Lippert Components COACH STEP Setup guide

LIPPERTCOMPONENTS,INC.
COACH STEP
INSTALLATION, OPERATION AND SERVICE MANUAL
AUTOMATIC ELECTRIC STEPS AND AUTOMATIC ELECTRIC SLIDING STEPS
FOR RECREATIONAL VEHICLES
INSTALLATIONPREP
WARNING!
Keepclearofstepsastheyaredeployed. Stepactuationtakesapproximatelytwosecondswhetherextendingorretracting.
Keephands and fingers away from step mechanism during actuation process to prevent serious bodily injury.
TESTPROCEDUREPRIORTO INSTALLATION
1. Stepswillinstalleasierwhenextended first. Placestepsupsidedownonworkbenchorfloor.
2. Cutandconnectfour(4)jumperwirestothe4-pinconnector. Matchthejumperwirestothepostsonthe connector color for color.
3. ConnectGREENWIREtotheNEGATIVE postofafullycharged,12Vautomotivebattery.
4. ConnectREDandWHITEWIRES to thePOSITIVEpostofthebattery.
5. ConnecttheBROWNWIREto theNEGATIVEpostofthebattery.
WARNING!
Stepswillextend immediately!
6. Disconnectjumperwiresfromthe battery.
INSTALLATION
Stepsmustbeinstalledusingfour(4)5/16”,GR8 bolts, lock washer andnutsfortheAutomaticElctricStepsand3/8”bolts,lockwashersand
nutsfortheAutomaticElectricSlideingStep. Retractstepsbyattachingwiresinthefollowingsequence:
1. GroundtheGREENWIREtothechassis.
2. Touchthe RED andWHITEwirestothepositiveterminalonthe battery.
WARNING!
Keepclearofthesteps as they willretractquickly.
Proceedtoinstalldoorswitchandpowerswitch(items not included). Thewiresofthefourpinconnectormustberoutedasfollows:
1. WHITE-Connecttopowerswitch(16ga.min.wire).
2. YELLOW-Mustbeconnectedtopowersourcethatisonlyhotwhenignitionis“ON.” Protectwith6Afuseorbreaker (16 ga. min. wire).
3. RED-Connectopowerformotor. Protectwith25Afuse(10ga.min.wire).
4. BROWN-Connecttodoorswitch(16 ga. min. wire).
3
2
1
4
Fig. 1

+ -
DOOR SWITCH
BATTERY
POWER
SWITCH
TO FUSE
PANEL
6A FUSE 6A FUSE
CIRCUIT
PROTECTOR
BROWN
YELLOW
WHITE
RED
GREEN-
GROUND TO
CHASSIS
OPERATION
WARNING!
Look downwards toward the steps prior to exiting the coach. It is possible to lock the steps in the retracted position.
Priortoexitingthecoach,passengersmustbesurestepsarefullydeployed.
STEPOPERATION - POWER “ON”
1. TurnPowerSwitchto“ON”position.
2. Opendoor.
3. Stepswillextendandlockwheninthefullyextendedposition.
4. Amberentrylampwill illuminateautomatically.
5. Closedoor.
6. Entrylightwillshutoffand steps will retract.
INSTALLATION - DOOR SWITCH
LippertComponents,Inc.(LCI)recommendsthe use oftheLCIsuppliedswitch. However,ifanotherswitchisto beused,itmustbeaswitchheld
openinthepresenceofamagnet andshouldhaveatriggeringdistanceofnomorethan one inch.
Stepsaredesignedtoextend whenthedoorswitchcloses(magnetis removed)andtheswitchcompletestheground.
TheDoorSwitchisideallyinstalled6inchesabovethe floor on the hingesideofthedoorframe. Themagnetwillbeinstalledonthedoor
immediatelyopposite. Thedistancebetweenthemagnetandtheswitchshouldbedeterminedbytrialunitthestepsbegintoextendwhenthedoor
isopenaround6inches.
Wiresarebestinstalledoutofsightandawayfrom sharp objects and potentialsnags. Itisveryimportantthatagoodgroundissuppliedinan
areanotlikelytocorrode,asthiscan contribute to stepfailure.
NOTE: InstallationoftheDoorSwitchisacriticalelementintheinstallationofthestep. The switch must be installed so that any flexingofthe
doorframedoesnot causethesteptoextend. Conversely,theswitchmusttripearlyenoughsowhenthedoorisopened,thestepsextendpriorto
thepassengerexitingthecoach. Thestepsshouldbeginextendingprior to the dooropening6inches.
Fig. 2
STEP LIGHT
SWITCH

WARNING!
With Power Switch “ON,” door open and steps extended, it is possible to drive off. Damage to steps or vehicle is possible, as well
asseriouspersonalbodilyinjuryordeath.
STEPOPERATION - POWER “OFF”
1. Withdooropen,stepsextendedandPowerSwitchturned“OFF,”stepsremainextended; amberlightshutsoff.
2. Ifthestepsaretoberetractedwiththedooropen,turnthe power switch ON, retract thestepsandturnpowerswitchOFF. Thestepswill
remainretracted.
3. Withdoorclosed,stepsextendedandPowerSwitch“OFF,”turningtheignition“ON”willautomaticallyretractsteps.
4. Whendoorisopened andignition turnedoff,stepswill extend onelasttime- lastmanoutfeature.
5. Ifdoorisopenedandclosedwithoutfull extension ofthesteps,thestepswillretractandstayuntilPower Switch is turned “ON” anddoor
reopened.
NOTE: Ifstep’sfullextensionisimpededbyan external object likeacurb,stepswillceaseoperation and shutdown. Stepswillretractnormally.
TROUBLESHOOTING
WARNING!
Steps must always be operated with a fully chargedbattery. Because the stepscandetectobstaclesin the way of operation by
sensingexcessiveamperage,afullychargedbatteryisimperative. Anydropinvoltagewillcausethestepstomalfunction.
WARNING!
With Power Switch “ON,” door open and steps extended, it is possible to drive off. Damage to steps or vehicle is possible, as well
asseriouspersonalbodilyinjuryordeath.
WARNING!
Due to the fact that the step detects obstacles by sensing excessive current draw, it is imperative that the step be tested with a fully
charged battery and test wires be at least 12 GA. Do not attempt to test the steps using a battery charger or bench type power
supply. Even though they may supply a full 12VDC, a momentary drop in the supply may fool the module into thinking that the
steps have encountered an obstacle.If using a battery to test the steps, care should be taken to connect jumpers to the battery
first and then to the steps. Battery acid can cause injury and automotive type batteries under load can produce hydrogen gas.
They may explode if shorted out or if a spark ignites the hydrogen gas when the battery is connected to a load.
WARNING!
No repairs should be attempted by anyone other than a qualified professional as the deployment or retraction of the steps can
cause injury if proper precautions are not taken.
TROUBLESHOOTING THE SYSTEM
1. Disconnecttheplugbetweenthechassisandthesteps. Usinga voltmeter, measure the voltageonthelargeredwireatthechassis
connectorwiththestepswitchinthe“ON”position. Themetershouldindicatemorethan12VDC. Turnthestepswitchtothe“OFF”position
andthemetershouldnotindicatevoltage. Ifthemeter indicated no voltage with the switch “ON”,checkthecircuitandthecircuitprotectors.
Ifitindicateslessthan12VDCwiththeswitch“ON”,chargethe battery. If 12VDCareindicatedontheredwirewiththeswitch“OFF”,replace
theswitch.
2. Withthevoltmeter,settomeasure resistance,measuretheresistancebetweenthegreenwirein theplugandtheframeofthevehicle. Ifthere
ismorethanoneohmofresistance,cleanthegroundeye(groundlug)orrelocatethegroundwire.
3. Usingavoltmeter,settoresistance,testforgroundonthebrownwiregoingtothedoorswitch. Themetershouldindicateanopen circuit
withthedoorclosedand a path to the groundwiththedooropen. Insurethatthedoorisopenatleast6inchesbeforeitcompletesthecircuit
to ground.
4. Withavoltmeter,checkfor12VDContheyellowwirewiththe ignition switch in the“ON”positionandnovoltagewiththeswitchinthe“OFF”
position. If there is no voltagewiththeswitch in the “ON” position, trace thecircuitandrepair.
5. Reconnectthestepstothechassisandproceedto test asfollows. Withstepswitch“ON”andtheignitionkey“OFF”opentheentrydoor and
thesteps should extendandthelightshouldcomeon.
6. Ifthelightcomeson,butthestepsdonotdeploy,removethestepassemblyfromthemotorhome.
7. Removethetwoboltsthathold thesteparmcollarstothedriveshaft. Thiswillallowyoutooperatethestepsmanually. Ifthestepsdonot
operatefreely, visually inspect for bent arms or tight joints. The shoulder boltsshouldrotateinthebushingswithverylittleeffort. Repairor
replaceasneeded.
8. Ifthestepmoves freely,unplugthemodule fromthemotorassemblyatthe twopinconnector. Connect12VDCfromthe batterytotheyellow
wiregoingtothemotorandgroundtheredwire. Thegearshouldrotateinthedeploymentdirectionuntilitgoesovercenterandcomesto
restagainstthestop. (Ifthestepsweredeployed,reversethewirestodrivethegearintheoppositedirection). Ifthegearandmotor
assemblywillnotfunctionnormally replacethem,otherwisereplacethemoduleassembly.

SERVICENOTES
A. Use locktite on any bolts removed and replaced.
NOTE: Itisrecommendedthatifthenutisremovedand replaced in the field,aliquid“Loctite”lockingcompoundbeappliedbeforetightening.
Thejointshoulderboltsshould be torqued to a minimum of140inchpounds.
B. How to adjust cams.
Itisnotrecommendedthatthetightnessofthestepbeadjustedinthefield. Someminormovementofthestepisconsiderednormal.
Excessivemovementcouldbeanindicationofamoreseriousprob-lemandthebottomcovershouldberemovedandathoroughvisualinspection
shouldbemadebeforeany attemptismadetorepairtheproblem byadjustingthecams. Thecamsarelocatedon theinsideofeachsideplate.
Shoulditbedeemeddesirabletoadjustthecams,theycan beadjustedbylooseningthenutontheoutsideofthesideplate, and rotatingthecam
andboltsothattheybearmoreheavilyagainst thesteparm. Careshouldbe takensothatbothcamsareadjustedapproximatelythesame
amount. Afteradjust-ment,thestepsshouldbe operatedseveraltimestoinsurethattheyare stilllockingovercenter. Thiscanbedeterminedby
watchingthestepsas theycompletetheirdeployment. Ifthesteps arelockingovercenter,theywilldeployfullyandthenretractapproximately 1/8”
astheylockin place.
C. Installation Precautions
Thestepsaredesignedtobemountedtothevehiclebyatleast4bolts. Itisrecommendedthatatleast10mmboltsandflangenutsbe
used. Innocaseshouldthestepbe welded tothevehicle. Thiscouldresultinwarpage,unreliableperformance,and electrical damage tothe
module.
D. Servicemotorasanassembly.
Itisstronglyrecommendedthatthemotor/gearbeservicedasanassemblyandthisisthewayreplacementsaresold. Themotor/
gearassemblycanbereplacedby disconnectingthetwopinconnectorfromthemodule to themotor,removingthe“p”clampholdingthe wire
harnesstothemotormount,removingthe ball jointlinkagefromthegear,theself-tappingscrewthatholds the groundwireandbyremovingthe3
boltsthatholdthemotormount to thestepbase. Careshouldbetakennottodisturbthe adjust-mentinthelengthoftheballjointlinkage. After
reassemblyinthereverseorder, noadjustmentshouldberequired.
E. Module replacement.
Removetheself-tappingscrewholdingthegroundwire,anddisconnectthe4-pinconnectortothemotorhomewiringandthetwo-pin
connectortothemotor.Removethe selftappingscrewsholdingthemoduleinplace,and reinstallthenewmoduleinthereverseorder.
F. Lubrication Coach
Stepsareequippedwithself-lubricatingbushings on the drive assemblyandallstep joints. Nolubrication is necessary.Ifin extreme
conditionslubricationisdeemednecessaryasilicon based grease orspraywillnotharmthebushingmaterial.Ifanydifficulty isencountered
eitherintheuse,installationorserviceofthestepsthatisnotcoveredinthe service instructions, please call the followingnumberforserviceor
warrantyinformation.Themanufacturer takesnoresponsibilityforunauthorizedserviceorinstallationprocedures.1-866-524-7821.