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Step Test Procedures
These 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 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).
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.
Read the entire procedure prior to
testing.
TESTING THE STEP
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.
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 the 4-way connector
on the underside of the step and
connect the step-half of the connector
with the four-way connector pigtail
(See Figure 5).
4. Set a 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 (_) post of the battery
to the green ground wire from the
control unit.
5. For the power supply, attach the
red wire from the pigtail to the battery's
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.
WARNING: Keep all
fingers, arms, and legs
clear of the 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.
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.
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.
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 (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 not, the plug should be
replaced.
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, 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 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 the wiring
instructions.
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.
Van Step
If your step is equipped with a
splash cover, the cover must be
removed to access the motor
assembly and control unit. If the step
is locked in the retracted (up)
position where the plastic cover
cannot be removed, the step tread
will have to be disassembled 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.
Reinstall the cover after completing
the test procedures and any
necessary repairs. The step should
be fully extended to reinstall the
cover. Be sure that the four-way
connector exits the notch in the
plastic cover when reassembling.
