Kwikee 22 Series User manual

Single Steps Double Steps Triple Steps Van Steps
Owner's
Manual
#888
© 3/11 Kwikee #1422279 Rev. 0G
Electric Steps
Equipped with a Permanent Magnet Motor
(For steps with Control Units 909510000 and steps without Control Units)
2Identification Information
3 Introduction
4Operation
5-6 Maintenance:
• Lubrication
•Cam Stop Adjustment
7General Service Notes
7-11 Troubleshooting and
Testing Procedures
12 Warranty
Table of Contents

Identication Information
Electric Steps #888 Page 2
Motor Assembly Drawing and Parts Key Numbers
CHART 1
Replacement Parts Kits for Series Steps
22,23, 28A*,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 #
________________________________________________________________
5 Gear/Linkage 'C' Straight 1101427
Replacement Parts Kits for
Series Steps 24 and 25
As shown in CHART 1 except for the following:
Parts Description Replacement
Key # Kit Part #
________________________________________________________________
6 Link/Assembly 24/25 3380050
________________________________________________________________
7 Motor Table 24/25 3392152
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 Replacement Part #
For all fully automatic steps 905305000
SELF-CENTER ROCKER SWTICH
Description Replacement Part #
Steps NOT equipped with control unit 905316000
CONTROL
Description Replacement Part #
Control with step lockout 909510000
Replacement part numbers for steps equipped with older style motor/gear box
are available online at: www.kwikee.com See 'Downloadable Documents'
STEP
IDENTIFICATION
AND
REPLACEMENT
PARTS
INFORMATION
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 step, near the
motor. Please take a moment to record this information:
CONTROL UNIT Complete the following only if your step is equipped with Control Unit.
Step Serial #
Year / Make / Model of RV
Date of Purchase
Step Series #
Control Unit Serial # Control Unit #
To determine replacement parts,refer to the chart for your Series Step.
1
2
3
4
5
6
7

Electric Steps #888 Page 3
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 for use with
a step lockout 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 the 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 (step lockout switch is in
the ‘off’ position), 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 step lockout switch is turned off. When the ignition is switched on, the
function of the step lockout 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.
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 control, the motor and/or the
vehicle wiring. Such damage may also result in voiding the
warranty
• An important change covered in this owner’s manual is the “Override Switch” (previously called the
“Power Switch”). The name changed because of a change of functionality from the former “Power Switch”.
• 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 (OVERRIDE SWITCH 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.
Please note that is a change from the “Power Switch”, which needed to be in the “OFF” position to
lock the step out.
WARNING

!
Step control wiring is only to
be used for step and step light
(provided with the step)
functions. Do not splice, cut
or tap into any of the step
wiring. Failure to heed this
warning may result in voiding
the warranty and/or failure of
step control, which may result
in loss of step function or fire
in the step control. Refer any
questions to the step manu-
facturer.
CAUTION

!
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.
NOTICE

!

Electric Steps #888 Page 4
Operation
STEP WITH CONTROL UNIT
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 operation is as follows:
● The light is ‘on’ when the step is extended
● The light is ‘off’ when the step is retracted
● In the event the coach door / screen door is left open, the light
will turn ‘off’ after 5 minutes
● The understep light is not available on all step models
4. If your step is equipped with an 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 step 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.
NOTE: If the yellow wire from the four-way connector is not connected to
an ignition power source, the ignition safety system will be inop
erative and the step will remain in the extended position. In this
case, the step override 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 ‘Auto Extend’ feature. When the vehicle ignition
is turned on, the step will always activate with the door movement, regardless of
the step 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 step override switch 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.
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
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).
CAUTION

!
If the vehicle is driven with
the step in the extended
position, there is the possi-
bility of causing major
damage to both the step and
the vehicle.
Stepping on a partially
extended step can cause
damage to the step frame.
Wait until the step is fully
extended before stepping
on it.
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.
CAUTION

!
CAUTION

!
CAUTION

!
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.

Electric Steps #888 Page 5
Maintenance
FIGURE 1
FIGURE 2
FIGURE 3
FIGURE 4
FIGURE 5
FIGURE 6
FIGURE 7
LUBRICATION
Clean all mud, salt, and road grime from the step before lubricating. Lubricate all
moving 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 on the left
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 the 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 connec
tors 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
MAINTENANCE IN SALT ENVIRONMENT
To maintain step finish when step is exposed to a salt environment for extended
periods of time, routinely spray with fresh water
KwikLube
TM
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 RV Dealer for KwikLube

Electric Steps #888 Page 6
FIGURE 9: Stop location and assembly
Push securely
against leg
Push securely
against leg
FIGURE 8: Gearbox and motor assembly.
Linkage
Gear
Case
These surfaces
must be in contact
for the step to be
fully extended.
Nylock
Nut
Tread side rail
Step top
Maintenance -Cont-
ADJUSTING THE CAM STOPS
24, 25, 27, 28A*, 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. 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 normal use
The cam stops are located under the step top on the 28A*, 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
1. Loosen the stops so they move freely and retract the step
2. Extend the step fully to its locked extended position (See FIG 8). Be sure that
the motor assembly linkage rests against the gear case as illustrated in FIGURE
8. Repeat if needed until the motor assembly locks in the extended position
3. Push the stops against the leg and tighten securely (See FIG 9). 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 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
*28A is Step Part Number 902829XXX
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

!
When working under the
step, be sure that the step
cannot be activated and that
nothing can get caught in the
step mechanism
CAUTION

!
Keep hands, feet, and
clothing away from the step
when extending and retract-
ing. Failure to do so may
result in personal injury.

Electric Steps #888 Page 7
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 step lockout
switch to the ‘on’ 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 between 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 or 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 opera-
tion
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 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 all wires meet the
minimum requirements specified in Figures 10, 11, and 12 on page 9
The step test procedures on page 8 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 12V DC automotive battery
- 4-way connector/pigtail (Part #909306000, available from Kwikee)
Read the entire procedure prior to testing.
Troubleshooting and Testing Procedures
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.

Electric Steps #888 Page 8
Troubleshooting and Testing Procedures, Cont
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. Diconnect 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
Page 9
4. Set a fully charged 12V DC automotive battery beside the step.
NOTE: 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 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
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 step lockout switch, and the yellow wire is the
ignition override
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
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 10.
If all of the step functions do work, the malfunction is either in the door switch, step
lockout switch, or the vehicle wiring. Proceed to “Testing the 4-way Connector”
section on Page 10.
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.
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
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
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 explo-
sive; keep cigarettes, open
flames, and sparks away from
the battery at all times
WARNING

!
Keep fingers, arms, and legs
clear of step mechanism while
performing these test. Failure
to do so may result in
personal injury
CAUTION

!
Do not allow the battery
terminals to come in
contact with the step.

Electric Steps #888 Page 9
Vehicle Wiring
Motor
assembly
Understep light
(not available on
all step models)
12 AWG green
ground to step top
Control unit
(black)
Four-way
connector
16 AWG brown
16 AWG yellow
12 AWG red
16 AWG white
Step Lockout
switch
Chassis ground
Normally OPEN
magnetic door switch
20-25 amp fuse or
curcuit breaker required
Battery
disconnect
box/switch
IMPORTANT:
If the switch is
'OFF' the step
will not
operate.
Chassis
ground
12 volt DC
battery
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 turned on.
Two-way
connector
12 AWG green ground wire
must be securely attached to
the chassis for step to operate
16 AWG purple
optional step light switch
may be connected to porch
light switch (see Inset 10A)
5-6 amp maximum fuse or
circuit breaker required
5-6 amp maximum fuse or
circuit breaker (not supplied)
Step Wiring
FIGURE 10: Wiring diagram for step with control unit
Vehicle Wiring
Step Wiring
Four-way
connector
16 AWG brown
12 AWG red
Chassis ground
Normally OPEN
magnetic door switch
20-25 amp fuse or
curcuit breaker required
Battery
disconnect
box/switch
IMPORTANT:
If the switch is
'OFF' the step
will not
operate.
Chassis
ground
12 volt DC
battery
16 AWG purple
optional step light switch
may be connected to porch
light switch (see Inset 10A)
Motor
assembly
Understep light
(not available on
all step models)
12 AWG green
ground to step top
Control unit
(black)
Two-way
connector
12 AWG green ground wire
must be securely attached to
the chassis for step to operate
FIGURE 11: Wiring diagram for steps with door switch only operation
FIGURE 12: Wiring diagram for
steps without control unit
12 volt DC
battery
Rocker
Switch
16 gauge red
16 gauge yellow
10 gauge to
chassis ground
25 amp
in-line
fuse
Automotive connectors
(not supplied)
10 gauge
minimum
Motor
assembly
Two-way
connector
INSET 10A: Wiring step light to porch light
switch: Understep light can be wired directly to the
RV porch light switch. If you choose to do this, a
5 amp maximum fuse or circuit breaker is required
and can be installed in either of two locations as
shown in the wiring diagram below.
Battery disconnect
box/switch
IMPORTANT: If the
switch is 'OFF' the
light will not operate.
Porch light switch Step Light
Control Unit
Butt connector
Porch light
To Battery
Purple wire
from Control Unit
Alternate
fuse location
Fuse location
1 amp max
or circuit breaker required
(not supplied)
Step control wiring is only to
be used for step and step
light (provided with the step)
functions. Do not splice or
tap into any of the step
wiring. Failure to heed this
warning may result in failure
of step control, which may
result in loss of step function
or fire in the step control.
Refer any questions to the
step manufacturer
WARNING

!

Electric Steps #888 Page 10
Troubleshooting and Testing Procedures, Cont
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 reverse polarity plug (Part #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 between the battery and the plug, including the ground
connection at the chassis
13. To check the step lockout 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 step lockout switch is on, there is a
problem in the step lockout switch circuit
Check the 6 amp in-line fuse, the step lockout 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
Red
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
Red
Brown
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
CAUTION

!
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
FIGURE 13: Main power
source
White
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 / step
lockout 'on'
0 volts DC / step
lockout 'off'
FIGURE 14: Step lockout
switch
FIGURE 15: Door Switch
12