART 1 Replacement Parts Kits for Series Steps 22 23 30 32 33 34 35 36 38 and 40 Parts Description Replacement Key Kit Part 1 Control Unit only na Step Frame only 908036000 n a Step Light only 909004000 3 Cotter and Clevis pin 14 IMGL A Control Replacement Kit 909770000 9095 10000 Control IMGL integrated Motor Gear Box Linkage
30. 24 tread with Motor Control Unit and Switch Kit 905325000 CHART 1 Replacement Parts Kits for Series Steps 22 23 30 32 33 34 35 36 38 and 40 Parts Description Replacement ___ Key Kit Part Retracted Profile Control Unit only Wa Step Frame only 908035000 n a Step Light only 909004000 3 Cotter and Clevis pin 1 4 IMGL A Control Replacement Kit 909770000 9095 10000 Control IMGL Integrated Motor Gear Box Linkage A Cotter and Clevis pin Four way pigtail Fasteners Door Switches Part Part Description White Black Closed Open t lt 3 STEP SERIES NUMBER To determine correct replacement part numbers it is necessary to know the Step Series Number t is located in the Owners Manual and printed under the top step 905312000 905323000 Magnetic small rectangular 905314000 905324000 Magnetic 3 4 core round 905306000 905326000 Magnetic large rectangular 905307000 905327000 Magnetic 3 8 core round 905302000 905328000 Plated plunger switch If you can not locate the number measure the step and refer to the dimensioned drawings above Confirm that you are using the correct step series replacement parts guide Used for all color controls manufactured prior to 2 99 Does NOT include black 909506000 909507000 Used for black controls since 2 99 including 909506000 909507000 and 909508000 Rocker Style Power Switch Part Description 90530500
31. 328000 Magnetic small rectangular Magnetic 3 4 core round Magnetic large rectangular Magnetic 3 8 core round Plated plunger switch Used for all color controls manufactured prior to 2 99 Does NOT include black 909506000 909507000 Used for black controls since 2 99 including 909506000 909507000 and 909508000 Rocker Style Power Switch Part Description 905305000 For all fully automatic steps Self Center Rocker Switch Part Description 905316000 For steps NOT equipped with control units Engineered Solutions for RVs Motor Assembly Drawing and Parts Key Numbers www kwikee com REV 4_2 05 PRODUCT SERVICE TRAINING 32 SERIES Step Replacement Guide RISE 7 RUN 9 Mounting bolt pattern 8 x 22 Motor Assembly Drawing and Parts Key Numbers Part 903200016 24 tread with Motor and Switch Kit 905316000 Part 903206025 24 tread with Motor Control Unit and Switch Kit 905325000 CHART 1 Replacement Parts Kits for Series Steps 22 23 30 32 33 34 35 36 38 and 40 Parts Description Replacement Key Kit Part 1 Control Unit only na Step Frame only 908032000 Wa Step Light only 909004000 3 Cotter and Clevis pin Retracted Profile 14 IMGL A Control Replacement Kit 909770000 9095 10000 Control IMGL integrated Motor Gear Box Linkage A Cotter and Clevis pin Four way pi
32. 905328000 Magnetic small rectangular Magnetic 3 4 core round Magnetic large rectangular Magnetic 3 8 core round Plated plunger switch Used for all color controls manufactured prior to 2 99 Does NOT include black 909506000 909507000 Used for black controls since 2 99 including 909506000 909507000 and 909508000 Rocker Style Power Switch Description For all fully automatic steps Part 905305000 Self Center Rocker Switch Description For steps NOT equipped with control units 230 Davidson Ave Cottage Grove OR 97424 800 736 9961 www kwikee com REV 4_2 05 PRODUCT SERVICE TRAINING 34 SERIES Step Replacement Guide PAGE RISE 7 RUN 9 Mounting bolt pattern 8 x 26 Motor Assembly Drawing and Parts Key Numbers Part 903400016 30 tread with Motor and Switch Kit 905316000 Part 903406025 30 tread with Motor Control Unit and Switch Kit 905325000 CHART 1 Replacement Parts Kits for Series Steps 22 23 30 32 33 34 35 36 38 and 40 Parts Description Replacement Key Kit Part 1 Control Unit only n a Step Frame only 908034000 Retracted Profile nee 3 Cotter and Clevis pin 1 4 IMGL A Control Replacement Kit 909770000 909510000 Control IMGL Integrated Motor Gear Box Linkage A Cotter and Clevis pin Four way pigtail Fasteners STEP SERIES NUMBER To determine correct rep
33. 9961 www kwikee com REV 4_2 05 PAGE Extended Profile 14 63 2 19 12 13 33 363 4 25 Retracted Profile STEP SERIES NUMBER To determine correct replacement part numbers it is necessary to know the Step Series Number It is located in the Owners Manual and printed under the top step If you can not locate the number measure the step and refer to the dimensioned drawings above Confirm that you are using the correct step series replacement parts guide KWIKEE PRODUCTS COMPANY INC 230 Davidson Ave Cottage Grove OR 97424 800 736 9961 31 SERIES Step Replacement Guide RISE 7 RUN 10 5 Mounting bolt pattern 7 5 x 14 5 Part 903100016 18 tread with Motor and Switch Kit 905316000 Part 903106025 18 tread with Motor Control Unit and Switch Kit 905325000 CHART 1 Replacement Parts Kits for Series Steps 22 23 30 32 33 34 35 36 38 and 40 Parts Description Replacement Key Kit Part 1 Control Unit only n a Step Frame only 908031000 n a Step Light only 909004000 3 Cotter and Clevis pin 14 IMGL B Control Replacement Kit 909772000 9095 10000 Control IMGL Integrated Motor Gear Box Linkage A Cotter and Clevis pin Four way pigtail Fasteners Door Switches Part Part Description White Black Closed Open 905312000 905323000 905314000 905324000 905306000 905326000 905307000 905327000 905302000 905
34. Description Part 1905316000 For steps NOT equipped with control units Engineered Solutions for RVs Motor Assembly Drawing and Parts Key Numbers PRODUCT SERVICE TRAINING 38 SERIES Step Replacement Guide Available with brackets for Sate RISE 4 RUN 10 75 Van applications Mounting bolt pattern 8 x 22 RV Part 903800016 24 tread with Motor and Switch Kit 905316000 RV Part 903806025 24 tread with Motor Control Unit and Switch Kit 905325000 VANS Part 903800000 1 24 tread with Motor and no Control Unit VANS Part 903806000 24 tread with Motor and Control Unit Motor Assembly Drawing and Parts Key Numbers 26 75 Extended Profile 9 aT 11 38 4 4 13 575 j Retracted Profile CHART 1 Replacement Parts Kits for Series Steps 22 23 30 32 33 34 35 36 38 and 40 STEP SERIES NUMBER Parts Description Replacement To determine correct Key Kit Part replacement part numbers it Control Unit only is necessary to know the Step Wa Step Frame only 908038000 Series Number t is located in n a Step Light only 909004000 the Owners Manual and 3 Cotter and Clevis pin printed under the top step 1 4 IMGL A Control Replacement Kit 909770000 9095 10000 Control IMGL Integrated If you can not locate the Motor Gear Box Linkage A Cotter and Clevis pin Four way pigtail Fasteners oo
35. ENT motor Please take a moment to record this information PARTS Step Serial Step Series INFORMATION Year Make Model of RV Date of Purchase CONTROL UNIT Complete the following only if your step is equipped with Control Unit Control Unit Serial Control Unit To determine replacement parts refer to the chart for your Series Step Motor Assembly Drawing and Parts Key Numbers CHART 1 Replacement Parts Kits for Series Steps 22 23 30 32 33 34 35 36 38 and 40 Parts Description Replacement Key Kit Part 1 Motor and screws 214 1101428 2 Cotter and Clevis pin 905205000 3 Gear Linkage A Curved 1101425 Step Frame only 9080 000 insert 2 digit Step Series number Step Light 909004000 Replacement Parts Kits for Series Steps 28 31 37 and 39 As shown in CHART 1 except for the following Parts Description Replacement Key Kit Part 4 Gear Linkage B Straight 1101426 Replacement Parts Kits for Series Steps 26 As shown in CHART 1 except for the following Parts Description Replacement Key Kit Part i 5 Gear Linkage C Straight 1101427 5 Replacement Parts All Step Series DOOR SWITCHES Description Replacement Part Black Open Magnetic small rectangular 905323000 3 4 core round 905324000 Magnetic large rectangular 905326000 Magnetic 3 8 core round 905327000 Plated plunger switch 905328000 ROCKER STYLE POWER SWITCH Description Replacem
36. NANCE sain Clean all mud salt and road grime from the step before lubricating Lubricate all moving FIGURE 1 parts bearings pivot points slides clevis pin and drive linkage ball every 30 days with a good quality moisture and heat resistant penetrating grease KwikLube Spray Grease is specially formulated to lubricate Kwikee Electric Steps and is recommended for lubricating all moving parts Refer to the figures below for lubrication locations NOTE Silicone lubricants and WD 40 are not recommended as they have a tendency to evaporate and dry the mating surfaces which leave them vulnerable to the elements NOTE Figures are to be used for general reference purposes only Some may not pertain to your particular step model 1 Figures 1 and 3 Square shaft bearing lubricate around outside and under head of bearing 2 Figure 4 On step models equipped with plastic cover this cover will have to be removed to lubricate center bearings Lubricate bearings under cover every 90 days 3 Figure 4 Lubricate around the bushing in bushings 4 Maintain clean dry electrical connections at the two way and four way connectors and any butt connections leading from the four connector to the vehicle A small dab of di electric grease at the connections and replacing corroded butt connections with heat shrink type crimp style automotive connectors will help maintain a good electrical source for the step KwikLube is a unique aerosol g
37. ON 1 After the installation is complete and with the entrance door open turn the override switch to the off position NOTE Some steps are not equipped with an override switch They are activated only with a door switch 2 Close the door The step should retract and lock in the up position 3 Open the door The step should extend and lock in the down position with the understep light illuminated NOTE The understep light is not available on all step models 4 If your step is equipped with a override switch turn it to the on position The step should remain in the extended position with the understep light off when the door is closed 5 With the override switch turned on the step extended and the entrance door closed turn the vehicle ignition on The ignition override system will go into effect and the step will automatically retract WARNING If the vehicle is driven with the step in the extended position A there is the possibility of causing major damage to both the step and the vehicle NOTE If the yellow wire from the four way connector is not connected to an ignition power source the ignition safety system will be inoperative and the step will remain in the extended position In this case the override switch must be turned off for the step to retract 6 Tum the vehicle ignition off and open the door The step will extend and lock in the down position This is the Auto Exte
38. Out feature 7 The Last Out feature is only operative the first time the door is opened after the vehicle ignition is turned off When the vehicle ignition is on the step will always activate with the door movement regardless of the power switch position NOTE If the yellow wire from the four way connector is not connected to an ignition power source the Last Out feature will not operate MAINTENANCE LUBRICATION FIGURE 1 Power wash and spray dry lubricant on bearings on both sides of step 1 Clean all mud salt and road grime from the step before lubricating Power wash and spray dry lubricant on the bearings see Figure 1 NOTE Silicone lubricants and WD 40 are not recommended as they have a tendency to evaporate and dry the mating surfaces which leave them vulnerable to the elements 2 Maintain clean dry electrical connections at the two way and four way connectors and any butt connections leading from the four connector to the vehicle A small dab of di electric grease at the connections and replacing corroded butt connections with heat shrink type crimp style automotive connectors will help maintain a good electrical source for the step Page 4 Introduction Kwikee 42 Series Step ADJUSTING THE OUT STOPS Kwikee steps are fitted with adjustable out stops on the step frame that help lock the step in the out position creating a firm stepping platform The out stop is adjusted at the fact
39. PRODUCT SERVICE TRAINING a PAGE W E L C O M E to the Kwikee Products Service Training It is our sincere hope that the information you gain from this training will enhance your confidence in and familiarity with the products we manufacture The information will give you overviews of the products and some details on installation maintenance and repair From time to time changes occur in procedures specifications and even the products themselves As with any product information keeping the lastest information at your disposal is an ongoing and intregal part of providing you with a quality product Every product we ship includes the most current documentation and RV manufacturers provide binders or files for owners to store Kwikee and other product documentation in the RV But we know that doesn t always happen We know too that RVs get serviced parts get KWIKTIP changed and changes aren t reflected or noted in the original On the front page of every Kwikee document is a literature number and the date the document was development or documentation If however there is documentation we encourage you to look it over before servicing the equipment even if you are fairly familiar with the product revised You can make sure you are looking at the most recent KEEPING SERVICE INFORMATION CURRENT documentation by comparing your document with the documents on Kwikee s website www kwikee com and look at the downloadable a
40. RV Dealer for KwikLube MAINTENANCE IN SALT ENVIRONMENT To maintain step finish when step is exposed to a salt environment for extended periods of time routinely spray step with fresh water Page 6 Maintenance Owner s Manual 880 Kwikee Electric Steps ADJUSTING THE CAM STOPS 24 25 27 32 34 35 36 38 and 40 Series Steps Kwikee steps are fitted with adjustable cam stops on the step frame that help lock the step in the out position creating a firm stepping platform and relieving load bearing stress on the motor and drive linkage The cam is adjusted at the factory but due to the rigors of shipping installation and normal use the cam may fall out of adjustment and need to be tightened The cam stops are located under the step top on the 32 36 and 38 Series Steps and on the bottom tread side rail on the 24 25 27 and 40 Series Steps There is one stop on each side of the step CAUTION When 1 Loosen the stops so they move freely and working under the step retract the step be sure that the step cannot be activated and 2 that nothing can get position see Figure 8 Be sure that the motor caught in the step assembly linkage rests against the gear case as mechanism illustrated in Figure 1 Repeat if needed until the motor assembly locks in the extended position 3 Push the stops against the leg and tighten securely see Figure 9 Be sure that both stops are tightened and that they rest securely agains
41. The name of the switch changed because of a change in functionality from the former Power Switch B Linkage used on Step Series 28 31 37 39 The new Control Units are equipped with an ignition override system designed to prevent the vehicle from being driven with the step in the extended position When the step is locked in the extended position OVERRIDE SWTICH IS IN THE ON POSITION the door is closed and the ignition is turned on the ignition override system will engage and the step will automatically retract S Please note that this is a change from the old Power Switch which needed to be MA in the OFF position to lock the step out C Linkage kea on Step Series 26 If you have questions contact your Kwikee salesperson or cail the Kwikee Service Department at 1 800 736 9967 PUB Step Improvements Released 12 04 PRODUCT SERVICE TRAINING 9 PAGE KWIK TIP ContrRoL UNIT Loic With the new IMGL and Control Unit logic WHEN THE OVERRIDE SWITCH IS ON THE STEP IS LOCKED IN THE EXTENDED POSITION IF THE IGNITION IS TURNED ON WHETHER THE OVERRIDE SWITCH IS ON OR OFF THE STEP WILL FOLLOW THE DOOR Door Open Step Extended Door Closed Step Retracted PAGE 10 Engineered Solutions for RVs KWIK TIP Look FOR THE STICKERS The new IMGL and Control Unit can easily be identified by the following stickers 214 on the printed sticker identifies an IMGL integrated motor
42. WITH BUTT CONNECTORS Remove the old control unit from the step frame Save the mounting screws for mounting the new control unit to the step frame B Attach the 31 long 12 ga green wire to the vehicle chassis Scrape the connection point clear for a good ground connection On steps with a braided ground cable the braided NOTE The 909510000 Control Unit is to be used only with the AM Equipment 214 motor The 214 number will be on a sticker on the motor Using the screws saved from the old cable may be removed 7 Reinstall the Splash cover if the step control mount the new control to the was so equipped step frame C Connect the black wire from the control unit to the understep light On 8 Reconnect the vehicle battery Reconnect the wiring A Ground the 16 ga green wire from the control unit to the step frame Remove any corrosion at the attachment point Attach it placing the external tooth lock washer supplied with the new control unit between the ring terminal on the end of the green wire and the step frame steps not equipped with an understep light wrap the black wire to protect it from the weather and secure it to keep it from dangling D Connect the connector to the step motor Test the step functions 214 IMGL Assembly and Control Replacement Instructions Page 4 23 and 34 Series Step Motor Replacement The four way connector should be FIGURE 3 23 Series Ste disconnected and the old gearbox
43. asure the step and refer to the dimensioned drawings above Confirm that you are using the correct step series replacement parts guide Used for all color controls manufactured prior to 2 99 Does NOT include black 909506000 909507000 Used for black controls since 2 99 including 909506000 909507000 and 909508000 Rocker Style Power Switch Part Description 9905305000 For all fully automatic steps Self Center Rocker Switch Part Description 905316000 For steps NOT equipped with control units KWIKEE PRODUCTS COMPANY INC 230 Davidson Ave Cottage Grove OR 97424 800 736 9961 www kwikee com REV 4_2 05 Installation Instructions 214 2005 Kwikee Document release date 02 05 Document 1421480 IMGL and 9510 Control Replacement Kits Integrated Motor Gear Box Linkage Aver attempting any electric step assembly repair work please read all of the following instructions Disconnect the power at the vehicle battery once the step is extended Refer to the Electric Step Replacement Part Schematic Figure 1 for item numbers referenced in these instructions IMGL Integrated Motor Gear 4 Remove the cotter pin from the clevis pin at the linkage assembly Remove the clevis pin Item 2 from the cast U block in the end of the linkage assembly Items 3 4 or 5 Note the direction the clevis pin goes into the cast block If the step is in its locked positio
44. cam stops may cause damage to the motor assembly and or the drive linkage Kwikee steps are fitted with adjustable cam stops on the step frame that help lock the step in the out position creating a firm stepping platform and relieving load bearing stress on the motor and drive linkage The cam is adjusted at the factory but due to the rigors of shipping installation and normal use the cam may fall out of adjustment and need to be tightened The cam stops are located under the step top on the 32 36 and 38 Series Steps and on the bottom tread side rail on the 24 25 27 and 40 Series Steps There is one stop on each side of the step foy N Uh 0 HE When working under the step be sure that the step cannot be activated and that nothing can get caught in the step mechanism 1 Loosen the stops so they move freely and retract the step OZH Be sure that nothing can get caught in the step mechanism 2 Extend the step fully to its locked extended position see Figure 1 Be sure that the motor assembly linkage rests against the gear case as illustrated in Figure 1 Repeat if needed until the motor assembly locks in the extended position 3 Push the stops against the leg and tighten securely see Figure 2 Be sure that both stops are tightened and that they rest securely against the leg 4 Retract and fully extend the step Check the motor assembly to be sure that it is locked all the way out and that both stops are secur
45. cut will result in voiding of the warranty It is important to read and understand all product o o ear ane Ora apan Inc documentation thoroughly before initiating Cy lt a Suso PARA snes ety 541 942 3888 FAX 541 942 5515 improper installation or operation PEZE EEE EEEE EEEE EEEE A tue Kee Steps ARR A A A AAA A A i i i i i Warranty Procedures This advisory is intended to explain warranty procedures with regard to Kwikee Automatic Electric Steps Observing proper warranty procedures will expedite the processing of warranty claims and reduce the number of claims that are denied Please take note of the following advice to avoid the denial of warranty or a reduction in the reimbursement to your warranty claim 1 Do not replace entire assemblies when repairing a step under warranty Replace only those parts that are actually defective Motors gear cases gears linkage assemblies and control units are all replaceable as individual parts If you exchange a complete assembly when only the replacement of an individual part is required the non defective parts will be returned and only the defective part will be credited to you Example If a linkage assembly breaks and the entire motor assembly is replaced to repair the step the motor gear case and gears will be returned to you and only the linkage assembly will be credited to you Meanwhile you bought and paid for an entire motor assembly that you did not need 2 Do not
46. d be zero 0 volts DC If the voltage reading is more the white wire is connected to 12 volts and should be cut If you have additional questions or need more assistance contact Kwikee s Service Representative at 1 800 736 9961 FIGURE 16 Ignition override FIGURE 17 Connector 4 way connector 4 way connector Page 8 Yellow vehicle side vehicle side a Zz Ground wire green ground wire Ground wire green ground wire must be attached to vehicle must be attached to vehicle chassis a good ground is needed chassis a good ground is needed for proper step operation Voltmeter should Voltmeter should read 12 volts DC ignition on read zero 0 volts DC 0 volts DC ignition off Kwikee Products 230 Davidson Avenue Cottage Grove OR 97424 9545 541 942 3888 www kwikee com Page 12 Troubleshooting and Testing Procedures Owner s Manual 888 Kwikee Electric Steps WARNING Be sure the vehicle battery is disconnected before starting any wiring procedure Before beginning any wiring procedure be sure you understand the wiring diagrarm for your particular step model Be careful to select the proper wire size length and color as well as the proper crimp on terminals and connectors for each application as called for in wiring diagram and instruction sheet Improper wiring can cause damage to the step control unit and the vehicle s wiring system Improper wiring will void the step warranty Tools n
47. d is needed for proper step operation for proper step operation sis be Voltmeter should read 2 12 volts DC when door is closed Ground wire green ground wire Voltmeter should read Voltmeter should read P 0 volts DC when door Volts n Vol houl 12 volts DC override on pice age 0 volts DC override off open For Steps with and without Control Unit Troubleshooting and Testing Procedures Page 11 15 To check the ignition override system connect a voltmeter between the yellow wire from the 4 way connector vehicle half and the ground terminal on the end of the control unit s green ground wire see Figure 16 on Page 12 The voltage reading should be approximately 12 volts DC when ignition is on and zero 0 volts when ignition is off If the reading is zero when the ignition is on check all terminal connections wiring and the vehicle s ignition fuse NOTE The step wiring circuit must be independent No other device i e alarm systems step well lights etc can be connected to the step wiring circuit Any device connected to the steps wiring can cause the step to malfunction and will void the warranty 16 For steps equipped with door switch only operation Connect the white jumper wire from the vehicle half of the four way connector and the ground terminal at the end of the control unit s green ground wire see Figure 17 NOTE Be sure to use the terminal with only the white wire The reading shoul
48. determine correct replacement part numbers it Parts Description Replacement Key Kit Part 1 Control Unit only is necessary to know the Step n a Step Frame only 908030000 Series Number It is located in n a Step Light only 909004000 the Owners Manual and 2 Cotter and Clevis pin only printed under the top step 1 4 IMGL A Control Replacement Kit 909770000 9095 10000 Control IMGL Integrated Motor Gear Box Linkage A Cotter and If you can not locate the Clevis pin Four way pigtail Fasteners number measure the step and refer to the dimensioned drawings above Confirm that you are using the correct step Door Switches Part Part Description series replacement parts White Black Closed Open guide 905312000 905323000 Magnetic small rectangular 905314000 905324000 Magnetic 3 4 core round 905306000 905326000 Magnetic large rectangular 905307000 905327000 Magnetic 3 8 core round 905302000 905328000 Plated plunger switch Used for all color controls manufactured prior to 2 99 Does NOT include black 909506000 909507000 Used for black controls since 2 99 including 909506000 909507000 and 909508000 Part Description 905305000 For all fully automatic steps Self Center Rocker Switch Part Description 905316000 For steps NOT equipped with control units KWIKEE PRODUCTS COMPANY INC 230 Davidson Ave Cottage Grove OR 97424 800 736
49. ding the warranty Owner s Manual Step Identification and Replacement Parts Information Page 3 1 After the installation is complete and with the entrance door open turn the power OPERATION switch on NOTE Some steps are not equipped with a power switch They are activated only with a door switch 2 Close the door The step should retract and lock in the in position 3 Open the door The step should extend and lock in the out position WARNING If the vehicle is driven with the step in the extended position there is the possibility of causing major damage to both the step and the vehicle 4 If your step is equipped with a power switch turn it off The step should remain in the extended position when the door is closed Turning off the power with the step retracted will hold the step in a retracted position as well 5 With the power switch off the step extended and the entrance door closed turn on the vehicle ignition The ignition override system will go into effect and the step will automatically retract NOTE If the yellow wire from the four way connector is not connected to an ignition power source the ignition safety system will be inoperative and the step will remain in the extended position In this case the power switch must be turned on for the step to retract 6 Turn the vehicle ignition off and open the door The step will extend and lock in the out position This is the Last
50. e 1 To extend the step push and hold the bottom half of the rocker switch Make sure the step is completely extended and locked in position before releasing the switch 2 Push and hold the top of the rocker switch to retract the step Be sure the step is completely retracted and locked in position before releasing the switch WARNING Do not hold the switch in for longer IN than it takes to either extend or retract the step or damage to the motor will result NOTE Always be sure that the step is fully retracted before traveling If the step is left extended and strikes an obstruction while the vehicle is moving major damage to both the step and the vehicle could result NOTE The extend retract function will be reversed if the red and yellow terminal connections are reversed or the step is equipped with a reverse driven motor assembly such as on the 37 and 42 Series steps For Steps with and without Control Unit Operation Page 5 MAINTENANCE ssi Clean all mud salt and road grime from the step before lubricating Lubricate all moving FIGURE 1 parts bearings pivot points slides clevis pin and drive linkage ball every 30 days with a good quality moisture and heat resistant penetrating grease KwikLube Spray Grease is specially formulated to lubricate Kwikee Electric Steps and is recommended for lubricating all moving parts Refer to the figures below for lubrication locations NOTE Silicone
51. e and troubleshooting of any Kwikee electric step manufactured after January 2002 that is equipped with a door switch a power switch control unit and a permanent magnet motor It does not apply and should not be used as a reference to any other previous versions of a Kwikee electric step The control unit is essentially a current sensor as well as a switching device When the motor assembly moves the step tread to its extended position or stops moving because of an obstruction such as a curb or the binding of a damaged or bent step frame the motor draws a larger amount of current The control unit senses the larger current draw and shuts off power to the motor All control units are equipped with an ignition override system This system is designed so that the vehicle will not be driven with the step in the extended position When the step is locked in the extended position the door closed and the ignition is turned on the ignition override system will engage and the step will automatically retract The Last Out feature is another safety feature designed to extend the step when the door is opened for the first time after the vehicle ignition is turned off even if the power switch is turned off When the ignition is switched on the function of the power switch is disabled and the step will always extend when the door is opened and retract when the door is closed Some van steps use door switch only operation When the door is o
52. e must be securely attached to the chassis for step to operate Fuse block a IMPORTANT ON The yellow wire must go to a terminal marked IGN ignition or to another terminal that is hot 16 AWG purple when the ignition is turned on optional step light switch 2 may be connected to porch light 6 amp maximum fuse or circuit breaker required Vehicle Wiring an 4 20 ampfuseor _ J curcult breaker required Normally OPEN magnetic switch if the switch is OFF the step L 5 amp maximum fuse or will not circuit breaker not supplied 10 If any of the step functions do not work the source of the malfunction is either in the control unit and or the motor Proceed to the Testing the Motor section on Page 11 If all of the step functions do work the malfunction is either in the door switch power switch or the vehicle wiring Proceed to Testing the 4 way Connector section on Page 11 FIGURE 11 Wiring diagram for steps with door switch only operation FIGURE 12 Wiring diagram for Understep fight steps without control unit ao fe Molor not available on a assembly wer son ENA a gt S sz 12 AWG green Step Wiring Two way URS connector N 12 AWG green ground wire must be securely attached to the chassis for step to operate CS 16 AWG purple optional step light switch may be connected to porch light 16 AWG brown __ 12 AWG red Vehicle Wiring Ej Chassis ground 20 amp
53. e aed listed OFTHIS ipped with sens pe tepall peti are no lon prior to Octobe 7 of this a a Kits li ee isted RECORDS mg the Step pecomes necessaTy the information that you supply pelow will CSS m pse me he Step Series NU or Serial number d Control Unit numbers unit and ihe underside the step near the Step Serial Step Series Year make Model ot RV Date of Put chase C o NTROL UNIT Complete the following only if your step 18 equipped with C ontrol Unit control Unit Control Unit serial gids 314 st hex washer head 2 mao pearing bracket geama 9 Mator agamot 9a papia g shaft main gem 12 Gest case covet 1 4 Motor mantini plate yfa 20 peg Htobal forrang crew control Ut wus Replacement part numbers are also parts Descriptor pepiacement parts Key number 4 pirat Facies in Kit iable online at 8 nage assert E 1 378 8 2 paor bearing OME 909536000 2 www kwikee re 909521000 1 48 15 166 see pownioadable Documents yea Mapte pr o unag gsseenly Step Identification and Replacement P ts Infor jon j Page 3 INTRODUCTION Page 4 Introduction STEPS WITH CONTROL UNIT This manual has been provided to assist you with the identification operation maintenanc
54. e against the legs Repeat the above procedures if needed to properly adjust the stops 5 Push on the front edge of the step tread If the step seems loose repeat the above procedures The stops may not be properly adjusted so that they rest tightly against the leg FIGURE 1 This view shown with motor removed and parts exploded for clarity only These parts need not be disassembled to adjust cam stops These surfaces must be in contact for the step to be fully extended FIGURE 2 Stop location and assembly for 24 25 27 and 40 Series Steps Push Step securely against leg Push Step securely against leg Stop location and assembly for 32 34 35 36 and 38 Series Steps PRODUCT SERVICE TRAINING PAGE MAINTENANCE MANUAL RETRACTION OF THE STEP exile Before attempting any motor assembly 3 repair work please read all of the following instructions 1 To manually retract the step the step needs to be partially or fully extended to expose the drive linkage If possible extend the step with the standard Door Switch operation If that is not possible it is necessary to remove the clevis pin 2 Unplug the four way connector from the Control Unit Rivet OY below S Clevis pin Remove the cotter pin from the clevis pin at the linkage assembly Remove the clevis pin from the case U block in the end of the linkage assembly Note the direction the clevis p
55. e clevis pin Item 2 through the drive arms attached to the step frame and the cast block in the linkage assembly Items 3 4 or 5 Be sure to reinstall the clevis pin in the same direction it was removed Install the cotter pin in the clevis pin 9 Reconnect the wiring A Wiring to a 909510000 Control Unit Plug the motor connector from the Control Unit into the motor B Wiring to toggle switch only Using the motor adapter pigtail connect the mating connector to the connector on the motor Connect the red and yellow pigtail wires to the vehicle switch wires using heat shrink insulated butt connectors Plug in the 4 way connector between the control unit and the vehicle NOTE On 23 and 34 Series steps see the mounting instruction Figure 3 and 4 when replacing a 8287 double reduction motor with a permanent magnet motor assembly IMGL and Control Unit Replacement Kits Linkage For Step Series 909770000 A 22 23 30 32 33 34 35 36 38 40 909772000 B 28 31 37 39 909774000 C 26 Replacement Kits contain an IMGL integrated motor gear box linkage assembly a Control Unit four way pigtail and fastener kit Replacing the motor gear box and linkage with the IMGL on a step that has any control other than a 909510000 Control Unit as included requires the installation of the 909510000 Control included in the Replacement Kit Note Any control unit or motor repair needed on steps using a
56. ectric step INTRODUCTION The control unit is essentially a current sensor as well as a switching device When the motor assembly moves the step tread to its extended position or stops moving because of an obstruction such as a curb or the binding of a damaged or bent step frame the motor draws a larger amount of current The control unit senses the larger current draw and shuts off power to the motor All control units are equipped with an ignition override system This system is designed so that the vehicle will not be driven with the step in the extended position When the step is locked in the extended position the door closed and the ignition is turned on the ignition override system will engage and the step will automatically retract The Last Out feature is another safety feature designed to extend the step when the door is opened for the first time after the vehicle ignition is turned off even if the power switch is turned off When the ignition is switched on the function of the power switch is disabled and the step will always extend when the door is opened and retract when the door is closed Some van steps use door switch only operation When the door is opened the step extends and the step retracts when the door is closed NOTE Follow the instructions in this manual carefully Failure to do so may result in damage to the step control the motor andlor the vehicle wiring Such damage may also result in voi
57. ed position with the understep light off when the door is closed Turning off the power with the step retracted will hold the step in a retracted position as well 5 With the power switch off the step extended and the entrance door closed turn on the vehicle ignition The ignition override system will go into effect and the step will automatically retract WARNING If the vehicle is driven with the step in the extended position 1N there is the possibility of causing major damage to both the step and the vehicle NOTE If the yellow wire from the four way connector is not connected to an ignition power source the ignition safety system will be inoperative and the step will remain in the extended position In this case the power switch must be turned on for the step to retract 6 Turn the vehicle ignition off and open the door The step will extend and lock in the down position This is the Last Out feature 7 The Last Out feature is only operative the first time the door is opened after the vehicle ignition is turned off When the vehicle ignition is on the step will always activate with the door movement regardless of the power switch position NOTE If the yellow wire from the four way connector is not connected to an ignition power source the Last Out feature will not operate STEPS WITHOUT CONTROL UNIT WARNING Stepping on a partially extended step can cause damage to the step fram
58. eeded Electric drill 15 32 dia drill or 3 8 drill and a round file Wire cutters Wire strippers Terminal crimper Electrical tape Flashlight or drop light Safety glasses Kit Contents Qty Description Wiring Harness 2 green 16 ga wire 20 amp inline fuse holder 5 amp inline fuse holders Wire ties Blue butt connectors Yellow butt connectors 1 4 male push on terminal 5 16 blue ring terminal 5 16 yellow ring terminal 6 blue ring terminal 6 external tooth lock washer 1 of caulking compound Power switch toggle switch Caution sticker Instructions ttf 5 230 Davidson Avenue Cottage Grove Oregon 97424 9545 541 942 3888 www kwikee com d d d f ee ee er er NIOO N G Wiring Instructions 7543 01 05 Kwikee Kwikee 1421225 Rev 2 Wiring Installation Instructions For steps operated by a Door Switch and Power Switch with Control 909510000 NOTE The step mounting brackets should be mounted and the door switch should be installed before continuing with any wiring Installation Instructions Step 1 Wrap electrical tape around the black plastic loom of the wiring harness every 10 12 Step 2 Route the wirng harness from the vehicle battery to the step with the four way Packard style connector terminating at the step WARNING Keep the wiring harness away from any heat generating or moving parts on the vehicle Step 3 Mount the step if not already done The
59. een the red and yellow motor wires to be sure no voltage registers If any voltage registers disconnect the four way connector to keep the step motor from overheating If zero voltage is present the control unit has shut off and is normal If the step does not work or operates erratically for example extends part way and shuts off the first item to check is the vehicle battery Low supply voltage may cause erratic operation of the step Poor ground connections may also cause erratic operation of the step Check battery voltage and condition A battery in good condition and properly charged will have a no load voltage of approx 12 6 volts Check the voltage at the battery and at the four way connector at the control unit Insure that all battery and step control unit connections are clean and secure Recharge or replace the battery as necessary and retest the step for proper operation The step may also operate erratically if it is operating directly from a converter and the converter output is not adequate or properly filtered for clean DC voltage The converter must be capable of producing a minimum of 30 amps for proper step operation The step will not function if the ground to the control unit is lost between the step control unit and the vehicle chassis the long green ground wire or between the vehicle battery and the ground negative battery cable Make sure the battery terminals and all wire connections are clean and tight Verify that
60. ehicle Cut the wires just above the connector and butt connect the pigtail wires to the vehicle wiring Make sure that the vehicle wires that were connected to the old pigtail are connected to the new pigtail in the identical way 2 Disconnect the black wire leading from the control unit to the understep light at the connector Do not cut this wire NOTE Not all steps are equipped with an understep light Number Description 3 On steps with a blue red green yellow brown or orange control unit remove the screw securing the green Cotter and clevis pins wire from the control unit to the step Gear box with linkage A frame Save the screw for securing Gear box with linkage B the green wire on the new control Gear box with linkage C unit On orange control units manufactured after 1991 remove the screw securing the 31 long 10 ga green ground wire from the control unit to the vehicle chasis Motor and screws FIGURE 2 12 AWG green ground wire must be securely attached to the chassis for step to operate Cr 16 AWG purple wire Optional step light switch 214 IMGL Assembly and Control Replacement Instructions IMGL Integrated motor Ss gear box linkage Cy aa FOUR WAY CONNECTOR KS FOUR WAY PIGTAIL Page 3 Understep light not available on all step models 16 AWG green ground wire to step top VAN STEP lt PIGTAIL Step with door switch COACH WIRING J only operation
61. em that should be checked is the vehicle s battery Low supply voltage may cause erratic operation of the step Poor ground connections may also cause erratic operation of the step Check battery voltage and condition A battery in good condition and properly charged will have a no load voltage of approx 12 6 volts Check the voltage at the battery and at the four way connector at the control unit Insure that all battery and step control unit connections are clean and secure Recharge or replace the battery as necessary and retest the step for proper operation The step may also operate erratically if the step is being operated directly from a converter and the output from the converter is not adequate or properly filtered for clean DC voltage The converter must be capable of producing a minimum of 30 amps for proper step operation If the ground to the control unit is lost either between the step control unit and the vehicle chassis the long green ground wire or between the vehicle battery and the ground negative battery cable the step will not function Make sure the battery terminals and all wire connections are clean and tight Verify that all wires meet the minimum requirements specified in Figures 4 and 5 on Page 8 The following Step Test Procedures have been provided to troubleshoot and test all of the Kwikee automatic electric step functions They are designed to initially check the step s basic functions separately from the RV wiri
62. ent Part For all fully automatic steps 905305000 SELF CENTER ROCKER SWTICH Description Replacement Part Replacement part numbers for steps equipped with older style motor gear box Steps NOT equipped with control unit 905316000 are available online at www kwikee com See Downloadable Documents For Steps with and without Control Unit Step Identification and Replacement Parts Information Page 3 INTRODUCTION Page 4 Introduction STEPS WITH CONTROL UNIT This manual has been provided to assist you with the identification operation maintenance and troubleshooting of the Kwikee electric step equipped with a door switch override switch control unit and permanent magnet motor This manual does not apply and should not be used as a reference to previous versions of a Kwikee electric step The control unit is essentially a current sensor as well as a switching device When the motor assembly moves the step tread to its extended position or stops moving because of an obstruction such as a curb or the binding of a damaged or bent step frame the motor draws a larger amount of current The control unit senses the larger current draw and shuts off power to the motor All control units are equipped with an ignition override system This system is designed so that the vehicle will not be driven with the step in the extended position When the step is locked in the extended position override switch is in the on positi
63. es Page 11 fike 4 To check the ignition override system connect a voltmeter between the yellow wire from the 4 way connector vehicle half and the ground terminal on the end of the control unit s green ground wire see Figure 9 The voltage reading should be approximately 12 volts DC when ignition is on and zero 0 volts when ignition is off If the reading is zero when the ignition is on check all terminal connections wiring and the vehicle s ignition fuse NOTE The step wiring circuit must be independent No other device i e alarm systems step well lights etc can be connected to the step wiring circuit Any device connected to the steps wiring can cause the step to malfunction and will void the warranty 5 For steps equipped with door switch only operation Connect the white jumper wire from the vehicle half of the four way connector and the ground terminal at the end of the control unit s green ground wire see Figure 10 NOTE Be sure to use the terminal with only the white wire The reading should be a minimum of 12 volts DC If the voltage reading is low there may be a loose or corroded connection at the battery a low charge level on the battery itself or a poor ground If the voltage reading is zero 0 volts check the step fuse circuit breaker all connections and the condition of the wiring between the battery and the plug including the ground connection at the chassis If you have additional quest
64. fic parts on Kwikee Electric Steps with improved components New parts include Linkage and Gear Box Motor and e Control Unit on Kwikee Electric Step Series 22 23 26 28 30 31 32 33 34 35 36 37 38 39 and 40 The step improvements were made to increase performance amp reliability and longevity of step operation The changes also simplify parts replacement Motor procedures used on all steps Improved linkage and gear box Investment cast zinc plated steel linkage asssembly is strong and more resistant to corrosion Brass spherical outer cage hardened Cotter and bail in linkage is stronger wears longer and will not oblong improved gear box has fully levis pins used sealed dual ball bearing for greater efficiency and no maintenance Case halves seal for on all steps consistent alignment and gear protection from the elements Improved motor 40 more motor torque give step a strong lock out and solid feel Improved control unit logic Step is always open when door is open Step can be locked in the extended position Step cannot be locked in retracted position Automatic ignition override makes step follow the door Step Series 22 23 30 32 33 34 35 36 38 and 40 New Owners Manual A new 888 Owners Manual ships with all steps that have the impraved step components An important change covered in the 888 Owners Manual is the Override Switch previously call the Power Switch in Kwikee 880 manuals
65. ground connections complete all functions of the control unit can be checked at the four wires of the pigtail The brown wire is the door switch the white wire is the power switch and the yellow wire is the ignition override WARNING Keep fingers 1N arms and legs clear of step mechanism while performing these tests 7 To extend the step touch the white wire to the battery s positive post The step should extend and remain extended 8 To retract the step hold the white wire to the battery s positive terminal and touch the brown wire to the negative terminal 9 To test the Ignition Override feature extend the step as in Step 7 With the step extended disconnect the white wire from the battery and attach the brown wire to the battery s negative terminal Next touch the yellow wire to the battery s positive terminal The step should retract Remove the brown wire and the step should extend To test the Last Out feature touch the brown wire to the negative terminal to retract the step While holding the brown wire to the negative terminal remove the yellow from the positive terminal The Step will stay retracted Now remove the brown wire The step should extend Troubleshooting and Testing Procedures Page 9 FIGURE 10 Wiring diagram for step with control unit Understep light not available on Step Wiring Two way connector 12 AWG green ground wir
66. gtail Fasteners Door Switches STEP SERIES NUMBER To determine correct replacement part numbers it is necessary to know the Step Series Number t is located in the Owners Manual and printed under the top step Part Part Description White Black Closed Open 905312000 905323000 Magnetic small rectangular 905314000 905324000 Magnetic 3 4 core round 905306000 905326000 Magnetic large rectangular 1905307000 905327000 Magnetic 3 8 core round 1905302000 905328000 Plated plunger switch Used for all color controls manufactured prior to 2 99 Does NOT include black 909506000 909507000 Used for black controls since 2 99 including 909506000 909507000 and 909508000 Rocker Style Power Switch Part Description 905305000 For all fully automatic steps If you can not locate the number measure the step and refer to the dimensioned drawings above Confirm that you are using the correct step series replacement parts guide Self Center Rocker Switch Part Description 9905316000 For steps NOT equipped with control units KWIKEE PRODUCTS COMPANY INC 230 Davidson Ave Cottage Grove OR 97424 800 736 9961 www kwikee com REV 4_2 05 PAGE Engineered Solutions for RVs 33 SERIES Step Replacement Guide Available with brackets for Van applications Extended Profile 6389 25 62 gt 21 88 Retracted Profi
67. he 4 way Connector section Page 8 General Service Notes Kwikee 42 Series Step FIGURE 5 Wiring diagram for steps with door switch only operation 12 AWG green N ground to kaas top T 12 AWG green ground wire a must be securely attached to Step Wiring the chassis for step to operate 16 AWG purple optional step light switch may be connected to porch light connector Motor assembl connector 16 AWG brown gt 1 Vehicle Wiring 2 AWG red 20 amp fuse or Chassis ground curcuit breaker required Normally OPEN magnetic door switch Battery disconnect box switch IMPORTANT If the switch is OFF the step will not operate TESTING THE MOTOR 1 Disconnect the two way connector between the step motor and the control unit Connect the motor s yellow wire to the positive terminal of the battery and touch the motor s red wire to the negative terminal of the battery to extend the step To retract the step reverse the connections If the step extends and retracts during this test the condition of the step motor is good TESTING THE 4 WAY CONNECTOR 1 To check the main power source connect a voltmeter between the red wire from the 4 way connector vehicle half and the ground terminal at the end of the control unit s green ground wire see Figure 6 on Page 9 The reading should be a minimum of 12 volts DC If the voltage reading is low there may be a loose or corroded connection at the bat
68. his Training 42 Series Steps have not been changed over to the new IMGL and 909510000 Control Unit This changed is scheduled to happen mid year 2005 at which time information relating to the control unit motor and gearbox will be updated Check www kwikee com downloadable documents for updates If you have a service or repair related question contact the Kwikee Customer Service Department at 1 800 736 9961 wners pee 842 Co inc products 3104 ol oe 1422259 az series Sia otor p anent magnet M Table of Conten ion warranty informe nation jdentificarion T pform ton miro odut 4 Step nae the a O i Main 45 4 jon vst Adjust ent e Oud otes General Sery ice N 6 and 642 rrot ena ey WARRANTY For questions regarding these warranty procedures or technical assistance call 1 800 736 9961 Be sure to visit us online for updates and downloadable documents Go to www kwikee com Page 2 Warranty 1 We warrant that the equipment is free from defects in material and workmanship under normal use and service The provisions of this warranty shall not apply to any equipment that has been subject to misuse negligence alteration accident improper installation such as the welding of the step to the vehicle frame or mounting brackets normal deterioration due to wear or has been repaired outside our place of business in any way as in ou
69. hout Control Units Single Steps Double Steps Triple Steps Van Steps ouanh WN Warranty Information Identification Information Introduction Operating the Step Maintenance Lubrication Cam Stop Adjustment General Service Notes Troubleshooting and Testing Procedures WARRANTY For questions regarding these warranty procedures or technical assistance call 1 800 736 9961 Be sure to visit us online for updates and downloadable documents Go to www kwikee com Page 2 Warranty 1 We warrant that the equipment is free from defects in material and workmanship under normal use and service The provisions of this warranty shall not apply to any equipment that has been subject to misuse negligence alteration accident improper installation such as the welding of the step to the vehicle frame or mounting brackets normal deterioration due to wear or has been repaired outside our place of business in any way as in our reasonable judgement to adversely affect its performance and reliability 2 Our obligation under this warranty is limited to repairing or replacing at our option any product that is returned to our place of business and when in its examination shall disclose to our reasonable satisfaction that it is defective The repair or replacement of the defective parts under this warranty will be made without charge for parts or labor Shipping charges for returning parts to Kwikee Products Compa
70. ies Steps Push securely againt leg These surfaces must be in contact Push securely for the step to be fully extended againt leg For Steps with and without Control Unit Maintenance Page 7 GENERAL SERVICE NOTES These general service notes and the Step Test Procedures address the most common questions about Kwikee electric steps Due to the number of variable conditions you may experience symptoms other than those covered Please feel free to contact the Customer Service Department at 1 800 736 9961 for further information or assistance TROUBLE SHOOTING AND TESTING PROCEDURES Page 8 General Service Notes If the power wire to the step is disconnected from its source and reconnected a spark is common This is caused by the momentary charging of the control unit and does not necessarily indicate the system is staying on which would cause a drain on the battery To determine if a control unit is not shutting off remove the four way connector to the chassis and the two way connector between the step motor and the contol unit Place a voltmeter between the red and yellow motor wires at the two way connector from the control unit Reconnect the four way Connector Turn the override switch to the off position If any voltage registers on the meter for more than 5 seconds the control unit is not shutting off and may be defective When doing this test switch the voltmeter leads back and forth betw
71. in goes into the cast block If the step is in its locked position the pin may have to be pried or driven out of the block Once the clevis pin is removed the step tread s should now swing freely If they do not check for a bent step frame or jammed pivot point s Engineered Solutions for RVs Door SWITCHES When troubleshooting a coach you may run into any of these door switches The important thing to determine is whether the switch is normally open or normally closed Use the chart below to identify the switch The current IMGL integrated motor gear box linkage and 909510000 Control Unit operates properly with any of the belowed list ed NORMALLY OPEN switches Kwikee Door Switch Replacement Magnetic Magnetic Magnetic Magnetic Plated small 3 4 core large 3 8 core plunger Parts Guide rectangular White Normally Closed ON 1 Used for all color controls manufactured bi ip prior to 2 99 Does NOT include black y Ly wh controls 909506000 909507000 Sy YA Part 905312000 905307000 905302000 round rectangular round switch Black Normally Open VM Used for black controls since 2 99 Ss Z including controls 909506000 lt Q a a 909507000 and 909508000 a Ns Z Part 905323000 905324000 905326000 905327000 905328000 MIMI AIIM MAAN MADD hee PAGE LAA HHH HH i i i i i i i i i Warranty Policy Kwikee warrants to the o
72. ions or need more assistance contact Kwikee s Service Representative at 1 800 736 9961 230 Davidson Avenue Cottage Grove OR 97424 9545 541 942 3888 www kwikee com KwikTest Part 909518000 includes 4 way connector NOTE On steps fitted with the rubber four way plug use the four way plug pigtail included with the KwikTest to make the connection between the step control unit and the tester Perform tests in sequence 2 230 Davidson Avenue Cottage Grove OR 97424 541 942 3888 www kwikeepowergear com KwikTest Users Manual 909518000 02 05 Kwikee Products Co Inc Kwikee 1420994 Rev 3 KwikTest Users Manual Part 909518000 Connecting the KwikTest unit to the Step See Figure 1 Page 2 Step 1 Attach the Packard style four way connector from the KwikTest to the four way connector on the step control unit Step 2 Connect the red wire clip to the positive post on the battery Step 3 Attach one of the green wire clips to the negative post of the battery Attach the other green wire clip to the ring terminal on the end of the 12 gauge green ground wire coming from the step control unit KwikTest Set Up For all steps except those with Control Unit 909510000 Step 4A Set the Control Switch to black or white depending on the color of the control unit on the step being tested A Testing Procedures For all steps except those with Control Unit 909510000 Run the foll
73. l rr E em tests in witch A Step Function Light PODO ornm BI TY SESE rests setios m m m Ael oo o o lero Trest2setings m m m FPO oO ojo rest 3 Settings m m m rest 4 Settings mi m m rest Settings m m m Trest6setings m m m Trest7 settngs m m mm Check step response Figure 1 Connecting the KwikTest unit to the Step Understep light not available on all step models Motor __ assembly 12 AWG green ground way connector pigtail a Used only when testing S components fitted with wrest a rubber 4 way plug PRODUCT SERVICE TRAINING MAINTENANCE LUBRICATE WITH KWIKLUBE Ae Silicone lubricants and WD 40 are not recommended as they tend to evaporate and dry the mating surfaces leaving them vulnerable to the elements Clean all mud salt and road grime from the step before lubricating With a good quality moisture and heat resistant penetrating grease lubricate all moving parts including Bearings e Clevis pin Pivot points Drive linkage ball e Slides Refer to diagrams below for lubrication points Please note that diagrams are to be used for general reference only Some may not pertain to your particular step model KwikLube Spray Grease is specially formulated to lubricate Kwikee Electric Steps andis recommended for lubricating all moving parts KwikLube is a unique aerosol grease with hundreds of automotive
74. lacement part numbers it is necessary to know the Step Series Number t is located in the Owners Manual and printed under the top step Door Switches Part Part Description White Black Closed Open 905312000 905323000 Magnetic small rectangular 905314000 905324000 Magnetic 3 4 core round 905306000 905326000 Magnetic large rectangular 905307000 905327000 Magnetic 3 8 core round 905302000 905328000 Plated plunger switch If you can not locate the number measure the step and refer to the dimensioned drawings above Confirm that you are using the correct step series replacement parts guide Used for all color controls manufactured prior to 2 99 Does NOT include black 909506000 909507000 Used for black controls since 2 99 including 909506000 909507000 and 909508000 Rocker Style Power Switch Part Description 905305000 For all fully automatic steps Self Center Rocker Switch Part Description 905316000 For steps NOT equipped with control units KWIKEE PRODUCTS COMPANY INC 230 Davidson Ave Cottage Grove OR 97424 800 736 9961 www kwikee com REV 4_2 05 PAGE Engineered Solutions for RVs 35 SERIES Step Replacement Guide RISE 5 RUN 10 75 Mounting bolt pattern 8 x 22 Motor Assembly Drawing and Parts Key Numbers Part 903500016 24 tread with Motor and Switch Kit 905316000 Part 903506025
75. le STEP SERIES NUMBER To determine correct replacement part numbers it is necessary to know the Step Series Number t is located in the Owners Manual and printed under the top step If you can not locate the number measure the step and refer to the dimensioned drawings above Confirm that you are using the correct step series replacement parts guide KWIKEE PRODUCTS COMPANY INC RISE 8 RUN 16 75 Mounting bolt pattern 6 5 x 22 RV Part 903300016 28 13 tread with Motor and Switch Kit 905316000 RV Part 903306025 28 13 tread with Motor Control Unit and Switch Kit 905325000 VANS Part 903300000 28 13 tread with Motor and no Control Unit VANS Part 903306000 28 13 tread with Motor and Control Unit VANS Part 909315000 Plastic Splash Cover for 30 and 33 Series Steps Motor Assembly Drawing and Parts Key Numbers CHART 1 Replacement Parts Kits for Series Steps 22 23 30 32 33 34 35 36 38 and 40 Parts Description Replacement Key Kit Part 1 Control Unit only n a Step Frame only 908033000 n a Step Light only 909004000 3 Cotter and Clevis pin 1 4 IMGL A Control Replacement Kit 909770000 9095 10000 Control IMGL Integrated Motor Gear Box Linkage A Cotter and Clevis pin Four way pigtail Fasteners Part Part Description White Black Closed Open 905312000 905323000 905314000 905324000 905306000 905326000 905307000 905327000 905302000
76. lubricants and WD 40 are not recommended as they have a tendency to evaporate and dry the mating surfaces which leave them vulnerable to the elements NOTE Figures are to be used for general reference purposes only Some may not pertain to your particular step model 1 Figures 1 and 3 Square shaft bearing lubricate around outside and under head of bearing 2 Figure 4 On step models equipped with plastic cover this cover will have to be removed to lubricate center bearings Lubricate bearings under cover every 90 days 3 Figure 4 Lubricate around the bushing in bushings 4 Maintain clean dry electrical connections at the two way and four way connectors and any butt connections leading from the four connector to the vehicle A small dab of di electric grease at the connections and replacing corroded butt connections with heat shrink type crimp style automotive connectors will help maintain a good electrical source for the step KwikLube is a unique aerosol grease that has hundreds of automotive household and industrial uses in addition to lubricating Kwikee Electric Steps KwikLube sprays on and into places that are hard to reach Then it changes from a penetrating fluid to a tough protective grease in a matter of minutes The cured KwikLube film is impervious to moisture and can withstand temperatures above 400 F 204 C This formulation also contains additives to prevent rust and reduce wear Ask your local
77. ment Guide RISE 7 RUN 8 5 Mounting bolt pattern Call for drawing RV Part 903700016 30 tread with Motor and Switch Kit 905316000 RV Part 903707025 30 tread with Motor Control Unit 909507000 and Switch Kit 905325000 VANS Part 903700000 30 tread with Motor and no Control Unit VANS Part 903707000 30 tread with Motor and Control Unit 909507000 CHART 1 Replacement Parts Kits for Series Steps 22 23 30 32 33 34 35 36 38 and 40 Parts Description Replacement Key Kit Part 1 Control Unit only n a Step Frame only 908039000 n a Step Light only 909004000 3 Cotter and Clevis pin 14 IMGL B Control Replacement Kit 909772000 9095 10000 Control IMGL Integrated Motor Gear Box Linkage A Cotter and Clevis pin Four way pigtail Fasteners Door Switches Part Part Description White Black Closed Open 905312000 905323000 905314000 905324000 905306000 905326000 905307000 905327000 905302000 905328000 Magnetic small rectangular Magnetic 3 4 core round Magnetic large rectangular Magnetic 3 8 core round Plated plunger switch Used for all color controls manufactured prior to 2 99 Does NOT include black 909506000 909507000 Used for black controls since 2 99 including 909506000 909507000 and 909508000 Rocker Style Power Switch Part Description 905305000 For all fully automatic steps Self Center Rocker Switch
78. most common questions about Kwikee electric steps Due to the number of variable conditions you may experience symptoms other than those covered Please feel free to contact the Customer Service Department at 1 800 736 9961 for further information or assistance TROUBLE SHOOTING AND TESTING PROCEDURES Page 8 General Service Notes If the power wire to the step is disconnected from its source and reconnected a spark is common This is caused by the momentary charging of the control unit and does not necessarily indicate the system is staying on which would cause a drain on the battery If battery drain is suspected observe the understep light if so equipped while the step is extending The power switch must be on for the understep light to operate To determine if a control unit is not shutting off remove the four way connector to the chassis and the two way connector between the step motor and the contol unit Place a voltmeter between the red and yellow motor wires at the two way connector from the control unit Reconnect the four way Connector Turn the power switch on If any voltage registers on the meter for more than 5 seconds the control unit is not shutting off and may be defective When doing this test switch the voltmeter leads back and forth between the red and yellow motor wires to be sure no voltage registers If any voltage does register disconnect the four way connector to keep the step motor from
79. n 905305000 For all fully automatic steps Self Center Rocker Switch Part Description 905316000 For steps NOT equipped with control units KWIKEE PRODUCTS COMPANY INC 230 Davidson Ave Cottage Grove OR 97424 800 736 9961 www kwikee com REV 4_2 05 Engineered Solutions for RVs 28 SERIES Step Replacement Guide RISE A RUN 10 Motor Assembly wing and Parts Key Numbe Mounting bolt pattern 6 5 x 22 Part 902800016 23 75 tread with Motor and Switch Kit 905316000 Part 902806025 23 75 tread with Motor Control Unit and Switch Kit 905325000 Extended Profile CHART 1 Replacement Parts Kits for Series Steps ae as 22 23 30 32 33 34 35 36 38 and 40 o Retracted Profile 1 Control Unit only wa Step Frame only 908028000 STEP SERIES NUMBER n a Step Light only 909004000 To determine correct 3 Cotter and Clevis pin replacement part numbers it 1 4 IMGL B Control Replacement Kit 909772000 is necessary to know the Step Motor Geor Bor Lnkoge A Conter ond Series Number It is located in Clevis pin Four way pigtail Fasteners the Owners Manual and printed under the top step L Door Switches Part Part Description If you can not locate the White Black Closed Open number measure the step and 7 s 1905312000 905323000 Magnetic small rectangular refer to the dimensioned 1905314000 905324000 Magnetic 3 4 core round drawings above Confirm that 1905306000 905326000
80. n the pin may have to be pried or driven out of the block The step tread s should now swing freely if not check for a bent step frame or jammed pivot point s Part Box Linkage Assembly Instructions for removing and replacing the IMGL Assembly 1 On Van Steps remove plastic splash cover if so equipped If the step is locked in the retracted up position where the plastic cover cannot be removed the step tread will have to be dissassebled to access the plastic cover To disassemble the tread remove the 8 1 4 20 x 1 long hex head bolts in the tread side rails connecting the tread and the sliding blocks to the side rail This will allow the tread to be dropped out of the way to access the plastic cover Reassemble the tread after removing the cover To remove the IMGL assembly from the step it is easiest if the step is partially or fully extended If possible extend the step with the standard door switch operation NOTE See drawings on Page 2 and 3 for item numbers specified in the following steps 3 Steps using a control Unit Unplug the 4 way connector to the control unit Item 6 Disconnect the wiring between the motor and the control unit Item 7 Steps without a control Unit Cut the wires at the butt connectors approximately 12 from the motor 6 Unbolt the motor assembly from the step frame 7 Install new IMGL assembly on step frame and tighten all mounting bolts 8 Install th
81. nal at the end of the control unit s green ground wire see Figure 17 NOTE Be sure to use the terminal with only the white wire The reading should be a minimum of 12 volts DC If the voltage reading is low there may be a loose or corroded connection at the battery a low charge level on the battery itself or a poor ground If the voltage reading is zero 0 volts check the step fuse circuit breaker all connections and the condition of the wiring between the battery and the plug including the ground connection at the chassis If you have additional questions or need more assistance contact Kwikee s Service Representative at 1 800 736 9961 FIGURE 16 Check ignition FIGURE 17 Check connector override 4 way connector 4 way connector Page 8 Yellow vehicle side vehicle side a Ground wire green ground wire ttf j Kwikee Products Company Inc 230 Davidson Avenue Cottage Grove OR 97424 9545 541 942 3888 www kwikee com Ground wire green ground wire must be attached to vehicle chassis a good ground is needed for proper step operation Voltmeter should read 12 volts DC ignition on 0 volts DC ignition off Page 12 Troubleshooting and Testing Procedures must be attached to vehicle chassis a good ground is needed for proper step operation Voltmeter should read minimum of 12 volts DC Owner s Manual 880 Kwikee Electric Steps PLEASE NOTE At the time of the printing of t
82. nd feature When the vehicle ignition is turned on the step will always activate with the door movement regardless of the override switch position NOTE If the yellow wire from the four way connector is not connected to an ignition power source the ignition will not cause the step to retract if the override swtich is on regardless of the door position STEPS WITHOUT CONTROL UNIT 1 To extend the step push and hold the bottom half of the rocker switch Make sure the step is completely extended and locked in position before releasing the switch WARNING Stepping on a partially extended step can cause damage to the step frame 2 Push and hold the top of the rocker switch to retract the step Be sure the step is completely retracted and locked in position before releasing the switch WARNING Do not hold the switch in for longer than it takes to either extend or retract the step or damage to the motor will result NOTE Always be sure that the step is fully retracted before traveling If the step is left extended and strikes an obstruction while the vehicle is moving major damage to both the step and the vehicle could result NOTE The extend retract function will be reversed if the red and yellow terminal connections are reversed or the step is equipped with a reverse driven motor assembly such as on the 37 and 42 Series steps For Steps with and without Control Unit Operation Page 5 MAINTE
83. nd curcuit breaker required C Normally OPEN magnetic door switch Override disconnect box switch IMPORTANT if the switch is OFF the step will not operate 5 amp maximum fuse or circuit breaker not supplied Test Step Operation Step 18 With the override switch off close the van door and the step should retract Step 19 Open the door and the step should extend Step 20 With the door open turn on the override switch The step should remain extended when the door is closed Step 21 To test the ignition override system with the step extended the door closed and the override switch on turn on the vehicle ignition and start the vehicle The step should retract step automatically retracts do not open the door until the step completely retracts If the door is opened before the step completely retracts and locks in the up position the step will stop moving The step may only be partially extended Stepping on a partically extended step may cause damage to the step frame andlor the motor assembly When the door is closed the step will finish retracting WARNING When the ignition safety system goes into effect and the If the entrace door is opened at any time the step will extend or stay extended Owner s Manual 880 9 02 Kwikee Products Co Inc Kwikee 1422257 Equipped with a Permanent Magnet Motor For steps with Control Units 909506000 909507000 or 909508000 and steps wit
84. ned drawings above Confirm that you are using the correct step series replacement parts guide Used for all color controls manufactured prior to 2 99 Does NOT include black 909506000 909507000 Used for black controls since 2 99 including 909506000 909507000 and 909508000 Rocker Style Power Switch Part Description 905305000 For all fully automatic steps a a zma n Self Center Rocker Switch Part Description 905316000 For steps NOT equipped with control units KWIKEE PRODUCTS COMPANY INC 230 Davidson Ave Cottage Grove OR 97424 800 736 9961 www kwikee com REV 4_2 05 PAGE Retracted Profile STEP SERIES NUMBER To determine correct replacement part numbers it is necessary to know the Step Series Number t is located in the Owners Manual and printed under the top step If you can not locate the number measure the step and refer to the dimensioned drawings above Confirm that you are using the correct step series replacement parts guide 23 SERIES Step Replacement Guide RISE 8 RUN 8 Mounting bolt pattern 9 x 25 25 Part 902300016 24 tread with High torque Motor and Switch Kit 905316000 Part 902308025 24 tread with High torque Motor Control Unit and Switch Kit 905325000 CHART 1 Replacement Parts Kits for Series Steps 22 23 30 32 33 34 35 36 38 and 40 Parts Description Replacement Key Ki
85. ng to determine whether or not the step is malfunctioning The following procedures test the various components of the step until the source of the malfunction is located Using these procedures will shorten and reduce the time spent troubleshooting Some portions of the test procedures require additional equipment This equipment includes a voltmeter a well charged 12 volt DC automotive battery and a 4 way connector pigtail Part 909306000 available from Kwikee Products Company Read the entire procedure prior to testing If you need assistance contact Kwikee s Service Line at 1 800 736 9961 Kwikee 42 Series Step TESTING THE STEP WARNING Keep fingers arms and legs clear of step mechanism while performing these tests 1 Inspect the step for visible damage that might restrict the step s operation 2 Obtain a 4 way pigtail connector part 909306000 from Kwikee 3 Disconnect 4 way connector on underside of step and connect step half of the connector to the four way connector pigtail See Figures 4 and 5 on Pages 8 and 9 4 Seta fully charged 12 volt DC automotive battery beside the step ATTENTION Do not allow the battery terminals to come in contact with step Complete a ground for step testing by connecting 10 gauge wire from the negative battery post to the green ground wire of the control unit WARNING 12 volt automotive batteries contain sulfuric acid which can cause severe burns
86. normal use The cam stops are located under the step top on the 32 36 and 38 Series Steps and on the bottom tread side rail on the 24 25 27 and 40 Series Steps There is one stop on each side of the step CAUTION When 1 Loosen the stops so they move freely working under the step and retract the step be sure that the step cannot be activated and 2 Extend the step fully to its locked extended that nothing can get position see Figure 8 Be sure that the motor caught in the step assembly linkage rests against the gear case as mechanism illustrated in Figure 8 Repeat if needed until the motor assembly locks in the extended position CAUTION Be sure that nothing can get 3 Push the stops against the leg and tighten securely see Figure 9 Be sure that both caught in the step stops are tightened and that they rest securely against the leg 4 Retract and fully extend the step Check the motor assembly to be sure that it is locked all the way out and that both stops are secure against the legs Repeat the above procedures if needed to properly adjust the stops 5 Push on the front edge of the step tread If the step seems loose repeat the above procedures The stops may not be properly adjusted so that they rest tightly against the leg FIGURE 8 Gearbox and motor assembly FIGURE 9 Stop location and assembly 32 34 36 and 38 Series Steps Nylock Gear Stop location and assembly 27 and 40 Ser
87. nversion of older steps with field wound motors to the newer permanent magnet motor system 3 A Returned Goods Authorization RGA number must be obtained before any parts or claims are sent in Call Kwikee s Service Line at 1 800 736 9961 for an RGA number 4 Our warranty does not cover travel time mileage or other incidental costs It is limited solely to the replacement of defective parts under warranty Kwikee 42 Series Step STEP IDENTIFICATION AND FILL OUT AND SAVE WITH VEHICLE RECORDS In the event that servicing the step becomes necessary the information that you supply below will improve service response time The Step Series number Serial number and Control Unit numbers are on the identification labels attached to the control unit and the underside of the REPLACEMENT step near the motor Please take a moment to record this information PARTS INFORMATION Step Serial Step Series Year Make Model of RV Date of Purchase CONTROL UNIT Complete the following only if your step is equipped with Control Unit Control Unit Serial Control Unit This manual has been provided to assist you with the identification operation maintenance and troubleshooting of any Kwikee electric step manufactured after January 2002 that is equipped with a door switch a power switch control unit and a permanent magnet motor It does not apply and should not be used as a reference to any other previous versions of a Kwikee el
88. ny Inc Kwikee shall be the responsibility of the customer Kwikee will pay shipping charges when returning warrantable parts to the customer Kwikee will not accept C O D shipments of any returned goods 3 The warranty is effective as of the date of sale to the original purchaser and extends two years for parts and labor on step mechanisms and one year for step finish Since it is the responsibility of the owner to verify the original purchase date Kwikee recommends that a bill of sale or sales receipt be kept for that purpose 4 The duration of any implied warranty of merchantability or fitness for a particular purpose shall be limited in all respects to the duration of the limited warranty and the warranty described above shall be in lieu of any other express warranty Some states do not allow limitations on how long implied warranties last so the above limitations may not apply to you We neither assume or authorize any other persons to assume any other liability in connection with our products 5 The buyer s sole and exclusive remedy against the seller shall be for the repair or replacement of defective merchandise as provided above No other remedy including but not limited to incidental or consequential damages for lost profits lost sales injury to property or any other incidental or consequential loss shall be available to him Some states do not allow the exclusion or limitation of incidental or consequential damages so
89. od metal to metal contact A good ground is required for 6 With the power and proper step operation ground connections complete all functions of the control unit can be checked at the four wires of the pigtail The brown wire is the door switch the white wire is the override switch and the yellow wire is the ignition override WARNING Keep fingers arms and legs clear of step mechanism while performing these tests db 7 To retract the step touch the brown wire to the negative terminal 8 To extend the step remove the brown wire from the negative terminal 9 To test the ignition override feature extend the step as in Step 8 With the step extended connect the white wire to the positive terminal and attach the brown wire to the negative terminal Next touch the yellow wire to the battery s positive terminal The step should retract Remove the brown wire and the step should extend To test the Auto Extend feature touch the brown wire to the negative terminal to retract the step While holding the brown wire to the negative terminal remove the yellow from the positive terminal Touch the white wire to the positive terminal The step will stay retracted Now remove the brown wire and the step should extend Next touch the brown wire to the negative terminal The step should stay extended Troubleshooting and Testing Procedures Page 9 FIGURE 10
90. om sources other than Kwikee 7 This warranty gives you specific legal rights and you may have other rights which vary from state to state WARRANTY GUIDELINES AND PROCEDURES 1 Replace only those parts that are actually defective Motors gear cases gears linkage assemblies and control units are all replaceable as individual parts If you exchange a complete assembly when only the replacement of an individual part is required the non defective parts will be returned and only the defective part will be credited to you or replaced 2 Do not use conversion kits for warranty repairs Conversion kits are intended for the conversion of older steps with field wound motors to the newer permanent magnet motor system 3 A Returned Goods Authorization RGA number must be obtained before any parts or claims are sent in Call Kwikee s Service Line at 1 800 736 9961 for an RGA number 4 Our warranty does not cover travel time mileage or other incidental costs It is limited solely to the replacement of defective parts under warranty Owner s Manual 888 Kwikee Electric Steps FILL OUT AND SAVE WITH VEHICLE RECORDS STEP In the event that servicing the step becomes necessary the information that you supply below will IDENTIFICATION improve service response time The Step Series number Serial number and Control Unit numbers AND are on the identification labels attached to the control unit and the underside of the step near the REPLACEM
91. on the door closed and the ignition is turned on the ignition override system will engage and the step will automatically retract The Auto Extend feature is another safety feature designed to extend the step when the door is opened for the first time after the vehicle ignition is turned off even if the override switch is turned on When the ignition is switched on the function of the override switch is disabled and the step will always extend when the door is opened and retract when the door is closed Some van steps use door switch only operation When the door is opened the step extends and the step retracts when the door is closed NOTE Follow the instructions in this manual carefully Failure to do so may result in damage to the step control the motor and or the vehicle wiring Such damage may also result in voiding the warranty STEPS WITHOUT CONTROL UNIT This manual has been provided to assist you with the identification operation maintenance and troubleshooting of the Kwikee electric step equipped with a self centering rocker switch This manual does not apply and should not be used as a reference to previous versions of a Kwikee electric step NOTE Follow the instructions in this manual carefully Failure to do so may result in damage to the step the motor and or the vehicle wiring Such damage may also result in voiding the warranty Owner s Manual 888 Kwikee Electric Steps STEPS WITH CONTROL UNIT OPERATI
92. or parts and labor on step mechanisms and one year for step finish Since it is the responsibility of the owner to verify the original purchase date Kwikee recommends that a bill of sale or sales receipt be kept for that purpose 4 The duration of any implied warranty of merchantability or fitness for a particular purpose shall be limited in all respects to the duration of the limited warranty and the warranty described above shall be in lieu of any other express warranty Some states do not allow limitations on how long implied warranties last so the above limitations may not apply to you We neither assume or authorize any other persons to assume any other liability in connection with our products 5 The buyer s sole and exclusive remedy against the seller shall be for the repair or replacement of defective merchandise as provided above No other remedy including but not limited to incidental or consequential damages for lost profits lost sales injury to property or any other incidental or consequential loss shall be available to him Some states do not allow the exclusion or limitation of incidental or consequential damages so the above limitation or exclusion may not apply to you Before using user shall determine the suitability of the product for its intended use and user assumes all risk and liability whatsoever in connection there with 6 Kwikee will not under any circumstances reimburse the cost of warranty parts purchased fr
93. ory but due to the rigors of shipping installation and normal use the stop may fall out of adjustment and need to be tightened WARNING When the A stops are out of adjust ment the step may feel loose when stepped on 1 Loosen the stops so they move freely and retract the step CAUTION When working under the step 2 Extend the step fully to its locked extended be sure that the step position Be sure that the motor assembly linkage cannot be activated and rests against the steel plate as illustrated in Figure 2 j that nothing can get Repeat if needed until the motor assembly locks in caught in the step the extended position mechanism 3 Push the stops against the lower tread and tighten securely Be sure that both stops are tightened and that they rest securely against the lower tread 4 Retract the step Check to be sure that both stops are secure against the top tread see CAUTION Be sure Figure 3 Repeat the above procedures if needed to properly adjust the stops that nothing can get caught in the step FIGURE 3 Secure against top tread Adjust extension Secure against lower tread Owner s Manual Operation Page 5 GENERAL SERVICE NOTES These general service notes and the Step Test Procedures address the most common questions about Kwikee electric steps Due to the number of variable conditions you may experience symptoms other than those covered Please feel free to contac
94. other liability in connection with our products 5 The buyer s sole and exclusive remedy against the seller shall be for the repair or replacement of defective merchandise as provided above No other remedy including but not limited to incidental or consequential damages for lost profits lost sales injury to property or any other incidental or consequential loss shall be available to him Some states do not allow the exclusion or limitation of incidental or consequential damages so the above limitation or exclusion may not apply to you Before using user shall determine the suitability of the product for its intended use and user assumes all risk and liability whatsoever in connection there with 6 Kwikee will not under any circumstances reimburse the cost of warranty parts purchased from sources other than Kwikee Products Company Inc 7 This warranty gives you specific legal rights and you may have other rights which vary from state to state WARRANTY GUIDELINES AND PROCEDURES 1 Replace only those parts that are actually defective Motors gear cases gears linkage assemblies and control units are all replaceable as individual parts If you exchange a complete assembly when only the replacement of an individual part is required the non defective parts will be returned and only the defective part will be credited to you or replaced 2 Do not use conversion kits for warranty repairs Conversion kits are intended for the co
95. owing test a minimum of 6 cycles allowing 3 to 5 seconds between opening and closing the Door Switch to give the control unit internal relays enough time to reset Step Step Function Light STAYS GOES STAYS ON IN OUT OUT At this point the step should remain extended until one of the following occurs a The Door Switch is flipped close and the Power Switch is in the on position or b The Door Switch is flipped close and the Ignition Switch is in the on position NOTES 1 The ignition override will not work until the door is closed 2 For steps fitted with a white control unit the last out feature will be disabled by turning the power switch on and then off between steps 16 and 17 or if the power switch is on when the ignition is turned off and is then turned off before the door is opened These sequences will disable the last out feature and the step will not extend KwikTest Users Manual Troubleshooting If a problem is discovered during the testing procedure follow the troubleshooting guide below to determine the source of the problem Disconnect the motor leads from the control unit Apply 12 volts to the red wire on the motor only and attach the yellow wire to ground This will cause the motor to extend the step Reverse the polarity to retract the step Repeat this function 15 20 times If the step functions properly the motor i
96. pened the step extends and the step retracts when the door is closed NOTE Follow the instructions in this manual carefully Failure to do so may result in damage to the step control the motor and or the vehicle wiring Such damage may also result in voiding the warranty STEPS WITHOUT CONTROL UNIT This manual has been provided to assist you with the identification operation maintenance and troubleshooting of any Kwikee electric step equipped with the self centering rocker switch manufactured after January 2002 It does not apply and should not be used as a reference to any other previous versions of a Kwikee electric step NOTE Follow the instructions in this manual carefully Failure to do so may result in damage to the step the motor and or the vehicle wiring Such damage may also result in voiding the warranty Owner s Manual 880 Kwikee Electric Steps STEPS WITH CONTROL UNIT OPERATION 1 After the installation is complete and with the entrance door open turn the power switch on NOTE Some steps are not equipped with a power switch They are activated only with a door switch 2 Close the door The step should retract and lock in the up position 3 Open the door The step should extend and lock in the down position with the understep light on NOTE The understep light is not available on all step models 4 If your step is equipped with a power switch turn it off The step should remain in the extend
97. ps Van Steps WARRANTY For questions regarding these warranty procedures or technical assistance call 1 800 736 9961 Be sure to visit us online for updates and downloadable documents Go to www kwikee com Page 2 Warranty 1 We warrant that the equipment is free from defects in material and workmanship under normal use and service The provisions of this warranty shall not apply to any equipment that has been subject to misuse negligence alteration accident improper installation such as the welding of the step to the vehicle frame or mounting brackets normal deterioration due to wear or has been repaired outside our place of business in any way as in our reasonable judgement to adversely affect its performance and reliability 2 Our obligation under this warranty is limited to repairing or replacing at our option any product that is returned to our place of business and when in its examination shall disclose to our reasonable satisfaction that it is defective The repair or replacement of the defective parts under this warranty will be made without charge for parts or labor Shipping charges for returning parts to Kwikee shall be the responsibility of the customer Kwikee will pay shipping charges when returning warrantable parts to the customer Kwikee will not accept C O D shipments of any returned goods 3 The warranty is effective as of the date of sale to the original purchaser and extends two years f
98. r reasonable judgement to adversely affect its performance and reliability 2 Our obligation under this warranty is limited to repairing or replacing at our option any product that is returned to our place of business and when in its examination shall disclose to our reasonable satisfaction that it is defective The repair or replacement of the defective parts under this warranty will be made without charge for parts or labor Shipping charges for returning parts to Kwikee Products Company Inc Kwikee shall be the responsibility of the customer Kwikee will pay shipping charges when returning warrantable parts to the customer Kwikee will not accept C O D shipments of any returned goods 3 The warranty is effective as of the date of sale to the original purchaser and extends two years for parts and labor on step mechanisms and one year for step finish Since it is the responsibility of the owner to verify the original purchase date Kwikee recommends that a bill of sale or sales receipt be kept for that purpose 4 The duration of any implied warranty of merchantability or fitness for a particular purpose shall be limited in all respects to the duration of the limited warranty and the warranty described above shall be in lieu of any other express warranty Some states do not allow limitations on how long implied warranties last so the above limitations may not apply to you We neither assume or authorize any other persons to assume any
99. rease that has hundreds of automotive household and industrial uses in addition to lubricating Kwikee Electric Steps KwikLube sprays on and into places that are hard to reach Then it changes from a penetrating fluid to a tough protective grease in a matter of minutes The cured KwikLube film is impervious to moisture and can withstand temperatures above 400 F 204 C This formulation also contains additives to prevent rust and reduce wear Ask your local RV Dealer for KwikLube MAINTENANCE IN SALT ENVIRONMENT To maintain step finish when step is exposed to a salt environment for extended periods of time routinely spray step with fresh water Page 6 Maintenance Owner s Manual 888 Kwikee Electric Steps ADJUSTING THE CAM STOPS 24 25 27 32 34 35 36 38 and 40 Series Steps WARNING When the cam stops are out of adjustment the step may feel loose or mushy when stepped on If the cam stops are not properly adjusted the step may not extend fully to the locked out position Using a step with loose or out of adjustment cam stops may cause damage to the motor assembly and or the drive linkage Kwikee steps are fitted with adjustable cam stops on the step frame that help lock the step in the out position creating a firm stepping platform The cam is adjusted at the factory but may fall out of adjustment and need to be tightened due to the rigors of shipping installation and
100. riginal purchaser that its products are free from defects in material and workmanship from the date of purchase for the periods of time listed in the chart below See RV manufacturer s warranty for specific details on product warranty for individual applications Kwikee s obligation under this warranty is limited to the repair or replacement of defective parts returned to Kwikee s factory See individual Warranty Procedures for each product Kwikee will pay for the labor required to repair or replace its products on claims submitted within the time period listed in the chart below from the date of purchase by original purchaser See RV manufacturer s warranty for specific details on product warranty for individual applications The warranty on repaired or replaced parts shall be limited to the unexpired duration of the original warranty This warranty does not apply to products or parts that in Kwikee s opinion have been subject to abuse accident alteration improper installation repair inadequate maintenance or deterioration due to normal wear Level Best System warranty does not apply to electrical wiring or hydraulic hoses Cargo slide and utility tray warranty does not apply to base plywood or carpet or other material used to cover base in installation Purchaser shall pay all shipping or other transportation charges for any warranty claim Kwikee makes no warranty and disclaims any implied warranty regarding the merchantability fitness for a
101. rned on Motor 4 assembly 6 amp maximum fuse or connector circuit breaker required x f 16 AWG brown EN 16 AWG yellow ESEA l 12 AWG red EN i ay ell 16 AWG white Vehicle Wiring avan Chassis ground 20 amp fuse or p curcuit breaker required S i Chassis Normally OPEN Power ground 1a mE magnetic door switch switch Ka 4 disconnect box switch IMPORTANT If the switch is OFF the step will not operate 5 amp maximum fuse or circuit breaker not supplied 9 To test the Ignition Override feature extend the step as in Step 7 With the step extended disconnect the white wire from the battery and attach the brown wire to the battery s negative terminal Next touch the yellow wire to the battery s positive terminal The step should retract Remove the brown wire and the step should extend 10 To test the Last Out feature touch the brown wire to the negative terminal to retract the step While holding the brown wire to the negative terminal remove the yellow from the positive terminal The Step will stay retracted Now remove the brown wire The step should extend 11 Ifany of the step functions do not work the source of the malfunction is either in the control unit and or the motor Proceed to the Testing the Motor section on Page 9 If all of the step functions do work the malfunction is either in the door switch power switch or the vehicle wiring Proceed to Testing t
102. s fine Examine the step frame Check to see if there is any binding or obstruction impeding the movement of the step To thoroughly check the frame you must disconnect the drive linkage from the frame by removing the cotter pin and clevis pin from the end of the linkage Removing the pins is easier if the step is not fully extended To stop the step midway out simply apply enough pressure with your hand to the leading edge of the step to stop its motion The control will sense the load and stop the step Disconnect power to the step either at the battery or by disconnecting the four way connector between the step control unit and the coach wiring harness Once the pins have been removed manually push and pull the step in and out The frame will need to be free from binding or stiffness in both directions If the motor and frame check out the source of the problem may be in the coach wiring including the door switch low voltage fuses etc If there are any questions please call Awikee Customer Service at 1 800 736 9961 Page 2 B KwikTest Set Up For all steps with Control Unit 909510000 Step 4B Set the Control Switch to black B Testing Procedures For all steps with Control Unit 909510000 Run the following test a minimum of 6 cycles allowing 3 to 5 seconds between opening and closing the Door Switch to give the control unit internal relays enough time to reset For steps with 909510000 Contro
103. side and securing it with the face plate and nut Step 10 Run the yellow wire to the vehicle fuse block and cut to length Cut the orange wire on the 5 amp fuse holder at the halfway point on the loop Crimp a 1 4 male push on terminal to one lead of the fuse holder Connect the other lead to the yellow wire with a blue butt connector Wrap this connection with electrical tape Connect the wire to the vehicle s fuse block at the terminal marked IGN ignitition or to another temrinal that is hot only when the ignition is turned on WARNING Do not connect the yellow wire to the curcuit connected to the vehicle s computer or damage to the computer or the step control unit may result Wiring Instructions 7543 Step 11 Under the hood run the other end white 16 ga wire from the override switch to the battery location Cut both the white and red wires to length Step 12 Cut the orange wire on the remaining 5 amp fuse holder at the midway point of the loop Crimp a blue 5 16 ring terminal to one lead of the fuse holder Connect the other lead to the white wire with a blue butt connector Wrap this connection with electrical tape Step 13 Cut the wire loop on the 20 amp fuse holder at the midway point of the loop Crimp a yellow 5 16 ring terminal to one lead to the red wire from the wiring harness with a yellow butt connector Wrap this connection with electrical tape Step 14 Connect the red and white wires to the positive
104. t operate Page 10 Troubleshooting and Testing Procedures Owner s Manual 888 Kwikee Electric Steps TESTING THE MOTOR 11 Disconnect the two way connector between the step motor and the control unit Connect the motor s red wire to the positive terminal of the battery and touch the motor s yellow wire to the negative terminal of the battery to extend the step To retract the step reverse the connections If the step extends and retracts during this test the condition of the step motor is good WARNING Do not leave the wires connected during this test once the step has cycled 1N either in or out Failure to remove the wires from the battery will burn out the motor voiding any warranty NOTE On steps with reverse polarity plug part number 1800711 reverse the red and yellow wire connections to perform the previous test TESTING THE 4 WAY CONNECTOR 12 To check the main power source connect a voltmeter between the red wire from the 4 way connector vehicle half and the ground terminal at the end of the control unit s green ground wire see Figure 13 The reading should be a minimum of 12 volts DC If the voltage reading is low there may be a loose or corroded connection at the battery a low charge level on the battery itself or a poor ground If the voltage reading is zero 0 volts check the step fuse circuit breaker all connections and the condition of the wiring be
105. t Part 1 Control Unit only n a Step Frame only 908023000 n a Step Light only 909004000 3 Cotter and Clevis pin 14 IMGL A Control Replacement Kit 909770000 9095 10000 Control IMGL integrated Motor Gear Box Linkage A Cotter and Clevis pin Four way pigtail Fasteners Part Part Description White Black Closed Open 905312000 905323000 Magnetic small rectangular 905314000 905324000 Magnetic 3 4 core round 905306000 905326000 Magnetic large rectangular 905307000 905327000 Magnetic 3 8 core round 905302000 905328000 Plated plunger switch Used for all color controls manufactured prior to 2 99 Does NOT include black 909506000 909507000 Used for black controls since 2 99 including 909506000 909507000 and 909508000 Rocker Style Power Switch Part Description 905305000 For all fully automatic steps Self Center Rocker Switch Part Description 905316000 For steps NOT equipped with control units Engineered Solutions for RVs KWIKEE PRODUCTS COMPANY INC 230 Davidson Ave Cottage Grove OR 97424 800 736 9961 www kwikee com REV 4_2 05 PRODUCT SERVICE TRAINING 26 SERIES Step Replacement Guide RISE 5 RUN 8 5 Mounting bolt pattern 7 5 x 20 5 Motor Assembly Drawing and Parts Key Numb Part 902600016 23 5 tread with Motor and Switch Kit 905316000 Part 902606025 23 5 tread with Motor Control Uni
106. t and Switch Kit 905325000 P83 FT 1375 0 Extended Profile CHART 1 Replacement Parts Kits for Series Steps 22 23 30 32 33 34 35 36 38 and 40 Parts Description Replacement KtPans 684 1375 Retracted Profile 1 Control Unit only n a Step Frame only 908026000 n a Step Light only 909004000 STEP SERIES NUMBER To determine correct replacement part numbers it is necessary to know the Step Series Number It is located in the Owners Manual and printed under the top step 3 Cotter and Clevis pin 14 IMGL C Control Replacement Kit 909774000 9095 10000 Control IMGL Integrated Motor Gear Box Linkage A Cotter and Clevis pin Four way pigtail Fasteners Door Switches Part Part Description White Black Closed Open 905312000 905323000 Magnetic small rectangular 905314000 905324000 Magnetic 3 4 core round 1905306000 905326000 Magnetic large rectangular 905307000 905327000 Magnetic 3 8 core round 905302000 905328000 Plated plunger switch If you can not locate the number measure the step and refer to the dimensioned drawings above Confirm that you are using the correct step series replacement parts i Used for all color controls manufactured prior to 2 99 guide Does NOT include black 909506000 909507000 Used for black controls since 2 99 including 909506000 909507000 and 909508000 Rocker Style Power Switch Part Descriptio
107. t the Customer Service Department at 1 800 736 9961 for further information or assistance TROUBLE SHOOTING AND TESTING PROCEDURES Page 6 Maintenance If the power wire to the step is disconnected from its source and reconnected a spark is common This is caused by the momentary charging of the control unit and does not necessarily indicate the system is staying on which would cause a drain on the battery If battery drain is suspected observe the understep light if so equipped while the step is extending The power switch must be on for the understep light to operate To determine if a control unit is not shutting off remove the four way connector to the chassis and the two way connector between the step motor and the contol unit Place a voltmeter between the red and yellow motor wires at the two way connector from the control unit Reconnect the four way Connector Turn the power switch on If any voltage registers on the meter for more than 5 seconds the control unit is not shutting off and may be defective When doing this test switch the voltmeter leads back and forth between the red and yellow motor wires to be sure no voltage registers If any voltage does register disconnect the four way connector to keep the step motor from overheating If zero voltage is present the control unit has shut off and is normal If the step does not work or operates erratically such as extending part way and shutting off the first it
108. t the leg 4 Retract and fully extend the step Check the motor assembly to be sure that it is locked all the way out and that both stops are secure against the legs Repeat the above procedures if needed to properly adjust the stops 5 Push on the front edge of the step tread If the step seems loose repeat the above procedures The stops may not be properly adjusted so that they rest tightly against the leg FIGURE 8 This view shows motor removed and parts exploded for clarity only These parts need not be disassembled to adjust cam stops Stop location Linkage g 5 and assembly 27 and 40 Series Steps These surfaces must be in contact for the step to be fully extended For Steps with and without Control Unit Extend the step fully to its locked extended WARNING When the cam stops are out of adjustment the step may feel loose or mushy when stepped on If the cam stops are not properly adjusted the step may not extend fully to the locked out position Using a step with loose or out of adjustment cam stops may cause damage to the motor assembly and or the drive linkage CAUTION Be sure that nothing can get caught in the step FIGURE 9 Stop location and assembly 32 34 36 and 38 Series Steps Push securely againt leg Push securely againt leg Maintenance Page 7 GENERAL SERVICE NOTES These general service notes and the Step Test Procedures address the
109. t www kwikee com You may want to regularly check our website documentation section Here you will find the most recent versions of all of our documentation You can view these documents online or print them out to keep your binder up to date emanon 3 04 Kwikee Products mE 1422259 We are also available to help you by phone Kwikee Customer Service Department 1 800 736 9961 Weekdays 7 00 am to 4 00 pm PST Engineered Solutions for RVs Currently Kwikee makes 19 different styles of electric steps 10 with S single treads 5 with double treads and 4 with triple treads Each TE PS style is identified by a Series number Single Tread Step Series Series 26 aw Rise 5 Run 8 5 Bolt pattern 7 5 x 20 5 Retracted Profile Series 28 pean mg 16 31 Rise 7 Run 10 Bolt pattern 6 5 x 22 Retracted Profile Series 30 EETA Pi Rise 7 5 Run 16 75 Bolt pattern 6 x 31 Retracted Profile p 22 63 Series 31 2 19 m 14 63 r i 1213 33 Rise 7 Run 10 5 i CEEE a Shon as Bolt pattern 7 4 x 14 5 Rii Extended Profile Retracted Profile Series 33 16 75 9 25 Rise 8 Run 16 75 Bolt pattern 6 x 23 5 Extended Profile Retracted Profile Series 35 Rise 5 Run 10 75 Bolt pattern 8 x 22 Extended Profile Retracted Profile Series 36 213 11 38 Rise 5 Run 10 75 lt pa 9 38 Vi Je 41 Bolt pattern 8 x 26 j 5 88 10 75
110. tery a low charge level on the battery itself or a poor ground If the voltage reading is zero 0 Owner s Manual Troubleshooting and Testing Procedures Page 9 volts check the step fuse circuit breaker all connections and the condition of the wiring between the battery and the plug including the ground connection at the chassis 2 To check the power switch connect a voltmeter between the white wire from the 4 way connector vehicle half and the terminal at the end of the control unit s green ground wire see Figure 7 The reading should be a minimum of 12 volts DC the same as in Step 1 when the switch is on and zero 0 volts DC when the switch is off WARNING Do not leave the wires connected during this test once the step has cycled either in or out Failure to remove the wires from the battery will burn out the motor voiding any warranty If the voltmeter reads zero 0 volts when the power switch is on there is a problem in the power switch circuit Check the 6 amp in line fuse the power switch itself and the condition of the circuit s wiring and terminal connections 3 To check the door switch connect a voltmeter between the red wire from the 4 way connector vehicle half and the brown in the same connector see Figure 8 on Page 11 The voltage should be a minimum of 12 volts DC the same as in Step 1 when the door is closed and zero 0 volts when the door is open If the
111. top so the p motor assembly will sit level This is 1 4 Shim drili important for proper step operation see NOTE C see NOTE A NOTE C If the step was originally Fender installed flush against the step well a 1 4 i washer i thick shim may be needed not provided PRP so the motor assembly mounting bolt St a shid heads will clear the mounting surface erp 1 4 20 x 1 hex bolt 2 www kwikeepowergear com a 230 Davidson Avenue Cottage Grove Oregon 97424 9545 541 942 3888 PRODUCT SERVICE TRAINING 31 PAGE STEP OWNERS MANUALS 888 Owners Manual For all Kwikee Electric Steps equipped with the 9095100000 Control Unit these steps began shipping in October 2004 880 Owners Manual For Kwikee Electric Steps except the 42 Series equipped with any control other than the 9095100000 842 Owners Manual For 42 Series Electric Steps equipped with a Permanent Magnet Motor Owner s Manual 888 9 04 Kwikee Products Co Inc Kwikee 1422279 Rev 1 Electric Steps Equipped with a Permanent Magnet Motor For steps with Control Units 909510000 and steps without Control Units Table of Contents Warranty Information Identification Information 2 3 4 Introduction 5 Operating the Step 6 Maintenance Lubrication Cam Stop Adjustment 8 General Service Notes 9 Troubleshooting and Testing Procedures Single Steps Double Steps Triple Ste
112. tween the battery and the plug including the ground connection at the chassis 13 To check the override switch connect a voltmeter between the white wire from the 4 way connector vehicle half and the terminal at the end of the control unit s green ground wire see Figure 14 The reading should be a minimum of 12 volts DC the same as in Step 12 when the switch is on and zero 0 volts DC when the switch is off If the voltmeter reads zero 0 volts when the override switch is on there is a problem in the power switch circuit Check the 6 amp in line fuse the override switch itself and the condition of the circuit s wiring and terminal connections 14 To check the door switch connect a voltmeter between the red wire from the 4 way connector vehicle half and the brown in the same connector see Figure 15 The voltage should be a minimum of 12 volts DC the same as in step 12 when the door is closed and zero 0 volts when the door is open If the readings are incorrect there is a problem with the switch Check the door switch and the condition of the circuit s wiring and terminal connections FIGURE 13 Main power source FIGURE 14 Override switch FIGURE 15 Door switch 4 way connector 4 way connector i i vehicle side 4 way connector vehicle side Red vehicle side nd wire green ground wire must be attached to vehicle must be attached to vehicle id chassis a good ground is needed chassis a good groun
113. use conversion kits for warranty repairs Conversion kits are intended for the conversion of older out of warranty steps with field wound motors to the newer permanent magnet motor system If an entire conversion kit is used to repair a step under warranty labor will only be credited for repair time associated with the defective part The purchase of conversion kits for warranty work will only cost you money 3 An RMA Returned Materials Authorization number must be obtained before any parts or claims are sent in Call Kwikee s Service Line at 1 800 736 9961 for an RMA number Claims or parts sent in without this number attached will not be processed risk the chance of being lost and will only delay the processing of your claim 4 Unless prior authorization is given by Kwikee reimbursement of labor claims will be limited to the periods of time authorized as listed in the table below DEFECTIVE PART DIAGNOSTIC TIME REPAIR TIME TOTAL TIME Control Unit Only 0 3 hours 0 3 hours 0 6 hours Motor 0 2 hours 0 4 hours 0 6 hours Linkage 0 0 3 hours 0 3 hours Gear Gear Case 0 3 hours 0 5 hours 0 8 hours Door Switch 0 3 hours 0 2 hours 0 5 hours Frame Only 0 2 hours 0 8 hours 1 0 hours 5 Our warranty does not cover travel time mileage or other incidental costs It is limited solely to the replacement of defective parts under warranty and the flat rate labor schedule listed above 6 Do not cut any wires on control units

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