© 7/00 Kwikee Products Co., Inc.Kwikee #1422255

Electric StepsEquipped with a Permanent Magnet Motor and Control Unit

Single Steps Double Steps Triple Steps Van Steps

Owner'sManual#875

(For steps using control units 909506000, 909507000, or 909508000)

Step Identification Information .........2Introduction ..................................3

Operating the Step ........................3

Extending the Step forInstallation ...............................4

Installation - Mounting theStep and Retracting the Step ......4

Installation - Wiring the Step .........5

Installation - Door Switch ..............6Step Test Procedures .....................7

General Service Notes ..................9

Step Motor Parts Key .................. 10

Step Motor Assembly Diagram ... 11

Instructions for the StepMotor Assembly ..................... 12

Maintenance and Lubrication ..... 13

Table of Contents

Page 2

SAVE WITH YOUR VEHICLE RECORDSStep Identification Information

In the event that servicing the step becomes necessary, the information that you supply below will improveservice response time. Please take a moment to record this information:

Step Serial #: _______________________________________________________________Step Series #: _______________________________________________________________Control Unit #: ______________________________________________________________

Control Unit Serial #: _________________________________________________________Year & Manufacturer of the recreation vehicle: _____________________________________Date of Purchase: ____________________________________________________________

The Step Series #, Serial #, and Control Unit #s are on the identification labels attached to thecontrol unit and the underside of the step, near the motor. If the information on the labels is notavailable, the Step Motor Parts Key on page 10 contains information that will help you identitywhich step you have.

Page 3

Introduction

This manual has been provided to assistyou with the identification, operation,installation, and troubleshooting of anyKwikee electric step manufactured afterJanuary 1999 that is equipped with adoor switch, a power switch, control unitand a permanent magnet motor. It doesnot apply and should not be used as areference to any other previous versionsof a Kwikee electric step.

The control unit is essentially a currentsensor as well as a switching device.When the motor assembly moves thestep tread to its extended position, orstops moving because of an obstructionsuch as a curb or the binding of adamaged or bent step frame, the motor

1. After the installation is complete andwith the entrance door open, turn thepower switch on.

NOTE: Some steps are not equippedwith a power switch. They are activatedonly with a door switch.

2. Close the door. The step shouldretract and lock in the "up" position.

3. Open the door. The step shouldextend and lock in the "down"position with the understep light on.

NOTE: The understep light is notavailable on all step models.

4. If your step is equipped with a powerswitch, turn it off. The step shouldremain in the extended position withthe understep light off when the dooris closed. Turning off the power withthe step retracted will hold the step ina retracted position as well.

5.5.5.5.5. With the power switch off, the stepextended, and the entrance doorclosed, turn on the vehicle ignition.The ignition override system will gointo effect and the step will automati-cally retract.

Operating the Step

draws a larger amount of current. Thecontrol unit “senses” the larger currentdraw and shuts off power to the motor.

All control units are equipped with an"ignition override system". This system isdesigned so that the vehicle will notbe driven with the step in the extendedposition. When the step is locked in theextended position, the door closed, andthe ignition is turned on, the ignitionoverride system will engage and the stepwill automatically retract.

The “Last Out” feature is another safetyfeature designed to extend the step whenthe door is opened for the first time afterthe vehicle ignition is turned off, even if

the power switch is turned off. When theignition is switched on, the function ofthe power switch is disabled and the stepwill always extend when the door isopened and retract when the door isclosed.

Some van steps use door switch onlyoperation. When the door is opened thestep extends and the step retracts whenthe door is closed.

NOTE: Follow the instructions in thismanual carefully. Failure to do so mayresult in damage to the step control,the motor and/or the vehicle wiring. Suchdamage may also result in voiding thewarranty.

NOTE: If the yellow wire from the four-way connector is not connected to anignition power source, the ignition safetysystem will be inoperative and the stepwill remain in the extended position. Inthis case, the power switch must beturned on for the step to retract.

WWWWWARNINGARNINGARNINGARNINGARNING: If the vehicle is: If the vehicle is: If the vehicle is: If the vehicle is: If the vehicle isdriven with the step in thedriven with the step in thedriven with the step in thedriven with the step in thedriven with the step in theeeeeextended position, there isxtended position, there isxtended position, there isxtended position, there isxtended position, there is

the possibility of causing majorthe possibility of causing majorthe possibility of causing majorthe possibility of causing majorthe possibility of causing majordamage to both the step and thedamage to both the step and thedamage to both the step and thedamage to both the step and thedamage to both the step and thevehicle.vehicle.vehicle.vehicle.vehicle.

6. Turn the vehicle ignition off andopen the door. The step will extendand lock in the "down" position. Thisis the "Last Out" feature.

7. The “Last Out” feature is onlyoperative the first time the door isopened after the vehicle ignition isturned off.

When the vehicle ignition is on, thestep will always activate with thedoor movement, regardless of thepower switch position.

NOTE: If the yellow wire from the four-way connector is not connected to anignition power source, the "Last Out"feature will not operate.

!BE SAFE.

ALWAYS LOOK BEFORE YOUSTEP OUT OF YOUR VEHICLE.

Installation - Mounting the Stepand Retracting the StepWith 5/16-18 (minimum) bolts, lockwashers, and nuts, mount the step usinga minimum of four of the holes locatedin the top of the step frame.

NOTE: Welding the electric step directlyto the chassis frame or mounting bracketcan distort the frame and severelydamage the control unit. This damagewill not be covered under the warranty.

1. Ground the control unit by attachingthe long green ground wire from thecontrol unit to the negative (_)terminal of a well charged 12 voltDC automotive battery. The step willnot operate without a good groundconnection.

2. Attach the red and white pigtail wiresto the positive (+) terminal of thebattery.

3. Keeping hands and fingers clearfrom the step mechanism, touch thebrown wire from the four-wayconnector/pigtail to the negative (_)terminal of the 12 volt battery. Whileholding the brown wire to the battery,remove the red and white wires fromthe battery to keep the step retracted.

Note: For van step mounting instructionsrefer to the Van Step Mounting BracketInstruction Sheet included with the step.

Page 4

Extending the Step for Installation

1. For easier installation, extend thestep by placing it upside-down on itsmounting surface.

WWWWWARNINGARNINGARNINGARNINGARNING: Making the wire: Making the wire: Making the wire: Making the wire: Making the wireconnections detailed in thisconnections detailed in thisconnections detailed in thisconnections detailed in thisconnections detailed in thisprocedure will cause the stepprocedure will cause the stepprocedure will cause the stepprocedure will cause the stepprocedure will cause the step

to quickly eto quickly eto quickly eto quickly eto quickly extend and retract. Keepxtend and retract. Keepxtend and retract. Keepxtend and retract. Keepxtend and retract. Keephands and fingers clear of the stephands and fingers clear of the stephands and fingers clear of the stephands and fingers clear of the stephands and fingers clear of the stepeeeeextension mechanism.xtension mechanism.xtension mechanism.xtension mechanism.xtension mechanism.

2. Connect the four-way connector fromthe control unit with the four-wayconnector/pigtail that has beenincluded with the step. Figure 1.

3. Ground the control unit by attachingthe long green ground wire from thecontrol unit to the negative (_)terminal of a well charged 12 voltDC automotive battery. The step willnot operate without a good groundconnection.

NOTE: If it is necessary to use jumpers toconnect the wire leads from the pigtail tothe battery, a minimum of 10 gauge wire(8 gauge for wiring runs over 25 feet) isrecommended for use as jumper wire.

4. Attach the red wire from the pigtail tothe positive (+) terminal of thebattery. Keeping hands and fingersclear from the step mechanism,touch the white wire from the pigtailto the positive (+) terminal to extendthe step.

5. After the step has been extended,disconnect the red and white pigtailwires prior to disconnecting thegreen ground wire from the battery.This will keep the step in the ex-tended position.

Figure 1 - Extending the step for installation

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ATTENTION: For van steps equippedfor door switch only operation, connectthe green ground wire from the controlunit and the brown wire from thepigtail to the negative (-) terminal ofthe battery. Attach the red wire from thepigtail to the positive (+) terminal ofthe battery. Remove the brown wirefrom the battery and the step willextend.

Page 5

Figure 2 - Step Wiring Diagram (For Van Step wiring kits order part #7541000)

IMPORTANT INSTALLER NOTES:

Kwikee recommends wiring theKwikee recommends wiring theKwikee recommends wiring theKwikee recommends wiring theKwikee recommends wiring thestep to the vehicle battery insteadstep to the vehicle battery insteadstep to the vehicle battery insteadstep to the vehicle battery insteadstep to the vehicle battery insteadof the “house” battery due toof the “house” battery due toof the “house” battery due toof the “house” battery due toof the “house” battery due topotential interference from otherpotential interference from otherpotential interference from otherpotential interference from otherpotential interference from othercircuits. When in doubt callcircuits. When in doubt callcircuits. When in doubt callcircuits. When in doubt callcircuits. When in doubt callKwikee’s service department atKwikee’s service department atKwikee’s service department atKwikee’s service department atKwikee’s service department at1(800) 736-9961.1(800) 736-9961.1(800) 736-9961.1(800) 736-9961.1(800) 736-9961.

Step controls require groundingprior to installation of the positive12 volt connections.

All Circuits noted as requiring fusesmust be fused. Fuses should belocated as close as practical to thepwer source in order to providemaximum protection to the wiringcircuits. Failure to provide requiredfuses may void warranty.

NOTE: Prior to connecting any wiring,disconnect the vehicle’s power source atthe battery.

1. Ground the control unit by attachingthe long green ground wire from thecontrol unit to the chassis (see figure2 for all wiring details). For Van Stepwiring, follow the wiring schematicillustrated in figure 3.

NOTE: A good ground connection isrequired for proper step operation. Toinsure a good ground connection(metal-to-metal), scrape any paint and/or undercoating from the ground wire/vehicle chassis connection.

2. Determine the switch configurationfor the step that is being installed.The step will be controlled by anormally open magnetic door switch.

3. Once preliminary preparations arefinished for the door switch installa-tion (See Figure 4), connect thebrown wire lead from the vehiclehalf of the four-way connector toone of the terminals or wire leadsfrom the door switch. Use a mini-mum of 16 gauge wire.

NOTE: Do not pull this lead tight. Leavesome slack to avoid damaging theswitch.

Installation - Wiring the Step

Figure 3 - Step Wiring Diagram: Van steps with door switch only operation (ForVan Step wiring kits order part #7540000)

Page 6

NOTE: It is recommended that the switchbe installed on the latch side of the door.However, hinge-side installation isacceptable.

1. Some experimentation with theswitch position may be necessary toachieve proper step operation. Thestep should begin to extend whenthe door is opened between oneand four inches. Position the mag-netic switch in the door jamb. Locatethe magnet opposite the switch.

Door Switch Installation

2. Check for ample clearance in thedoor frame for the door switch body.Do not force the door switch into itsmounting position. Wiring to theswitch should come up through thehollow door frame. After wiring iscompleted, mount the switch to thedoor jamb.

3. Install the magnet in the door,opposite the switch. Vertical place-ment of the magnet is critical to doorswitch operation. See Figure 4.

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Figure 4 - Door switch installation

4. Connect a 16 gauge (minimum) wirefrom the remaining door switchterminal or wire lead to the chassisground. A good ground connection isnecessary to insure proper stepoperation. Attach using a machinescrew, external or internal-tooth lockwasher, and a nut. Place the externalor internal-tooth lock washer betweenthe cable and the vehicle chassis.Scrape any paint clear at this connec-tion point to insure a good ground.

5. Locate and cut a hole to mount thepower switch.

NOTE: There must be enough roombehind the switch to connect the wires tothe switch terminals. A rocker type switchis available and may be used if desired.

If the rocker switch is supplied byKwikee, the power switch may bemounted as is by cutting a 1 9/16" x7/8" hole for the switch to snap into.

NOTE: This hole must be very accurate.The switch may also be mounted using abezel. Cut a 1 1/8" x 1 3/4" hole tomount the switch using the bezel.

NOTE: Do not install the power switchcompletely until all wiring to the switch isin place.

6. Connect the white wire from the four-way connector to one of the termi-nals on the power switch. Use 16gauge wire minimum.

7. Connect the yellow wire lead fromthe four-way connector to the vehiclefuse block. The yellow wire must goto a terminal marked IGN (ignition)or to another terminal that is hot onlywhen the ignition is turned on. A 6amp maximum fuse or circuitbreaker is required in the yellowwire. Use 16 gauge wire minimum.

8. Connect a 16 gauge minimum wirefrom the other power switch terminalto the red 12 gauge power wire. A 6amp maximum fuse or circuitbreaker attached as close as pos-sible to the red power wire is re-quired in this line. The wire must be

connected to the red power wireanywhere between the four-wayconnector and the 20 amp fuse orcircuit breaker discussed in Step 9.

9. Connect the red power wire from thefour-way connector to the 12 volt DCvehicle battery through a 20 amp fuseor circuit breaker which is designatedfor step use only.

WARNING: Do not connect thiswire to any other circuit thatruns other functions. The

circuit must be dedicated to step use

only. Failure to do so will cause severedamage to the control unit, and willnot be covered under warranty. Use12 gauge wire minimum.

10.OPTIONAL: Step Light Switch Connec-tion- Attach the 16 gauge purple wirefrom the control unit to the switchedlead of the porch light.

11.Wrap any exposed connection withshrink wrap or electrical tape toprotect them from the weather.Mount the power switch. Reconnectthe battery.

These Step Test Procedures have beenprovided to troubleshoot and test all ofthe Kwikee automatic electric stepfunctions. They are designed to initiallycheck the step's basic functions sepa-rately from the RV wiring to determinewhether or not the step is malfunction-ing. The following procedures test thevarious components of the step until thesource of the malfunction is located.Using these procedures will shorten andreduce the time spent troubleshooting.

Some portions of the test proceduresrequire additional equipment. Thisequipment includes: a voltmeter, a wellcharged 12 volt DC automotive battery,and a 4-way connector/pigtail (Part#909306000, available from KwikeeProducts Company).

WARNING: 12 volt automo-tive batteries contain sulfuricacid which can cause severe

burns. Avoid contact with the skin,eyes and clothing. 12 volt automo-tive batteries produce hydrogen gaswhich is explosive; keep cigarettes,open flames and sparks away fromthe battery at all times.

Read the entire procedure prior totesting. Should you need assistance inthe course of performing these testprocedures, feel free to contact Kwikee’stoll free Service Line at1 (800) 736-9961.

Testing the Step

IMPORTANT INSTALLER NOTES:

Be sure that all ground connectionsare securely fastened with good metal-to-metal contact. A good ground isrequired for proper step operation.

1. Inspect the step for visible damagethat might restrict the step’s opera-tion.

2. Obtain a 4-way pigtail connector(part #909306000) from Kwikee.

3. Disconnect the 4-way connector onthe underside of the step and connectthe step-half of the connector with the

Figure 5 - Step Test Procedures wiring diagram

Step Test Procedures

four-way connector pigtail(See Figure 5).

4. Set a fully charged 12 volt DCautomotive battery beside the step.AAAAATTENTIONTTENTIONTTENTIONTTENTIONTTENTION: Do not allow the: Do not allow the: Do not allow the: Do not allow the: Do not allow thebattery terminals to come in contactbattery terminals to come in contactbattery terminals to come in contactbattery terminals to come in contactbattery terminals to come in contactwith the step.with the step.with the step.with the step.with the step. Complete a ground forthe step tests by connecting a 10gauge wire from the negative (_) postof the battery to the green groundwire from the control unit.

5. For the power supply, attach the redwire from the pigtail to the battery'spositive (+) post.

6. With the power and ground connec-tions complete, all functions of thecontrol unit can be checked at thefour wires of the pigtail. The brownwire is the door switch, the white wireis the power switch, and the yellowwire is the ignition override.

WARNING: Keep all fingers,arms, and legs clear of thestep mechanism while per-

forming these tests.

7. To extend the step, touch the whitewire to the battery's positive (+) post.The step should extend and remainextended.

8. To retract the step, hold the white wireto the battery's positive (+) terminaland touch the brown wire to thenegative (-) terminal.

9. To test the Ignition Override feature,extend the step as in Step 7. Withthe step extended, disconnect thewhite wire from the battery andattach the brown wire to the battery'snegative (-) terminal. Next, touch theyellow wire to the battery's positive(+) terminal. The step should retract.Remove the brown wire and the stepshould extend.

To test the "Last Out" feature, touchthe brown wire to the negative (-)terminal to retract the step. Whileholding the brown wire to thenegative (-) terminal, remove theyellow from the positive (+) terminal.The Step will stay retracted. Now,remove the brown wire. The stepshould extend.

10. If any of the step functions do notwork, the source of the malfunctionis either in the control unit and/orthe motor. Proceed to the "Testing theMotor" section.

If all of the step functions do work,the malfunction is either in the doorswitch, power switch, or the vehiclewiring. Proceed to "Testing the 4-wayConnector" section.Page 7

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Page 8

Step Test Procedures

Figure 6 - Checking the main powersource

TTTTTesting the Motoresting the Motoresting the Motoresting the Motoresting the Motor

11. Disconnect the two-way connectorbetween the step motor and thecontrol unit.

Connect the motor’s red wire to thepositive (+) terminal of the batteryand touch the motor’s yellow wire tothe negative (_) terminal of thebattery to extend the step. To retractthe step, reverse the connections. Ifthe step extends and retracts duringthis test, the condition of the stepmotor is good.

NOTE: On steps with control unit#909507000 reverse the red and yellowwire connections to perform the afore-mentioned test.

WARNING: Do not leave thewires connected during thistest once the step has cycled

either in or out. Failure to removethe wires from the battery will burnout the motor voiding any warranty.

TTTTTesting the 4-way Connectoresting the 4-way Connectoresting the 4-way Connectoresting the 4-way Connectoresting the 4-way Connector

12. To check the main power source,connect a voltmeter between the redwire from the 4-way connector(vehicle half) and the groundterminal at the end of the controlunit’s green ground wire (see Figure6). The reading should be a mini-mum of 12 volts DC.

If the voltage reading is low, theremay be a loose or corroded connec-tion at the battery, a low charge levelon the battery itself, or a poorground. If the voltage reading is zero(0) volts, check the step fuse/circuitbreaker, all connections, and thecondition of the wiring between thebattery and the plug, including theground connection at the chassis.

13. To check the power switch, connecta voltmeter between the white wirefrom the 4-way connector (vehiclehalf) and the terminal at the end ofthe control unit’s green ground wire(see Figure 7). The reading shouldbe a minimum of 12 volts DC (the

Figure 7 - Checking the power switch

Figure 8 - Checking the door switch Figure 9 - Checking the ignitionoverride system

same as in Step 12) when the switch ison, and zero (0) volts DC when theswitch is off.

If the voltmeter reads zero (0) volts whenthe power switch is on, there is a problemin the power switch circuit.

Check the 6 amp in-line fuse, thepower switch itself and the conditionof the circuit’s wiring and terminalconnections.

14. To check the door switch, connect avoltmeter between the red wire fromthe 4-way connector (vehicle half)and the brown in the same connec-tor (see Figure 8). The voltageshould be a minimum of 12 volts DC

(the same as in step 12) when thedoor is closed and zero (0) voltswhen the door is open.

If the readings are incorrect, there isa problem with the switch. Check thedoor switch and the condition of thecircuit's wiring and terminal connections.

15. To check the ignition overridesystem, connect a voltmeter betweenthe yellow wire from the 4-wayconnector (vehicle half) and theground terminal on the end of thecontrol unit’s green ground wire (seeFigure 9). The voltage readingshould be approximately 12 volts DCwhen the ignition is on and zero (0)volts when the ignition is off.

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Page 9

Step Test Procedures

ground terminal at the end of thecontrol unit’s green ground wire(figure 10).

NOTE: Be sure to use the terminal withonly the white wire.

The reading should be a minimumof 12 volts DC. If not, the plugshould be replaced.

If you have additional questions or needmore assistance, contact Kwikee’sService Representative at 1 (800) 736-9961.

If the reading is zero when the ignitionis on, check all terminal connections,wiring, and the vehicle's ignition fuse.

NOTE: The step wiring circuit must beindependent. No other device (i.e. alarmsystems, step well lights, etc.) can beconnected to the step wiring circuit. Anydevice connected to the steps wiring cancause the step to malfunction and willvoid the warranty.

16.For steps equipped with door switchonly operation: Connect the whitejumper wire from the vehicle half ofthe four-way connector and the

General Service NotesIf the power wire to the step is discon-nected from its source and reconnected,a spark is common. This is caused by themomentary charging of the control unitand does not necessarily indicate thesystem is staying on, which would causea drain on the battery. If battery drain issuspected, observe the understep light (ifso equipped) while the step is extending.The power switch must be on for theunderstep light to operate.

To determine if a control unit is notshutting off, remove the four-wayconnector to the chassis and the two-wayconnector between the step motor andthe contol unit. Place a voltmeterbetween the red and yellow motor wiresat the two-way connector from thecontrol unit. Reconnect the four-wayConnector. Turn the power switch on. Ifany voltage registers on the meter, thecontrol unit is not shutting off and maybe defective. When doing this test,switch the voltmeter leads back and forthbetween the red and yellow motor wiresto be sure no voltage registers.If any voltage does register, disconnectthe four-way connector to keep the stepmotor from overheating. If zero voltageis present, the control unit has shut offand is normal.

If the step does not work or operateserratically, such as extending part wayand shutting off, the first item that shouldbe checked is the vehicle’s battery. Low

supply voltage may cause erratic opera-tion of the step. Poor ground connectionsmay also cause erratic operation of thestep. Check battery voltage and condition.A battery in good condition and properlycharged will have a no load voltage ofapprox. 12.6 volts. Check the voltage atthe battery and at the four-way connectorat the control unit. Insure that all batteryand step control unit connections areclean and secure. Recharge or replace thebattery as necessary and retest the step forproper operation.

The step may also operate erratically ifthe step is being operated directly from aconverter, and the output from theconverter is not adequate or properlyfiltered for clean DC voltage. Theconverter must be capable of producinga minimum of 30 amps for proper stepoperation.

If the ground to the control unit is lost,either between the step control unit andthe vehicle chassis (the long greenground wire) or between the vehiclebattery and the ground (negative batterycable) the step will not function. Makesure the battery terminals and all wireconnections are clean and tight. Verifythat all wires meet the minimum require-ments specified in the wiring instructions.

These general service notes and the StepTest Procedures address the mostcommon questions about Kwikee electric

steps. Due to the number of variableconditions, you may experience symp-toms other than those covered. Pleasefeel free to contact the Customer ServiceDepartment at 1 (800) 736-9961 forfurther information or assistance.

Van Step:If your step is equipped with asplash cover, the cover must beremoved to access the motorassembly and control unit. If thestep is locked in the retracted (up)position where the plastic covercannot be removed, the step treadwill have to be disassembled toaccess the plastic cover. To disas-semble the tread, remove the (8)1/4-20 x 1" long hex head bolts inthe tread side rails connecting thetread and the sliding blocks to theside rail. This will allow the tread tobe dropped out of the way toaccess the plastic cover. Reas-semble the tread after removing thecover. Reinstall the cover aftercompleting the test procedures andany necessary repairs. The stepshould be fully extended to reinstallthe cover. Be sure that the four-wayconnector exits the notch in theplastic cover when reassembling.

Figure 10 - Checking the connector

Page 10

Step Motor Parts Key

The motor assembly part numbers listed in the gray box below contain the motor, linkage, gears, and gear box for the correspondingstep series number.

Step Series #Step Series #Step Series #Step Series #Step Series # Motor AssemblyMotor AssemblyMotor AssemblyMotor AssemblyMotor Assembly Description of StepDescription of StepDescription of StepDescription of StepDescription of Step22 Series Step #909502000 double tread step; 24" wide tread; frame measures 10" tall in retracted position23 Series Step #909503000 triple tread step; 24" wide tread26 Series Step #909504000 single tread step; 24" wide tread; tread angled downward to front when retracted27 Series Step #909502000 double tread step; 24 1/2'’ wide tread28 Series Step #909501000 single tread step; 23 3/4" wide tread; frame measures 5 7/8” tall in retracted position29 Series Step #909501000 single tread step; 23 3/4" wide tread; tread is 9 1/8" deep: frame is 4 1/2" tall - retracted30 Series Step #909502000 single tread step; 36" wide tread31 SeriesStep #909501000 single tread step; 17 3/4" wide tread32 Series Step #909502000 double tread step; 24" wide tread; frame measures 7 1/8” tall in retracted position33 Series Step #909502000 single tread step; 28 1/8" wide tread34 Series Step #909502000 double tread step; 30" wide tread35 Series Step #909502000 single tread step; 24" wide tread; 17 1/2" deep from front of tread to back of ext. arms36 Series Step #909502000 single tread step; 30" wide tread; mounted to underside of step mounting surface37 Series Step #909501000 single tread step; 30" wide tread; mounted to an angled bracket at the back of step38 Series Step #909502000 single tread step; 24" wide tread; 20 1/2" deep from front of tread to back of ext. arms39 Series Step #909501000 single tread step; 23 3/4" wide tread; tread is 10 3/8” deep; frame is 4 1/2" tall - retracted40 Series Step #909502000 double tread step; 24" wide tread; frame measures 6 1/2" tall in retracted position42 Series Step #909505000 double tread step; 24 3/4" wide tread

*Motor assemblies are shipped assembled.

Motor Assemblies* Motor Assemblies* Motor Assemblies* Motor Assemblies* Motor Assemblies* MotorsMotorsMotorsMotorsMotors LinkagesLinkagesLinkagesLinkagesLinkages Gears & Gear BoxGears & Gear BoxGears & Gear BoxGears & Gear BoxGears & Gear Box HardwareHardwareHardwareHardwareHardware

Part # Descriptio Kit# 909501 909502 909503 909504 909520 909521 909532 909533 909534 909524 909525 909526 909527 909530 909535 909536 905205

1 #10 x 1 3/4” selt-tapping hex washer-head screw

2 Motor bearing bracket

3 Bearing

4A Motor

4B Motor (high torque - for use with 23 Series steps)

5 Adaptor gear

6 Adaptor gear shaft

7A Linkage assy. (for motor assys. #909502 & #909503)

7B Llnkage assemby (for motor assembly #909501)

7C Linkage assembly (tor motor assembly #909504)

8 Cotter pin

9 Clevis pln

10 Gear case

11 Gear

12 Gear case cover

13 Motor mounting plate

14 1/4-20 x 1 1/4’’ tri-labal tread forming screw

When a complete motor assemblyreplacement isn't required, the Kwikeestep parts illustrated on the facingpage can be order as part of a kit. It'sas easy as one, two, three.

1. Identify the requiredreplacement part on thefacing page.

2. Find the correspondingpart number in the far leftcolumn in the table below.

3. Cross reference the partnumber with the replace-ment kit number in thesecond row of the table.

The shaded boxes below the Kit #s indicate all the parts in that kit

Page 11

Step Motor Assembly Diagram

Parts shown in this illustration are only available inkit form and cannot be obtained individually; referto the illustration below and use the Step MotorParts Key on the preceding page to select the kit thatcontains the necessary part.

Part# Description

1 #10 x 1 3/4” self-tapping hex washer-head screw

2 Motor bearing bracket

3 Bearing

4A Motor

4B Motor (high torque - for use with 23 Series steps)

5 Adaptor gear

6 Adaptor gear shaft

7A Linkage assy. (for motor assys. #909502 & #909503)

7B Linkage assembly (for motor assembly #909501)

7C Linkage assembly (for motor assembly #909504)

8 Cotter pin

9 Clevis pin

10 Gear case

11 Gear

12 Gear case cover

13 Motor mounting plate

14 1/4-20 x 1 1/4’’ tri-lobal thread forming screw

Page 12

Instructions for Step Motor Assembly

Instructions for removing the motorInstructions for removing the motorInstructions for removing the motorInstructions for removing the motorInstructions for removing the motorand gearboand gearboand gearboand gearboand gearbox from the step framex from the step framex from the step framex from the step framex from the step frameand disassembly of the motorand disassembly of the motorand disassembly of the motorand disassembly of the motorand disassembly of the motorgearbogearbogearbogearbogearbox.x.x.x.x.

Befor attempting any motor assem-bly repair work, please read all ofthe following instructions:

Refer to the motor assembly exploded-view drawing for item numbers refer-enced in these instructions.

1. To remove the motor from the stepassembly the step needs to bepartially or fully extended. If possibleextend the step with the standarddoor switch operation.

2. Unplug the four-way connector fromthe control unit.

3. Remove the cotter pin (Item #8) fromthe clevis pin (Item #9) at thelinkage assembly.

4. Remove the clevis pin (Item #9) fromthe cast "U" block in the end of thelinkage assembly (Items #7a, 7b, or7c). Note the direction the clevis pingoes into the cast block. If the step isin its locked position, the pin mayhave to be pried or driven out of theblock. The step tread(s) should nowswing freely, if not check for a bentstep frame or jammed pivot point(s).

5. Motor removal: The motor may beremoved without removing thegearbox (Item 4a or 4b) Disconnectthe motor two-way connector.Remove the three screws (Item #1)along with the bearing bracket(Item #2).

6. Gear case removal: Unbolt themotor mounting plate (Item #13)from the step frame.

7. Remove the bearing (Item #3) andthe linkage assembly (Items #7A,#7B or #7C) from the gear case(Item #10) along with the adaptorgear (Item #5) and shaft (Item #6).

8. Turn the gear case assembly over andremove the 4 screws (Item #14) fromthe gear case. Lift off the mountingplate (Item #13).

9. Remove the bearing (Item #3). Liftoff the gear case cover (Item #12)and lift out the gear (Item #11), notewhich side of the gear goes up.

Reassembly and installation of themotor assembly (Part #909501,#909502, #909503, #909504) tothe step frame.

Refer to the motor assembly exploded-view drawing on the previous page forthe item numbers referenced in theseinstructions.

NOTE: In the following assembly be sureall bearing pockets and surfaces, gearteeth, and the gear hub socket that is inthe gear case are well lubricated with asuitable grease. We recommendKwikLubeTM Spray Grease.

1. Install the gear (Item #11) in thegear case (Item #10). Be sure thegear is reinstalled the same way itwas removed (with the penny-sizeddepressions facing down).

2. Place the gear case cover (item #12)on the gear case. Set the bearing(Item #3) in the center hole of thegear case cover (the flange of thebearing should be up) and align thesquare hole in the bearing with thesquare hole in the gear.

3. Place the mounting plate (Item #13)on the gear case cover (the squareholes in the mounting plate shouldbe away from the motor) and installand tighten the 4 screws (Item #14).

4.4.4.4.4. Turn the motor assembly over and setit on the flat mounting plate (Item#13). Install the linkage assembly(Item #7A, #7B or #7C) into thegear case. Be sure the linkageassembly sets all the way into thegear and bearing or the bearingbracket (Item #2) will not set prop-erly. The swivel ball-and-cast block

should face the front of the motorassembly.

5. Place the bearing (Item #3) on thelinkage assembly shaft. Place theflange of the bearing facing down.

6. Lubricate and set the adaptor gear(Item #5) and adaptor gear shaft(Item #6) in place and mesh themwith the main gear.

7. Replace the motor (Items #4A or#4B) by aligning the motor andadaptor gear (Item #5) so they slidetogether. Align the screw holes andpush the motor into the screw holealignment pockets in the gear case.

8. Place the bearing bracket (Item #2)on the motor assembly and attach itwith the three motor screws (Item#1). These screws must be verysecure.

9. Reinstall the motor assembly on thestep frame and tighten all mountingbolts. Be sure the motor assembly ispositioned the same way the old onewas prior to removal.

10. Install the clevis pin (Item #9)through the drive arms attached tothe step frame and the cast block inthe linkage assembly (Items #7A,#7B or #7C). Be sure to reinstall theclevis pin in the same direction it wasremoved. Install the cotter pin (Item#8) in the clevis pin.

11. Reconnect the two-way connectorbetween the motor and the controlunit. Reconnect the four-wayconnnector between the control unitand the vehicle. Test the stepfunctions.

Page 13

Maintenance and Lubrication

Clean all mud, salt, and road grime from the step before lubricating. Lubricate all moving parts (bearings, pivot points, slides, clevispin, and drive linkage ball) every 30 days with a good quality moisture and heat resistant penetrating grease. KwikLubeTM SprayGrease is specially formulated to lubricate Kwikee Electric Steps and is recommended for lubricating all moving parts. Refer to thefigures below for lubrication locations. NOTE: Silicone lubricants and WD-40 are not recommended as they have a tendency toevaporate and dry the mating surfaces which leave them vulnerable to the elements.

1. Figures 1 & 3 - square shaft bearing- lubricate around outside and underhead of bearing.

2. Figure 4 - on step models equippedwith plastic cover, this cover will haveto be removed to lubricate centerbearings. Lubricate bearings undercover every 90 days.

3. Figure 4 - Lubricate around thebushing-in-bushings.

4. Maintain clean, dry electricalconnections at the two-way and four-way connectors and any butt con-nections leading from the four-connector to the vehicle. A small dabof di-electric grease at the connec-tions and replacing corroded buttconnections with heat shrink typecrimp style automotive connectorswill help maintain a good electricalsource for the step.

KwikLubeKwikLubeKwikLubeKwikLubeKwikLubeTMTMTMTMTM is a unique aerosolgrease that has hundreds of automo-tive, household, and industrial usesin addition to lubricating KwikeeElectric Steps. It sprays on and intohard to reach places. KwikLubeTM

changes from a penetrating fluid to atough, protective grease in a matterof minutes! The cured film is impervi-ous to moisture and can withstandtemperatures above 400° F (204° C).This formulation also containsadditives to prevent rust and reducewear.

Ask for Kwik Lube at yourlocal RV Dealer

NOTE: Figures are to be used for generalreference purposes only. Some may notpertain to your particular step model.

Adjusting the stops on 27, 32, 34, 35, 36, 38, and 40 Series Steps

The 27, 32, 34, 35, 36 38, and 40 Series steps are fitted with adjustable cam stops on the step frame which help lock thestep in the out position, creating a firm stepping platform while relieving load bearing stess on the motor and drive linkage.The stops are adjusted at the factory but may become loose during shipping, installation and/or normal use. The followingprocedure outlines the proper method for adjusting the cam stops.

WARNING: When the cam stops are out of adjustment the step may feel loose or "mushey" whenstepped on. If the cam stops are not properly adjusted the step many not extend to its full and lockedout position. Using a step with loose or out of adjustment cam stops may cause damage to the motorassembly or drive linkage. A broken drive linkage will allow the step to move freely in and out creat-ing an unsafe stepping platform.

TO ADJUST THE STOPS:The stops are located under the step top on 32,36, and 38 Series Steps, and on the bottom treadside rail on 27 and 40 Series Steps. There is onestop on each side of the step.

CAUTION: WHEN WORKING UNDER THESTEP, BE SURE THAT THE STEP CANNOTBE ACTIVATED OR THERE IS A DANGEROF GETTING CAUGHT IN THE STEPMECHANISM.

1. Loosen the stops so they move freely.

2. Retract the step.

CAUTION: BE SURE THAT NOTHING CAN GETCAUGHT IN THE STEP MECHANISM.

3. Extend the step fully to its locked extendedposition (see Figure 1, right, top). Be surethat the motor assembly linkage rests againstthe gear case as illustrated in the figure.

4. Using 2, 1/2" wrenches, loosen the cam stopnut with one wrench and rotate the cam stopwith the other wrench. Once the stop ispushing against the leg and taken all the playout of the step frame, tighten the cam step nutso it won't back off. Be sure that both stopsare tightened and that they rest securelyagainst the leg.

5. Retract and fully extend the step. Check themotor assembly to be sure that it is locked allthe way out, and that both stops are securelyagainst the legs.

6. Push on the front edge of the step tread. Ifthe step seems loose, repeat the cam stopadjustment procedures.

Maintenance and Lubrication

FIGURE 1

FIGURE 2

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